Variable-Width Wind Tunnel Cooling in Welding Power Supplies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Welding power supplies face challenges in cooling their electronic components due to restricted natural convection and the introduction of particulates through airflow, which can lead to reduced component lifespan, and existing wind tunnels do not accommodate varying component sizes and airflow needs effectively.
Innovation Solution
A welding power supply with a wind tunnel that has varying widths and airflow directions to accommodate different components, with some components placed inside the tunnel for forced cooling and others outside for natural convection, allowing for tailored airflow and protection from dirt, featuring a fan at one end and potentially multiple fans or no fans, with the tunnel's width and height adjusted to suit specific components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fans are incorporated to facilitate improved cooling of electrical components, then cooling efficiency is improved, but heavy particulate flow is introduced into the interior of the housing which can build up on components and shorten their life
Solution Approach 1:
The housing is divided into a clean area and a dirty area separated by a partition wall. The wind tunnel is positioned in the dirty area to handle particulate-laden airflow, while sensitive components are placed in the clean area protected from particulates. This segmentation allows fans to provide cooling without exposing all components to harmful particulate flow.
Solution Approach 2:
A partition wall acts as an intermediary barrier between the wind tunnel airflow and sensitive electrical components. This partition wall blocks particulate-laden air from reaching components that would be damaged by them, while still allowing the wind tunnel to effectively cool components that require forced airflow.
2Temperature
If a wind tunnel is used to provide airflow to components needing cooling, then cooling is improved, but the tunnel provides constant size and constant airflow throughout which is not suitable for components of varying sizes and airflow requirements
Solution Approach 1:
The wind tunnel cross-sectional area varies along its length, creating regions with different airflow characteristics. This dynamic geometry allows the tunnel to accommodate components of varying sizes and provides different airflow velocities and volumes to different sections, matching the diverse cooling requirements of various electrical components.
Solution Approach 2:
Different sections of the wind tunnel have different cross-sectional areas optimized for specific components. Components with higher cooling requirements are positioned in sections with larger cross-sectional areas and higher airflow, while smaller components with lower cooling needs are placed in sections with smaller cross-sectional areas. This local optimization ensures each component receives appropriate cooling without waste.
3Volume of moving object
If the housing restricts natural convection cooling, then compact housing design is achieved, but electronic components need additional cooling mechanisms
Solution Approach 1:
The housing is segmented into regions with different cooling strategies. Some components are placed in the wind tunnel for forced cooling, while other components are positioned in areas where natural convection can occur. This segmentation allows the compact housing to accommodate multiple cooling approaches simultaneously.
Solution Approach 2:
Components that do not require high cooling rates are allowed to cool themselves through natural convection in designated areas of the housing. This self-service cooling reduces the burden on the wind tunnel system and allows for more efficient use of the compact housing space.
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 enhances cooling efficiency for components within the wind tunnel while protecting others from contamination, extending the lifespan of electrical components and optimizing airflow for various component sizes, thereby improving the overall performance and reliability of the welding power supply.
Implementation Method 1
Fans have been incorporated into the assembly of the welding power supply to facilitate improved cooling of the electrical components
Implementation Method 2
These particulates can build up on various components and can effectively shorten the life of certain electrical components of the power supply
Data Source
AI summary
A method and apparatus for providing a welding type power is disclosed. It includes an outer housing having a wind tunnel within the outer housing. Air flows through the wind tunnel in an air flow direction. The width of the tunnel is less at one location than at another location. Electrical components receive power and provide a welding type output. A first group of those components require air flow for cooling, and are disposed at least partially in the wind tunnel. A second group of components are not disposed in the wind tunnel. The wind tunnel can also change direction.