Welding Power Source Layout for EMI-Resistant Human-Machine Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Temporary malfunctions in human-machine interface devices of welding power sources occur due to electromagnetic fields generated during welding, leading to susceptibility to errors.
Innovation Solution
A welding power source design featuring a metallic housing that separates the welding process computing unit and human-machine computing unit with a communication connection, such as a CAN bus, and uses optocouplers or inductive couplers for galvanic separation, along with a human-machine interface device connected externally to the housing, forming a computer network for enhanced robustness and error reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the human-machine interface device is integrated inside the housing with the welding process computing unit, then the device structure is simpler and more compact, but the electromagnetic fields generated during welding cause human-machine interface functions to malfunction
Solution Approach 1:
The system is divided into two separate computing units: the welding process computing unit housed inside the metallic housing, and the human-machine computing unit mounted externally. This segmentation physically separates the electromagnetic field generation source from the sensitive interface processing, eliminating interference while maintaining functional integration through network communication.
Solution Approach 2:
A communication connection (fieldbus or Ethernet) acts as an intermediary between the welding process computing unit and the human-machine computing unit. This mediator transmits control signals and data between the two units without requiring direct physical integration, allowing the interface device to remain externally mounted while maintaining system coherence.
2Reliability
If the human-machine interface device is placed outside the housing, then electromagnetic interference is reduced, but the connection between the interface device and the welding process computing unit becomes more complex
Solution Approach 1:
The communication connection serves as an intermediary that simplifies the external connection architecture. By using standardized fieldbus or Ethernet protocols, the patent creates a reliable, interference-resistant communication path between the external human-machine computing unit and the internal welding process computing unit, avoiding complex direct wiring while maintaining signal integrity.
Solution Approach 2:
The patent replaces direct mechanical/electrical connections with optical or electromagnetic communication (fieldbus/Ethernet). This substitution eliminates galvanic loops and direct electrical pathways that would be susceptible to electromagnetic interference, while providing robust communication between the externally mounted interface device and the welding control system.
3Reliability
If a separate human-machine computing unit is added outside the housing, then susceptibility to electromagnetic errors is reduced, but the number of components and network connections increases
Solution Approach 1:
The computing functions are segmented into two specialized units: the welding process computing unit handles arc control and welding parameters, while the external human-machine computing unit handles user interaction and display. This functional segmentation places the sensitive interface functions outside the electromagnetic field environment, reducing error susceptibility despite increasing component count.
Solution Approach 2:
The network communication infrastructure acts as an intermediary that manages the increased complexity. By using standardized communication protocols and a structured network architecture, the system efficiently coordinates between the two computing units, making the added complexity manageable while achieving the reliability benefit of physical separation.
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 configuration significantly reduces the susceptibility to errors and enhances the robustness of the welding power source by shielding the human-machine interface from electromagnetic interference, ensuring reliable operation.
Implementation Method 1
the electromagnetic fields generated during welding cause human-machine interface functions to malfunction... the housing made of metallic material... as a partition between the welding process computing unit/welding inverter and the human-machine computing unit/human-machine interface device
Implementation Method 2
the human-machine processing unit and the welding process processing unit are galvanically isolated from each other by means of one or more optocouplers or inductive couplers
Implementation Method 3
the human-machine processing unit and the welding process processing unit are galvanically isolated from each other by means of one or more optocouplers or inductive couplers
Data Source
Figure 1~2
AI summary
Welding power source (1) comprising a housing (10) made of metallic material, a welding inverter (50), a digital electronic welding process control unit (20) and a human-machine interface device (30), wherein the welding process control unit (20) is configured to control the welding inverter (50), wherein the welding process control unit (20) and the welding inverter (50) are arranged in the housing (10) and the human-machine interface device (30) is attached to the welding power source (1) outside the housing (10), wherein the welding power source (1) additionally comprises a digital electronic human-machine control unit (40) which is attached to the welding power source (1) outside the housing (10), and wherein the human-machine interface device (30) is connected to the human-machine control unit (40),and wherein the human-machine computing unit (40) and the welding process computing unit (20) are interconnected via a communication link (60) and form a computer network.