Welding Machine Frequency Converter for Electromagnetic Field Minimization
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Solution Overview
Problem
Industrial-type resistance welding machines generate electromagnetic fields that expose welders and others to harmful magnetic fields, with exposure levels varying based on welding circuit dimensions, shape, and current waveform characteristics.
Innovation Solution
An electric welding machine equipped with a frequency converter, control circuit, and welding transformer that adjusts voltage, switching frequency, and pulse duration to minimize electromagnetic field exposure, using an AC/DC converter and DC/AC converter to optimize the waveform of the welding current, reducing frequency components and phase characteristics that contribute to exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional welding machines operate with standard current waveforms, then welding functionality is maintained, but electromagnetic field exposure to human body increases
Solution Approach 1:
The patent applies parameter changes by modifying the welding current waveform characteristics (frequency, amplitude, duty cycle) to minimize electromagnetic field exposure. The control circuit adjusts these parameters dynamically during welding operations, transforming the standard continuous waveform into optimized pulsed waveforms that reduce harmful frequency components while maintaining welding effectiveness.
Solution Approach 2:
The system implements dynamics through the control circuit that continuously monitors and adjusts welding current parameters in real-time. The frequency converter dynamically modifies the current waveform based on welding conditions, transitioning from static standard waveforms to adaptive dynamic waveforms that optimize both safety and performance.
2Object-affected harmful factors
If frequency converter with control circuit is added to optimize current waveform, then electromagnetic field exposure is minimized, but device complexity increases
Solution Approach 1:
The control circuit acts as an intermediary between the power source and welding circuit, mediating the current waveform to eliminate harmful electromagnetic components. This intermediary component processes the raw welding current and transforms it into an optimized waveform, reducing direct exposure without requiring complete system redesign.
Solution Approach 2:
The patent replaces traditional mechanical welding control methods with electronic frequency conversion and digital control. Instead of mechanical switches and analog regulators, the system uses electronic frequency converters and microprocessor-based control circuits to achieve waveform optimization, reducing electromagnetic interference inherent in mechanical systems.
3Object-affected harmful factors
If welding current waveform is optimized to reduce electromagnetic exposure, then health safety is improved, but energy consumption may increase
Solution Approach 1:
The optimized welding current uses periodic pulsed waveforms instead of continuous current. By applying periodic on-off cycles with optimized duty ratios, the system reduces electromagnetic field exposure during the off periods while maintaining welding effectiveness during on periods, thereby reducing overall energy consumption compared to continuous welding current.
Solution Approach 2:
The control circuit maintains continuous useful welding action through optimized pulsed waveforms that prevent interruption of the welding process. The frequency converter ensures continuous adaptation of current parameters to maintain effective welding while minimizing electromagnetic exposure, avoiding energy waste from process interruptions or retries.
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 effectively minimizes human exposure to electromagnetic fields, ensuring safer operating conditions for welders by optimizing the waveform of the welding current, thereby reducing health risks associated with electromagnetic field exposure.
Implementation Method 1
at least one frequency converter (2), powered by the electrical mains (R), and adapted to generate an alternating current (A)
Implementation Method 2
at least one welding transformer (4), functionally connected to the frequency converter (2), and adapted to generate a welding current (S)
Data Source
Figure 1~4
AI summary
An electric welding machine suitable to minimize exposure of the human body to the electromagnetic fields generated by the machine, comprising at least one frequency converter (2), which is powered by the electrical mains (R) and is adapted to generate an alternating current (A), at least one control circuit (3), which is functionally connected to the frequency converter (2), and at least one welding transformer (4), which is functionally connected to the frequency converter (2) and is adapted to generate a welding current (S), the frequency converter (2) comprising at least one input stage (5) constituted by at least one AC/DC converter, at least one bank of capacitors (6) which is functionally connected to the AC/DC converter (5), and at least one output stage (7), which is constituted by at least one DC/AC converter, which is functionally connected to the bank of capacitors (6), the control circuit (3) being adapted to manage the input stage (5) so as to adjust the voltage (V) across the bank of capacitors (6) so as to obtain a waveform of the welding current (S) whose frequency components have amplitude and phase characteristics which minimize human exposure to electromagnetic fields.