Removable Battery-Powered Welder for Cable-Free Remote Welding
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Solution Overview
Problem
Conventional welding-type power supplies are large, require additional infrastructure, and long cables are prone to damage and interference, limiting their usability in remote or hard-to-reach areas.
Innovation Solution
An engine-driven welding-type power system that includes a removable welder with an energy storage device, allowing for independent operation and recharging via a docked connection to the power system, eliminating the need for long cables and additional infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding-type power supplies are used, then welding operations can be performed, but the power supply is large and requires additional platforms and infrastructure
Solution Approach 1:
The system is divided into two main segments: a stationary power system (engine-driven generator with dock) and a portable welder unit with energy storage device. This segmentation allows the welding function to be separated from the heavy power generation equipment, enabling portability while maintaining access to sufficient power through the energy storage device that recharges at the dock.
2Adaptability or versatility
If long cables are employed to reach workpieces beyond power supply reach, then welding operations can be performed, but the cables are subject to damage, interference, and power loss
Solution Approach 1:
The portable welder unit extracts the welding function from the stationary power system and contains its own energy storage device. This allows the welder to operate independently at a distance from the power system without requiring long cables to transmit power, thereby eliminating cable-related reliability issues while maintaining adaptability to reach distant workpieces.
3Productivity
If conventional power supplies are used, then welding operations can be performed, but additional infrastructure such as roads and trucks are required
Solution Approach 1:
The system segments the welding operation into a mobile component (welder unit with energy storage) and a stationary component (power system with dock). This allows the welding unit to be transported to jobsites using simple means rather than requiring trucks and roads, reducing infrastructure complexity while maintaining full welding productivity.
4Ease of operation
If the removable welder operates independently, then portability and flexibility are improved, but the energy storage device requires recharging
Solution Approach 1:
The energy storage device is preliminarily charged at the dock before the welder unit is deployed to the jobsite. This preliminary charging action ensures that the welder has sufficient energy for independent operation during the workday, and the dock serves as a charging station that can be visited periodically to extend operational 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 flexible and portable welding operations at a distance from the power system, reducing infrastructure requirements and minimizing cable-related issues, while also allowing for efficient recharging without utility power.
Implementation Method 1
a removable welder with an energy storage device, allowing for independent operation and recharging
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.