Welding Power System Starter Battery Boost Control
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Solution Overview
Problem
Conventional welding-type power systems require manual intervention to start and stop the engine, leading to degraded arc starts and increased fuel consumption, noise, and emissions, as operators often miss steps or lose remote controls, resulting in inefficient power management.
Innovation Solution
A welding-type power system that includes a starter battery, an electric generator, a power bus, and a controller that automatically adjusts engine speed and connects the starter battery to the power bus via a boost converter to supplement power during high demand periods, allowing for automatic start and stop functionality and efficient power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to start and stop the engine, then the system can be operated, but arc starts are degraded and fuel consumption increases
Solution Approach 1:
The system uses automatic control mechanisms where the controller monitors power demand and autonomously activates the engine or draws from the starter battery without requiring operator intervention. This self-service approach ensures consistent arc start quality and optimal fuel management by eliminating manual operation errors.
Solution Approach 2:
The controller continuously monitors power demand from welding tools and uses this feedback to determine when to start the engine or activate the starter battery. This closed-loop control ensures the engine or battery is activated only when needed, improving arc start reliability while minimizing fuel consumption.
2Reliability
If the engine is kept running to ensure power availability, then power demand can be met, but fuel consumption and emissions increase
Solution Approach 1:
The system dynamically transitions between different power sources based on real-time demand. The controller adjusts the engine operating state or activates the starter battery only when welding power is required, rather than keeping the engine continuously running. This dynamic adaptation reduces emissions while maintaining power availability.
Solution Approach 2:
The starter battery serves multiple functions: it can start the engine, provide supplemental power during welding operations, and replace the engine during low-demand periods. This multi-functionality allows the system to meet power requirements while minimizing engine runtime and associated emissions.
3Reliability
If the starter battery is used to supplement power during high demand, then arc starts are improved, but the battery charge level decreases
Solution Approach 1:
The controller monitors the starter battery's charge level and uses this feedback to manage battery discharge during welding operations. When charge level drops below thresholds, the controller prioritizes recharging by adjusting engine operation or reducing battery load, ensuring the battery maintains sufficient charge for future arc starts.
Solution Approach 2:
The system proactively recharges the starter battery during periods of low or no welding demand by operating the engine to generate excess power stored in the battery. This preliminary charging action ensures the battery is ready to provide supplemental power for the next high-demand welding operation, maintaining arc start quality.
4Productivity
If automatic control is implemented, then operation efficiency is improved, but device complexity increases
Solution Approach 1:
The controller performs multiple functions using a single integrated unit: monitoring power demand, controlling engine start/stop operations, managing starter battery charge/discharge, and coordinating power flow between sources. This multi-functionality improves operational efficiency while minimizing the increase in device complexity by consolidating control tasks.
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
The system provides improved arc starts, reduced fuel consumption, lower emissions, and extended engine life by automatically managing power demands, maintaining consistent weld starts and stops regardless of engine speed, and optimizing power output through the integrated starter battery and generator.
Implementation Method 1
a boost converter configured to connect the starter battery to the power bus and to convert power from the starter battery to provide supplemental power to the power bus
Implementation Method 2
an electric generator configured to be turned by the engine
Implementation Method 3
the measured power demand corresponds to an arc start of a welding-type tool
Data Source
AI summary
Apparatus and methods are provided for a welding-type power system that includes an engine comprising a starter battery. An electric generator is turned by the engine. A power bus connects an output of the generator to a welding-type output. A sensor measures a power demand on the power bus. A controller is configured to control the engine to adjust speed in response to a measured power demand on the power bus, and to control a converter to connect the starter battery to output power to the power bus in response to the measured power demand.