Variable-Speed Welding Generator With Battery Peak Power Support
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Solution Overview
Problem
Existing engine-driven welding systems are inefficient due to constant engine speed changes to match dynamic welding loads, leading to energy wastage and inability to provide peak power when needed, especially during hot starts.
Innovation Solution
A welding-type power supply system with a variable speed engine, variable frequency generator, preregulator, and energy storage device, controlled by a module that adjusts engine speed and power output based on feedback from welding and auxiliary operations to optimize energy usage and store excess energy for peak demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the engine runs at constant high speed to provide peak power, then power availability is improved, but energy consumption increases
Solution Approach 1:
The engine speed is made variable rather than constant. The controller dynamically adjusts engine speed based on actual load demands, running at lower speeds during normal operation and only increasing to peak speeds when additional power is required, thereby reducing overall fuel consumption while maintaining peak power availability when needed.
Solution Approach 2:
An energy storage device (battery) is charged in advance during periods of low power demand. This stored energy is then discharged during peak demand periods such as hot starts, allowing the engine to operate at lower speeds overall while still providing peak power when needed, thus reducing fuel consumption.
2Use of energy by moving object
If the engine speed is reduced to save energy, then fuel consumption is improved, but power delivery capability deteriorates
Solution Approach 1:
An energy storage device (battery) is introduced as an intermediary between the engine and the welding load. The battery compensates for the reduced power delivery capability of the slow-running engine by providing additional power during peak demands, allowing the engine to operate efficiently at lower speeds while maintaining adequate power delivery capability.
Solution Approach 2:
The energy storage device is charged in advance during low-demand periods. This preliminary energy storage enables the system to meet peak power demands without requiring the engine to run at high speeds continuously, thus maintaining power delivery capability while reducing fuel consumption.
3Adaptability or versatility
If separate stators are used for welding and auxiliary power, then power output versatility is improved, but device complexity increases
Solution Approach 1:
A single stator is designed to perform multiple functions by providing power for both welding operations and auxiliary loads. The controller intelligently manages the power distribution from this single stator to meet different load requirements, thereby reducing system complexity while maintaining power output versatility through software-based control rather than hardware multiplication.
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 efficiently manages energy by storing excess power and providing it during peak demands, reducing engine speed and fuel consumption, and ensuring consistent power delivery during hot starts without increasing engine RPM.
Implementation Method 1
a variable frequency generator driven by the engine
Implementation Method 2
A welding-type power supply system with a variable speed engine, variable frequency generator, preregulator, and energy storage device
Data Source
AI summary
A method and apparatus for providing welding-type power derives motive power from a variable speed engine and driving a variable frequency generator with the motive power to provide a generator output. The generator output is preregulated to provide an intermediate signal, and the preregulating is controlled at least in response to feedback indicative of the welding-type output power. Welding-type output power is derived from the bus, and controlled at least in response to the welding feedback. Auxiliary output power is also derived from the bus, and controlled at least in response to feedback indicative of the auxiliary output power. The speed of the engine is controlled at least in response to one of the auxiliary feedback and the welding feedback. Energy produced by the engine that is not used as an output is stored by batteries. When the output exceeds the energy generated, the difference is supplied by the batteries.