Inverter Power Source for Lightweight Stud Welder
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Solution Overview
Problem
Stud welder power sources are typically large, bulky, and heavy due to their iron core design, limiting portability and accessibility, and existing inverter power sources do not provide sufficiently high or fast current outputs for efficient stud welding.
Innovation Solution
A stud welder power supply with an inverter power source and a control circuit that uses power switching transistors to provide short bursts of high amperage power at frequencies above 15 kHz, achieving a rise time of at least 600 amps per millisecond and a rise time to pulse width ratio of approximately 1:750, allowing for lightweight and durable construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an iron core based transformer rectifier power source is used, then sufficient power output is achieved, but the power source becomes large, bulky, and heavy
Solution Approach 1:
The patent changes the operating parameters of the power source by using an inverter circuit that converts DC to high-frequency AC, then back to DC through a smaller transformer. This parameter change (frequency conversion) allows the transformer to be much smaller while delivering the same power output, directly resolving the contradiction between power output and weight.
Solution Approach 2:
The patent replaces the traditional mechanical/electromagnetic transformer rectifier system with an inverter-based electronic control system. This substitution uses electronic switching devices (transistors, diodes) and control circuits to achieve power conversion, eliminating the need for large iron core transformers and significantly reducing weight while maintaining power output capability.
2Weight of moving object
If an inverter power source is used, then weight is reduced, but current output is insufficient and response speed is too slow for stud welding
Solution Approach 1:
The patent employs periodic switching action through the inverter circuit, where power switching transistors rapidly switch on and off at high frequency. This periodic action, controlled by the microprocessor, generates the necessary high current bursts for stud welding while maintaining the lightweight inverter architecture, thus resolving the contradiction between weight and current output capability.
Solution Approach 2:
The patent introduces dynamic control through a microprocessor that continuously monitors and adjusts the inverter's output parameters. This dynamic adjustment allows the system to deliver high current outputs on demand for welding operations while maintaining low average power consumption and lightweight construction, resolving the contradiction between weight and peak current capability.
3Power
If SCR-based control is used, then power control is achieved, but switching speed is limited and system complexity increases
Solution Approach 1:
The patent replaces the SCR-based control system with a microprocessor-based digital control system. This substitution enables much faster switching speeds through electronic PWM (pulse width modulation) techniques controlled by the microprocessor, while also simplifying the overall system architecture by integrating control functions into a single programmable device, thus resolving the contradiction between power control and switching speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a lightweight, durable, and efficient stud welder that can generate high current outputs rapidly, improving portability and welding efficiency with faster response times and reduced weld times, capable of handling larger studs at lower operating currents.
Implementation Method 1
Inverter power sources first rectify incoming power to a direct current. This signal is then filtered for smoothness and sent through power switches that convert the signal back to AC, but at an increased frequency. A transformer steps-down the signal prior to the signal being rectified a second time to DC current.
Implementation Method 2
Stud welding is a welding process that utilizes a localized burst of current between a metallic fastener and a metallic work piece
Data Source
AI summary
An appartus and method for a stud welder power source is disclosed. The power source has a control circuit connected to an inverter which converts an electrical signal from a power source into an electrical signal that can perform stud welding. The inverter conditions the power signal such that a current of at least 1000 amps can be generated nearly instantaneously. Additionally, having a power source that includes a control circuit with an inverter allows for a smaller and lighter appartus when compared to known stud welders.