Welding Power Bus for Auxiliary Tool Power Distribution
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Solution Overview
Problem
Welding systems face challenges in providing convenient power and control functionalities, especially when operating at a considerable distance from the welding power source, requiring frequent manual adjustments and separate cabling for different devices, which can be cumbersome and inefficient.
Innovation Solution
A welding power supply system with control and power conversion circuitry that adapts output power for various devices, allowing multiple devices to be connected via a welding power bus, eliminating the need for separate cabling and enabling power distribution to both welding and non-welding tools directly from the welding cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If auxiliary outlets are located on the welding power source, then power can be provided to auxiliary devices, but the user must stop welding and return to the power source to plug in devices, which is time-consuming and inconvenient
Solution Approach 1:
The system divides the power distribution function by placing auxiliary power outlets at both the welding power source and the welding cable, allowing power access at multiple locations rather than requiring all devices to be connected at the source location
Solution Approach 2:
The welding cable acts as an intermediary power distribution point, receiving power from the welding power source and providing it to auxiliary devices through integrated outlets, eliminating the need for devices to be connected directly at the power source location
2Ease of operation
If separate extension cords or cables are run for auxiliary devices, then power can be provided to devices, but the system complexity and cabling requirements increase
Solution Approach 1:
The system merges the welding power cable with auxiliary power distribution functionality by integrating auxiliary outlets directly into the welding cable assembly, combining multiple functions (welding power transmission and auxiliary device power supply) into a single integrated system
Solution Approach 2:
The welding cable is designed to serve multiple functions: transmitting welding power to the welding torch and simultaneously providing power to auxiliary devices through integrated outlets, making the cable a universal power distribution medium
3Adaptability or versatility
If different welding cables or components are connected to the source for different processes, then various welding processes can be supported, but the setup time and operational complexity increase
Solution Approach 1:
The welding cable assembly is designed with universal compatibility to support multiple welding processes (stick, MIG, TIG) through a single integrated cable system, with the ability to connect different welding devices to the same cable interface without requiring cable 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
This solution enhances operational efficiency by allowing welding operators to use multiple devices without needing to return to the power source, reducing setup time and improving workflow in complex environments by providing a centralized power solution for a range of tools.
Implementation Method 1
power conversion circuitry configured to convert input power to output welding power
Data Source
AI summary
A system and device operating using a welding power bus are provided. One welding power supply includes control circuitry configured to control the operation of the welding power supply and power conversion circuitry configured to convert input power to output welding power. The welding power supply also includes welding terminals configured to receive the output welding power from the power conversion circuitry and to provide the output welding power to a device that does not use the welding power for a welding operation. The control circuitry is configured to adapt the output welding power to the device.