Portable Welding Arrangement with Mode-Adaptive Charge Controller
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Solution Overview
Problem
Existing portable welding apparatuses can only operate on battery power and require charging after use, lacking a hybrid mode that allows simultaneous connection to a power supply network for charging during operation, which is essential for difficult-to-access locations or where direct electricity is inadmissible.
Innovation Solution
A portable welding arrangement with a charger and charge controller that adapts charging based on the operating mode, switching between standby and welding modes, and utilizing a communication link between the welding control unit and charge controller to optimize battery charging according to the mode and type of battery, ensuring efficient charging and maximum performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the portable welding apparatus operates exclusively on battery power, then it can be used in difficult-to-access locations and where direct electricity is inadmissible, but it requires charging after each use and has limited operating duration
Solution Approach 1:
The system dynamically switches between battery-powered operation and grid-connected operation based on availability. The welding apparatus can operate in three modes: battery-only mode for portability, grid-connected mode for extended operation, and hybrid mode where the battery serves as a buffer during grid connection, optimizing both portability and operating duration.
Solution Approach 2:
The welding apparatus is designed with multi-functionality to operate in multiple power supply modes. It can function as a purely portable device using only battery power, or it can connect to the power supply network to extend operating duration. The battery serves dual purposes: as the primary power source for portability and as a buffer or backup when connected to the grid.
2Device complexity
If the battery is charged at a constant rate regardless of operating mode, then the charging process is simple, but it does not optimize battery life or charging efficiency during welding operations
Solution Approach 1:
The charge controller continuously monitors the operating mode of the welding apparatus and adjusts the charging current accordingly. When the apparatus is in welding mode (high current consumption), the controller provides maximum charging current to quickly replenish battery charge. When in standby mode (low current consumption), the controller reduces charging current to prevent overcharging and extend battery life. This feedback-based dynamic adjustment optimizes both charging efficiency and battery reliability.
Solution Approach 2:
The charging parameters (current, voltage) are dynamically changed based on the operating mode. The charge controller adjusts these parameters in real-time: using higher charging currents during welding operations when the battery is heavily discharged, and lower currents during standby periods when the battery is already charged, thereby optimizing charging efficiency and protecting battery health.
3Duration of action of moving object
If the welding apparatus connects to the power supply network during welding operations, then operating duration is extended, but the system complexity increases with additional connection requirements
Solution Approach 1:
The power supply network connection serves multiple functions simultaneously: it provides extended operating duration by supplementing battery power, and it acts as a charging source to replenish the battery during welding operations. This multi-functional approach extends operating duration without proportionally increasing system complexity, as the same connection pathway is used for both power supply and battery charging.
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
Enables both grid-connected and off-grid operation, optimizing battery charging based on operating mode and type, reducing charging time, conserving battery life, and supporting high performance in welding mode.
Implementation Method 1
a portable welding arrangement comprising a welding apparatus (2) having a storage battery (3), a power source (4), a welding control unit (5)
Implementation Method 2
a charger (17) that can be connected to a power supply network (21) and to the welding apparatus (2) and has a charge controller (20) for charging the storage battery (3)
Implementation Method 3
in the welding mode the welding process is carried out, which means that there is an arc burning between the welding torch and the work piece
Data Source
AI summary
A portable welding arrangement includes a welding apparatus having a storage battery, a power source, a welding control means and a connection for a welding torch. The operating mode of the welding apparatus can be changed between a standby mode and a welding mode. The portable welding arrangement includes a charging apparatus that can be connected to a power supply network and to the welding apparatus and has a charge controller for charging the storage battery. In a method for operating such a portable welding arrangement, for optimum charging of the battery, the charge controller of the charging apparatus is designed to control the charge of the accumulator of the welding apparatus in accordance with the operating mode of the welding apparatus.