Welding Power Input Control to Prevent Source Overload

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Solution Overview

Problem

Conventional welding systems rely on operator knowledge to select power settings, often leading to excessive power demand from the power source, resulting in issues like tripped breakers or overloads, as operators may not be aware of the power source's capabilities.

Innovation Solution

A welding power system that monitors and adjusts power input to prevent exceeding the power source's limits by comparing supply power components to predetermined thresholds, dynamically controlling output power and limiting current or power to prevent overloads, and presenting only available welding parameters to the operator through a user interface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If operator selects high power settings for welding, then welding quality and productivity improve, but power source overload and breaker tripping occur

Engineering Contradiction:

Improvewelding speedVSAvoidpower source stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary assessment of power source capabilities before welding begins. The controller pre-calculates the maximum available power from the power source and uses this information to constrain the welding parameters that can be selected, preventing operators from choosing settings that would cause overload.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the available welding parameters based on real-time power source conditions. The controller continuously monitors power source status and updates the set of allowable welding parameters accordingly, enabling the system to adapt to changing power availability during operation.

Inventive Principle:

Principle #15Dynamics

2Power

If operator increases power demand, then welding performance improves, but power source and equipment are damaged

Engineering Contradiction:

Improvewelding power outputVSAvoidpower source damage

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The system applies preliminary anti-action by pre-establishing power constraints based on the power source's maximum capacity. Before allowing welding operations, the controller determines the safe power limit and configures the system to prevent any welding parameters from exceeding this limit, thereby preventing harmful overload conditions before they can occur.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The controller continuously monitors the actual power consumption during welding and compares it against the predetermined power source limits. When approaching the threshold, the system provides feedback to adjust welding parameters automatically, ensuring power demand remains within safe operating boundaries.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If system provides all welding parameters, then operator flexibility is maximized, but operator cannot select safe parameters without knowledge

Engineering Contradiction:

Improvewelding parameter optionsVSAvoidparameter selection simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system performs preliminary filtering of welding parameters based on power source capabilities before presenting options to the operator. The controller pre-determines which welding parameters are safe to use given the power source limits and only displays or enables those parameters in the user interface.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The controller acts as an intermediary between the operator's welding requirements and the power source's capabilities. It translates operator welding needs into safe parameter selections by automatically adjusting parameters to remain within power limits while still achieving the desired welding outcome.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4091753A1Systems and methods for control of primary input current in a welding program

Publication Date: 2022.11.23 ILLINOIS TOOL WORKS INC

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AI summary

Disclosed example welding power systems and methods monitor supply power inputs from a primary power source (108). The supply power is compared to current and/or power threshold values corresponding to limits associated with the primary power source. If the supply power exceeds a threshold value associated with the limits, the welding power system controls welding parameters or devices to adjust a supply power demand, thereby ensuring the draw on supply power does not exceed the capabilities of the power source. In some examples, the disclosed welding power system (102) presents a subset of welding parameters identified as available for operation based on the capabilities of the power source. The user interface (114) displays only the subset of available welding parameters to an operator for selection, thereby ensuring the draw on supply power does not exceed the capabilities of the power source.