Multi-Source Welding Power Conversion for Higher Output
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Solution Overview
Problem
Conventional welding power supplies are limited by their rated output, which restricts the types of welding tasks that can be performed and often requires reconfiguration between charging and welding, especially when higher power levels are needed, and may not function optimally with available input power sources such as 230 VAC.
Innovation Solution
The development of welding-type power supplies that can utilize multiple sources of AC and DC input power, including mains power, battery-powered inverter sources, and engine-driven generators, with separate power converters and control circuitry to manage and convert power effectively, allowing for higher power levels and flexibility in welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional welding power supplies use a single input power source, then the device complexity is reduced, but the power output capability and adaptability to different welding tasks are limited
Solution Approach 1:
The welding power supply system is segmented into multiple independent power converters, each dedicated to a specific input power source (mains power, battery, generator). Each converter independently processes power from its source and contributes to the common DC bus, enabling the system to handle higher total power while maintaining modular architecture that manages complexity through functional decomposition
Solution Approach 2:
The control circuitry is designed with multi-functionality to manage multiple types of input power sources simultaneously. It can detect, identify, and control different power source types (mains AC, battery DC, generator AC) and automatically switch between them or combine their output, making the system adaptable to various welding tasks without requiring separate dedicated equipment for each power source type
2Adaptability or versatility
If conventional welding power supplies are reconfigured between charging and welding modes, then the ease of operation is reduced, but the adaptability to different power sources is improved
Solution Approach 1:
The system maintains continuous welding capability by eliminating the need to switch between charging and welding modes. The control circuitry continuously manages power from multiple sources simultaneously, allowing the welding operation to proceed without interruption while power sources are recharged or replaced, ensuring uninterrupted useful action
Solution Approach 2:
The control circuitry automatically detects the type of each connected power source and self-configures the system without requiring manual reconfiguration by the operator. It autonomously manages power distribution, identifies suitable power sources for charging versus welding, and adjusts operational parameters accordingly, making the system self-sufficient and easy to operate across different power source combinations
3Productivity
If welding power supplies are limited to rated output based on single power source, then the device complexity is reduced, but the productivity for high-power welding tasks is reduced
Solution Approach 1:
Multiple power converters process power from different input sources and merge their outputs onto a common DC bus, combining their power delivery capabilities. This allows the system to achieve higher total power output for demanding welding tasks by aggregating power from multiple sources simultaneously, while each converter remains a manageable modular unit that contributes to the overall power capacity
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 higher-power welding operations and increased flexibility by allowing the use of various input power sources, including different voltages and frequencies, thereby expanding the range of weldable materials and processes without the need for reconfiguration.
Implementation Method 1
two or more power converters configured to receive at least two different sources of input power and to convert the at least two different sources of input power to welding-type power
Data Source
AI summary
Disclosed example welding-type power supplies include: two or more power converters configured to receive at least two different sources of input power, and to convert the at least two different sources of input power to welding-type power; and control circuitry configured to: determine a type of source of each of the sources of input power; and control the two or more power converters based on the type of source.