Summary of the invention
The current regulator that the purpose of this invention is to provide a kind of internal combustion direct current arc welding machine, it adopts simple structure, can reduce the fault rate of arc-welding machine, guarantees the stability of arc-welding machine work, has the welding quality of raising and the high advantage of welding efficiency.
The object of the present invention is achieved like this: a kind of current regulator of internal combustion direct current arc welding machine comprises the rectification circuit that connects the generator excitation winding; And microcontroller that connects the generator excitation winding, this microcontroller is used to produce pwm control signal with the control excitation voltage, micro controller I/O interface is connected with the digital display that shows the electric current gear respectively, with the operation keyboard that benchmark control electric current is set, and a start-up circuit that connects Exciting Windings for Transverse Differential Protection, this start-up circuit is used to generator to set up the required excitation voltage of steady operation; And error-detector circuit that is connected between Exciting Windings for Transverse Differential Protection and the microcontroller, error-detector circuit compares the excitation voltage signal of sampling and the reference current signal of microcontroller input, and operation result is outputed to the dutycycle that is used to adjust microcontroller output pwm control signal after microcontroller is handled; An on-off circuit is connected between Exciting Windings for Transverse Differential Protection and the microcontroller, and on-off circuit is controlled by the pwm signal of microcontroller output, and excitation voltage is carried out the discontinuity Push And Release.
Adopted such scheme, microcontroller is used to produce pwm control signal with the control excitation voltage, this micro controller I/O interface is connected with the digital display that shows the electric current gear, pass through digital display, can distinguish the welding current and the actual welding voltage of display setting, can observe the working condition of arc-welding machine constantly, so that the output current of arc-welding machine is controlled or regulated.Micro controller I/O interface is connected with the operation keyboard that benchmark control electric current is set, operation keyboard is used for the operated key that benchmark control electric current increases, subtracts by UP and two of DOW and constitutes, its structure is comparatively simple, respectively UP and DOW operated key are operated, the selection reference that can circulate from small to large control current value, this electric current is handled the pwm control signal that is produced by microcontroller and be can be used for the output of constant weld electric current, to guarantee the stability in the welding process; Pin two keys simultaneously and can enter the reference signal debugging, so that when reality is used, current parameters is proofreaied and correct or debugged.By error-detector circuit the excitation voltage signal of sampling and the reference current signal VREF of microcontroller input are compared, can improve the precision of the pwm control signal of microcontroller output, and improve excitation voltage stability, promptly improve the stability of output current.
In sum, the present invention is by connecting the operation keyboard of microcontroller, the pwm control signal of distinct pulse widths can be set, with the control signal source of this pwm control signal as the exciting current adjusting, be upgraded to the numeric type button control of being convenient to operate by original mechanization control, avoided problem in the former slide resistor adjustment process, the problem includes: the big problem of temperature rise can reduce welding machine operational failure rate.And the present invention be advantageous in that when having stopped above-mentioned shortcoming that its volume is little, Installation and Debugging convenient; Control accuracy height, stable and reliable for performance; The arc-welding machine welding quality is good, the efficient height.
The invention will be further described below in conjunction with the drawings and the specific embodiments.
Referring to figs. 1 through Fig. 5, the current regulator of internal combustion direct current arc welding machine of the present invention comprises the rectification circuit 1 that connects the generator excitation winding; And a microcontroller that produces pwm control signal with the control excitation voltage, this micro controller I/O interface is connected with the digital display 3 that shows the electric current gear respectively and the operation keyboard 4 of benchmark control electric current is set; And a start-up circuit 5 that connects Exciting Windings for Transverse Differential Protection, this start-up circuit is used to motor to set up the required excitation voltage of steady operation; And error-detector circuit 6 that is connected between Exciting Windings for Transverse Differential Protection and the microcontroller, error-detector circuit compares the excitation voltage signal of sampling and the reference current signal VREF of microcontroller U3 input, and operation result is outputed to the dutycycle that is used to adjust microcontroller output pwm control signal after microcontroller is handled; And an on-off circuit 7 that is connected between Exciting Windings for Transverse Differential Protection and the microcontroller, this on-off circuit is in parallel with error-detector circuit, and on-off circuit 7 receives the pwm control signal of microcontroller U3 output Exciting Windings for Transverse Differential Protection voltage is carried out the discontinuity Push And Release; An on-off circuit is connected between Exciting Windings for Transverse Differential Protection and the microcontroller, and on-off circuit is subjected to the control of the pwm control signal of microcontroller output, and excitation voltage is carried out the discontinuity Push And Release.
With reference to Fig. 2, the microcontroller U3 in this practical example is the STC series monolithic, and this single-chip microcomputer is built-in with the internal RAM of 2K FLASH program storage and 256 bytes.Micro controller I/O interface is connected with the digital display 3 that shows the electric current gear respectively and the operation keyboard 4 of benchmark control electric current is set.Wherein digital display 3 is used for the welding current gear and indicates, digital display 3 can adopt 38 sections charactron, perhaps adopts to be connected in series with micro controller I/O interface (P1.0 to P1.7 interface and P3.0 and P3.1) by resistance as the LED lamp D17~D26 among this figure.Be used to be provided with benchmark control electric current by operation keyboard 4, this benchmark control electric current is divided into two signals after microcontroller is handled, and one of them is the pwm control signal of interface P 3.7 outputs of this microcontroller; Another is the reference current signal VREF that is used for comparison of the interface P3.5 output of this microcontroller.Operation keyboard 4 is button UP, the DOW that is connected with microcontroller U3 interface P3.3, P3.2, and wherein, button UP is used to increase the key that is provided with of benchmark control electric current, and button DOW is used to reduce the key that is provided with of benchmark control electric current; Pin two keys simultaneously and can enter the debugging of benchmark control electric current, be used for when reality is used, proofreading and correct.
With reference to Fig. 3, comprised the rectified current 1 and the start-up circuit 5 of excitation voltage in this circuit, the rectification circuit 1 that wherein connects Exciting Windings for Transverse Differential Protection is the bridge rectifier that 4 diodes constitute.When prime mover (internal combustion engine) drawing generator rotor rotates, epitrochanterian Exciting Windings for Transverse Differential Protection cutting residual magnetic field, produce a very little remanence electromotive force, will produce a very little exciting current on the Exciting Windings for Transverse Differential Protection, the DC voltage that this exciting current obtains after by the rectification circuit rectification is about 2.5V.Start-up circuit 5 comprises the first biasing resistor R1, the second biasing resistor R2, the first triode Q1, the second triode Q2, the 3rd triode Q 3 and Zener diode ZD1, wherein the first triode Q1, the second triode Q2 are the triode of NPN type, and the 3rd triode Q3 is the triode of positive-negative-positive.The first biasing resistor R1 be connected between the base stage of the Exciting Windings for Transverse Differential Protection positive ends and the first triode Q1 after Zener diode ZD1 connects, wherein the negative electrode of Zener diode ZD1 is connected with the Exciting Windings for Transverse Differential Protection positive ends.The second biasing resistor R2 is connected between the colelctor electrode of the Exciting Windings for Transverse Differential Protection positive ends and the first triode Q1, the second triode Q2 base stage connects the first triode Q1 colelctor electrode, the 3rd triode Q3 base stage connects the second triode Q2 colelctor electrode, the 3rd triode Q3 emitter stage connects Exciting Windings for Transverse Differential Protection negative polarity end, and the emitter stage of the first triode Q1, the second triode Q2 and the colelctor electrode of the 3rd triode Q3 all are connected with signal ground.
With reference to Fig. 4, error-detector circuit 6 comprises in-phase proportion computing circuit U2A, voltage follower U2B, calculus of differences circuit U 2C and in-phase proportion computing circuit U2D.Be connected divider resistance R4 between the homophase input pin 3 of in-phase proportion computing circuit U2A and the Exciting Windings for Transverse Differential Protection, be connected divider resistance R7 between its homophase input pin 3 and the ground, divider resistance R7 two ends are parallel with the electrochemical capacitor C10 that is used for filtering; In-phase proportion computing circuit U2A homophase input pin 3 is connected with divider resistance R4, R7 respectively by resistance R 3.The reversed input pin 2 of in-phase proportion computing circuit U2A is connected with ground by resistance R 6, its anti-phase input is drawn 2 and also is connected with its output pin 1 by feedback resistance R5 and capacitor C 13 respectively, and its output pin 1 connects the reversed input pin 6 of calculus of differences circuit U 2B.The reversed input pin 6 of calculus of differences circuit U 2B connects the output pin 1 of in-phase proportion computing circuit U2A by resistance R 11, its output pin 7 connects the error sample signal interface P3.4 of microcontroller U3, and its output pin 7 also connects its homophase input pin 5 by feedback resistance R14.The homophase input pin 5 of calculus of differences circuit U 2B connects the output pin 14 of in-phase proportion computing circuit U2D, the output pin 14 of in-phase proportion computing circuit U2D connects its reversed input pin 13 by feedback resistance R10, capacitor C 14 respectively, and its reversed input pin 13 also is connected with ground by resistance R 13.The homophase input pin 12 of in-phase proportion computing circuit U2D connects the output pin 8 of voltage follower U2C, the output pin 8 of voltage follower U2C is connected with capacitance-resistance filter and resistance R 9 respectively by resistance R 8, wherein, capacitance-resistance filter is made of the resistance R 12 electrochemical capacitor C6 in parallel with it; Resistance R 9 connects the homophase input pin 12 of in-phase proportion computing circuit U2D.The output pin of voltage follower U2C-8 directly is connected with its reversed input pin 9, and the homophase input pin 10 of voltage follower U2C connects the reference current signal VREF output interface P3.5 of microcontroller U3.
With reference to Fig. 5, on-off circuit comprises the 4th triode Q4, the 5th triode Q7, photoelectrical coupler U1, the first FET Q5, the second FET Q6, the base stage of the 5th triode Q7 connects the pwm control signal output interface P3.7 of microcontroller U3, its grounded emitter.Photoelectrical coupler U1 is connected between the 5th triode Q7 emitter stage and the 4th triode Q4 base stage, photoelectrical coupler U1 is made up of the phototriode of light emitting diode and open base, wherein the light-emitting diodes tube cathode connects the colelctor electrode of the 5th triode Q7, and its anode connects the dc signal of ten 5V that produced by accessory power supply by resistance R 32; The emitter stage of phototriode connects signal ground, and its colelctor electrode connects the base stage of the 4th triode Q4.Be connected with biasing resistor R31 between the colelctor electrode of the 4th triode Q4 and the base stage, the output of the 4th triode Q4 is connected with Zener diode D16, the emitter stage of the 4th triode Q4 respectively with the first FET Q5, the grid of the second FET Q6 connects, the colelctor electrode of the 4th triode Q4 and the first FET Q5, the source electrode of the second FET Q6 all is connected with signal ground, the first FET Q5, the drain electrode of the second FET Q6 all is connected with the negative polarity end of Exciting Windings for Transverse Differential Protection, the drain electrode of the first FET Q5 connects Exciting Windings for Transverse Differential Protection by diode D15, and the drain electrode of the second FET Q6 connects Exciting Windings for Transverse Differential Protection by resistance R 30.The first FET Q5, the second FET Q6 are the NMOS pipe of depletion type.
The course of work of the present invention is, after starting arc-welding machine, under the dragging of prime mover, excitation voltage is by the about 2.5V of DC voltage after rectification circuit 1 rectification, and this voltage is very low, when outputing to start-up circuit, because the Zener diode operate as normal needs high breakdown reverse, this undertension is so that Zener diode punctures, so Zener diode ZD1 ends, the first triode Q1 is the remain off state still.This voltage is added to the base stage of the second triode Q2 by the second biasing resistor R2, make the second triode Q2 conducting, and after amplifying, the second triode Q2 outputs to the 3rd triode Q3 base stage, make the 3rd triode Q3 conducting, output to Exciting Windings for Transverse Differential Protection through the further amplification of the 3rd triode Q3 and make it produce exciting current.Because the magnetic potential and the remanent magnetism of exciting current are equidirectional, therefore the rotor in the rotation produces magnetic field and makes the excitation voltage rising, and excitation voltage raises electric current is also raise in succession, also can add the magnetic field of greater trochanter simultaneously.When excitation voltage rose to setting value, this voltage made its conducting with anti-phase puncture Zener diode ZD1, after electric current passes through Zener diode ZD1, the first biasing resistor R1 successively, voltage is added to the first triode Q1 base stage make its work.To make the second triode Q2 base terminal voltage over the ground after the first triode Q1 work, and make the second triode Q2, the 3rd triode Q3 by finishing startup.
End the situation of finishing startup according to the above-mentioned second triode Q2, the 3rd triode Q3, at this moment show that excitation voltage has reached setting value, this voltage is through divider resistance R4, R7 dividing potential drop, and by electrochemical capacitor C10 the spike of this signal is removed (in order to reduce sensitivity) and send into in-phase proportion computing circuit U2A and amplify, and output to calculus of differences circuit U 2B.By the benchmark control electric current that operation keyboard 4 is provided with, this benchmark control electric current is divided into two signals after microcontroller is handled, and one of them is the pwm control signal of the interface P3.7 output of this microcontroller; Another is the reference current signal VREF that is used for comparison of the interface P3.5 output of this microcontroller.Reference current signal VREF is input to U2C improving signal gain,, is input to in-phase proportion computing circuit U2D and amplifies through resistance R 9, R12 dividing potential drop and after by capacitor C 9 filtering from the signal of voltage follower output.Reference current signal VREF is after voltage follower U2C and in-phase proportion computing circuit U2D processing, output to calculus of differences circuit U 2B by in-phase proportion computing circuit U2D, compare with treated excitation voltage, signal after will comparing by calculus of differences circuit U 2B, error sample signal P3.4R interface by microcontroller is sent into microcontroller U3 inside, after this signal is handled by the initialize program in the microcontroller, be used to adjust the dutycycle of microcontroller output pwm control signal.Can limit excitation voltage after this pwm control signal signal output.By microcontroller U3 pwm control signal is outputed to on-off circuit 7, when adding to the base stage of the 5th triode Q7, impels this signal this triode work, and then this pwm control signal inflow photoelectronic coupler U1 makes photoelectronic coupler U1 work, the 4th triode Q4 conducting this moment, its emitter stage closes it grid potential of first FET Q5, the second FET Q6 with pulling down to, the first FET Q5, the second FET Q6 conducting when pwm control signal is low level, excitation voltage is controlled, promptly the Exciting Windings for Transverse Differential Protection electric current is controlled.Can make microcontroller produce the pwm control signal of different sizes by operation keyboard, therefore, during arc-welding machine work, different reference currents is set, can regulate exciting current by operation keyboard.
Though the present invention discloses as above with preferred embodiment; right its is not in order to limit the present invention; any person of ordinary skill in the field; without departing from the spirit and scope of the invention; when can doing a little change and improvement, so the present invention's protection domain is as the criterion when looking the claim person of defining.