Transformer-Free Resistance Welding With Supercapacitor Voltage Control
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Solution Overview
Problem
Traditional electrical resistance welding systems face inefficiencies due to high inductive losses in transformers and resistive losses in DC rectifier diodes, leading to inconsistent welds, overheating, and complex maintenance requirements.
Innovation Solution
A welding system that utilizes a bank of supercapacitors and MOSFET-based switches to provide direct current without transformers or DC rectifier diodes, allowing for precise control of welding voltage and current based on the workpiece dimensions, with switching times under 0.3 milliseconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional transformer-based AC welding systems are used, then welding current can be obtained, but significant inductive losses occur in the transformer leading to energy waste and overheating
Solution Approach 1:
The patent removes the transformer from the welding system entirely, extracting the source of inductive losses. The system uses a DC power supply with controllable current output directly, eliminating the need for AC-to-DC conversion through rectifier diodes and the associated transformer-based voltage transformation, thereby eliminating significant inductive losses and improving energy efficiency
Solution Approach 2:
The patent replaces the traditional electromagnetic transformer-based AC welding system with a solid-state DC-controlled system. Instead of using electromagnetic induction and mechanical switching, the system employs electronic current control with MOSFETs or IGBTs to regulate DC current, substituting inefficient electromagnetic transformation with efficient electronic control
2Loss of energy
If DC rectifier diodes are used to convert AC to DC, then direct current for welding is obtained, but resistive losses occur in the diodes causing energy waste and heating
Solution Approach 1:
The patent removes the rectifier diode stage from the power conversion chain. Instead of converting AC to DC through diode rectification, the system uses a DC power supply that directly provides controllable DC current, extracting out the source of resistive losses in the rectifier diodes and eliminating the need for AC-to-DC conversion
Solution Approach 2:
The patent replaces the passive diode rectification system with an active solid-state DC power supply system. Instead of relying on the unidirectional conduction property of diodes, the system uses electronically controlled switches (MOSFETs/IGBTs) with feedback control to regulate current, substituting resistive rectification with efficient electronic current control
3Ease of repair
If transformer-based AC welding is used, then welding can be performed, but the system becomes complex and requires frequent maintenance of transformers and cooling systems
Solution Approach 1:
The patent removes the transformer and associated cooling systems from the welding equipment. By using a DC power supply with integrated current control, the system extracts out the components requiring maintenance (transformer windings, cooling pumps, heat exchangers), significantly simplifying the device and reducing maintenance requirements
Solution Approach 2:
The patent replaces the complex electromagnetic transformer system with a solid-state DC power supply system. Instead of maintaining large electromagnetic transformers and liquid cooling systems, the invention uses electronic current regulation with semiconductor switches, substituting mechanical/electromagnetic components with solid-state electronics that have no moving parts and require minimal maintenance
4Power
If high current at low voltage is achieved through transformer, then sufficient welding power is obtained, but the transformer only works with alternating current requiring rectification
Solution Approach 1:
The patent removes the AC-to-DC conversion stage (rectifier diodes and associated circuitry) from the system. By using a DC power supply that directly outputs controllable current, the invention extracts out the unnecessary conversion step, simplifying the system while maintaining the ability to deliver high current at low voltage for welding
Solution Approach 2:
The patent replaces the AC-to-DC rectification system with a DC power supply system. Instead of converting AC to DC through diode bridges and filtering circuits, the system uses electronic current control with MOSFETs or IGBTs to directly regulate DC output, substituting complex conversion circuitry with efficient solid-state current control
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
This approach eliminates inefficiencies, enables consistent welds, reduces maintenance needs, and allows for portable and reliable welding operations with precise control over welding parameters.
Implementation Method 1
electrical resistance welding
Implementation Method 2
A welding system that utilizes a bank of supercapacitors
Data Source
AI summary
Components of an electrical resistance welding system include a DC power supply, an energy storage assembly, a switch, and an electrical resistance welding assembly configured to weld a work piece. The system may be free of any transformer which permits the system to operate in an infinite number of variable voltages between a minimum and maximum system setting. The variable voltage control permits greater operability of the electrical resistance welding system by creating a specific weld voltage dependent on parameter, such as a dimension, of the work piece that is to be welded.