CN110539055A - large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation device and method - Google Patents
large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation device and method Download PDFInfo
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- CN110539055A CN110539055A CN201910757618.5A CN201910757618A CN110539055A CN 110539055 A CN110539055 A CN 110539055A CN 201910757618 A CN201910757618 A CN 201910757618A CN 110539055 A CN110539055 A CN 110539055A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
- B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
- B23K9/092—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits characterised by the shape of the pulses produced
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
- B23K9/1043—Power supply characterised by the electric circuit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
- B23K9/321—Protecting means
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Abstract
the invention relates to a large-current high-frequency arbitrary waveform electric arc coupling ultrasonic energy field excitation device and a method, wherein the device is connected with an electric arc welding power supply of an electric welding machine, the device comprises a signal generation assembly and a small-signal waveform amplification assembly, the signal generation assembly is used for generating a small-signal superaudio waveform, and the small-signal waveform amplification assembly is used for receiving and amplifying the small-signal superaudio waveform and outputting large-current high-frequency alternating current with the same waveform, amplitude and frequency. Compared with the prior art, the invention has the advantages of capability of outputting large-current high-frequency alternating current, good stability of output current, good safety when the external current is overloaded and the like.
Description
Technical Field
the invention relates to an arc coupling ultrasonic energy field excitation device and method, in particular to a large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation device and method.
Background
The ultrasonic energy field is coupled in the arc welding process, so that the method is an effective means for improving the welding quality of the metal component. For high-end engineering fields such as nuclear power unit construction, turbofan engine manufacturing and the like, electric arc welding is widely used for producing welding components such as stainless steel, low alloy steel, Ni-based alloy, Ti alloy and the like. The welding components are used in large amount and are generally used in a high-temperature, high-pressure, high-radiation and high-load working environment, so that high safety and robustness are required. Therefore, the improvement of the traditional arc welding process, the improvement of the welding efficiency, the improvement of the microstructure of a welding part and the improvement of the comprehensive mechanical property of the welding part are urgently needed. The ultrasonic energy field is a special external physical field, and the essence of the ultrasonic energy field is the transmission process of mechanical vibration waves and waves with the frequency of 20 kHz. When the ultrasonic energy field is coupled with the welding pool, special physical effects such as jet stirring, cavitation bubble growth, blasting and the like can be brought to the welding pool, and further the forming process of the metal welding seam is expected to be changed so as to artificially intervene and regulate and control the welding quality of the metal component. The method for coupling the ultrasonic energy field to the electric arc welding process mainly comprises two modes of mechanical coupling and electrical coupling.
The mode of mechanically coupling the ultrasonic energy field is mainly that the ultrasonic energy field is superposed on a welding pool through a mode of adding an energy converter outside a mechanical vibrator and through intermediaries such as a welding workpiece, a welding electric arc and the like. For example, patent CN201710157697.7 couples the ultrasonic energy field emitted by the mechanical transducer to the GTAW welding process through the welding arc by retrofitting the GTAW welding gun. The coupling mode of the ultrasonic energy field is visual, but the ultrasonic energy field has some defects, such as that the mechanical vibrator is not suitable for working in a high-temperature environment for a long time, the structure of a welding gun needs to be greatly changed, the frequency of the ultrasonic energy field is a discrete value, and the like. These drawbacks are preferably avoided by electrically coupling the ultrasonic energy field. This approach forces the welding arc to vibrate periodically by introducing an alternating current with a frequency greater than 20kHz into the DC welding current, which in turn couples the ultrasonic energy field to the weld puddle. For example, patent CN01143444.9 superimposes a high frequency AC current on a DC current by connecting the high frequency AC power source in parallel on both sides of the welding power source; patent CN201710157697.7 develops a device for superimposing high-frequency AC current on a GMAW power supply, where the AC current frequency is 20-100 kHz, and the current peak-to-peak value is 100A. The frequency and amplitude of the ultrasonic energy field can be continuously adjusted by virtue of the characteristics of the alternating current; the excitation device for generating the high-frequency alternating current can be arranged far away from the welding arc and is not easily influenced by the welding heat; the alternating current can be directly led in from the joint end of the welding gun without changing the structure of the welding gun. The electric coupling ultrasonic energy field has strong advantages in the aspects of high-frequency alternating current controllability, welding adaptability and the like.
according to the characteristics of the electric coupling ultrasonic energy field, the key point for generating the ultrasonic energy field in an electric mode is to design and manufacture an ultrasonic energy field excitation device to generate alternating current with large amplitude, high frequency, undistorted waveform and continuously adjustable amplitude frequency. The high-power, large-current and high-frequency arbitrary waveform electric arc coupling ultrasonic energy field excitation device can generate an ultrasonic energy field with higher power and more perfect waveform, and is favorable for fully exerting the advantage of an external ultrasonic energy field in the electric arc welding process. However, the frequency of the existing ultrasonic energy field excitation device is usually lower than 100kHz, the current amplitude is small, the waveform appearance quality is poor, the sine and other current appearances are difficult to reproduce, and the ultrasonic energy field excitation device is not beneficial to exerting the advantages of the ultrasonic energy field.
disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation device and method.
The purpose of the invention can be realized by the following technical scheme:
a large-current high-frequency arbitrary waveform electric arc coupling ultrasonic energy field excitation device is connected with an electric arc welding power supply of an electric welding machine and comprises a small signal generation assembly and a small signal waveform amplification assembly, wherein the small signal generation assembly is used for generating an arbitrary waveform (voltage is 0-5V, amplitude is-5 to +5V, and frequency is 16-150 kHz) of a superaudio frequency, and the small signal waveform amplification assembly is used for receiving and amplifying a small signal superaudio frequency waveform and outputting large-current high-frequency alternating current with the same waveform, amplitude and frequency.
The small signal waveform amplifying assembly comprises a small signal ultrasonic frequency arbitrary waveform input end, a small signal waveform pre-amplifying circuit module, a high-power transistor driving matrix module and a high-power transistor matrix module, the small signal ultrasonic frequency arbitrary waveform input end is connected with the signal generating assembly and the small signal waveform pre-amplifying circuit, the small signal waveform pre-amplifying circuit module is connected with the high-power transistor driving matrix module, the high-power transistor driving matrix module is connected with the high-power transistor matrix module,
the small-signal ultrasonic frequency arbitrary waveform input end is used for receiving a small-signal ultrasonic frequency waveform, the small-signal waveform pre-amplifying circuit module is used for pre-amplifying the small-signal ultrasonic frequency waveform so as to carry a high-power transistor driving matrix module, the high-power transistor driving matrix module is used for pushing the high-power transistor matrix module to operate by utilizing the pre-amplified small-signal ultrasonic frequency waveform, and the high-power transistor matrix module is used for amplifying the large-signal ultrasonic frequency waveform and outputting alternating current waveforms with the same waveform, amplitude and frequency.
The high-power transistor driving matrix module comprises a three-level high-power driving matrix, and the high-power transistor driving matrix comprises a column driving matrix and a row driving matrix.
The high-power tube matrix module comprises N pairs of high-power transistors, a current-sharing circuit network is additionally arranged in each high-power transistor, each pair of high-power transistors is used for amplifying a small voltage signal received by any small signal waveform input end and outputting an alternating current waveform with the same waveform, amplitude and frequency, and the current-sharing circuit network is used for ensuring that the current amplitude output by each high-power tube is the same.
the signal generating component comprises an industrial personal computer and a data acquisition card, the industrial personal computer is connected with the data acquisition card,
The industrial personal computer is used for setting characteristic parameters of the small-signal superaudio waveform, and the data acquisition card is used for generating the small-signal superaudio waveform.
And a conditioning circuit is arranged in the data acquisition card.
The device comprises a high-voltage arc striking spike pulse protection device, wherein the high-voltage arc striking spike pulse protection device comprises a TVS diode and a blocking circuit, the high-voltage arc striking spike pulse protection device is connected with a high-power tube matrix module and an electric arc load, and the high-voltage arc striking spike pulse protection device is used for absorbing and limiting serially-connected arc striking high voltage and external spike pulse high voltage.
A large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation method comprises the following steps:
S1: connecting the device to both ends of a welding arc load by a high frequency power cable;
s2: taking an electric arc welding power supply as direct current welding current, adjusting an electric welding machine to be in a constant current mode, and connecting the electric arc welding power supply to two ends of a welding electric arc load;
s3: the industrial personal computer sets characteristic parameters of the waveform appearance, amplitude, frequency and phase of the alternating current;
S4: starting an electric arc welding power supply;
s5: when the arc welding power supply is stably output, the data acquisition card generates a small-signal superaudio waveform under the control of the industrial personal computer;
S6: the small signal waveform amplifying assembly receives and amplifies the small signal waveform and outputs a large-current high-frequency alternating current waveform with the same waveform, amplitude and frequency;
s7: the alternating current is coupled into the welding arc load through a high voltage arc strike spike protection device.
the S6 specifically includes:
S61: the small signal ultrasonic frequency arbitrary waveform input end receives a small signal ultrasonic frequency waveform;
s62: the small signal waveform pre-amplifying circuit module pre-amplifies a small signal superaudio waveform;
s63: the high-power transistor driving matrix module utilizes the pre-amplified small signal superaudio frequency waveform to push the high-power transistor matrix module to operate;
S64: the high-power tube matrix module amplifies the small signal superaudio frequency waveform and outputs an alternating current waveform with the same waveform, amplitude and frequency.
compared with the prior art, the invention has the following advantages:
(1) According to the invention, the small-signal waveform amplification assembly is used for outputting alternating current, the current peak value exceeds 420A, the frequency can be continuously adjusted within a wider superaudio frequency range of 16 kHz-150 kHz, and the waveform distortion degree is smaller;
(2) the high-power tube matrix module can balance the output current of each pair of high-power transistors and ensure the stability of the output current;
(3) the invention utilizes the high-voltage arc striking spike pulse protection device, and when the voltage and current overload problem caused by an external circuit, such as an electric welding machine, the voltage can be limited below the safe voltage until the system stops working.
drawings
FIG. 1 is a block diagram of the apparatus of the present invention;
FIG. 2 is a column driver module of a high power tube driver matrix of the apparatus of the present invention;
FIG. 3 is a row driver module of a high power tube driver matrix of the apparatus of the present invention;
FIG. 4 is a high voltage arc strike spike protection arrangement of the apparatus of the present invention;
the device comprises an industrial personal computer (1), an industrial personal computer (2), a data acquisition card (3), a small-signal ultrasonic frequency arbitrary waveform input end, a small-signal waveform pre-amplification circuit module (4), a high-power transistor driving matrix module (5), a high-power tube matrix module (6), a high-voltage arc striking spike pulse protection device (7), an electric arc load (8), and an electric welding machine (9).
Detailed Description
the invention is described in detail below with reference to fig. 1 and the specific examples. Note that the following description of the embodiments is merely a substantial example, and the present invention is not intended to be limited to the application or the use thereof, and is not limited to the following embodiments.
Examples
The device is connected with an arc welding power supply of an electric welding machine 9, the frequency range of an ultrasonic energy field which can be output by the device is 16-150 kHz, and the peak value of output alternating current is more than or equal to 420A.
The device comprises an industrial personal computer 1, a data acquisition card 2, a small signal ultrasonic frequency arbitrary waveform input end 3, a small signal waveform pre-amplification circuit 4 module, a high-power transistor driving matrix module 5, a high-power tube matrix module 6 and a high-voltage arc striking spike pulse protection device 7, wherein the data acquisition card 2 is respectively connected with the industrial personal computer 1 and the small signal ultrasonic frequency arbitrary waveform input end 3, the small signal waveform pre-amplification circuit 4 module is respectively connected with the small signal ultrasonic frequency arbitrary waveform input end 3 and the high-power transistor driving matrix module 5, the high-power tube matrix module 6 is respectively connected with the high-power transistor driving matrix module 5 and the high-voltage arc striking spike pulse protection device 7, the high-voltage arc striking spike pulse protection device 7 is connected with a welding arc load 8, the maximum peak-to-peak value of the output current of the device is greater than or equal to 420A, and the maximum frequency of the output waveform is 150 kHz.
in this embodiment, the data acquisition card 2 is connected with the industrial personal computer 1 through a USB cable, the data acquisition card 2 is connected with the small-signal ultrasonic frequency arbitrary waveform input end 3 through a high-frequency signal cable, and the high-voltage spike pulse protection device is connected to two ends of the welding arc load 8 through a high-frequency power cable.
the data acquisition card 2 is internally provided with a conditioning circuit, and the data acquisition card 2 is used for generating any voltage waveform with the amplitude of-5V and the frequency of 16-150 kHz, including but not limited to sine wave, triangular wave, sawtooth wave, square wave and sparse-dense wave.
the small signal ultrasonic frequency arbitrary waveform input end 3 is used for receiving a small signal ultrasonic frequency waveform, the small signal waveform pre-amplifying circuit 4 module is used for pre-amplifying the small signal ultrasonic frequency waveform so as to carry a high-power transistor driving matrix module 5, the high-power transistor driving matrix module 5 comprises a three-level high-power driving matrix, the high-power transistor driving matrix comprises a column driving matrix and a row driving matrix, and the high-power transistor driving matrix module 5 is used for pushing a high-power transistor matrix module 6 to operate by utilizing the pre-amplified small signal ultrasonic frequency waveform.
The high-power tube matrix module 6 comprises 100 pairs of high-power transistors, each high-power transistor is internally provided with a current-sharing circuit network, each pair of high-power transistors is used for amplifying a small voltage signal received by any small signal waveform input end and outputting an alternating current waveform with the same waveform, amplitude and frequency, and the current-sharing circuit network is used for ensuring that the current amplitude output by each high-power tube is the same so as to improve the overall working efficiency of the high-power tube matrix module 6.
The high-voltage arc striking spike pulse protection device 7 comprises a TVS diode and a blocking circuit, the high-voltage arc striking spike pulse protection device 7 is connected with the high-power tube matrix module 6 and the arc load 8, and the high-voltage arc striking spike pulse protection device 7 is used for absorbing and limiting the high voltage of arc striking and the high voltage of external spike pulse which are connected in series, and limiting the high voltage which is led in from the outside to be below a safe voltage of 72V.
the industrial personal computer 1 is used for setting characteristic parameters of the small-signal superaudio waveform generated by the signal generating assembly.
In this embodiment, the appearance of the current flowing through the welding arc load 8 is detected by a Hall current sensor and a data acquisition card through virtual instrument software and displayed on the industrial personal computer 1.
A large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation method comprises the following steps:
S1: connecting a high-voltage arc striking spike pulse protection device 7 to two ends of a welding arc load 8 through a high-frequency power cable;
S2: taking an electric arc welding power supply as direct current welding current, adjusting an electric welding machine 9 to a constant current mode, and connecting the positive electrode and the negative electrode of the electric arc welding power supply to two ends of a welding electric arc load 8;
s3: the software of the industrial personal computer 1 sets characteristic parameters such as alternating current waveform appearance, amplitude, frequency, phase and the like;
S4: starting an electric arc welding power supply;
s5: when the arc welding power supply is stably output, the data acquisition card 2 generates a small voltage signal under the control of the industrial personal computer 1;
s6: the small signal waveform amplifying assembly receives and amplifies the small signal waveform and outputs an alternating current waveform with the same waveform, amplitude and frequency
s7: the alternating current is coupled through a high voltage arc strike spike protection 7 into a welding arc load 8.
step S6 specifically includes:
S61: the small signal ultrasonic frequency arbitrary waveform input end 3 receives a small signal ultrasonic frequency waveform;
S62: the small signal waveform pre-amplifying circuit 4 module pre-amplifies the small signal superaudio waveform;
s63: the high-power transistor driving matrix module 5 utilizes the pre-amplified small signal superaudio waveform to push the high-power transistor matrix module 6 to operate;
S64: the high-power tube matrix module 6 amplifies small-signal superaudio frequency waveforms and outputs large-current high-frequency alternating current with the same waveform, amplitude and frequency.
In this embodiment, the industrial personal computer 1 sets the small-signal alternating current to be sine-shaped, and by observing the waveform characteristics displayed by the virtual instrument, the sine-shaped current with extremely small waveform distortion degree appears in the current flowing through the welding arc load 8, the peak value of the current is as high as 420A, the frequency reaches 150kHz, and it is indicated that the ultrasonic energy field is coupled in the welding process. Then, metallographic analysis was performed on the welded Ni-based sample, and it was found that the crystal grains of the Ni-based alloy were refined and the brittle phase was reduced.
the above embodiments are merely examples and do not limit the scope of the present invention. These embodiments may be implemented in other various manners, and various omissions, substitutions, and changes may be made without departing from the technical spirit of the present invention.
Claims (9)
1. The device is connected with an arc welding power supply of an electric welding machine (9), and is characterized by comprising a signal generation assembly and a small signal waveform amplification assembly, wherein the signal generation assembly is used for generating a small signal superaudio arbitrary waveform, the small signal waveform amplification assembly is used for receiving and amplifying a small signal superaudio waveform, and outputting a large-current high-frequency alternating current with the same waveform, amplitude and frequency.
2. The arc-coupled ultrasonic energy field excitation device of a large-current high-frequency arbitrary waveform as claimed in claim 1, wherein the small-signal waveform amplifying assembly comprises a small-signal ultrasonic frequency arbitrary waveform input end (3), a small-signal waveform pre-amplifying circuit module (4), a high-power transistor driving matrix module (5) and a high-power transistor matrix module (6), the small-signal ultrasonic frequency arbitrary waveform input end (3) is connected with the signal generating assembly and the small-signal waveform pre-amplifying circuit (4), the small-signal waveform pre-amplifying circuit module (4) is connected with the high-power transistor driving matrix module (5), and the high-power transistor driving matrix module (5) is connected with the high-power transistor matrix module (6);
The small-signal ultrasonic frequency arbitrary waveform input end (3) is used for receiving a small-signal ultrasonic frequency waveform, the small-signal waveform pre-amplifying circuit module (4) is used for pre-amplifying the small-signal ultrasonic frequency waveform so as to carry a high-power transistor driving matrix module (5), the high-power transistor driving matrix module (5) is used for pushing a high-power tube matrix module (6) to operate by utilizing the pre-amplified small-signal ultrasonic frequency waveform, and the high-power tube matrix module (6) is used for amplifying the small-signal ultrasonic frequency waveform and outputting an alternating current waveform with the same waveform, amplitude and frequency.
3. a large current high frequency arbitrary waveform arc coupled ultrasonic energy field excitation device as claimed in claim 2, wherein said high power transistor driving matrix module (5) comprises a three-level high power driving matrix, and said high power transistor driving matrix comprises a column driving matrix and a row driving matrix.
4. The arc-coupled ultrasonic energy field excitation device of any large-current high-frequency waveform according to claim 2, wherein the large-power tube matrix module (6) comprises N pairs of large-power transistors, each large-power transistor is internally provided with a current-sharing circuit network, each pair of large-power transistors is used for amplifying a small-voltage signal received by any small-signal waveform input end and outputting an alternating current waveform with the same waveform, amplitude and frequency, and the current-sharing circuit network is used for ensuring that the current amplitude output by each large-power tube is the same.
5. A large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation device as claimed in claim 1, wherein the signal generation component comprises an industrial personal computer (1) and a data acquisition card (2), and the industrial personal computer (1) is connected with the data acquisition card (2);
the industrial personal computer (1) is used for setting characteristic parameters of the small-signal superaudio frequency waveform, and the data acquisition card (2) is used for generating the small-signal superaudio frequency waveform.
6. a large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation device as claimed in claim 5, wherein a conditioning circuit is arranged in said data acquisition card (2).
7. a large current high frequency arbitrary waveform arc coupling ultrasonic energy field excitation device according to claim 1, characterized in that, said device comprises a high voltage arc striking spike protection device (7), said high voltage arc striking spike protection device (7) comprises TVS diode and DC blocking circuit, and said high voltage arc striking spike protection device (7) is connected with high power tube matrix module (6) and arc load (8);
The high-voltage arc striking spike pulse protection device (7) is used for absorbing and limiting the arc striking high voltage and the external spike pulse high voltage which are connected in series.
8. A large-current high-frequency arbitrary waveform arc coupling ultrasonic energy field excitation method is characterized by comprising the following steps:
s1: connecting the device to both ends of a welding arc load (8) by means of a high-frequency power cable;
S2: adjusting the electric welder (9) to a constant current mode with the electric arc welding power source as a direct current welding current and connecting the electric arc welding power source to both ends of a welding arc load (8);
S3: the industrial personal computer (1) sets characteristic parameters of the waveform appearance, amplitude, frequency and phase of the alternating current;
s4: starting an electric arc welding power supply;
S5: after the arc welding power supply is stably output, the data acquisition card (2) generates a small-signal superaudio waveform under the control of the industrial personal computer (1);
S6: the small signal waveform amplifying assembly receives and amplifies the small signal waveform and outputs a large-current high-frequency alternating current waveform with the same waveform, amplitude and frequency;
S7: the alternating current is coupled into a welding arc load (8) through a high voltage arc strike spike protection device (7).
9. The method for exciting an arc coupling ultrasonic energy field with large current and high frequency according to claim 8, wherein the step S6 specifically comprises:
s61: the small signal ultrasonic frequency arbitrary waveform input end (3) receives a small signal ultrasonic frequency waveform;
S62: the small signal waveform pre-amplifying circuit module (4) pre-amplifies the small signal superaudio waveform;
s63: the high-power transistor driving matrix module (5) utilizes the pre-amplified small signal superaudio frequency waveform to push the high-power transistor matrix module (6) to operate;
S64: the high-power tube matrix module (6) amplifies the small-signal superaudio frequency waveform and outputs an alternating current waveform with the same waveform, amplitude and frequency.
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| CN112404662A (en) * | 2020-11-03 | 2021-02-26 | 江苏科技大学 | Ultrasonic narrow-gap welding system and method for aluminum alloy |
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