Hybrid Welding Power Control for Battery Energy Conservation
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Solution Overview
Problem
Conventional hybrid battery/mains-powered welding systems do not optimally conserve battery energy, as they draw a fixed amount of power from the batteries, leading to unnecessary discharge and shortened battery life.
Innovation Solution
An adaptive battery power control system that optimizes battery energy usage by selectively supplying supplementary power from batteries based on AC mains power availability, circuit breaker settings, and output current settings, ensuring efficient power sharing and conservation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a fixed amount of power is drawn from the battery to meet the desired hybrid boost power level, then the power output requirement is satisfied, but the battery energy is not optimally conserved and battery life is shortened
Solution Approach 1:
The system dynamically adjusts the battery power draw based on real-time monitoring of AC mains power availability. Instead of a fixed power draw, the battery power contribution varies adaptively - drawing more power when AC power is insufficient and less power when AC power is abundant, thereby optimizing battery energy conservation while meeting power output requirements
Solution Approach 2:
The system implements a feedback control mechanism where the actual power draw from the battery is continuously monitored and adjusted based on the available AC mains power. This feedback loop ensures that battery power is only drawn to the extent necessary to supplement AC power, preventing unnecessary battery discharge and extending battery life
2Power
If a fixed amount of power is drawn from the battery, then the hybrid boost power level is maintained, but unnecessary battery discharge occurs when AC mains power is sufficient
Solution Approach 1:
The battery power contribution transitions from a static fixed value to a dynamic variable that adapts to AC mains power conditions. The system continuously adjusts the battery power draw to match the actual supplement needed, thereby maintaining the hybrid boost power level only when necessary and extending battery life by avoiding unnecessary discharge
Solution Approach 2:
The system changes the operating parameter of battery power draw from a constant fixed value to a variable parameter that changes based on AC mains power availability. This parameter change allows the system to optimize between maintaining hybrid boost power and conserving battery energy, directly addressing the contradiction between power level maintenance and battery life extension
Data Source
AI summary
A method of operating a hybrid power supply includes supplying to a power source, from a first energy source, power for a welding or a cutting process, selectively supplying to the power source, from a second energy source, supplementary power for the welding or the cutting process, and controlling an amount of the supplementary power that is supplied for the welding or the cutting process based on at least one of (a) a circuit breaker value of a circuit breaker arranged as a safety device in the first energy source (b) a voltage level presented by the first energy source, and (c) an output current setting of the power source.