Welding Power Cord System With Interchangeable Adapters
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Solution Overview
Problem
Conventional welding-type devices require frequent and cumbersome changes of power cords or plugs to accommodate different outlet configurations, leading to potential misconnections, machine malfunctions, and reduced efficiency due to the need for manual adjustment of power settings.
Innovation Solution
A power cord system with a transformer and multiple adapters that allow a welding-type device to connect to various outlet configurations, featuring a power cord with more conductors than prongs, enabling easy switching between different power signals without manual reconfiguration of the device's controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the plug or entire power cord is changed to engage different outlet configurations, then the welding-type device can operate with different power signals, but the process becomes time-consuming and reduces efficiency
Solution Approach 1:
The power cord system is segmented into a main power cord with a common connector and separate interchangeable adapters. Each adapter is designed for a specific outlet configuration (e.g., 115V, 230V, 50A). This segmentation allows the user to quickly swap only the adapter portion rather than the entire power cord, significantly reducing the time required to adapt to different outlet configurations while maintaining full compatibility across various power sources.
Solution Approach 2:
The main power cord is designed with a universal connector that can work with multiple adapter types. The common connector serves multiple functions by interfacing with different adapters designed for various outlet configurations. This multi-functionality allows a single power cord to operate with different power signals and outlet types, eliminating the need for multiple dedicated cords and reducing the time required for changes.
2Adaptability or versatility
If the plug or entire power cord is changed, then different power signals can be engaged, but the complexity of the connection process increases and potential for improper connection rises
Solution Approach 1:
By segmenting the power cord system into a standardized main connector and specialized adapters, the complexity is distributed. The main connector maintains a simple, consistent interface that reduces connection errors, while the adapters handle the variability of different outlet configurations. This segmentation simplifies the overall connection process by providing clear, standardized interfaces at each stage.
Solution Approach 2:
The adapters serve as intermediaries between the universal power cord connector and the various outlet configurations. Each adapter is pre-configured with the correct wiring and connector geometry for its specific outlet type, acting as a mediator that translates between the standardized cord interface and the diverse outlet requirements. This intermediary approach eliminates the need for users to understand or perform complex wiring operations.
3Reliability
If manual adjustment of controls is required to match power source settings, then the welding-type device can be properly configured, but the ease of operation is reduced and efficiency decreases
Solution Approach 1:
The adapter system incorporates self-service functionality through automatic detection or pre-configured settings. When an adapter is connected, the welding-type device automatically detects the adapter type and configures the power settings accordingly, or the adapter itself contains the configuration information. This eliminates the need for manual control adjustments, maintaining proper configuration while significantly improving ease of operation and reducing the time required to switch between different power sources.
Solution Approach 2:
The system implements feedback mechanisms where the welding-type device detects which adapter is connected and automatically adjusts the power settings based on this feedback. The device receives information about the connected adapter type and automatically configures the appropriate voltage and current parameters, ensuring reliable operation without requiring manual intervention from the user.
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 seamless operation of welding-type devices across multiple outlet configurations, reducing the risk of misconnections and improving efficiency by automatically adapting to different power signals, thus ensuring reliable and efficient operation in diverse electrical environments.
Implementation Method 1
a power cord having a first end connected to a transformer of a welding-type device
Data Source
AI summary
A system and method for powering a welding-type device from a plurality of distinct outlet configurations is disclosed. The power cord system includes a power cord having a plurality of conductors extending therethrough. An end of the power cord is constructed to engage an individual adapter of a plurality of adapters. Each of the plurality of adapters has a prong configuration that is different than a prong configuration of the other adapters such that each of the plurality of adapters is constructed to electrically connect the power cord to a uniquely configured outlet. A welding-type device according to the present invention is quickly and efficiently adaptable to operate at a plurality of different input power signals.