Welding Power Supply Splitters for Fast Multi-Process Setup

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Solution Overview

Problem

Welding operators face inefficient and time-consuming machine setup changes when switching between different welding systems due to inadequate electrical infrastructure, leading to reduced productivity.

Innovation Solution

A system with a work lead splitter and power splitter that allows multiple welding-type power supplies to be concurrently set up, connecting outputs to a single work clamp and inputs to a single power source, reducing the need for lengthy cord swaps and enabling rapid transitions between processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple welding-type power supplies are used for different welding processes, then welding process versatility is improved, but machine setup time increases due to repeated connection and disconnection of power and workpiece connections

Engineering Contradiction:

Improvewelding process versatilityVSAvoidmachine setup time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent combines multiple power supply connections into a single shared electrical infrastructure. A common power source with multiple outlets allows simultaneous connection of multiple welding-type power supplies, while a common work clamp provides a shared workpiece connection point. This merging eliminates the need to repeatedly connect and disconnect power cords and work leads when switching between welding processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrical infrastructure is designed with universal components that serve multiple functions. The common power source with multiple outlets can supply power to any welding-type power supply, and the common work clamp can serve as the workpiece connection for any welding process. This multi-functionality allows operators to switch between different welding processes without reconfiguring the electrical connections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If dedicated fabrication shop electrical infrastructure is not invested in, then equipment cost is reduced, but productivity decreases due to inefficient machine setup changes

Engineering Contradiction:

Improveequipment costVSAvoidproductivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent creates a universal electrical infrastructure that can accommodate multiple types of welding equipment without requiring expensive dedicated infrastructure for each machine. The common power source with multiple outlets and common work clamp provide a flexible, multi-functional setup that supports various welding processes, improving productivity while avoiding the need for costly dedicated fabrication shop infrastructure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4393627B1Systems and methods to have multiple welding-type power supplies concurrently set up

Publication Date: 2026.01.28 ILLINOIS TOOL WORKS INC

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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.