Integrated Torch Power Unit for High Density Plasma Cutting
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Solution Overview
Problem
Portable plasma cutting systems face challenges in achieving high power output while maintaining portability, due to low switching frequencies and low power densities, which result in increased weight, size, and cost from externally mounted components.
Innovation Solution
A torch power unit with integrated power electronics and a compressor, utilizing high-frequency power converters and transformers like planar or foil-wound transformers mounted on a single circuit board to achieve high power densities of at least 2 watts per cubic inch and 80 watts per pound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If externally mounted components are used in power converters, then device assembly is simplified, but power density and switching frequency remain low
Solution Approach 1:
The patent merges multiple previously externally mounted components (power converters, control electronics, and other devices) into a single integrated circuit board. This consolidation increases power density by concentrating functional elements in a smaller volume while maintaining manufacturing simplicity through modular board-level integration.
Solution Approach 2:
The patent transitions from three-dimensional externally mounted component arrangement to a two-dimensional planar integration on a circuit board. This dimensional change enables higher component density and improved power concentration while simplifying assembly processes through standardized board mounting techniques.
2Device complexity
If externally mounted components are used in power converters, then device complexity is reduced, but weight and size increase
Solution Approach 1:
The patent combines multiple discrete components into a single integrated circuit board assembly, reducing the overall number of separate parts. This merger decreases total system weight by eliminating redundant mounting structures, connectors, and housing requirements while maintaining functional complexity through integrated circuit design.
3Ease of manufacture
If externally mounted components are used in power converters, then manufacturing cost is reduced, but power output density decreases
Solution Approach 1:
The patent employs planar integration of power converter components on a circuit board, transitioning from volumetric external mounting to surface-level integration. This dimensional approach increases power output density by maximizing power delivery within the board's surface area while maintaining cost-effectiveness through standardized PCB manufacturing processes.
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 solution enables a portable plasma cutting system with high power density, improving portability, reliability, and reducing weight and cost, while maintaining high performance.
Implementation Method 1
an electrical arc converts a gas (e.g., compressed air) into plasma, which is sufficiently hot to melt the work piece
Implementation Method 2
the power converter comprises a planar transformer, a foil wound transformer, or a combination thereof
Data Source
AI summary
Systems and methods are provided for a torch power system having a high power density. In one embodiment, a system is provided that includes a torch power unit having a compressor and power electronics that include one or more power converters, wherein the torch power unit has a power output density of at least 2 watts per cubic inch, 80 watts per pound, or a combination thereof. A power conversion assembly for a torch power unit is provided that includes a single circuit board, a torch power converter mounted on the single circuit board, and a non-torch power converter mounted on the single circuit board. An electrical torch system is also provided that includes a circuit board and a power converter coupled to the circuit board, wherein the power converter includes a planar transformer, a foil wound transformer, or a combination thereof.