Portable Welding Power Priority Control Under Engine Load Limits

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Solution Overview

Problem

Welding systems face challenges in efficiently managing power distribution to multiple loads, such as welding generators and air compressors, leading to potential overload conditions and decreased system performance due to limited engine power capacity.

Innovation Solution

A portable welding system with a priority load controller that adjusts power distribution among the engine, generator, and compressor based on a priority control scheme, using a governor and power regulators to manage engine speed and load engagement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple devices (generator, compressor, welding equipment) are added to provide diverse outputs, then system versatility is improved, but engine power capacity becomes insufficient leading to overload conditions

Engineering Contradiction:

Improvesystem versatilityVSAvoidengine power capacity

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The system dynamically adjusts engine speed and load distribution based on real-time power availability and load priority. The controller continuously monitors engine power capacity and redistributes power to multiple devices according to predetermined priorities, allowing the system to adapt to varying power demands without overload

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters by adjusting engine speed and power allocation to different devices. When power capacity is exceeded, the controller modifies the power distribution parameters among devices based on priority levels, enabling the system to operate within engine capacity limits while maintaining versatility

Inventive Principle:

Principle #35Parameter changes

2Power

If the engine operates at high power output to satisfy multiple devices, then power availability is improved, but system efficiency decreases due to excessive fuel consumption

Engineering Contradiction:

Improvepower availabilityVSAvoidfuel consumption

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The controller periodically monitors engine power output and load demands, adjusting power distribution in cycles. This periodic control allows the engine to operate at optimal efficiency points while still meeting power demands through timely adjustments in load allocation

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system optimizes fuel efficiency by dynamically changing engine operating parameters such as speed and load. The controller adjusts these parameters to keep the engine operating in its most efficient range while maintaining adequate power availability through intelligent load management

Inventive Principle:

Principle #35Parameter changes

3Power

If the engine speed is increased to provide more power, then power output is improved, but system reliability decreases due to increased wear and overheating

Engineering Contradiction:

Improvepower outputVSAvoidsystem reliability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The system incorporates feedback mechanisms that monitor engine temperature, speed, and load conditions. Based on this feedback, the controller adjusts power output and load distribution to prevent overheating and excessive wear, maintaining reliability while providing adequate power output

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts engine operating conditions based on real-time monitoring of temperature and wear indicators. This dynamic control allows the engine to operate at higher power levels when conditions permit while automatically reducing load when approaching thermal or wear limits, thus maintaining reliability

Inventive Principle:

Principle #15Dynamics

4Power

If power is reduced to lower-priority devices to prevent overload, then engine overload is prevented, but device performance deteriorates

Engineering Contradiction:

Improveengine overload preventionVSAvoiddevice performance

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The system segments the total power demand into priority levels for different devices. By dividing loads into high, medium, and low priority categories, the controller can selectively reduce power to lower-priority devices while maintaining full power to critical equipment, preventing overload while minimizing impact on overall productivity

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12551962B2Engine-driven air compressor/generator load priority control system and method

Publication Date: 2026.02.17 ILLINOIS TOOL WORKS INC

AI summary

A system, in one embodiment, may include a portable unit having an engine, a generator coupled to the engine, a compressor coupled to the engine, and a priority load controller. The controller may be configured to adjust various loads on the engine, the generator, or the compressor, or a combination thereof, in response to a priority control scheme. A computer-implemented method, in another embodiment, may include adjusting power output to various loads on an engine, a welding generator coupled to the engine, or an air compressor coupled to the engine, or a combination thereof, in a portable welding unit in response to a priority control scheme.