Portable Ignition Controller Using Power Tool Battery Coupling
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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
1Ease of operation
If a portable power tool battery is used to power the exothermic welding ignition system, then portability and ease of operation are improved, but the device requires a complex housing structure to accommodate the battery while maintaining electrical coupling and actuator functionality
Solution Approach 1:
The patent combines the ignition controller housing with the battery pack into a single integrated unit. The housing is configured to receive the battery, and the circuit board is electrically coupled to the battery through contacts within the housing. This merging eliminates the need for separate battery compartments or external power connections, achieving portability while managing structural complexity through functional integration.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains the circuit board and electrical components, accommodates the battery, and houses the actuator mechanism. By making the housing multi-functional, the patent reduces the need for additional separate components, thereby improving portability without proportionally increasing overall device complexity.
2Weight of moving object
If the housing is designed to receive only a portion of the battery with the remainder external, then the housing size and weight are reduced, but the electrical coupling and actuator engagement become more complex
Solution Approach 1:
The battery is divided into two portions: an internal portion received within the housing and an external portion extending outside. The circuit board is electrically coupled to the battery through contacts that engage with the battery's electrical terminals. This segmentation allows the housing to be lighter while maintaining electrical connectivity through a simplified contact mechanism designed for the specific battery interface.
3Reliability
If the actuator is designed for selective power discharge to the connection terminal, then control precision and reliability are improved, but the circuit board complexity increases
Solution Approach 1:
The actuator is directly operatively engaged with the circuit board, allowing it to selectively make or break electrical connections between the battery and the connection terminal. This self-service mechanism provides reliable selective power discharge through a simple mechanical switching action on the circuit board, avoiding the need for complex control electronics while maintaining operational reliability.
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 maintaining versatility for various applications.
Implementation Method 1
a portable exothermic welding ignition controller includes a housing configured to receive a portion of a portable power tool battery. 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.
Implementation Method 2
The method further includes actuating the actuator to establish electrical communication between the portable power tool battery and the igniter, whereby power is discharged from the portable power tool battery to the igniter to heat the filament.
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.