Portable ignition controller
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Solution Overview
Problem
Existing ignition systems for exothermic welding lack a portable and efficient method to discharge power from portable power tool batteries to heat the welding igniter, limiting the portability and ease of use in welding applications.
Innovation Solution
A portable exothermic welding ignition controller with a housing configured to receive a portable power tool battery, a circuit board for electrical coupling, and an actuator in the form of pushbuttons to selectively discharge power to the igniter, enabling efficient heating of the welding filament.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a portable power tool battery is used to power the ignition system, then portability is improved, but the ability to selectively control power discharge to the igniter is insufficient
Solution Approach 1:
A circuit board is introduced as an intermediary device between the portable power tool battery and the exothermic welding igniter. The circuit board receives electrical power from the battery and provides controlled power discharge to the igniter through a connector, enabling selective and safe power transfer while maintaining portability
Solution Approach 2:
The housing is designed to directly receive and house the portable power tool battery, eliminating the need for separate power supply equipment. The battery serves dual purposes as both power source and structural component, improving portability while the circuit board manages the selective power discharge function
2Device complexity
If the housing receives the entire portable power tool battery, then electrical coupling is simplified, but the housing size and weight increase
Solution Approach 1:
The battery integration is segmented into two approaches: the housing can receive either a portion of the battery (reducing housing weight and size) or the entire battery (simplifying electrical coupling). This segmentation allows users to choose based on their specific needs for portability versus ease of connection
Solution Approach 2:
The housing is designed with universal compatibility to accommodate different battery configurations - it can receive the entire battery or just a portion, and the circuit board is configured to work with various battery types and sizes, providing flexibility across different application scenarios
3Reliability
If the circuit board is fully integrated within the housing, then protection is improved, but accessibility for electrical coupling is reduced
Solution Approach 1:
The circuit board is nested within the housing for protection, while the connector extends outward from the housing. This nested configuration allows the circuit board to be protected inside the housing structure while the connector remains accessible outside for electrical coupling with the igniter, resolving both protection and accessibility requirements
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 provides a portable and efficient means to heat the exothermic welding igniter using a readily available portable power tool battery, enhancing the portability and usability of the welding process while supporting various applications beyond exothermic welding.
Implementation Method 1
power is discharged from the portable power tool battery to the exothermic welding device to heat the filament
Implementation Method 2
actuating the actuator to establish electrical communication between the portable power tool battery and the terminal
Data Source
AI summary
A portable exothermic welding ignition controller includes a housing configured to receive a first portion of a portable power tool battery with a second portion of the portable tool battery external to the housing. A circuit board is positioned within the housing and configured for electrical coupling to the portable power tool battery. An actuator is operatively engageable with the circuit board for selectively discharging power from the portable power tool battery to a connection terminal electrically coupled to the circuit board.