Switchable Transformer Windings for Portable Welding and Cutting
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Solution Overview
Problem
Existing multi-process welding and cutting machines struggle to efficiently and economically support both welding and cutting processes in a single, portable machine, as they often require different power configurations and voltage/current ranges for each process, making it challenging to design a machine that is both versatile and lightweight.
Innovation Solution
A multi-process welding machine is designed with a main transformer and output diodes capable of handling high and low current, and high and low voltage, using switch configurations to alter the winding arrangements for either welding or cutting modes, allowing for efficient power delivery across a range of processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single machine supports both welding and cutting processes, then versatility is improved, but device complexity increases
Solution Approach 1:
The patent implements a single welding machine that can perform multiple processes including welding, cutting, and gouging by using a universal power supply system with switchable configurations. The main transformer and power board can be reconfigured through switching mechanisms to provide appropriate power characteristics for different processes, eliminating the need for separate dedicated machines for each process.
Solution Approach 2:
The patent employs dynamic reconfiguration of the power supply circuitry through switches that can change the electrical connections in real-time. The switching mechanism allows the system to dynamically alter its output characteristics (voltage, current, power level) depending on which process is being performed, enabling a single static physical system to adapt to multiple operational requirements.
2Weight of moving object
If the machine is designed to be portable and lightweight, then ease of transport is improved, but power delivery capability for both welding and cutting deteriorates
Solution Approach 1:
The patent combines the power supply systems for welding and cutting into a single integrated unit with a shared main transformer and power board. By merging these previously separate systems, the overall weight is reduced while still maintaining the capability to deliver appropriate power levels for both processes through intelligent switching and control of the shared components.
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 machine effectively provides the necessary power for both welding and cutting processes, ensuring efficient operation and portability by utilizing a single transformer and diodes to manage voltage and current requirements, enabling seamless transitions between welding and cutting modes.
Implementation Method 1
a main transformer having first primary winding, a second primary winding, and a secondary winding
Implementation Method 2
a switch having an input connected to an output of the power board and outputs connected to the first primary winding of the main transformer and to the second primary winding of the main transformer
Implementation Method 3
a power board configured to receive mains power and to convert the mains power to converted power to be input to the main transformer
Data Source
AI summary
A welding machine includes a main transformer having first primary winding, a second primary winding, and a secondary winding; a power board configured to receiving mains power and to convert the mains power to converted power to be input to the main transformer; a switch having an input connected to an output of the power board, a first output connected to the first primary winding of the main transformer, and a second output connected to the second primary winding of the main transformer; and a control board configured to control the switch to be arranged in one of (i) a first configuration in which the converted power is supplied, in series, to a first primary winding of a main transformer switching and a second primary winding of the main transformer, and (ii) a second configuration in which the converted power is supplied, in parallel, to the first primary winding of the main transformer and to the second primary winding of the main transformer.