Switched-Mode Power Supply Mode Selection via Rotary Encoder
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Solution Overview
Problem
Conventional engine-driven welding power sources require separate switches for selecting weld processes and battery charge modes, complicating operation and increasing user effort.
Innovation Solution
A single input device, such as a rotary switch or rotary encoder, is used to select between welding processes and battery charging modes, with control circuitry automatically determining battery type, voltage, and charging mode, and visible indicators providing feedback on selected modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate switches are used for selecting weld processes and battery charge modes, then each function can be controlled independently, but the device complexity and user effort increase
Solution Approach 1:
The patent combines multiple control functions (weld process selection and battery charge mode selection) into a single rotary switch with multiple positions. Each position of the rotary switch corresponds to a specific function mode, allowing the operator to select between welding processes and battery charging modes using one unified control device rather than separate switches for each function.
Solution Approach 2:
The rotary switch is designed as a universal control device that performs multiple functions: selecting different welding processes (SMAW, GMAW, GTAW, etc.) and different battery charging modes (12V/24V charging, jump starting). This multi-functional input device replaces what would traditionally require multiple separate switches, simplifying the control interface while maintaining full operational capability.
2Adaptability or versatility
If multiple toggle switches are used for selecting battery charge modes, then specific charging parameters can be controlled, but the ease of operation deteriorates
Solution Approach 1:
The patent merges the selection of battery voltage (12V/24V) and charging mode (charging/jump starting) into a single rotary switch interface. Instead of requiring operators to manipulate multiple toggle switches in sequence, the rotary switch provides a unified selection mechanism where all charging parameters can be configured through one rotational movement to a single position.
3Reliability
If separate controls are used for weld process selection and battery charging, then each function can be optimized independently, but the operational complexity increases
Solution Approach 1:
The rotary switch serves as a universal control interface that maintains precise control over different functions through its multiple positions. Each position is dedicated to a specific function (e.g., SMAW, GMAW, GTAW, battery charging, jump starting), ensuring that the control precision for each function is preserved while presenting a simplified single-device interface to the operator.
Data Source
AI summary
Methods and apparatus to control an output of a switched-mode power supply in a service pack are disclosed. An example power system includes: an engine; a generator configured to generate electrical power from mechanical power delivered by the engine; a switched-mode power supply, comprising an inverter, configured to convert the electrical power from the generator to output power, the output power comprising at least one of welding-type power or battery charging power; a user input device configured to receive an input selecting at least one of a first mode representative of a first welding-type process or a second mode representative of a first battery charging mode; and control circuitry configured to: when the first mode is selected, control the switched-mode power supply to output welding-type power; and when the second mode is selected, control the switched-mode power supply to output battery charging power.