Solid-State Welder Using Battery Power Extraction
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Solution Overview
Problem
Existing field welding systems are cumbersome, unreliable, and costly due to their reliance on heavy and complex portable generators, which are prone to overheating and failure, especially in harsh environments, and often require external power sources, limiting their applicability and safety.
Innovation Solution
A portable and compact welding system powered by industrial-grade batteries, capable of operating in both field and shop environments, utilizing a solid-state high-energy circuit with a feedback loop to generate resonant electromagnetic waves for efficient and reliable welding, independent of traditional power grids, and featuring a scalable design for varying metal thicknesses and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional portable generators are used for field welding, then welding capability is provided, but the system becomes heavy and cumbersome
Solution Approach 1:
The patent extracts the internal combustion engine and generator components from the welding system, eliminating the need for heavy mechanical power generation. Instead, the system uses external power sources (vehicle batteries, utility power) combined with solid-state power conversion electronics to provide welding current, thereby removing the weight burden while maintaining welding capability
Solution Approach 2:
The patent replaces the mechanical system (engine-driven generator) with an electrical system (solid-state power converter). The mechanical energy conversion process is substituted with direct electrical power conversion using IGBTs and power electronics, dramatically reducing system weight while maintaining or improving welding performance
2Ease of operation
If integrated circuits are used to regulate welder output, then welding control is improved, but heating and vibration cause rapid entropy increase and component failure
Solution Approach 1:
The patent employs dynamic control through IGBT (Insulated Gate Bipolar Transistor) switching devices that can rapidly adjust welding current in real-time based on arc conditions and user requirements. This dynamic solid-state switching provides precise welding control while generating less heat than traditional AC regulation methods, improving both ease of operation and component reliability
Solution Approach 2:
The system changes the operating parameters by using DC power with solid-state switching instead of regulated AC power. The IGBTs switch at high frequencies to regulate current, operating in a parameter regime that reduces thermal stress on components compared to traditional AC voltage regulation, thereby improving reliability while maintaining control precision
3Power
If Gen-Set portable welder power sources are used, then welding power is delivered, but the system becomes large and heavy with derated duty cycle
Solution Approach 1:
The patent creates a universal welding power system that can accept multiple power sources (vehicle batteries, utility AC power, alternative power sources) and adapt to different welding applications. The solid-state power converter is designed to handle various input configurations and deliver appropriate welding current, eliminating the need for dedicated heavy generator-welder combinations while maintaining full welding power capability
Solution Approach 2:
The system changes from fixed AC frequency/voltage operation to flexible DC operation with electronic current control. By converting to DC and using solid-state switching, the system achieves higher power density and more efficient power delivery without requiring large transformer and generator components, thereby reducing system size while maintaining or increasing welding power capability
4Power
If internal combustion engine is used to motivate alternator, then power generation is achieved, but noxious exhaust gases are produced and fire hazard increases
Solution Approach 1:
The patent extracts and removes the internal combustion engine component entirely from the welding system. By eliminating the engine, the source of noxious exhaust gases and fire hazards is removed. The system instead relies on external power sources (vehicle electrical systems, utility power) to provide the energy needed for welding, achieving power generation without combustion-related harmful emissions
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 system provides a reliable, efficient, and cost-effective solution for welding in remote locations with a high performance duty cycle, capable of handling diverse metal compositions and conditions, while minimizing waste heat and emissions, and offering simultaneous charging and jump-starting capabilities.
Implementation Method 1
utilizing a solid-state high-energy circuit with a feedback loop to generate resonant electromagnetic waves for efficient and reliable welding
Implementation Method 2
utilizing a solid-state high-energy circuit with a feedback loop to generate resonant electromagnetic waves
Data Source
AI summary
The system provides both a portable and appliance welding system. It can be use in the shop and field. In either location it can be plugged in or battery driven. When plugged in it can weld while charging simultaneously offering 100% duty cycle for heavy shop use, and a full range of metal thicknesses can be welded with ease. The system is implemented with a solid state high energy circuit; unrestricted and unfiltered, offering a wide spectrum of pure analog power. The systems is compact for maximum portability and use in remote field operations, yet can handle deep welds in a variety of metal compositions, conditions, environments, and sizes. The system uses a proven and robust storage medium of direct electric potential energy that is supplied by industrial batteries.