Transformerless Resistance Welding Power Supply With Supercapacitors
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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
Engineering Contradiction Analysis
1Power
If transformers are used in resistance welding systems, then high welding current at low voltage can be achieved, but significant inductive losses occur in the transformer
Solution Approach 1:
The patent removes the transformer from the welding system entirely, replacing it with a capacitor bank and switching circuit. This extraction eliminates the source of inductive losses while maintaining the ability to deliver high current pulses for welding through direct capacitor discharge.
Solution Approach 2:
The patent substitutes the electromagnetic transformer mechanism with an electrostatic capacitor discharge mechanism. The capacitor bank stores energy and releases it directly through the workpiece via electronic switching, replacing the inductive energy transfer method with a more efficient capacitive approach.
2Stability of the object's composition
If DC rectifier diodes are used, then direct current welding can be achieved, but resistive losses occur in the diodes
Solution Approach 1:
The patent removes the rectifier diodes from the system, eliminating the need for AC-to-DC conversion. Instead, the system uses capacitor discharge to provide direct current welding, thereby eliminating the resistive losses that would occur in the diodes.
Solution Approach 2:
The capacitor bank is pre-charged to the required voltage before welding. This preliminary charging action stores the energy needed for welding in advance, allowing direct current to be delivered without passing through lossy rectifier diodes during the actual welding process.
3Power
If transformers and rectifiers are used, then welding power supply can be achieved, but the system becomes complex and requires frequent maintenance
Solution Approach 1:
The patent removes both the transformer and rectifier components from the welding power supply system. This extraction dramatically simplifies the system architecture, leaving only the capacitor bank, switching circuit, and control electronics, thereby reducing maintenance requirements while maintaining welding power capability.
Solution Approach 2:
The capacitor bank serves multiple functions: it stores energy, provides voltage multiplication through series connection of capacitors, and delivers the welding current directly. This multi-functionality eliminates the need for separate transformer and rectifier components, reducing overall system complexity.
4Temperature
If transformers are used, then voltage transformation can be achieved, but cooling fluid must be pumped through the transformer resulting in wasted energy
Solution Approach 1:
The patent removes the transformer from the system, eliminating the need for cooling fluid circulation. By replacing the transformer with a capacitor bank, the system eliminates the thermal management infrastructure entirely, thereby eliminating the energy waste associated with pumping cooling fluid.
Solution Approach 2:
The patent substitutes the electromagnetic transformation process with an electrostatic energy storage and release process. This substitution eliminates the thermal losses inherent in transformer operation, removing the need for active cooling systems and the associated energy consumption.
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 approach simplifies the welding process, reduces energy waste, and ensures consistent weld quality by eliminating the need for transformers and rectifiers, while enabling rapid switching times and efficient energy use.
Implementation Method 1
an energy storage assembly (14) comprising at least one supercapacitor
Implementation Method 2
a switch (16) that switches current from the energy storage device between an off-state and an on-state
Implementation Method 3
an electrical resistance welding assembly (18)... welding a work piece with direct current in the electrical resistance welding assembly
Data Source
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.