MOSFET Welding Switch With Supercapacitor DC Power Control

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Solution Overview

Problem

Traditional electrical resistance welding systems face inefficiencies due to high inductive losses in transformers and resistive losses in DC rectifier diodes, leading to inconsistent welds, overheating, and complex maintenance requirements.

Innovation Solution

A welding system that utilizes a bank of supercapacitors and MOSFET-based switches to provide direct current without the need for transformers or DC rectifier diodes, allowing for precise control of welding voltage and current based on the workpiece dimensions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If transformers are used in resistance welding systems to convert high-voltage input to low-voltage high-current output, then welding power is achieved, but significant inductive losses occur in the transformer

Engineering Contradiction:

Improvewelding powerVSAvoidinductive losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent removes the transformer from the welding system entirely, replacing it with a capacitor bank that stores electrical energy and discharges it directly to the welding electrodes. This extraction of the transformer eliminates inductive losses while maintaining the ability to deliver high current at low voltage for welding operations.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the electromagnetic transformation mechanism (transformer) with a capacitive energy storage and discharge mechanism. The capacitor bank stores energy in an electric field and releases it rapidly during welding, substituting the inductive field-based power conversion with a capacitive field-based approach that avoids inductive losses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If DC rectifier diodes are used to convert AC to DC for welding, then direct current is achieved, but resistive losses occur in the diodes

Engineering Contradiction:

Improvedirect currentVSAvoidresistive losses

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The patent removes the rectifier diodes from the system by using a capacitor bank that is charged from the AC power supply and then discharged directly to provide DC welding current. This extraction eliminates the rectification step and associated resistive losses in the diodes.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The capacitor bank is charged in advance from the AC power supply before the welding operation begins. This preliminary charging action stores the electrical energy needed for welding, allowing the system to deliver DC current without requiring real-time rectification during the welding process itself.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If transformers are used to provide high current at low voltage, then welding control is improved, but the system becomes less portable

Engineering Contradiction:

Improvewelding controlVSAvoidsystem portability

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent removes the heavy transformer from the welding system, replacing it with a capacitor bank that can be charged from standard AC power sources. This extraction of the transformer significantly reduces system weight and improves portability while maintaining the ability to control welding parameters through capacitor charge voltage and discharge timing.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This system achieves consistent and efficient welding with reduced energy loss, simplified maintenance, and improved portability by eliminating transformers and rectifiers, enabling precise control over welding parameters.

Implementation Method 1

The welding system utilizes a bank of supercapacitors and MOSFET-based switches to provide direct current without the need for transformers or DC rectifier diodes

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

MOSFET-based switches to provide direct current without the need for transformers or DC rectifier diodes, allowing for precise control of welding voltage and current based on the workpiece dimensions

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 3

Electrical resistance welding has been widely used for over 100 years, for machines such as spot welders

Methodology Applied

Scientific EffectJoule Heating: Joule Heating

Data Source

PatentUS20250339917A1Switch in a resistance welding system and method thereof

Publication Date: 2025.11.06 CLIFFORD GROUP FZCO

AI summary

Components of an electrical resistance welding system include a DC power supply, an energy storage assembly, a switch, and an electrical resistance welding assembly configured to weld a work piece. The system may be free of any transformer which permits the system to operate in an infinite number of variable voltages between a minimum and maximum system setting. The variable voltage control permits greater operability of the electrical resistance welding system by creating a specific weld voltage dependent on parameter, such as a dimension, of the work piece that is to be welded.