Supercapacitor Welding Power Assembly Without Transformer Losses

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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 the need for transformers or DC rectifier diodes, allowing for precise control of welding voltage and current based on the workpiece dimensions.

Engineering Contradictions & Design Principles

VSEngineering 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 and rectifier diodes

Engineering Contradiction:

Improveinductive losses in transformer and rectifier diodesVSAvoidtransformer and rectifier diode components

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent removes the transformer and rectifier diode components from the welding system, replacing them with a capacitor bank that directly stores and discharges DC electrical energy. This extraction of problematic components eliminates the source of inductive and resistive losses while simplifying the overall system architecture.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the mechanical/electromagnetic transformation system (transformer with moving magnetic fields) with an electrical energy storage system (capacitor bank). This replacement eliminates inductive losses associated with magnetic field transformation and rectifier diode resistive losses, achieving more efficient energy delivery to the welding electrodes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If high welding current is achieved through transformer-based systems, then welding power is sufficient, but the system becomes less portable and requires complex cooling infrastructure

Engineering Contradiction:

Improvewelding current and power outputVSAvoidsystem portability

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The patent extracts the heavy transformer and associated cooling infrastructure from the system, replacing them with a compact capacitor bank. This removal of bulky components significantly improves system portability while maintaining the ability to deliver high welding currents when needed.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The capacitor bank charges during non-welding periods and discharges rapidly during welding operations. This periodic charge-discharge cycle allows the system to deliver high power output only when needed, reducing the need for continuous heavy-duty cooling infrastructure and improving overall system portability.

Inventive Principle:

Principle #19Periodic action

3Loss of energy

If AC welding with transformers is used, then welding can be performed, but the current must be rectified through diodes causing additional energy loss

Engineering Contradiction:

Improveresistive losses in rectifier diodesVSAvoidwelding current control

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

Instead of converting AC to DC through rectifier diodes (the traditional approach), the patent inverts the approach by directly storing DC energy in the capacitor bank and then discharging it during welding. This eliminates the need for rectifier diodes and their associated resistive losses while maintaining precise control over the welding current.

Inventive Principle:

Principle #13The other way round (Inversion)

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 system achieves consistent and efficient welding with reduced energy loss, simplified maintenance, and improved portability by eliminating transformers and rectifiers, enabling precise control over welding parameters.

Implementation Method 1

an energy storage assembly comprising at least one supercapacitor

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

electrical resistance welding assembly that receives direct current from the direct current power supply via the energy storage assembly

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250339915A1Energy storage assembly for resistance welding

Publication Date: 2025.11.06 CLIFFORD GROUP FZCO

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.