CN101352782B - Stud welder and stud welder high-frequency transformator - Google Patents
Stud welder and stud welder high-frequency transformator Download PDFInfo
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- CN101352782B CN101352782B CN2008102160419A CN200810216041A CN101352782B CN 101352782 B CN101352782 B CN 101352782B CN 2008102160419 A CN2008102160419 A CN 2008102160419A CN 200810216041 A CN200810216041 A CN 200810216041A CN 101352782 B CN101352782 B CN 101352782B
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Abstract
The invention discloses a stud welder and a transformer. The stud welder includes a three-phase rectifier circuit, a high frequency inverter circuit, a high frequency transformer, a rectifier and filter circuit and a pulse width control circuit; the three-phase rectifier circuit converts a three-phase AC into a DC; the high frequency inverter circuit under the control of the pulse width control circuit converts the DC output by the three-phase rectifier circuit into a high frequency AC; after the voltage of the high frequency AC is reduced by the high frequency transformer, a pulsation DC welding current is generated by the rectifier and filter circuit; an annular iron core of an iron-based nano material is adopted by the high frequency transformer; secondary coils and a primary coil are arranged by layers; the secondary coils consist of one to six secondary coils; each secondary coil consists of 3 sub-coils; the 3 sub-coils are arranged along the circumferential direction of the annular iron core at 120 degrees; the 3 sub-coils are connected in parallel by the ends with the same name. The stud welder has the advantages of small size, light weight, large output power, good welding quality and high integral stability and reliability.
Description
[technical field]
The present invention relates to welding equipment, relate in particular to stud welder and stud welder high-frequency transformator.
[background technology]
Stud welding machine divides three major types, and the one, energy storage stud welding machine, the 2nd, the short period stud welding machine, weld interval, arcing time factor was about 10% at 30-200mS; The 3rd, the long period stud welding machine, usually at steel make up and build the welding that be used for peg at 300-2000mS weld interval, is commonly called as to be stud welder.Stud welder is to utilize the porcelain ring protection to carry out long period (300-2000mS) arcing time factor about 30%.Commonly used in the market have a thyristor controlled electric arc stud welder of power frequency.Control mode divides simulation control and MCU to control two kinds.Power frequency controllable silicon electric arc stud welder and since welding current at 600-3150A, power between 200-300KW, so power consumption is big, efficient is low; It is huge, heavy that volume seems, general weight moves and use all inconveniences at 500Kg-600Kg.The welding current climbing speed is slow, and welding current, weldingvoltage and control weld interval are accurate inadequately, and welding quality is difficult to ensure.When using in the building site, the welding quality of peg is subject to the influence of voltage ripple of power network.
[summary of the invention]
It is big that the technical problem to be solved in the present invention provides a kind of power output, little power consumption, little, the lightweight stud welder of volume.
It is good that the technical problem that the present invention further will solve provides a kind of welding quality, the stud welder that complete machine stability and reliability are high.
The technical problem that the present invention further will solve provides a kind of stud welder that can reduce the pollution of electrical network.
Another technical problem that will solve of the present invention provide a kind of power output big (maximum can reach 2500A), little power consumption (only for the power frequency welding machine of constant power 70%), volume little (only for the power frequency welding machine of constant power 8%), in light weight (only for the power frequency welding machine of constant power 5%) stud welder high-frequency transformator.
In order to solve the problems of the technologies described above, the technical solution used in the present invention is, a kind of stud welder, comprise rectified three-phase circuit, comprise high-frequency inverter circuit, high frequency transformer, current rectifying and wave filtering circuit and pulse width control circuit, described rectified three-phase circuit is transformed into direct current with three-phase alternating current, high-frequency inverter circuit converts the direct current of rectified three-phase circuit output to high-frequency alternating current under the control of pulse width control circuit, after the high frequency transformer step-down, produce the pulsating direct current welding current by current rectifying and wave filtering circuit, described high frequency transformer adopts annular iron based nano crystal iron core, secondary coil and primary coil layered arrangement; Secondary coil is made up of 1 to 6 secondary coil group; Each secondary coil group has 3 subcoils, and described 3 subcoils are circumferentially uniform by 120 ° along annular iron based nano crystal iron core, and described 3 subcoils are by end parallel connection of the same name.
Above-described stud welder, described subcoil is made up of 2 molecule coils, described 2 molecule coils series connection, being connected in series of molecule coil of 3 subcoils a little links together, and draws as the centre cap of subcoil group.Described secondary coil is made up of 4 secondary coil groups.
Above-described stud welder, described secondary coil is arranged in internal layer, and primary coil is arranged in skin, and the lead of primary coil and secondary coil adopts stranded the forming of enamel-covered wire of 0.2 to 0.6 millimeter of 20 to 40 strands of diameter; The saturation induction density 1.25T of described annular iron based nano crystal iron core, residual magnetic flux density 0.2T, permeability 20000, core lamination stack parameter 0.7.
Above-described stud welder comprises PI Current Control feedback circuit, and described PI Current Control feedback circuit is from the sampling of the output of current rectifying and wave filtering circuit, and sampled value is imported the signal input part of pulse width control circuit, realizes constant current control; Described high-frequency inverter circuit comprises IGBT bridge circuit on-off circuit and isolated drive circuit; Described pulse width control circuit produces 4 road pwm signals, through the break-make of isolated drive circuit control IGBT bridge circuit on-off circuit.
Above-described stud welder, comprise PI Control of Voltage feedback circuit and PID current feedback circuit, described PI Control of Voltage feedback circuit is from the sampling of the output of current rectifying and wave filtering circuit, and sampled value is imported the signal input part of pulse width control circuit, realizes pressure limiting control; Described PID current feedback circuit is from the sampling of the input of high frequency transformer, and sampled value is imported the signal input part of pulse width control circuit, realizes the qualification of immediate current peak value.
Above-described stud welder, described rectified three-phase circuit is followed successively by electromagnetic compatibility circuit, three phase rectifier module, soft starting circuit and second current rectifying and wave filtering circuit, described electromagnetic compatibility circuit absorbs the due to voltage spikes that suppresses on the three-phase alternating current bus, reduces electromagnetic interference; Described three phase rectifier module is converted to direct current with the three-phase alternating current of electromagnetic compatibility circuit output; Described second current rectifying and wave filtering circuit comprises filter capacitor, and the direct current that the three phase rectifier module is exported carries out filtering; Described soft starting circuit control three phase rectifier module output major loop just makes the major loop energising after described filter capacitor charges to setting voltage.
Above-described stud welder, the electromagnetic compatibility circuit is in series with input inductance respectively on the phase line of three-phase electricity input, be parallel with peak clipping electric capacity between phase line respectively.
The technical scheme of stud welder high-frequency transformator is, comprises iron core, primary coil and secondary coil, and the described iron core of described stud welder adopts annular iron based nano crystal iron core, secondary coil and primary coil layered arrangement; Secondary coil is made up of 1 to 6 secondary coil group; Each secondary coil group has 3 subcoils, and described 3 subcoils are circumferentially uniform by 120 ° along annular core, and described 3 subcoils are by end parallel connection of the same name.
Above-described stud welder high-frequency transformator, described secondary coil is made up of 4 secondary coil groups; Described subcoil is made up of 2 molecule coils, described 2 molecule coils series connection, and being connected in series of molecule coil of 3 subcoils a little links together, and draws as the centre cap of subcoil group.
Stud welder of the present invention adopts high-frequency inverter circuit and high frequency transformer, high frequency transformer adopt annular iron based nano crystal iron core, subcoil along annular core circumferentially by 120 ° of uniform structures.
[description of drawings]
The present invention is further detailed explanation below in conjunction with the drawings and specific embodiments.
Fig. 1 is the schematic block circuit diagram of stud welder embodiment of the present invention.
Fig. 2 is the circuit theory diagrams of stud welder embodiment of the present invention.
Fig. 3 is a stud welder embodiment high frequency transformer wiring diagram of the present invention.
[specific embodiment]
Stud welder embodiment of the present invention as shown in Figure 1, complete machine by 8 the part form: the 1st, rectified three-phase circuit; The 2nd, high-frequency inverter circuit; The 3rd, high frequency transformer; The 4th, current rectifying and wave filtering circuit; The 5th, pulse width control circuit; The 6th, the little control and treatment circuit of P1C; The 7th, the peg welding gun; The 8th, liquid crystal touch screen.
The course of work of stud welder embodiment of the present invention is as shown in Figure 2: rectified three-phase circuit 1 is followed successively by electromagnetic compatibility circuit, three phase rectifier module D1, soft starting circuit and second current rectifying and wave filtering circuit, the electromagnetic compatibility circuit comprises filter inductance L1 and filter capacitor CA, CB, CC, soft starting circuit comprises the soft start controllable silicon, and second current rectifying and wave filtering circuit comprises dc filter capacitor C1, C2.Wherein L1, CA, CB, CC be used for the filtering electrical network High-frequency Interference and reduce of the contamination of this machine to electrical network.D1 is becoming direct current after the three-phase electricity rectification of power frequency, and being convenient to provides electric energy to inverter.Soft starting circuit mainly is the time to reduce bus current in start, when prolonging start to the charging interval of C1, reduce since large bulk capacitance when high-voltage charging to the impact of electrical network and aluminium electroloysis C1, reach the purpose of safety opening terminal.C1, C2 except the effect of bus filtering, also have an effect be inverter circuit under on off state, with high frequency transformer 3, carry out energy exchange.To improve the power factor of complete machine.
High-frequency inverter circuit 2 is made up of 4 IGBT pipe Q1, Q2, Q3, Q4 and 4 M57962L driver modules.The frequency of high-frequency inverter circuit 2 output is the high frequency electric of 20KHZ, is added on the high frequency transformer 3 by 2 of A, B, through high frequency conversion high frequency 520V high pressure is reduced to high frequency low voltage electric current about 100V.
Current rectifying and wave filtering circuit 4 is by diode D5, D6; Filter inductance L2 and filter capacitor C 3 form.It is to change the secondary current that high frequency transformer B1 exports into DC current after commutation diode D5, D6 rectification.L2 also has an even more important characteristic to limit maximum output current exactly except that filter action, causes components from being damaged when preventing the welding gun short circuit because of electric current is excessive.
Present embodiment is made up of current mode pulse-width controlled chip and three feedback control loops.The one, the high speed PID current feedback circuit of high frequency transformer primary current sampling; The 2nd, the PI Current Control feedback circuit of output current sampling; The 3rd, the PI voltage feedback circuit of output voltage sampling.The 1st pin of current-control type pulse width modulating chip UC3846 is the input of current limiting signal, and the 3rd, 4 pin are current detecting ends, has the characteristics of reaction at a high speed, and only there is the time of 300-600nS the current slow time.1st, 3,4 pin are under the effect of fast PID current feedback loop I1, inverter signal is pursued the real-time monitoring of cycle, reach the effect of the too high output current of too fast electric current degreeization of control and restriction, realize the qualification of immediate current peak value, reduce the electric current rate of change, improve the security of power device.The 5th, 6 pin of UC3846 are at the PI electric current, voltage feedback loop, and the effect of I2, U1 is got off to stablize output current and is limited the purpose of output voltage.Two kinds of output characteristics are arranged under the common situation, the one, constant current control characteristic, the 2nd, constant current pressure limiting characteristic.
The main effect of P1C micro-processor interface circuit (chip model PIC18F6720) 6 be to output hand over, monitoring, the alarm of straight, voltage, bus current, IGBT, transformer, rectifying tube and welding gun temperature, finish setting, storage and the management of welding parameters.Finish the management and the control of welding gun welding sequential.
Peg welding gun 7 is made up of output welding cable, control cable and welding gun.Mainly finish the weld task of peg on workpiece.Liquid crystal touch screen and operation interface 8 are mainly used to show welding parameter and warning information, are used for setting welding parameter and relevant information.
The high frequency transformer of welding machine adopts annular iron based nano crystal iron core, and its electric property is: saturation induction density 1.25T, residual magnetic flux density 0.2T, permeability 20000, core lamination stack parameter 0.7.Primary and secondary lead adopts that stranded conductor is stranded to form, and diameter of wire is less than 0.6 millimeter, and insulating tape adopts thickness less than 0.1 millimeter polyester film (6020).
The primary and secondary no-load voltage ratio of high frequency transformer is (4-7): 1; Elementary leakage inductance should be less than 6 microhenrys; Output current is 1500-2500A; Power output is between 90-200KW; Arcing time factor is 15--30%.
High frequency transformer secondary coil and primary coil layered arrangement, secondary coil is arranged in internal layer, and primary coil is arranged in skin.Secondary coil is made up of 4 secondary coil groups; Each secondary coil group is by there being 3 subcoils, and 3 subcoils are circumferentially uniform by 120 ° along annular core, and 3 subcoils are by end parallel connection of the same name.Each subcoil is made up of 2 molecule coils, and these 2 molecule coils are connected mutually, and being connected in series of molecule coil of 3 subcoils a little links together, and draws as the centre cap of subcoil group.Primary coil is that many groups are in parallel, and is evenly distributed in skin.Each coil of primary and secondary coil is evenly distributed, compactness, secondaryly should be controlled at below 6 microhenrys elementary leakage inductance.
The process structure of present embodiment medium-high frequency transformer is as follows:
Adopt the annular iron based nano crystal iron core of OUL-1308050, it is 0.5 millimeter stranded the forming of enamel-covered wire that primary and secondary lead all adopts 30 strands of diameters.Its outside adopts the high strength insulating tape of 10 millimeters of thick 0.05 mm wides to wrap up four to six layers.
Secondary coil is by being arranged in order along ring structure iron core clockwise, and as shown in Figure 3, its coil sequence number is 21,22,31,32,23,24,33,34,25,26,35,36,27,28,37,38,29,210,39,310,211,212,311,312.Coil winding is evenly distributed, and around full ground floor, the lead end of coil is drawn on left side, the right side of iron core respectively, and fix with band.
The coil that secondary coil goes between to the left has 12, and lead terminal has 24.Wherein: 212 and 311,252 and 351,292 and 391 backs that are in series are the centre cap of coil separately, are that the centre cap of first group of secondary wire bag is 1590 after the three links to each other.211,251,291 of three-winding is linked to each other as lead terminal 1591 (head); The tail 312,352,392 of three-winding links to each other as lead terminal 1592 (tail).232 and 331,272 and 371,2112 and 3111 backs that are in series are the centre cap of coil separately, and the three is the centre cap 37110 of first group of secondary wire bag after linking to each other.231,271,2111 of three-winding links to each other as lead terminal 37111 (head); The tail 332,372,3112 of three-winding links to each other as lead terminal 37112 (tail).As shown in Figure 3.
The coil that secondary coil goes between to the right has 12, and lead terminal has 24.Wherein: its lead terminal 222 and 321,262 and 361,2102 and 3101 back that is in series is the centre cap of coil separately, is that the centre cap of first group of secondary wire bag is 26100 after the three links to each other.Then 221,261,2101 of three-winding is linked to each other as lead terminal 26101 (head); The tail 322,362,3102 of three-winding links to each other as lead terminal 26102 (tail).242 and 341,282 and 381,2122 and 3121 backs that are in series are the centre cap of coil separately, and the three is the centre cap 48120 of first group of secondary wire bag after linking to each other.Then 241,281,2121 of three-winding is linked to each other as lead terminal 48121 (head); The tail 342,382,3122 of three-winding links to each other as lead terminal 48122 (tail).As shown in Figure 3.
Primary coil is made up of three coils, and promptly 11,12,13, it is positioned at skin.Three coils along annular iron based nano crystal iron core clockwise and around.The left side lead terminal is 111,122,131; The right side lead terminal is 112,122,132, as shown in Figure 3.
The fixed form of transformer and lead-in wire is as follows, with thick be the epoxy natural gum plate of 3-5 millimeter, according to the shape of iron core and line bag, be cut into two semi-circular plates, at two semicircle places, according to the position of primary and secondary lead terminal, boring rationally.Its aperture is suitable with the diameter of first lead, is convenient to just, inferior line lead-in wire is by corresponding position, order passing successively.Following part is used for fixing whole transformer.
As shown in Figure 3, the secondary coil of present embodiment high frequency transformer is divided into 4 groups, and the output of 4 secondary coil groups connects rectifying and wave-filtering element separately respectively, and the output of stream filter element connects together again.Because each subcoil of each secondary coil group of present embodiment is all connected mutually by 2 molecule coils, being connected in series of molecule coil of 3 subcoils a little links together, centre cap as the subcoil group is drawn, and can adopt full-wave rectifying circuit, and the element cost is lower.If subcoil is a whole coil, do not adopt 2 molecule coils to connect mutually, there is not centre cap to draw, just have to adopt bridge rectifier, may increase the cost of product rectifier cell.
Claims (10)
1. stud welder, comprise rectified three-phase circuit, it is characterized in that, comprise high-frequency inverter circuit, high frequency transformer, current rectifying and wave filtering circuit and pulse width control circuit, described rectified three-phase circuit is transformed into direct current with three-phase alternating current, high-frequency inverter circuit converts the direct current of rectified three-phase circuit output to high-frequency alternating current under the control of pulse width control circuit, after the high frequency transformer step-down, produce the pulsating direct current welding current by current rectifying and wave filtering circuit, described high frequency transformer adopts annular iron based nano crystal iron core, secondary coil and primary coil layered arrangement; Secondary coil is made up of 1 to 6 secondary coil group; Each secondary coil group has 3 subcoils, and described 3 subcoils are circumferentially uniform by 120 ° along annular iron based nano crystal iron core, and described 3 subcoils are by end parallel connection of the same name.
2. stud welder according to claim 1, it is characterized in that described subcoil is made up of 2 molecule coils, described 2 molecule coils series connection, being connected in series of molecule coil of 3 subcoils a little links together, and draws as the centre cap of subcoil group.
3. stud welder according to claim 2 is characterized in that, described secondary coil is made up of 4 secondary coil groups.
4. stud welder according to claim 2 is characterized in that described secondary coil is arranged in internal layer, and primary coil is arranged in skin, and the lead of primary coil and secondary coil adopts stranded the forming of enamel-covered wire of 0.2 to 0.6 millimeter of 20 to 40 strands of diameter; The saturation induction density 1.25T of described annular iron based nano crystal iron core, residual magnetic flux density 0.2T, permeability 20000, core lamination stack parameter 0.7.
5. according to the described stud welder of arbitrary claim in the claim 1 to 4, it is characterized in that, comprise PI Current Control feedback circuit, described PI Current Control feedback circuit is from the output sampling of current rectifying and wave filtering circuit, sampled value is imported the signal input part of pulse width control circuit, realize constant current control; Described high-frequency inverter circuit comprises IGBT bridge circuit on-off circuit and isolated drive circuit; Described pulse width control circuit produces 4 road pwm signals, through the break-make of isolated drive circuit control IGBT bridge circuit on-off circuit.
6. stud welder according to claim 5, it is characterized in that, comprise PI Control of Voltage feedback circuit and PID current feedback circuit, described PI Control of Voltage feedback circuit is from the output sampling of current rectifying and wave filtering circuit, sampled value is imported the signal input part of pulse width control circuit, realize pressure limiting control; Described PID current feedback circuit is from the sampling of the input of high frequency transformer, and sampled value is imported the signal input part of pulse width control circuit, realizes the qualification of immediate current peak value.
7. according to the described stud welder of arbitrary claim in the claim 1 to 4, it is characterized in that, described rectified three-phase circuit is followed successively by electromagnetic compatibility circuit, three phase rectifier module, soft starting circuit and second current rectifying and wave filtering circuit, described electromagnetic compatibility circuit absorbs the due to voltage spikes that suppresses on the three-phase alternating current bus, reduces electromagnetic interference; Described three phase rectifier module is converted to direct current with the three-phase alternating current of electromagnetic compatibility circuit output; Described second current rectifying and wave filtering circuit comprises filter capacitor, and the direct current that the three phase rectifier module is exported carries out filtering; Described soft starting circuit control three phase rectifier module output major loop just makes the major loop energising after described filter capacitor charges to setting voltage.
8. stud welder according to claim 7 is characterized in that, the electromagnetic compatibility circuit is in series with input inductance respectively on the phase line of three-phase electricity input, be parallel with peak clipping electric capacity between phase line respectively.
9. a stud welder high-frequency transformator comprises iron core, primary coil and secondary coil, it is characterized in that, described iron core adopts annular iron based nano crystal iron core, secondary coil and primary coil layered arrangement; Secondary coil is made up of 1 to 6 secondary coil group; Each secondary coil group has 3 subcoils, and described 3 subcoils are circumferentially uniform by 120 ° along annular core, and described 3 subcoils are by end parallel connection of the same name.
10. stud welder high-frequency transformator according to claim 9 is characterized in that, described secondary coil is made up of 4 secondary coil groups; Described subcoil is made up of 2 molecule coils, described 2 molecule coils series connection, and being connected in series of molecule coil of 3 subcoils a little links together, and draws as the centre cap of subcoil group.
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| CN2008102160419A CN101352782B (en) | 2008-09-05 | 2008-09-05 | Stud welder and stud welder high-frequency transformator |
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| CN2008102160419A CN101352782B (en) | 2008-09-05 | 2008-09-05 | Stud welder and stud welder high-frequency transformator |
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| CN101352782B true CN101352782B (en) | 2011-05-11 |
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| CN101920383A (en) * | 2009-06-11 | 2010-12-22 | 徐小羚 | Ultra-miniature stud welding machine |
| CN103366932B (en) * | 2013-08-02 | 2016-01-13 | 深圳市鸿栢科技实业有限公司 | Medium/high frequency transformer |
| CN103633852A (en) * | 2013-12-11 | 2014-03-12 | 佛山市欧立电子有限公司 | Power transformation unit |
| CN105215511B (en) * | 2015-09-24 | 2016-09-07 | 珠海市持久电子科技有限公司 | A kind of automobile aluminum vehicle body quick repairing machine |
| CN106783067B (en) * | 2015-11-19 | 2019-07-12 | 中国石油化工股份有限公司 | A kind of coil shunting transformer |
| CN111098009B (en) * | 2019-12-30 | 2021-12-07 | 上海沪工焊接集团股份有限公司 | Novel arc voltage sampling method and circuit of inverter type plasma cutting machine |
| CN114310084A (en) * | 2021-12-31 | 2022-04-12 | 中国水利水电第七工程局有限公司 | Light-duty stud welding machine auxiliary device |
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| CN2605954Y (en) * | 2003-01-24 | 2004-03-10 | 徐小羚 | Miniature frequency variable capacitor screw post welder |
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| EP1484128A1 (en) * | 2003-06-04 | 2004-12-08 | Illinois Tool Works Inc. | Stud welding device |
| CN201275654Y (en) * | 2008-09-05 | 2009-07-22 | 深圳市鸿栢科技实业有限公司 | Stud welder and stud welder high-frequency transformator |
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Patent Citations (5)
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| WO1991001843A1 (en) * | 1989-08-07 | 1991-02-21 | Trw Nelson Bolzenschweiss-Technik Gmbh & Co. Kg | Stud welding machine with a plurality of welding outputs for welding guns of different polarity for various welding operations |
| CN2609702Y (en) * | 2002-10-26 | 2004-04-07 | 刘英善 | Contravariant automatic arc stud welding machine |
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