Welding Power Source EMI Reduction via Dynamic Mode Switching
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Solution Overview
Problem
Welding power sources face challenges in reducing electromagnetic interference (EMI) and power consumption, as existing power conversion circuitry and supplies continue to operate and incur losses even when not actively used, leading to increased weight, bulk, and complexity when attempting to mitigate EMI with filter boards.
Innovation Solution
The implementation of supervising circuitry that dynamically distributes input power within a welding power source, allowing for modes such as welding, monitoring, and accessory modes, where power conversion circuitry is turned off when not in use, and background power is maintained to control components, reducing EMI and power consumption without the need for filter boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power conversion circuitry and power supplies are kept on continuously to maintain functionality, then reliability and responsiveness are improved, but power consumption and electromagnetic interference increase
Solution Approach 1:
The patent implements dynamic power management by transitioning power conversion circuitry and power supplies between on and off states based on operational demand. The supervising circuitry monitors system state and activates components only when needed, making the power distribution dynamic rather than static, thereby reducing continuous power consumption while maintaining reliability.
Solution Approach 2:
The system employs periodic activation of power conversion circuitry and power supplies based on demand signals from welding operations. Instead of continuous operation, components are activated in periodic cycles aligned with actual usage requirements, reducing overall power consumption while ensuring functionality is available when needed.
2Object-generated harmful factors
If filter boards are added to reduce electromagnetic interference, then electromagnetic interference is reduced, but weight, bulk, and complexity increase
Solution Approach 1:
The patent extracts the source of electromagnetic interference by removing or disabling power conversion circuitry and power supplies when not in use, rather than adding filter boards to mitigate the interference. This approach eliminates the harmful electromagnetic emissions at their source without introducing additional complex filtering components.
Solution Approach 2:
Instead of the conventional approach of adding filtering components to reduce electromagnetic interference, the patent inverts the solution by reducing interference through selective deactivation of power components. This reverse approach achieves EMI reduction without increasing system complexity through additional hardware.
3Loss of energy
If power conversion circuitry is turned off to reduce power consumption and electromagnetic interference, then power consumption and electromagnetic interference are reduced, but responsiveness and functionality may be compromised
Solution Approach 1:
The supervising circuitry monitors system state and anticipates power demands, maintaining readiness to activate power conversion circuitry and power supplies quickly when welding operations are detected. This preliminary monitoring ensures rapid response while allowing components to remain off during idle periods, balancing responsiveness with energy savings.
Solution Approach 2:
The system employs feedback mechanisms where the supervising circuitry continuously monitors for demand signals from welding torches or control systems. When demand is detected, the supervising circuitry immediately activates the appropriate power conversion circuitry and power supplies, ensuring rapid responsiveness while maintaining energy efficiency during non-operational periods.
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 approach effectively reduces electromagnetic interference and power consumption by only activating power conversion circuitry and supplies when needed, minimizing thermal and load stresses on components and maintaining functionality on demand, thereby enhancing the efficiency and usability of welding power sources.
Implementation Method 1
power conversion circuitry configured to receive the input power as a weld input and to convert the weld input into weld power when turned on
Implementation Method 2
The background power supply is configured to convert the input power into background power to provide to control circuitry when turned on
Implementation Method 3
The supervising circuitry is configured to distribute the input power to the plurality of components based at least in part on a mode of the plurality of modes
Data Source
AI summary
A welding power source configured to receive an input power includes a plurality of components and supervising circuitry configurable in a plurality of modes. The plurality of components include power conversion circuitry and background power supply. The supervising circuitry is configured to distribute the input power to the plurality of components based at least in part on a mode of the plurality of modes. The plurality of modes include a welding mode configured to distribute the input power to the power conversion circuitry and to the background power supply. The plurality of modes also include a monitoring mode configured to distribute the input power to the background power supply, and to not distribute the input power to the power conversion circuitry.