Ultracapacitor Stud Welder for Steady Drawn Arc Power
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Solution Overview
Problem
Existing stud welding systems, particularly capacitive discharge systems, are unsuitable for producing full-strength welds required in structural applications due to abrupt power draws, leading to voltage regulation issues and high costs. Additionally, prior art systems are heavy and challenging to transport.
Innovation Solution
A drawn arc stud welding system that includes a charging circuit, an energy storage device, and a discharge circuit, configured to manage power steadily rather than in abrupt pulses. This system utilizes ultracapacitors to reduce weight and improve energy density, allowing for more efficient power management and reduced system weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If capacitive discharge systems are used for stud welding, then the welding process can be completed, but the weld strength is insufficient for structural applications
Solution Approach 1:
The patent changes the electrical parameters from capacitive discharge (high voltage, low current, short duration) to drawn arc welding (lower voltage, high current, longer duration). This parameter transformation enables full-strength welds suitable for structural applications by maintaining arc stability for the required weld duration while delivering sufficient thermal energy.
2Strength
If drawn arc stud welding systems with high current output are used, then full-strength welds can be produced, but the power draw is abrupt and causes voltage regulation issues
Solution Approach 1:
The system performs preliminary action by pre-charging ultracapacitors during a charging phase before the welding operation. This stored energy is then discharged during the welding process, providing the high current needed for full-strength welds without requiring the AC power supply to deliver abrupt high power draws, thus maintaining voltage regulation stability.
3Power
If traditional transformer-rectifier technology is used for drawn arc welding, then the required power output can be achieved, but the system weight increases significantly
Solution Approach 1:
The patent substitutes traditional transformer-rectifier technology with ultracapacitor-based energy storage and discharge circuitry. This replacement eliminates heavy iron and copper components while maintaining the capability to deliver 2000-2500 amps DC welding output current, reducing system weight by more than 50% to 400-450 lbs.
4Adaptability or versatility
If generator-powered drawn arc welding systems are used, then mobile welding capability is achieved, but the generator must be oversized to handle abrupt load changes
Solution Approach 1:
The ultracapacitors perform preliminary energy storage during a charging phase, accumulating the energy needed for the welding operation. During welding, this stored energy is discharged to provide the high current demand, allowing the generator to be sized for average power consumption rather than peak power draw, thus reducing generator size and diesel fuel operating costs.
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 achieves improved power management by drawing steady power, reducing the need for oversized generators and minimizing weight, thus enhancing efficiency and reducing costs while enabling the production of full-strength welds suitable for structural applications.
Implementation Method 1
an energy storage device operatively connected to the charging circuit and configured to (i) receive a charging current; and (ii) store a first amount(s) of energy
Implementation Method 2
The discharge circuit may be operatively connected to the energy storage device and be configured to (i) receive an output current from the energy storage device; and (ii) communicate a discharge current to a drawn arc stud welding tool
Implementation Method 3
the energy storage device is discharged to create an arc between a stud that is connected to the weld stud gun and the workpiece, thereby heating up the stud and the workpiece
Data Source
AI summary
Devices and systems are disclosed herein for drawn arc stud welding. These systems and devices allow welding operations while reducing the peak power draw of the input source, and include a charging circuit, an energy storage device comprising a plurality of low ESR ultracapacitors, and a discharge circuit.