Modular Energy Storage Caddy for Welding Systems
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Solution Overview
Problem
Welding systems that require portability and can operate independently of a primary power source face challenges due to high costs and increased bulkiness when incorporating alternate power sources, limiting their usability in remote locations.
Innovation Solution
An energy storage caddy that couples with welding power supplies to provide a direct current voltage output, featuring energy storage devices and control circuitry to regulate power based on charge level, load demand, and temperature, allowing the system to operate standalone and retrofit existing power supplies for enhanced portability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If alternate power sources are incorporated into the welder to enable standalone operation, then portability and independent operation capability are improved, but the cost increases and the bulkiness increases
Solution Approach 1:
The power storage system is segmented into modular battery packs that can be detached and replaced. The welder unit remains compact while power capacity can be adjusted by adding or removing battery packs, resolving the contradiction between standalone capability and portability.
Solution Approach 2:
The energy storage caddy is designed to be universally compatible with multiple welder models and can also serve as a charging station when connected to external power sources. This multi-functionality justifies the added bulk by providing multiple operational modes.
2Adaptability or versatility
If alternate power sources are incorporated into the welder to enable standalone operation, then portability and independent operation capability are improved, but the monetary cost increases
Solution Approach 1:
The system uses standardized, off-the-shelf battery packs rather than custom-integrated power systems. This segmentation allows users to purchase only the power capacity they need and enables easier replacement or upgrade without replacing the entire welder unit, reducing overall system cost.
Solution Approach 2:
The system includes automated control circuitry that manages battery charging, discharging, and temperature regulation without user intervention. This self-service capability reduces the need for expensive manual monitoring and maintenance systems.
3Duration of action of moving object
If energy storage devices are added to provide standalone power, then operating duration without external power is improved, but the bulkiness and weight increase
Solution Approach 1:
The total energy storage capacity is divided into multiple separate battery packs that can be attached to the welder as needed. Users can carry one pack for short-duration tasks and multiple packs for extended operations, allowing them to optimize the weight-carrying ratio based on specific job requirements.
Solution Approach 2:
The system dynamically manages power delivery based on real-time monitoring of battery charge levels, temperature, and welder power demands. This dynamic control optimizes the utilization of available energy storage, extending effective operating duration without requiring excessive battery capacity and associated weight.
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
Enables welding systems to operate for extended periods without external power, providing a cost-effective and portable solution by converting energy storage devices into a reliable power source, with the ability to recharge and alert users to low charge levels, thus enhancing remote operation capabilities.
Implementation Method 1
The energy storage caddy includes an energy storage device adapted to discharge to produce the power output
Data Source
AI summary
Embodiments of energy storage caddies adapted to couple to a welding power supply are provided. The energy storage caddies may include an energy storage device, a charger, control circuitry, and power conversion circuitry. Certain control circuitry may be adapted to control the energy storage device to discharge to provide a direct current (DC) voltage output to the welding power supply when a weld load demand is detected, to monitor a charge level of the energy storage device, and to alert a user to an error when the charge level of the energy storage device falls below a predetermined limit.