Portable Spot Welder Circuit With Battery Protection and Isolation
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Solution Overview
Problem
Existing spot welders are bulky due to the need for external power sources and lack effective protection against overcharge, overdischarge, and short circuits, making them inconvenient to use.
Innovation Solution
A portable spot welder with a control board, battery, ADC detection module, power MOS module, optical-coupler isolation module, battery protection module, and soldering iron module, which monitors battery state in real time, prevents overcharge/discharge, and detects short circuits, while allowing bidirectional charge/discharge and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the spot welder is powered by an external lithium battery, then the applicable voltage range is narrow and the device size becomes large, but portability is improved
Solution Approach 1:
The power supply module is designed to accept multiple types of power sources including battery packs, power banks, and wall adapters through a universal charging interface. The module can automatically or manually switch between different power sources, making the device adaptable to various voltage ranges and power capacities while maintaining a compact form factor.
2Reliability
If no battery protection module is used, then the device structure is simple, but the battery is prone to overcharge, overdischarge, overcurrent and short circuit damage
Solution Approach 1:
The battery protection module operates autonomously to monitor and protect the battery system. It automatically detects abnormal conditions such as overcharge, overdischarge, overcurrent, and short circuits, then activates protection mechanisms without requiring user intervention. The module provides visual feedback through LED indicators to inform users of the battery status and protection actions taken.
3Ease of operation
If the user manually monitors for short circuits, then the device structure is simple, but the user convenience deteriorates and damage risk increases
Solution Approach 1:
The system implements continuous real-time monitoring of battery status and welding operations through the protection module and ADC detection module. Visual feedback is provided via LED indicators that display battery level, charging status, and error conditions. The system automatically responds to detected abnormalities by activating protection mechanisms, eliminating the need for manual user monitoring while maintaining simplicity.
4Reliability
If optical-coupler isolation is implemented, then the control board is protected from interference and damage, but the device complexity increases
Solution Approach 1:
The optical-coupler isolation module serves as an intermediary between the control board and external circuits. It transmits control signals and data optically, providing electrical isolation that protects the control board from voltage spikes, interference, and damage while maintaining reliable communication. The isolation module integrates multiple functions including signal transmission, electrical isolation, and short-circuit detection.
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 portable spot welder reduces the risk of battery damage, improves safety during use, integrates power bank functionality, and allows for optimal welding power with automatic temperature adjustment, all while being compact and easy to carry.
Implementation Method 1
an optical-coupler isolation driving module, the optical-coupler isolation driving module being electrically connected to the power MOS module and the control board
Implementation Method 2
an analog-to-digital converter (ADC) detection module, the ADC detection module being electrically connected to the control board
Implementation Method 3
a power metal oxide semiconductor (MOS) module, the power MOS module being electrically connected to the battery, and being used for adjusting output power
Implementation Method 4
a light emitting diode (LED) module, the LED module being electrically connected to the control board
Data Source
AI summary
Disclosed is a portable spot welder. The spot welder includes a control board; a battery connected to the control board; an analog-to-digital converter (ADC) detection module connected to the control board; a power metal oxide semiconductor (MOS) module connected to the battery; an optical-coupler isolation driving module connected to the power MOS module and the control board; a battery protection module connected to the battery and the control board; a power supply module connected to the battery protection module and the control board; and a soldering iron module connected to the battery protection module and provided with spot welding pen interfaces. The spot welder can be connected to an external spot welding pen for use or used as an emergency power bank. A safety coefficient is improved, risks of overheating, overcurrent and a short circuit of a portable spot welder body are reduced, and a size is reduced.