Portable Hybrid Welding Module Segmentation
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Solution Overview
Problem
Conventional welding power supplies are limited by their rated output, and existing battery-assisted systems require reconfiguration between charging and welding, making them inconvenient for remote welding applications.
Innovation Solution
The development of portable hybrid welding modules that separate the charging module from the welding module, using a bidirectional DC-DC converter to charge and discharge an energy storage device, allowing for increased output power capacity without the need for reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional battery-assisted systems are integrated with the welding power supply, then the power output capacity is increased, but the device complexity and reconfiguration requirements increase
Solution Approach 1:
The system is divided into separate functional modules: a welding power supply unit and a portable battery-assisted welding module. The battery module can be independently attached or detached, eliminating the need to reconfigure an integrated system while maintaining increased power output capacity when needed.
Solution Approach 2:
The system transitions from a static integrated design to a dynamic modular configuration. The battery-assisted module can be connected when high power is needed and disconnected when not required, allowing the system to adapt its configuration based on operational requirements without permanent reconfiguration.
2Ease of operation
If the welding power supply is made portable for remote locations, then the ease of operation is improved, but the power output capacity is reduced
Solution Approach 1:
The welding system is segmented into a lightweight portable control module and a separate battery power module. The portable module can be easily transported to remote locations, while the battery module provides additional power capacity when attached, resolving the trade-off between portability and power output.
Solution Approach 2:
The portable battery-assisted welding module acts as an intermediary between the lightweight portable welding controller and the high-capacity battery power source. This intermediary enables the system to maintain portability while providing access to increased power output when the battery module is connected.
3Adaptability or versatility
If the charging module is included with the portable welding module, then the versatility is improved, but the weight of the portable module increases
Solution Approach 1:
The charging module is separated from the main portable welding module, allowing users to carry only the essential welding components to remote locations. The charging module can be left at the base or added when charging is required, maintaining versatility while minimizing the weight of the portable field equipment.
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 at remote locations with reduced equipment weight and increased power output, allowing operators to charge and disconnect the portable module for efficient welding operations.
Implementation Method 1
using a bidirectional DC-DC converter to charge and discharge an energy storage device
Data Source
AI summary
Hybrid welding systems and portable hybrid welding modules are disclosed. An example portable welding power supply includes an output converter circuit to convert direct current (DC) power to welding power, the DC power comprising at least one of DC input power or converted battery power. The portable welding power supply also includes a battery and a bidirectional DC-DC converter circuit configured to receive the DC input power and coupled to the battery. The portable welding power supply also includes a control circuit configured to control the output converter to output the welding power, control the bidirectional DC-DC converter circuit to convert the DC input power to charge the battery, and control the bidirectional DC-DC converter circuit to convert power from the battery to provide the battery power to the output converter.