Welding Torch Standby Mode Energy Reduction
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Solution Overview
Problem
Conventional welding or soldering devices consume excessive energy even during pauses or interruptions in the process, leading to high operational costs and reduced maintenance intervals due to continuous full-power operation of components.
Innovation Solution
Implementing a controllable switching mechanism that automatically switches external components, such as the welding torch, fan, and cooling water pump, into a more energy-efficient mode when energy consumption thresholds are met, allowing for partial or complete shutdown during breaks, with optional manual control and display feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are operated continuously at full power, then readiness for welding is maintained, but energy consumption increases and maintenance intervals decrease
Solution Approach 1:
The system dynamically adjusts the operating state of external components based on real-time detection of welding activity. During welding operations, components operate at full power; during pauses, they switch to reduced power mode. This dynamic adaptation resolves the contradiction by maintaining readiness only when actually needed, rather than operating continuously at full power.
Solution Approach 2:
The system uses detector means to automatically detect welding pauses and trigger switching means to change component states without manual intervention. The control unit monitors welding current and autonomously manages the power states of external components, enabling the system to self-regulate energy consumption while maintaining operational readiness.
2Use of energy by moving object
If components are switched to energy-saving mode during pauses, then energy consumption is reduced, but response time to resume welding increases
Solution Approach 1:
The system switches external components to reduced power mode immediately upon detecting a welding pause, before the pause fully extends. By anticipating the end of welding operations and pre-adjusting component states, the system minimizes energy consumption during pauses while ensuring components are already positioned to quickly resume full power when welding restarts, thereby reducing response time.
3Use of energy by moving object
If multiple external components are controlled independently, then energy optimization is improved, but device complexity increases
Solution Approach 1:
The system merges the control of multiple external components under a single centralized control unit that receives welding status signals from the power unit. Instead of implementing separate control systems for each component, the invention consolidates the switching logic in one control unit that can simultaneously manage multiple components based on a single welding detection signal, thereby reducing overall system complexity while maintaining energy optimization.
Data Source
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AI summary
The device comprises a supply voltage storage power section (1) for energy supply of welding or soldering process (3), a control unit (6) for the power section, an external component (4, 5), and a controllable switching element by which one of the assembly of the power section, the control unit and the external component is switchable from a first state into a second state reducing the energy consumption via the first state. The external component is welding torch, ventilator, cool water pump, and user interface of the welding or soldering device. The device comprises a supply voltage storage power section (1) for energy supply of welding or soldering process (3), a control unit (6) for the power section, an external component (4, 5), and a controllable switching element by which one of the assembly of the power section, the control unit and the external component is switchable from a first state into a second state reducing the energy consumption via the first state. The external component is welding torch, ventilator, cool water pump, and user interface of the welding or soldering device. The activation of switching means (8) is carried out during reaching a predetermined state regarding to the energy consumption of the device. The switching means is assigned a detector means for the detection of consumption of current, voltage or power of the assembly of power section, control unit and/or the external component. The detector means is assigned a discriminator means with a predetermined threshold value for the current, voltage or power. The switching means is assigned a delay element and the activation takes place at the end of its delay time duration T, which is pretended by an operating person. The activation of the switching means is manually carried out by an operating switch mounted on the assembly of the power section, control unit and/or the external component. The operating switch is mounted on the welding torch. The activation of the controllable switching means is automatically or manually carried out for switching from first state to the second state and/or for switching from second state to the first state. The manual activation of the switching means is carried out for manual switching from first state to the second state and/or for manual switching of second state to the first state through the operating switch mounted on the welding torch on one of the assembly of the power section, control unit and/or the external component. The first state is operating state and the second state is standby mode. The controllable switching means is assigned an optical or acoustic indicator means for the actual state of the device. An independent claim is included for a method for operating a welding or soldering device.