Welding Power-Line Communication for Cloud Data Access
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Solution Overview
Problem
Existing welding systems face challenges in communicating data effectively between components and with external systems due to environmental constraints, limiting the ability to share and analyze data efficiently.
Innovation Solution
A welding system that utilizes power cables to transmit data between welding power supply units, with integrated communication components that convert and aggregate data for transmission over AC power lines, enabling communication between units and with a cloud-based computing system using existing network connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding systems use separate communication links for data transmission, then data communication reliability is improved, but device complexity and installation cost increase
Solution Approach 1:
The power cable is designed to perform multiple functions: delivering electrical power to welding equipment and simultaneously transmitting data signals between welding power supply units. This eliminates the need for separate communication cables, reducing infrastructure complexity while maintaining reliable data transmission through the existing power distribution network
Solution Approach 2:
A communication component is integrated into the welding power supply units that acts as an intermediary, modulating data signals onto the power cable for transmission and demodulating received signals. This mediator enables bidirectional communication through the power infrastructure without requiring dedicated communication channels
2Device complexity
If welding systems are isolated without network connectivity, then system simplicity is maintained, but data accessibility and analytical capabilities deteriorate
Solution Approach 1:
The patent combines the power distribution function and data communication function into a single integrated system. By merging these functions, the system maintains simplicity (no additional communication infrastructure) while enabling data to be transmitted to cloud-based computing systems for remote accessibility and analysis
3Loss of information
If additional communication cables and infrastructure are installed for data transmission, then data transmission capability is improved, but installation cost and system complexity increase
Solution Approach 1:
The existing power cable infrastructure serves dual purposes by automatically carrying both power and data signals. The system utilizes the already-installed power distribution network, eliminating the need for additional communication cable installation and reducing overall system deployment costs
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
Facilitates data communication between welding systems and cloud-based computing systems, creating a local network for data sharing and analysis without additional communication links, enhancing operational efficiency and data accessibility.
Implementation Method 1
providing a welding system access to a network via power lines... a first communication component configured to couple to the one of the power cables, and wherein the first communication component is configured to receive data from welding system components and to convert them to a first set of data that may be transmitted via the one of the power cables
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A welding power supply unit may include a communication circuit that receives a first set of data via a power cable configured to provide power to the welding power supply unit for use in a welding operation. The communication circuit may then convert the first set of data into a second set of data configured to be interpretable by a network device and send the second set of data to the network device.