Welding Machine USB Power Input for Low-Power Training Modes

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Solution Overview

Problem

Conventional approaches for operating welding setups in non-normal modes, such as training or demonstration, are cumbersome, inefficient, and costly, often requiring significant modifications to power supplies and posing safety risks.

Innovation Solution

A welding system configured to support low-power operation modes using existing USB ports for power input, allowing transition to non-normal modes without external connections, and managing power requirements through internal adjustments, ensuring safety and cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional approaches are used to operate welding setups in non-normal modes, then training or demonstration operations can be performed, but the system becomes cumbersome, inefficient, and costly with significant modifications required

Engineering Contradiction:

Improvecapability to operate in non-normal modesVSAvoidmodifications to power supply

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The USB receptacle is designed to serve dual purposes: providing data communication interfaces in normal welding operation modes and accepting power input in non-normal modes such as training or demonstration. This multi-functionality eliminates the need for separate power supply modifications, allowing the same port to adapt across different operational contexts without adding device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If conventional approaches are used for non-normal modes, then training operations can be conducted, but safety risks increase

Engineering Contradiction:

Improvesupport for training modesVSAvoidsafety

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system dynamically adjusts its operational characteristics based on the mode of operation. In non-normal modes, the welding power supply operates at reduced power levels through controlled reduction of duty cycle and/or current output. This dynamic adaptation ensures safe operation during training or demonstration while maintaining full capability during normal welding operations, thereby improving reliability without sacrificing versatility.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If conventional approaches are used, then non-normal operation modes can be implemented, but cost increases

Engineering Contradiction:

Improvenon-normal mode operationVSAvoidcost of modifications

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The USB receptacle is integrated into the existing control circuitry and power supply system, allowing it to serve itself across multiple functions. In non-normal modes, the same USB receptacle that provides data interfaces in normal modes is utilized to accept power input, eliminating the need for separate external power connections or additional hardware components. This self-service approach reduces manufacturing costs while maintaining adaptability for different operational modes.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250375830A1Methods and systems for support of low-power operation in training modes in welding machines

Publication Date: 2025.12.11 ILLINOIS TOOL WORKS INC

AI summary

Systems and methods are provided for support of low-power operation in training modes in welding machines.