Welding Power Splitter Setup for Fast Multi-Process Switching

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Solution Overview

Problem

Welding operators face inefficiencies and increased setup times when switching between different welding machines due to the need to disconnect and reconnect power and workpiece connections, leading to reduced productivity.

Innovation Solution

The implementation of a work lead splitter and power splitter that allows multiple welding-type power supplies to be concurrently set up, connecting their outputs to a single work clamp and inputs to a single power source, reducing the need for multiple cords and facilitating rapid transitions between processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple welding machines are used for different welding processes, then welding capability and versatility are improved, but setup time and productivity deteriorate due to the need to disconnect and reconnect power and workpiece connections

Engineering Contradiction:

Improvewelding capabilityVSAvoidsetup time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The invention segments the power connection and workpiece connection into separate modular components. The power splitter divides the incoming power connection into multiple output connections for different welding machines, while the work lead splitter divides the workpiece connection into multiple output connections. This segmentation allows each welding machine to remain continuously connected to both power and workpiece, eliminating the need for repeated disconnection and reconnection during process switching.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The power splitter and work lead splitter serve universal functions by providing multiple output connections from a single input connection. These splitters enable multiple welding machines of different types to share common power and workpiece connections, making the system adaptable to various welding processes (MIG, TIG, Stick, etc.) without requiring separate dedicated connections for each machine.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple welding machines are used for different welding processes, then process variety is improved, but ease of operation deteriorates due to the need to swap power cords and workpiece connections

Engineering Contradiction:

Improveprocess varietyVSAvoidease of operation

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The invention segments the connection system into modular power splitter and work lead splitter components, each with multiple input/output connections. This segmentation allows welding operators to switch between different welding processes by simply selecting different machines that are already connected, without needing to physically swap power cords or workpiece connections, significantly improving ease of operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The power splitter and work lead splitter act as intermediary devices between the power source/workpiece and multiple welding machines. These intermediaries manage the connections automatically, allowing operators to switch between machines without directly handling connection cables, thus improving ease of operation while maintaining support for various welding processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If multiple welding machines are used for different welding processes, then system capability is improved, but device complexity increases due to the need for multiple power cords and workpiece connections

Engineering Contradiction:

Improvesystem capabilityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention merges multiple power connections and multiple workpiece connections into single consolidated connections through the power splitter and work lead splitter. Instead of requiring separate power cords and workpiece cables for each welding machine, the splitters combine these connections, reducing cable management complexity while maintaining the capability to support multiple welding machines and processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power splitter and work lead splitter provide universal connection interfaces that can accommodate multiple welding machines with different connection requirements. These multi-functional devices reduce overall system complexity by providing a standardized method for connecting diverse welding equipment to common power and workpiece sources.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12479039B2Systems and methods to have multiple welding-type power supplies concurrently set up

Publication Date: 2025.11.25 ILLINOIS TOOL WORKS INC

AI summary

Example systems to enable multiple welding-type power supplies to be concurrently set up for operation on a same workpiece include: a work lead splitter configured to couple respective work lead terminals of the multiple welding-type power supplies to a same work clamp; and a power splitter configured to couple respective input power terminals of the multiple welding-type power supplies to a same source of input power.