Modular Hybrid Engine Drive Welder System
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Solution Overview
Problem
Conventional hybrid engine drive welders are large and have limited versatility, making them cumbersome for use in remote or hard-to-reach locations, and they lack the flexibility to operate effectively without the primary engine and generator module.
Innovation Solution
A modular hybrid engine drive welding system comprising a primary module with an engine and generator, and a detachable power module equipped with an energy storage device and power conversion circuit, allowing the system to generate welding or cutting output power independently of the primary module, with adjustable peak output power and communication capabilities for optimized operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welder uses a hybrid engine drive design with battery, then the system can smooth power and add output power, but the system becomes large and less versatile
Solution Approach 1:
The welder is divided into two separate modules: a primary module containing the engine and generator, and a detachable power module containing the battery and power conversion circuit. This segmentation allows the battery to be removed when not needed, making the system more versatile and adaptable to different applications while maintaining the power smoothing capability when the modules are connected.
Solution Approach 2:
The system dynamically adjusts its configuration by allowing the detachable power module to be connected or disconnected based on application requirements. When connected, the system operates as a hybrid with power smoothing; when disconnected, it operates as a conventional engine-driven welder, providing dynamic adaptability.
2Device complexity
If the welder is designed as a single integrated unit, then the system is structurally simple, but it is large and cumbersome for remote locations
Solution Approach 1:
By segmenting the welder into a primary module and a detachable power module, the system reduces the weight that must be transported to remote locations. Only the lighter primary module needs to be moved, while the heavier battery module can remain at a base location or be transported separately.
Solution Approach 2:
The system transitions from a single fixed configuration to a multi-configuration system that can operate in different modes (connected or disconnected), adding a dimensional aspect of operational flexibility that reduces the effective weight burden for mobile operations.
3Adaptability or versatility
If the detachable module operates independently without the primary module, then the system is more versatile for remote use, but the peak output power is reduced
Solution Approach 1:
The segmentation into detachable modules enables the power module to operate independently with reduced power requirements for remote applications, while the full power capability is restored when the modules are connected, providing operational flexibility across different power levels.
Solution Approach 2:
The detachable power module is designed to provide sufficient power for remote applications independently, using only the necessary battery capacity and power conversion circuitry needed for those specific applications, rather than providing full system power capability in every configuration.
4Power
If the system always operates at maximum peak output power, then the welding capability is maximized, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts its power delivery based on the connection status of the modules and the actual welding requirements. The battery in the detachable module can provide supplemental power during high-demand welding operations, allowing the engine to operate at lower power levels and consume less fuel overall.
Solution Approach 2:
The battery in the detachable power module can be charged in advance during periods of low demand or when connected to the primary module, storing energy that can be used during high-power welding operations, thereby reducing the need for continuous high engine output and lowering overall energy consumption.
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 modular design enhances the system's versatility, allowing it to operate in remote locations with reduced size and weight, while maintaining high peak output power when connected, and providing efficient energy usage and reduced noise and exhaust issues.
Implementation Method 1
a generator coupled to the internal combustion engine, where the generator generates electrical power
Implementation Method 2
an energy storage device which receives the electrical power when the second module is coupled to the first module and uses the generated electrical power to charge the energy storage device, and the energy storage device generates an output power
Data Source
AI summary
Embodiments of the present invention are engine drive welding and/or cutting systems which optimize the utilization of engine drive systems, including hybrid engine drive systems. Embodiments include modular systems which allow for the remote utilization of a battery powered module which can be separated from an engine drive generator power supply. Other embodiments include engine drive power supplies that can communicate with a load coupled to the power supply, such as welders, cutters and wire feeders to determine an optimum operational level. Further embodiments include engine drive power supplies that can be coupled together to optimize fuel and system usage.