Integrated Welding Power Source for Wire Preheating

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Solution Overview

Problem

Conventional welding systems require multiple power sources and complex control circuitry to coordinate preheating and welding outputs, increasing complexity and cost.

Innovation Solution

A single welding power source with integrated power conversion circuitry that outputs both welding and preheating power, reducing the need for multiple power sources and simplifying control circuitry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple power sources are used to provide both welding and preheating power, then the welding and preheating functions can be performed, but the system complexity and cost increase

Engineering Contradiction:

Improvewelding and preheating functionalityVSAvoidnumber of power sources

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple power sources into a single integrated power source that can output both welding power and preheating power. The power source includes a controller that manages multiple output channels, allowing one device to perform functions that previously required separate devices, thereby reducing system complexity while maintaining versatility

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single power source is designed with multi-functionality to provide both welding output and preheating output through different channels. The controller can selectively activate different output modes based on the required operation, making one device universal enough to replace multiple specialized devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple power sources are used to provide welding and preheating power, then both functions are available, but the control circuitry complexity increases

Engineering Contradiction:

Improvepower output capabilitiesVSAvoidcontrol circuitry

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control circuitry of multiple power sources is merged into a single integrated controller within one power source. This unified controller manages all output channels (welding and preheating) through centralized control logic, eliminating the need for separate control systems and reducing overall circuitry complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The controller is designed as a universal control unit that can manage different output modes (welding, preheating, or both simultaneously) through a single interface and control architecture, simplifying the control system while maintaining the ability to perform multiple functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If a single power source provides both welding and preheating power, then the system complexity is reduced, but the power conversion requirements become more complex

Engineering Contradiction:

Improvenumber of power sourcesVSAvoidpower conversion circuitry

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The power conversion circuitry is segmented into multiple independent output channels within the single power source. Each channel (welding output, preheating output) has its own conversion circuitry that can be independently controlled, allowing modular manufacturing and assembly while achieving multiple outputs from one device

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If preheating is not performed separately, then the heat input to the weld increases, but using multiple power sources increases system complexity

Engineering Contradiction:

Improveheat input controlVSAvoidnumber of power sources

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The preheating function is merged into the single power source alongside the welding function. The controller can activate the preheating output channel independently or simultaneously with the welding output, allowing precise control of heat input to the workpiece while maintaining system simplicity through device integration

Inventive Principle:

Principle #5Merging (Combining)

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

Enables efficient wire preheating, reducing heat input to the weld, increasing deposition, and improving process efficiency by providing both welding and preheating power from a single source.

Implementation Method 1

power conversion circuitry configured to convert a first portion of the input power to a welding power output and a second portion of the input power to a preheating power output

Methodology Applied

Scientific EffectPower conversion:

Implementation Method 2

preheating circuit configured to heat the wire prior to an arc

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Data Source

PatentUS12240064B2Methods and apparatus to provide welding-type power and preheating power

Publication Date: 2025.03.04 ILLINOIS TOOL WORKS INC

AI summary

An example welding power supply includes: a power input configured to receive alternating current (AC) input power, and power conversion circuitry configured to: convert a first portion of the input power to welding power; output the welding power to a weld circuit; convert a second portion of the input power to preheating power; and output the preheating power to a preheater.