Removable Battery Welder for Cable-Free Remote Welding
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Solution Overview
Problem
Conventional welding-type power supplies are large, require additional infrastructure, and use long cables, which are prone to damage and interference, limiting their portability and accessibility for welding operations.
Innovation Solution
An engine-driven welding-type power system with a removable welder equipped with an energy storage device that can be recharged and operate independently, eliminating the need for extensive infrastructure and cables by providing a hybrid power generation and storage solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional welding-type power supplies are used, then power generation capability is provided, but the system requires additional platforms and infrastructure
Solution Approach 1:
The system is divided into two independent parts: a stationary power system (engine and generator) and a portable welding system (welder with battery). The portable welder can operate independently using its own battery, eliminating the need for infrastructure while maintaining power generation capability through the stationary system when available.
2Length of moving object
If long cables are employed to reach workpieces, then welding operations can be performed at distance, but the cables are subject to damage and power loss
Solution Approach 1:
The portable welder extracts the power source (battery) from the stationary system, allowing it to operate independently without cables. This eliminates cable-related reliability issues while maintaining the ability to perform welding operations at any distance from the stationary power system.
3Ease of operation
If the removable welder operates independently, then portability is improved, but the energy storage device requires recharging
Solution Approach 1:
The energy storage device (battery) is pre-charged from the stationary power system before the portable welder is deployed. This preliminary charging action ensures the welder has sufficient energy for independent operation, resolving the contradiction between portability and operating duration.
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 portable and flexible welding operations at a distance from the power system, maximizing fuel economy and extending the life of the engine and energy storage device while reducing noise and exhaust.
Implementation Method 1
a removable welder having an energy storage device to provide a second power output
Implementation Method 2
an engine to drive an electric generator to provide a first power output
Data Source
AI summary
Apparatus and methods are provided for an engine driven welding-type power system that includes an engine to drive an electric generator to provide a first power output, and a removable welder having an energy storage device to provide a second power output. The system includes a housing having a dock to store a removable welder. While stored within the dock, the energy storage device is recharged by the first power output. Once removed from the dock, the removable welder is configured to operate independently of the power system.