Power Transmission System for Welding Data Communication
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Solution Overview
Problem
Conventional welding systems cannot transmit user data between the welding device and the welding torch during the welding process, as data transmission occurs only during intervals when no electric current is being transmitted, preventing real-time parameter setting and feedback.
Innovation Solution
A power transmission system that uses parallel power lines in a power transfer cable to transmit user data signals simultaneously with electrical power, employing user data modems and current-compensated chokes to decouple data from the power transfer, allowing bidirectional data communication without interfering with the power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data transmission occurs only during intervals when no electric current is transmitted, then power transmission reliability is maintained, but data transmission real-time capability deteriorates
Solution Approach 1:
The patent segments the power transfer cable into multiple conductor pairs, designating specific pairs (e.g., pairs 2 and 3 in a four-pair cable) exclusively for data transmission while others handle power transmission. This segmentation allows data signals to be transmitted simultaneously with power without interference, resolving the contradiction between maintaining power reliability and achieving real-time data capability.
Solution Approach 2:
The patent introduces communication circuitry including modems and signal processing devices as intermediaries that enable data transmission over the power cable conductors. These intermediaries modulate data signals onto carrier frequencies and handle signal conditioning, allowing reliable simultaneous power and data transmission by mediating between the two functions.
2Loss of time
If user data signal is transmitted via power lines during power transmission, then data communication real-time capability is improved, but signal interference from power current increases
Solution Approach 1:
The patent assigns specific conductor pairs exclusively for data transmission, separating them from power transmission conductors. This physical segmentation isolates data signals from high-current power transmission, minimizing electromagnetic interference while enabling real-time data communication.
Solution Approach 2:
The patent employs communication circuitry that modulates data signals onto higher frequency carriers and uses signal processing techniques to differentiate data signals from power current interference. By changing the frequency parameters and signal characteristics, the system can extract data signals even in the presence of power current.
3Reliability
If separate signal cable is used for data transmission, then data transmission reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges power transmission and data communication functions into a single power transfer cable by utilizing multiple conductor pairs within the same cable assembly. This consolidation eliminates the need for separate signal cables, reducing system complexity while maintaining reliable data transmission through dedicated conductor pairs and communication circuitry.
Solution Approach 2:
The patent makes the power transfer cable multi-functional by enabling it to simultaneously carry both power transmission and data communication functions. Through proper conductor pair assignment and communication circuitry integration, the same cable infrastructure serves dual purposes, reducing overall system complexity.
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 real-time transmission of process parameters and sensor data during welding, enhancing the quality of the welded product and allowing for quick reaction to changes in the welding environment.
Implementation Method 1
a first pole of the power source with a first electrical potential is connected via parallel current lines of a first conductor pair and a second conductor pair of the power transfer cable to a first pole of the power sink
Data Source
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AI summary
The invention relates to a power transmission system (1) for the power transmission of an electrical power (P) from a power source (2a) to a power sink (4A) that is connected to the power source (2A) via a power transfer cable (3), wherein the power source (2A) has a first pole with a first electrical potential, connected to a first pole of the power sink (4A) via parallel power supply lines of a first line pair of the power transfer cable (3), and a second pole with a second electrical potential, connected to a second pole of the power sink (4A) via additional parallel power supply lines of a second line pair of the power transfer cable (3), wherein, during the power transmission via the power supply lines, a user data signal can be transmitted between the power source (2A) and the power sink (4A) via at least one line pair with power supply lines of the same electrical potential, unaffected by the power transmission.