Welding Control Switching Module with Potential-Free Cooling
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Solution Overview
Problem
Existing welding control systems face challenges in achieving compactness and cost-effectiveness due to the need for long, high-dielectric-strength cooling hoses connecting heat sinks at different electrical potentials, which occupy space and require expensive special hoses.
Innovation Solution
A compact switching module design featuring a second switching means, coolant, and power supply means arranged in an anti-parallel configuration with insulating film between them, allowing for effective cooling and powering from both sides, reducing the need for lengthy hoses and using inexpensive insulating materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long cooling hoses are used to connect heat sinks at different electrical potentials, then dielectric strength is ensured, but device compactness deteriorates and space is consumed
Solution Approach 1:
The patent merges the cooling function with the electrical insulation function by integrating the cooling liquid conduit directly into the heat sink structure. The heat sink serves dual purposes: dissipating heat and providing electrical insulation between different potential areas, eliminating the need for separate long cooling hoses
Solution Approach 2:
The heat sink is designed with multi-functionality, serving both as a thermal management component and as an electrical insulation barrier. The integrated cooling liquid conduit within the heat sink structure allows the same component to handle both cooling and insulation tasks simultaneously
2Reliability
If special high-dielectric-strength hoses are used to connect heat sinks, then electrical insulation is ensured, but manufacturing cost increases
Solution Approach 1:
The patent combines the insulation function with the heat sink structure itself, eliminating the need for separate special hoses. The heat sink material and structure provide the necessary dielectric strength, reducing component count and manufacturing complexity
Solution Approach 2:
The heat sink serves itself by providing both thermal management and electrical insulation functions. The integrated conduit system within the heat sink eliminates the need for external specialized components, allowing the system to achieve insulation without additional expensive parts
3Ease of operation
If multiple hose connections are made on the housing, then cooling functionality is achieved, but device complexity and assembly cost increase
Solution Approach 1:
The patent extracts the cooling liquid conduit from the external housing connections and integrates it directly into the heat sink structure. This eliminates the need for multiple external hose connections on the housing, simplifying the overall system architecture and reducing assembly steps
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
This design enables a space-saving, cost-effective integration of the switching module within the welding controller housing with enhanced heat dissipation and reduced material costs by minimizing the number of cooling supply lines.
Implementation Method 1
the components are usually screwed onto extruded hollow profiles in a heat-sealing manner, through which a fluid flows, for example by means of a cooling liquid guided in a cooling circuit
Implementation Method 2
through which a fluid flows, for example by means of a cooling liquid guided in a cooling circuit
Implementation Method 3
a first insulating means (8A) is located between the first power supply means (1A) and the first coolant (3A), and a second insulating means (8B) is located between the second power supply means (1B) and the second coolant (3B)
Implementation Method 4
Aluminum, for example, is suitable as a material for the extruded hollow profiles because of its properties, in particular its very good thermal conductivity
Data Source
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AI summary
The aim of the invention is to provide a compact and economical welding control system comprising an integrated power section. To this end, a switching module is provided for the power section of a welding control system, comprising a switching means (2A), a coolant (3A), a current supply means (IA) and an insulating means (8A), the arrangement of the insulating means (8A) enabling a potential-free coolant arrangement. The invention is advantageous in that the potential-free coolant arrangement allows the coolant tubes to be shortened so that less space is required inside the control system and the control system can therefore have a more compact structure. The invention enables even the requirements in terms of the coolant tubes to be reduced, due to the coolant being potential-free, allowing the use of cost-effective cooling tubes or even cooling pipes that are directly connected to the coolants.