CN101347866A - Direct current resistance welder with low input power and without secondary commutation and control method thereof - Google Patents

Direct current resistance welder with low input power and without secondary commutation and control method thereof Download PDF

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CN101347866A
CN101347866A CNA2007100725275A CN200710072527A CN101347866A CN 101347866 A CN101347866 A CN 101347866A CN A2007100725275 A CNA2007100725275 A CN A2007100725275A CN 200710072527 A CN200710072527 A CN 200710072527A CN 101347866 A CN101347866 A CN 101347866A
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welding
copped wave
input
capacitor group
current
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王清
孙东立
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Harbin Institute of Technology
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Harbin Institute of Technology
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Abstract

The invention relates to a low-input power non-secondary commutated direct current resistance welder and a control method thereof, in particular to the low-input power non-secondary commutated direct current resistance welder which is applied to various welding of metal points, convex and seams and the control method thereof; the invention aims at solving the contradiction that the power supply source is small and the power needed instantaneously by a resistance welder, thus leading the resistance welder not only to be applied in welders with small and medium power but also to be applied in welders with larger power; the charging voltage and the current of a transformer are monitored in a way that a current sensor I-S1 and I-S2 are connected with a primary input end and a secondary output end of a welding transformer Tr in series and a voltage sensor V-S is connected with the two ends of a capacitor bank C0 in parallel. The stepping control of the charging voltage of the capacitor bank C0 and the control method for supplying power to the two ends of the primary coil of the welding transformer Tr in asymmetric chopping pulse improve the energy output of the welding and are beneficial to the welding of the color metals.

Description

Direct current resistance welder with low input power and without secondary commutation and control method thereof
One, technical field
What the present invention relates to is a kind of direct current resistance welder with low input power and without secondary commutation and control method thereof, mainly is to be applied to various metal dots, protruding, the employed direct current resistance welder with low input power and without secondary commutation of seam welding and control method thereof.
Two, background technology
The present invention be national inventing patent " direct current resistance welder without secondary commutation and control method " (patent of invention number: ZL01133289.1) on the basis, the further research of being done.
In today that national economy grows continuously and fast, people often are subjected to the puzzlement of electrical problems.The electric resistance welding welding machine is on the one hand as a kind of high-efficiency cleaning, easy to operate, the welding equipment that is easy to realize mechanization, automation and extremely people's favor, big because of this equipment power consumption again on the other hand, be subjected to the influence of problems such as power supply capacity, increase-volume, thereby limited the application and the development of resistance welder.Though resistance welder has: the one, the welding current during the resistance welder welding is very big, is generally electric currents thousands of even tens thousand of amperes; The 2nd, the electric resistance welding welding time is very short, is generally less than for 0.5 second, and for non-ferrous metals such as aluminium, titanium alloys, its weld interval is often less than 0.02 second; The 3rd, the weld load water holdup of resistance welder is very low, adds that carrying, lifting workpiece, searching align factors such as welding position, welding machine gas circuit action delay, and the cyclic duration factor that really is used to weld often is lower than 10% or the like evident characteristic.But, in order to satisfy the requirement of the instantaneous high-power input of resistance welder, enough big power supply must be provided, and this is just in fact causing irrational utilization of power supply and waste, exists the contradiction of the little and instantaneous power demand of electric resistance welding equipment of power supply between big.
Have only condenser discharge resistance welder can utilize the energy storage characteristic of capacitor, utilize little electric current that capacitor is charged for a long time, when welding, utilize the instantaneous discharge of capacitor, reach the instantaneous high-power output of welding machine, the purpose that welded part is welded together.By changing capacity, the transformation ratio of welding transformer and the charging voltage of capacitor group of capacitor group, secondary current output waveform that can the control capacittance percussion welder.But when fixing other parameter, and when increasing the capacity of capacitor group, the maximum of secondary welding current increases gradually, increases discharge time, and the time that the peaked peak value of welding current occurs moves after gradually; When fixing other parameter, and when increasing the welding transformer transformation ratio gradually, the maximum of secondary welding current reduces gradually, increases gradually discharge time, and the time that the peaked peak value of welding current occurs moves after gradually; When fixing other parameter, and when increasing the charging voltage of capacitor group, the maximum of secondary welding current increases gradually, remains unchanged substantially discharge time, and the time that the peaked peak value of welding current occurs also remains unchanged substantially.Its shortcoming: the one,, regulate parameter in any case, its secondary output current wave does not always have too big variation, and electric current changes too violent, and the welding conditions adjustable range is narrower, is unfavorable for welding most of metal materials; The 2nd,, electric capacity go out can welding machine the welding transformer and the volume of capacitor group bigger, and the capacitor price is more expensive, needs regularly to change; The 3rd,, the energy loss that produces in the charge and discharge process of capacitor group is bigger, has data to show that this energy loss accounts for 50% of whole energy input.
Three, summary of the invention
Purpose of the present invention just is, at above-mentioned all deficiencies, solve power supply little with the contradiction of the instantaneous power demand of electric resistance welding equipment between greatly, make the use of resistance welder, not only can be applied in the welding machine of middle low power, and can be applied in the welding machine of bigger power.
Technical scheme of the present invention is, direct current resistance welder with low input power and without secondary commutation, power supply be through binding post input rectification circuit Rect, and alternating current is transformed into the DC current of pulsation, capacitor group C 0Be connected in parallel on the output of rectification circuit Rect, capacitor group C 0The power storage of pulsating direct current electric current input is got up four power switch component T 1, T 2, T 3, T 4With the welding main circuit that corresponding protection components and parts are formed, welding main circuit input and capacitor group C 0In parallel, the output of welding main circuit inserts the input of welding transformer Trans primary coil, continued flow resistance R of access in parallel at welding transformer Trans primary coil two ends, the secondary output end of welding transformer Trans inserts the welding machine secondary loop, for welding machine work provides electric current, it is characterized in that: at capacitor group C 0Two ends be connected in parallel to voltage sensor V-S, monitoring charging voltage inserts current sensor I-S1 in the series connection of the primary input terminal of welding transformer Trans, inserts current sensor I-S2, monitoring and protection in the secondary output end series connection of welding transformer Trans.
According to the applied control method of aforesaid direct current resistance welder with low input power and without secondary commutation, it is characterized in that: grading control capacitor group C 0Charging voltage, power to welding transformer Trans primary coil two ends with asymmetric copped wave impulse waveform, after some copped wave pulse inputs, rightabout in power supply copped wave pulse applies a pressure demagnetization pulse, with the magnetic saturation phenomenon of eliminating or minimizing produces owing to the unidirectional power supply of welding transformer, the duration of this pressure demagnetization pulse is depended on demagnetization effectiveness, and to account for the rate of carrying irrelevant with the conducting of the copped wave pulse of forward power supply, and specific implementation process is:
(1) connect power supply (three-phase or single-phase) afterwards, power supply is through binding post input rectification circuit Rect, and alternating current is transformed into the DC current of pulsation, and the pulsating direct current electric current outputs to capacitor group C 0It is charged;
(2) by and be connected in capacitor group C 0The voltage sensor V-S at two ends, controlling system of welder monitor capacitor group C in real time 0Charging voltage, when reach setting keep voltage after, rectification circuit Rect turn-offs, welding machine is in the welding job state of waiting for;
(3) at t 11Constantly, the welding machine welding is switch activated, and the welding machine top electrode moves under the driving of pressure system, applies welding pressure to welded part, meanwhile, rectification circuit Rect conducting, power supply passes through rectification circuit Rect to capacitor group C 0Carry out quick charge, make its charging voltage reach critical voltage rapidly, and in whole welding process, keep capacitor group C 0Quick-charge state;
(4) at t 12Constantly, circuits for triggering send trigger impulse, the power switch T on the welding main circuit 1, T 4Conducting simultaneously, capacitor group C 0Pass through T 1, T 4To the power supply of welding transformer, convert welding current to through welding transformer Trans;
(5) at t 13Constantly, when the copped wave pulse charging time that reaches setting, under the effect of controlling system of welder, power switch T 1(or T 4) end, the energy that is stored among the welding transformer Trans discharges by the secondary loop, keeps the continuity of welding current; The primary coil of welding transformer Trans forms discharge loop by continued flow resistance R;
(6) when arriving the copped wave pulse stop time t that sets 14The time, under the effect of controlling system of welder, power switch T 1(or T 4) conducting once more, power supply passes through T once more 1, T 4To welding transformer Trans input energy;
(7) under the effect of controller, repeat 5,6 action several times, reach after the copped wave pulse input number of times of setting, because the remanent magnetism among the copped wave stop time welding transformer Trans can not be eliminated fully, after several times copped wave pulse input, remanent magnetism among the welding transformer Trans runs up to a certain degree, at this moment (t 15), in input copped wave pulse opposite direction, import the asymmetrical pressure pulse of demagnetizing, the duration of this pulse, will decide according to actual measurement current sensor I-S1, I-S2 data;
(8) repeat above-mentioned action several times, until the weld interval that reaches setting;
(9) it should be noted that owing to when beginning to weld capacitor group C 0Charging voltage higher, excessive for fear of the rate of climb of welding current, copped wave pulse this moment obtains logical dutycycle should be less, afterwards along with capacitor group C 0The reduction of charging voltage should increase the copped wave pulse gradually and get the conducting dutycycle;
(10) adopt the welding process of the strong weld standard of big electric current, short time for needs, can remain under the situation of same copped wave pulse input direction and finish whole welding process, in weld cycle next time, change the input direction of copped wave pulse again; If adopt little electric current, when for a long time soft soldering connects standard and welds, the welding transformer iron core magnetic saturation phenomenon that produces for fear of long-time unidirectional energising occurring can change the input direction of copped wave pulse in welding process.
Useful technique effect of the present invention and obvious improvement are that with the prior art contrast, patent of the present invention has following advantage: at first, required power in the time of can significantly reducing the installation of resistance welder, experimental data shows, adopts this control method, can reduce power supply power demand about 30%; Secondly, can obviously reduce the impact of the higher hamonic wave that produces in the welding engineering to power supply grid; The 3rd adopts asymmetric control method can accurately control the input energy of welding transformer, can be according to the actual welding arts demand, and the secondary current output waveform of control welding transformer; The 4th, adopt asymmetric control technology, can reduce the volume and weight of welding transformer effectively; The 5th, because the input of welding transformer energy is a noncontinuity when adopting asymmetric control, and power supply is continuous to the charging process of capacitor group.Therefore, as long as the capacity of suitable design capacitance device group and the suitable welding procedure of employing just can solve the problem of low-power input and high-power output of short time.
Four, description of drawings
Fig. 1 is the direct current resistance welder with low input power and without secondary commutation principle schematic.
Wherein, a, b, c are three-phase alternating current, and Rect is a three phase full wave rectification, C 0Be electric capacity, T 1, T 2, T 3, T 4Be power switch component, R is a resistance, and Trans is a welding transformer, and V-S is a voltage sensor, and I-S1, I-S2 are current sensor.This welding machine is controlled by controller, operates under the fixed instruction programme-control of controller.
Fig. 2 imports asymmetric copped wave pulse schematic diagram for the electrode pressure and the welding transformer primary coil of direct current resistance welder with low input power and without secondary commutation control method.Wherein, horizontal week is time shaft t, and unit is second.Vertical pivot is voltage axis v and pressure axis p, and unit is volt and kilogram.
Provided two groups of asymmetric copped wave pulses and electrode pressure curve among Fig. 2, such process can repeated several times until the weld interval that reaches setting.T among Fig. 2 11, t 12, t 13, t 14, t 15, t 16, t 21, t 22, t 23, t 24, t 25, t 26, t 27Represent each pulse period respectively.
Five, specific implementation method
List following specific embodiment in conjunction with Figure of description, technical scheme of the present invention is described further.
Embodiments of the invention, direct current resistance welder with low input power and without secondary commutation schematic diagram as shown in Figure 1.The asymmetric copped wave pulse schematic diagram of direct current resistance welder with low input power and without secondary commutation control method as shown in Figure 2.
Direct current resistance welder with low input power and without secondary commutation, power supply be through binding post input rectification circuit Rect, and alternating current is transformed into the DC current of pulsation, capacitor group C 0Be connected in parallel on the output of rectification circuit Rect, capacitor group C 0The power storage of pulsating direct current electric current input is got up four power switch component T 1, T 2, T 3, T 4With the welding main circuit that corresponding protection components and parts are formed, welding main circuit input and capacitor group C 0In parallel, the output of welding main circuit inserts the input of welding transformer Trans primary coil, continued flow resistance R of access in parallel at welding transformer Trans primary coil two ends, the secondary output end of welding transformer Trans inserts the welding machine secondary loop, for welding machine work provides electric current, it is characterized in that: at capacitor group C 0Two ends be connected in parallel to voltage sensor V-S, monitoring charging voltage inserts current sensor I-S1 in the series connection of the primary input terminal of welding transformer Trans, inserts current sensor I-S2, monitoring and protection in the secondary output end series connection of welding transformer Trans.
According to the applied control method of aforesaid direct current resistance welder with low input power and without secondary commutation, it is characterized in that: grading control capacitor group C 0Charging voltage, power to welding transformer Trans primary coil two ends with asymmetric copped wave impulse waveform, after some copped wave pulse inputs, rightabout in power supply copped wave pulse applies a pressure demagnetization pulse, with the magnetic saturation phenomenon of eliminating or minimizing produces owing to the unidirectional power supply of welding transformer, the duration of this pressure demagnetization pulse is depended on demagnetization effectiveness, and to account for the rate of carrying irrelevant with the conducting of the copped wave pulse of forward power supply, and specific implementation process is:
(1) connect power supply (three-phase or single-phase) afterwards, power supply is through binding post input rectification circuit Rect, and alternating current is transformed into the DC current of pulsation, and the pulsating direct current electric current outputs to capacitor group C 0It is charged;
(2) by and be connected in capacitor group C 0The voltage sensor V-S at two ends, controlling system of welder monitor capacitor group C in real time 0Charging voltage, when reach setting keep voltage after, rectification circuit Rect turn-offs, welding machine is in the welding job state of waiting for;
(3) at t 11Constantly, the welding machine welding is switch activated, and the welding machine top electrode moves under the driving of pressure system, applies welding pressure to welded part, meanwhile, rectification circuit Rect conducting, power supply passes through rectification circuit Rect to capacitor group C 0Carry out quick charge, make its charging voltage reach critical voltage rapidly, and in whole welding process, keep capacitor group C 0Quick-charge state;
(4) at t 12Constantly, circuits for triggering send trigger impulse, the power switch T on the welding main circuit 1, T 4Conducting simultaneously, capacitor group C 0Pass through T 1, T 4To the power supply of welding transformer, convert welding current to through welding transformer Trans;
(5) at t 13Constantly, when the copped wave pulse charging time that reaches setting, under the effect of controlling system of welder, power switch T 1(or T 4) end, the energy that is stored among the welding transformer Trans discharges by the secondary loop, keeps the continuity of welding current; The primary coil of welding transformer Trans forms discharge loop by continued flow resistance R;
(6) when arriving the copped wave pulse stop time t that sets 14The time, under the effect of controlling system of welder, power switch T 1(or T 4) conducting once more, power supply passes through T once more 1, T 4To welding transformer Trans input energy;
(7) under the effect of controller, repeat 5,6 action several times, reach after the copped wave pulse input number of times of setting, because the remanent magnetism among the copped wave stop time welding transformer Trans can not be eliminated fully, after several times copped wave pulse input, remanent magnetism among the welding transformer Trans runs up to a certain degree, at this moment (t 15), in input copped wave pulse opposite direction, import the asymmetrical pressure pulse of demagnetizing, the duration of this pulse, will decide according to actual measurement current sensor I-S1, I-S2 data;
(8) repeat above-mentioned action several times, until the weld interval that reaches setting;
(9) it should be noted that owing to when beginning to weld capacitor group C 0Charging voltage higher, excessive for fear of the rate of climb of welding current, copped wave pulse this moment obtains logical dutycycle should be less, afterwards along with capacitor group C 0The reduction of charging voltage should increase the copped wave pulse gradually and get the conducting dutycycle;
(10) adopt the welding process of the strong weld standard of big electric current, short time for needs, can remain under the situation of same copped wave pulse input direction and finish whole welding process, in weld cycle next time, change the input direction of copped wave pulse again; If adopt little electric current, when for a long time soft soldering connects standard and welds, the welding transformer iron core magnetic saturation phenomenon that produces for fear of long-time unidirectional energising occurring can change the input direction of copped wave pulse in welding process.
Concrete work implementation process is: power supply process rectified three-phase circuit is to capacitor group C 0Charging, its charging voltage is by computer control.After reaching the setting charging voltage, rectification circuit turn-offs, and welding machine is in the welding job state of waiting for; In order to reach optimum energy-saving effect, the standby charging voltage is divided into two states, after opening the welding machine electric power switch or having welded a solder joint, welding machine capacitor group C 0Be in low-voltage and keep state; After starting the welding switch, utilize the welding machine pressing mechanism to move the needed time, to capacitor group C 0Carry out quick charge, make its charging voltage reach critical operating voltage.After starting the welding switch, welding machine enters weld cycle, when the welding machine top electrode is depressed, and after workpiece firmly stepped up, four power switch (T on the welding main circuit 1, T 2, T 3, T 4) conducting successively under the control of control module, capacitor group C 0To welding transformer Trans primary coil input electric energy, its waveform as shown in Figure 4 by power switch.As seen from Figure 4, under the control of control module, conducting dutycycle to welding transformer Trans primary coil input chopped waveform changes, several copped wave pulses of beginning, because this moment, the voltage of capacitance group was the highest, in order to control the rate of climb of secondary output current, the conducting dutycycle of copped wave pulse is less, increases the conducting dutycycle of copped wave pulse subsequently gradually; For fear of the unidirectional magnetic saturation of welding transformer, after several copped wave pulses, should in the opposite direction apply one and force the demagnetization pulse, promptly adopt asymmetrical copped wave pulse input, until finishing whole welding process.The duration of the conducting dutycycle of copped wave pulse and demagnetization pulse, all should decide according to the actual welding situation.After finishing a weld cycle, the magnetic saturation phenomenon that produces for fear of the long-term unidirectional energising of welding transformer Trans should change the input direction of importing the asymmetric copped wave pulse of welding transformer Trans primary coil.If welding procedure adopts little electric current, long soft standard, also can change the input direction of the asymmetric copped wave pulse of input welding transformer Trans primary coil on several times ground in welding process.

Claims (2)

1, direct current resistance welder with low input power and without secondary commutation, power supply be through binding post input rectification circuit Rect, and alternating current is transformed into the DC current of pulsation, capacitor group C 0Be connected in parallel on the output of rectification circuit Rect, capacitor group C 0The power storage of pulsating direct current electric current input is got up four power switch component T 1, T 2, T 3, T 4With the welding main circuit that corresponding protection components and parts are formed, welding main circuit input and capacitor group C 0In parallel, the output of welding main circuit inserts the input of welding transformer Trans primary coil, continued flow resistance R of access in parallel at welding transformer Trans primary coil two ends, the secondary output end of welding transformer Trans inserts the welding machine secondary loop, for welding machine work provides electric current, it is characterized in that: at capacitor group C 0Two ends be connected in parallel to voltage sensor V-S, monitoring charging voltage inserts current sensor I-S1 in the series connection of the primary input terminal of welding transformer Trans, inserts current sensor I-S2, monitoring and protection in the secondary output end series connection of welding transformer Trans.
2, the applied control method of direct current resistance welder with low input power and without secondary commutation according to claim 1 is characterized in that: grading control capacitor group C 0Charging voltage, power to welding transformer Trans primary coil two ends with asymmetric copped wave impulse waveform, after some copped wave pulse inputs, rightabout in power supply copped wave pulse applies a pressure demagnetization pulse, with the magnetic saturation phenomenon of eliminating or minimizing produces owing to the unidirectional power supply of welding transformer, the duration of this pressure demagnetization pulse is depended on demagnetization effectiveness, and to account for the rate of carrying irrelevant with the conducting of the copped wave pulse of forward power supply, and specific implementation process is:
(1) connect power supply (three-phase or single-phase) afterwards, power supply is through binding post input rectification circuit Rect, and alternating current is transformed into the DC current of pulsation, and the pulsating direct current electric current outputs to capacitor group C 0It is charged;
(2) by and be connected in capacitor group C 0The voltage sensor V-S at two ends, controlling system of welder monitor capacitor group C in real time 0Charging voltage, when reach setting keep voltage after, rectification circuit Rect turn-offs, welding machine is in the welding job state of waiting for;
(3) at t 11Constantly, the welding machine welding is switch activated, and the welding machine top electrode moves under the driving of pressure system, applies welding pressure to welded part, meanwhile, rectification circuit Rect conducting, power supply passes through rectification circuit Rect to capacitor group C 0Carry out quick charge, make its charging voltage reach critical voltage rapidly, and in whole welding process, keep capacitor group C 0Quick-charge state;
(4) at t 12Constantly, circuits for triggering send trigger impulse, the power switch T on the welding main circuit 1, T 4Conducting simultaneously, capacitor group C 0Pass through T 1, T 4To the power supply of welding transformer, convert welding current to through welding transformer Trans;
(5) at t 13Constantly, when the copped wave pulse charging time that reaches setting, under the effect of controlling system of welder, power switch T 1(or T 4) end, the energy that is stored among the welding transformer Trans discharges by the secondary loop, keeps the continuity of welding current; The primary coil of welding transformer Trans forms discharge loop by continued flow resistance R;
(6) when arriving the copped wave pulse stop time t that sets 14The time, under the effect of controlling system of welder, power switch T 1(or T 4) conducting once more, power supply passes through T once more 1, T 4To welding transformer Trans input energy;
(7) under the effect of controller, repeat 5,6 action several times, reach after the copped wave pulse input number of times of setting, because the remanent magnetism among the copped wave stop time welding transformer Trans can not be eliminated fully, after several times copped wave pulse input, remanent magnetism among the welding transformer Trans runs up to a certain degree, at this moment (t 15), in input copped wave pulse opposite direction, import the asymmetrical pressure pulse of demagnetizing, the duration of this pulse, will decide according to actual measurement current sensor I-S1, I-S2 data;
(8) repeat above-mentioned action several times, until the weld interval that reaches setting;
(9) it should be noted that owing to when beginning to weld capacitor group C 0Charging voltage higher, excessive for fear of the rate of climb of welding current, copped wave pulse this moment obtains logical dutycycle should be less, afterwards along with capacitor group C 0The reduction of charging voltage should increase the copped wave pulse gradually and get the conducting dutycycle;
(10) adopt the welding process of the strong weld standard of big electric current, short time for needs, can remain under the situation of same copped wave pulse input direction and finish whole welding process, in weld cycle next time, change the input direction of copped wave pulse again; If adopt little electric current, when for a long time soft soldering connects standard and welds, the welding transformer iron core magnetic saturation phenomenon that produces for fear of long-time unidirectional energising occurring can change the input direction of copped wave pulse in welding process.
CNA2007100725275A 2007-07-19 2007-07-19 Direct current resistance welder with low input power and without secondary commutation and control method thereof Pending CN101347866A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102554440A (en) * 2010-10-09 2012-07-11 罗伯特·博世有限公司 Method and device for operating a resistance welding device
CN110977128A (en) * 2019-12-31 2020-04-10 何社宏 Super farad capacitive resistance welder and independent capacitor balance management method thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102554440A (en) * 2010-10-09 2012-07-11 罗伯特·博世有限公司 Method and device for operating a resistance welding device
CN102554440B (en) * 2010-10-09 2016-05-11 罗伯特·博世有限公司 For moving the method and apparatus of electric resistance welder
CN110977128A (en) * 2019-12-31 2020-04-10 何社宏 Super farad capacitive resistance welder and independent capacitor balance management method thereof

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Open date: 20090121