Vehicle Welding Power Conversion for Auxiliary Loads

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current welding systems used in vehicles consume significant horsepower, limiting other functions and reducing fuel economy, especially at higher temperatures and elevations, due to the inclusion of belts to drive auxiliary systems, and lack the power density to effectively run high-output hydraulic pumps and HVAC systems.

Innovation Solution

A welding system with power conversion circuitry that receives power from a vehicle's first power source and generates different output powers, allowing switching between welding mode and a ranged output mode to power auxiliary systems, including high-voltage storage batteries above 30 volts, enabling the powering of hydraulic pumps, HVAC systems, and charging lithium-ion batteries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a belt-driven auxiliary system is included in the welding system, then the auxiliary systems can be powered, but significant horsepower is consumed from low horsepower engines

Engineering Contradiction:

Improveauxiliary system power capabilityVSAvoidavailable horsepower

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The patent replaces the mechanical belt-driven system with an electrical power transmission system. The welding system's power conversion circuitry generates electrical power that is transmitted to auxiliary systems through electrical connections, eliminating the need for mechanical belts and associated horsepower losses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The welding system is designed to perform multiple functions: it can generate power for welding operations and simultaneously generate power for auxiliary systems through its power conversion circuitry. This multi-functionality allows a single system to serve both welding and auxiliary power needs without requiring separate mechanical drive systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If belt-driven auxiliary systems are used, then auxiliary functions are provided, but fuel economy is reduced

Engineering Contradiction:

Improveauxiliary system operationVSAvoidfuel consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The electrical power transmission system replaces the mechanical belt-driven system, eliminating the need for the engine to mechanically drive auxiliary systems. This substitution reduces the engine's workload and improves fuel economy while still providing power to auxiliary systems through electrical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Speed

If welding systems operate at higher ambient temperatures and elevations, then vehicle mobility is maintained, but output power capability is reduced

Engineering Contradiction:

Improvevehicle mobilityVSAvoidoutput power capability

Core Design Contradiction:

SpeedVSPower

Solution Approach 1:

The patent utilizes the welding system's ability to control electrical wave form and voltage/amperage parameters to compensate for environmental conditions. The power conversion circuitry can adjust electrical output parameters to maintain adequate power levels for auxiliary systems even when engine output is reduced due to high temperature or elevation conditions.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If current charging methods are used for 12V battery systems, then battery charging is provided, but power density is insufficient for high-output auxiliary equipment

Engineering Contradiction:

Improvebattery charging capabilityVSAvoidpower density

Core Design Contradiction:

Ease of operationVSPower

Solution Approach 1:

The patent changes the voltage parameter by generating higher voltage output (above 30 volts, preferably above 48 volts) from the welding system's power conversion circuitry. This higher voltage provides the necessary power density to effectively run high-output hydraulic pumps, HVAC systems, and other auxiliary equipment that exceed the capabilities of conventional 12V charging systems.

Inventive Principle:

Principle #35Parameter changes

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 supplies power to auxiliary systems, increasing vehicle functionality and reducing horsepower consumption, while maintaining the ability to perform welding operations, and enhances battery charging capabilities for high-voltage systems.

Implementation Method 1

power conversion circuitry that receives power from at least a first power source on the vehicle and generates different output powers of the welding system characterized by different output voltages

Methodology Applied

Scientific EffectPower conversion: Electromagnetic Induction

Data Source

PatentUS20240009750A1Methods and systems for powering and/or charging auxiliary systems on vehicles

Publication Date: 2024.01.11 VANAIR MANUFACTURING INC

AI summary

Methods and systems for powering and/or charging auxiliary systems of a vehicle. Such methods and systems utilize a welding system having power conversion circuitry that receives power from at least a first power source on the vehicle and generates different output powers of the welding system characterized by different output voltages. At least two different auxiliary systems receive at least two of the different output powers of the welding system.