Hybrid Welder Battery Assist for AC Threshold Overload
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Solution Overview
Problem
Existing welders often face inefficiencies in power management when using both AC and DC power sources, leading to potential overloads and inefficiencies in power distribution, especially when AC power exceeds predefined thresholds.
Innovation Solution
A hybrid welder system that includes an electronic controller to manage power distribution by supplementing AC power with a removable battery pack when AC power exceeds predefined thresholds, using a battery pack interface and an AC power input, and providing alerts or switching to battery power alone in case of AC failure, with features like current limit settings and power sharing modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If AC power is used to power the welding circuit, then the welder can operate with external power source, but the system may experience overloads when AC power exceeds predefined thresholds
Solution Approach 1:
The electronic controller acts as an intermediary between the AC power source and the welding circuit. It monitors AC power input and determines when to supplement with battery pack power based on predefined thresholds, preventing direct overload of the welding circuit while maintaining operational capability.
Solution Approach 2:
The system dynamically adjusts power distribution by switching between AC-only mode, hybrid mode (AC + battery), and battery-only mode based on real-time AC power levels. This dynamic adaptation allows the system to maintain reliability while utilizing available power sources optimally.
2Power
If the welder uses both AC and DC power sources simultaneously, then power availability is improved, but power management complexity increases
Solution Approach 1:
The electronic controller automatically manages power distribution between AC and DC sources without requiring manual intervention. It autonomously determines when to supplement AC power with battery pack power, when to switch sources, and how to allocate power based on load requirements, simplifying operation despite the dual-power-source complexity.
Solution Approach 2:
The system continuously monitors AC power input levels and provides feedback to the electronic controller, which adjusts power distribution accordingly. This feedback mechanism enables automatic adaptation to changing power conditions, managing complexity through intelligent control rather than manual configuration.
3Reliability
If the system supplements AC power with battery pack power, then power threshold overloads are prevented, but energy consumption from battery increases
Solution Approach 1:
The system applies partial battery power supplementation rather than full battery operation. The electronic controller provides just enough battery pack power to bridge the gap between AC power output and the power threshold required for welding operations, minimizing battery energy consumption while ensuring threshold compliance.
Solution Approach 2:
The system changes operational parameters dynamically by adjusting the proportion of power drawn from each source based on AC power availability. When AC power is sufficient, battery consumption is minimized; when AC power drops below thresholds, battery contribution increases automatically to maintain reliable operation.
Data Source
AI summary
A device may include a housing, a battery pack interface and an alternating current (“AC”) power input configured to receive power from an AC power source, a battery pack interface configured to receive a removable battery pack, a welding circuit configured to provide power to a welding electrode using the AC power input, and a user interface including a plurality of predefined power thresholds. A device may include an electronic controller configured to receive power from the AC power source, receive a selection of one of the plurality of predefined power thresholds, determine whether the power from the AC power source exceeds the selected one of the plurality of predefined power threshold, and supplement the power provided to the welding circuit with power from the removable battery pack in response to the power exceeding the selected one of the plurality of predefined threshold.