CN110744173A - Pulse MIG welding power supply - Google Patents
Pulse MIG welding power supply Download PDFInfo
- Publication number
- CN110744173A CN110744173A CN201810812219.XA CN201810812219A CN110744173A CN 110744173 A CN110744173 A CN 110744173A CN 201810812219 A CN201810812219 A CN 201810812219A CN 110744173 A CN110744173 A CN 110744173A
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- China
- Prior art keywords
- current
- welding
- igbt
- control board
- power supply
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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
-
- 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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
Abstract
The utility model provides a pulse MIG welding source, includes filter, three-phase rectifier bridge, IGBT bridge type switch contravariant module, inverter transformer, secondary fast recovery rectifier diode, DSP digital control system main control board, IGBT contravariant drive control board, current-voltage feedback control board, coprocessing circuit module and control power transformer, the filter with the three-phase rectifier bridge links to each other, IGBT bridge type switch contravariant module with inverter transformer links to each other, inverter transformer with secondary fast recovery rectifier diode links to each other, DSP digital control system main control board output signal extremely send into behind the IGBT contravariant drive control board IGBT bridge type switch contravariant module. The invention has the innovation that the welding power supply can regulate and control the welding current and voltage in different frequency sections of 20kHz to 80kHz, and can adopt corresponding inversion frequency when different working conditions require.
Description
Technical Field
The invention relates to the technical field of welding power supplies, in particular to a pulse MIG welding power supply.
Background
The existing power sources of the Welding machine using IGBT inversion pulse MIG (Metal insert-Gas Welding, abbreviation of Metal Inert-Gas Welding) all use fixed inversion frequency, and the transformer frequency of the fixed inversion frequency is usually 20 kHz. In the pulse MIG welding process, the requirement on the precision of power pulse control is high, and particularly the requirements on the pulse peak current size, time, pulse current rising speed, pulse current falling speed, arc length control and the like are met. The welding power supply with the frequency of 20kHz can meet the process requirements under the control of a low current section, but when high-current welding is needed, the arc length is difficult to control due to limited frequency, the welding wire melting speed is too high, the welding base metal is not melted, the arc length of the electric arc is unstable, the phenomenon of jackscrew or arc breakage is caused, and the welding requirements are difficult to meet.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a pulse MIG welding power supply, which solves the problem that the conventional fixed-frequency IGBT inversion pulse MIG welding power supply cannot meet the welding process at a large current.
The pulse MIG welding power supply comprises a three-phase power supply air switch for controlling the power supply of the whole machine; the three-phase power-in filter prevents the pollution of an external power supply; the three-phase heavy-current rectifier bridge module converts alternating current input into direct current; soft starting the silicon controlled rectifier and the control module; an electrolytic capacitor filter assembly; an IGBT bridge switch inversion module; the inversion frequency of the inversion transformer can be commonly used within the range of 20-80 kHz; a primary current detector; a secondary fast recovery rectifier diode; the current divider is used for detecting the feedback of the actual value of the secondary current; the output inductor is connected to the output of the negative electrode of the welding power supply; outputting a follow current resistor; the control circuit transformer is used for providing a required power supply for the control circuit; the control power supply module is used for providing power for the main control board, the co-processing board, the IGBT inversion driving control board, the current and voltage feedback control board, the man-machine conversation control interface and the wire feeder; and the assistant processing circuit module is used for monitoring and protecting overvoltage, undervoltage, input current overcurrent, overhigh case environment temperature, overhigh power device, IGBT overcurrent, overhigh inverter transformer and secondary rectifier, water cooling of a welding gun and the like of the three-phase alternating-current input voltage. The DSP digital control system main control board takes the latest DSP TMS320F28335 and FPGAEP3C10E144 as the core, and the DSP control system comprises PWM constant current control and frequency conversion control; the man-machine conversation control interface sets welding process parameters including shield gas advance gas supply time, shield gas delay protection time, welding operation mode, welding materials, welding current, voltage and other relevant welding process parameters and transmits the parameters to the DSP digital processing center.
The working principle of the inverter power supply of the embodiment of the invention comprises the following processes: the three-phase power enters the equipment after passing through the air switch, firstly enters the filter to filter harmonic interference of an external power supply, then is rectified for the first time through the three-phase rectifier bridge, is sent into the filter to smooth waveforms, then is sent into the IGBT bridge type switch inversion module to generate alternating current, is sent into the inverter transformer, then is rectified for the second time through the secondary fast recovery rectifier diode, and is output to a welding end. After current and voltage sampling is carried out on the output end by using the current and voltage feedback control board, the input DSP digital control system main control board carries out operation with a given signal, and the output signal is sent to the IGBT inversion driving control board and then is sent to the IGBT bridge switch inversion module. Finally, the whole circuit forms closed-loop control to obtain stable welding current and voltage for welding.
In the working process of the embodiment, the main control board of the DSP digital control system can set the required voltage and current values by a user according to the actual welding requirements, and the output inversion frequency can be changed within the range of 20kHz to 80kHz to adjust the actual current and voltage through algorithm setting so as to adjust the actual current and voltage to the optimal welding effect.
After the DSP obtains human-computer interaction data set by a user, processing welding parameters and judging welding types are carried out, a welding thread processing stage is carried out by integrating welding switch signals, and then welding type signals such as manual welding or MIG welding are output.
The processing of the man-machine interaction data is realized through a control flow, a user inputs control parameters by using a man-machine conversation control interface, the DSP calls a communication thread of a display screen, on one hand, the sending module is used for refreshing data display at regular time, on the other hand, the receiving module is used for sending the man-machine interaction data into the ferroelectric memory for storage, the loss of working data after power failure is avoided, and the working reliability of the welding machine is ensured.
The welding machine also has a fault self-diagnosis function, a man-machine interaction input signal processing thread is arranged in the DSP, the welding type switching and the diagnosis type switching are carried out through the judgment of man-machine interaction parameters, then, a diagnosis mode processing module or a conventional mode processing module is called in a working mode, the self fault diagnosis is carried out on external I/O output or internal variable parameters, and the diagnosis result is displayed on a display screen module.
In order to simplify the design of a main processor, a co-processing board module is added, a full-time is responsible for the processing of welding machine peripherals, and a special thread is arranged in the DSP to carry out sending and receiving communication with the co-processor. The coprocessor is responsible for a cooling system externally provided with a welding machine, and the coprocessor is used for carrying out closing or operation mode selection after receiving a signal from the DSP control system.
The main program controls the time sequence flow, the flow is the core of DSP control signal, after entering the working mode, the flow can circulate in the testing state and the waiting state, the voltage and current can be judged in the testing state, and in the waiting state, when the welding signal is started, the flow can enter the continuous working state according to the parameters input by the user temporarily, the flow can feed air in advance, the wire is fed slowly to start the arc, the arc length control circulation is controlled, the arc is closed to remove the ball, the air feeding is delayed, and the flow can return to the waiting state again.
And after receiving the signal from the DSP control system, the wire feeder displays the wire feeding speed in real time through the receiving thread and gives the wire feeding speed through the sending thread, thereby assisting in adjusting the welding effect.
The average value of the output current under different frequencies can set a small current value when the welding current required by a user is low, and the DSP can send a low-frequency IGBT inversion driving signal to modulate the output current pulse to achieve the effect of low-current welding. When the welding current required by a user is higher, a larger current value can be set, the DSP outputs a high-frequency IGBT inversion driving signal, the output current pulse is promoted, the average current is obviously increased, and therefore the requirement of high-current welding is met.
The invention has the innovation that the welding power supply can regulate and control the welding current and voltage in different frequency sections of 20kHz to 80kHz, and can adopt corresponding inversion frequency when different working condition requirements are met, so that the process requirements are met, and good welding quality can be obtained.
Drawings
FIG. 1 is a schematic block diagram of MIG welding power control in accordance with a preferred embodiment of the present invention.
FIG. 2 is a flow chart of the operation mode control according to a preferred embodiment of the present invention.
FIG. 3 is a flow chart of the human-machine interaction control according to a preferred embodiment of the present invention.
FIG. 4 is a flow chart of the apparatus self-diagnostic control according to a preferred embodiment of the present invention.
FIG. 5 is a flow chart of the coprocessor and motherboard communication according to a preferred embodiment of the present invention.
FIG. 6 is a flow chart of the cooling system control according to a preferred embodiment of the present invention.
FIG. 7 is a flowchart illustrating the control procedure of the main routine according to a preferred embodiment of the present invention.
FIG. 8 is a flowchart illustrating a communication process of a wire feeder in accordance with a preferred embodiment of the present invention.
FIG. 9 shows the average value of the output current when the inversion frequency is changed according to a preferred embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments so that those skilled in the art can more clearly and completely understand the technical solutions of the present invention.
As shown in fig. 1, the principle block diagram of MIG welding power control is shown, and a three-phase power air switch 1 controls the power supply of the whole machine; the three-phase power supply filter 2 prevents external power supply pollution; the three-phase heavy-current rectifier bridge module 3 converts alternating current input into direct current; soft-starting the silicon controlled rectifier and control module 4; an electrolytic capacitor filter assembly 5; an IGBT bridge switch inversion module 6; the inverter transformer 7 has the inversion frequency which can be commonly used within the range of 20-80 kHz; a primary current detector 8; a secondary fast recovery rectifier diode 9; the current divider 10 is used for detecting the feedback of the actual value of the secondary current; an output inductor 11 connected to the welding power supply negative electrode output; an output freewheel resistor 12; a control circuit transformer 13 for providing a required power supply for the control circuit; the control power module 14 is used for providing power for the main control board 18, the co-processing board 15, the IGBT inversion driving control board 16, the current and voltage feedback control board 17, the man-machine conversation control interface 19 and the wire feeder 20; and the assistant processing circuit module is used for monitoring and protecting overvoltage, undervoltage, input current overcurrent, overhigh case environment temperature, overhigh power device, IGBT overcurrent, overhigh inverter transformer and secondary rectifier, water cooling of a welding gun and the like of the three-phase alternating-current input voltage. The DSP digital control system main control board takes the latest DSP TMS320F28335 and FPGAEP3C10E144 as the core, and the DSP control system comprises PWM constant current control and frequency conversion control; the man-machine conversation control interface sets welding process parameters including shield gas advance gas supply time, shield gas delay protection time, welding operation mode, welding materials, welding current, voltage and other relevant welding process parameters and transmits the parameters to the DSP digital processing center.
The working principle of the inverter power supply of the embodiment of the invention comprises the following processes: the three-phase power enters the equipment after passing through the air switch 1, firstly enters the filter 2 to filter harmonic interference of an external power supply, then is rectified for the first time through the three-phase rectifier bridge 3, is sent into the filter 5 to smooth waveforms, then is sent into the IGBT bridge type switch inversion module 6 to generate alternating current, is sent into the inverter transformer 7, then is rectified for the second time through the secondary fast recovery rectifier diode 9, and is output to a welding end. After the current and voltage sampling is carried out at the output end by using the current and voltage feedback control board 17, the sent DSP digital control system main control board 18 carries out operation with a given signal, and the output signal is sent to the IGBT inversion driving control board 16 and then sent to the 6IGBT bridge switch inversion module. Finally, the whole circuit forms closed-loop control to obtain stable welding current and voltage for welding.
In the working process of this embodiment, the DSP digital control system main control board 18 sets the required voltage and current values by the user according to the actual welding requirements, and through the algorithm setting, the output inversion frequency can be changed within the range of 20kHz to 80kHz to adjust the actual current and voltage to the best welding effect.
After the DSP obtains human-computer interaction data set by a user, processing welding parameters and judging welding types are carried out, a welding thread processing stage is carried out by integrating welding switch signals, and then welding type signals such as manual welding or MIG welding are output.
The processing of man-machine interaction data is realized through the control flow shown in fig. 3, a user inputs control parameters by using a man-machine conversation control interface 19, the DSP calls a communication thread of a display screen, on one hand, the sending module is used for refreshing data display at regular time, on the other hand, the receiving module is used for sending the man-machine interaction data into the ferroelectric memory for storage, the loss of working data after power failure is avoided, and the working reliability of the welding machine is ensured.
The welding machine also has a fault self-diagnosis function, a man-machine interaction input signal processing thread is arranged in the DSP shown in the figure 4, the welding type switching and the diagnosis type switching are carried out through the judgment of man-machine interaction parameters, then a diagnosis mode processing module or a conventional mode processing module is called in a working mode, the self fault diagnosis is carried out on external I/O output or internal variable parameters, and the diagnosis result is displayed on a display screen module.
In order to simplify the design of the main processor, a co-processing board module is added, and a full-time is responsible for the processing of the welding machine peripheral, as shown in a work flow chart 5, a special thread is arranged in the DSP and performs sending and receiving communication with the co-processor. The co-processor board is responsible for a cooling system externally provided with a welding machine, the operation flow of the co-processor board is shown in fig. 6, and the co-processor performs shutdown or operation mode selection after receiving a signal from the DSP control system.
The flow chart of the main program control timing is shown in fig. 7, and the flow is the core of the DSP control signal, and after entering the working mode, the flow circulates between the test state and the waiting state, and the voltage and current can be determined in the test state, and in the waiting state, when the welding signal is started, the flow enters the continuous working state according to the parameters input by the user, and the flow is advanced, the gas is supplied, the wire is slowly fed for arc striking, the arc length control circulation is welded, the arc is closed and the ball is removed, the gas is supplied for a delay, and the flow returns to the waiting state again.
Fig. 8 illustrates the control of the wire feeder, and after the wire feeder receives the signal from the DSP control system, the wire feeder performs real-time wire feeding speed display through the receiving thread, and performs wire feeding speed setting through the sending thread, thereby assisting in adjusting the welding effect.
The average value of the output current under different frequencies is shown in fig. 9, when the welding current required by a user is low, a small current value is set, and at the moment, the DSP sends a low-frequency IGBT inverter driving signal to modulate the output current pulse, so that the low-current welding effect is achieved. When the welding current required by a user is higher, a larger current value can be set, the DSP outputs a high-frequency IGBT inversion driving signal, the output current pulse is promoted, the average current is obviously increased, and therefore the requirement of high-current welding is met.
The above embodiments are only for the purpose of facilitating understanding of the technical solutions of the present invention, and should not be construed as limiting the present invention. Simple substitutions and modifications according to the technical solution of the present invention still fall within the protection scope covered by the claims and the specification of the present invention.
Claims (5)
1. The utility model provides a pulse MIG welding source, its characterized in that includes filter, three-phase rectifier bridge, IGBT bridge type switch contravariant module, inverter transformer, secondary fast recovery rectifier diode, DSP digital control system main control board, IGBT contravariant drive control panel, current-voltage feedback control panel, coprocessing circuit module and control power transformer, the filter with the three-phase rectifier bridge links to each other, IGBT bridge type switch contravariant module with inverter transformer links to each other, inverter transformer with secondary fast recovery rectifier diode links to each other, DSP digital control system main control board output signal extremely send into behind the IGBT contravariant drive control panel IGBT bridge type switch contravariant module.
2. The pulsed MIG welding power supply of claim 1 wherein the DSP digital control system main control panel is configured to allow a user to set a desired voltage current level and to adjust the actual current voltage by algorithmic settings such that the output inverter frequency is variable from 20kHz to 80 kHz.
3. The pulsed MIG welding power supply of claim 1 wherein the inverter transformer is also operable at a different frequency range of 20kHz to 80 kHz.
4. The pulsed MIG welding power supply of claim 1 wherein the DSP digital control system main control board has built in human machine interaction input signal processing threads to switch between welding type and diagnostic type by human machine interaction parameter determination.
5. The pulsed MIG welding power supply of claim 1 wherein the DSP digital control system main control panel is capable of sending a low frequency IGBT inverter drive signal to modulate the output current pulse to achieve low current welding; the DSP digital control system main control board can also output high-frequency IGBT inversion driving signals, output current pulses are improved, average current is obviously increased, and the requirement of high-current welding is met.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201810812219.XA CN110744173A (en) | 2018-07-23 | 2018-07-23 | Pulse MIG welding power supply |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201810812219.XA CN110744173A (en) | 2018-07-23 | 2018-07-23 | Pulse MIG welding power supply |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN110744173A true CN110744173A (en) | 2020-02-04 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201810812219.XA Withdrawn CN110744173A (en) | 2018-07-23 | 2018-07-23 | Pulse MIG welding power supply |
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| CN (1) | CN110744173A (en) |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN201168848Y (en) * | 2008-03-22 | 2008-12-24 | 太原市星云焊接设备有限公司 | Multifunctional full-digitalized contravariant welding machine |
| CN201889572U (en) * | 2010-12-07 | 2011-07-06 | 上海瑞凌电器有限公司 | Single-tube IGBT inversion electric-arc welding machine |
| CN201900364U (en) * | 2010-12-02 | 2011-07-20 | 浙江肯得机电股份有限公司 | Circuit of inversion shielded ace welding machine of single-tube IGBT (insulated gate bipolar transistor) and circuit board structure of circuit |
| CN202224811U (en) * | 2011-08-25 | 2012-05-23 | 深圳市鸿栢科技实业有限公司 | High-frequency stud welder with two transformers |
| CN202344104U (en) * | 2011-09-29 | 2012-07-25 | 熊猫电子集团有限公司 | Multifunctional digital welding machine |
| CN203621708U (en) * | 2013-11-29 | 2014-06-04 | 深圳市鸿栢科技实业有限公司 | Drawn-arc inverter stud welding machine |
| US9199327B2 (en) * | 2013-01-29 | 2015-12-01 | Shenzhen Jasic Technology Co., Ltd. | Portable IGBT arc welding machine |
-
2018
- 2018-07-23 CN CN201810812219.XA patent/CN110744173A/en not_active Withdrawn
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN201168848Y (en) * | 2008-03-22 | 2008-12-24 | 太原市星云焊接设备有限公司 | Multifunctional full-digitalized contravariant welding machine |
| CN201900364U (en) * | 2010-12-02 | 2011-07-20 | 浙江肯得机电股份有限公司 | Circuit of inversion shielded ace welding machine of single-tube IGBT (insulated gate bipolar transistor) and circuit board structure of circuit |
| CN201889572U (en) * | 2010-12-07 | 2011-07-06 | 上海瑞凌电器有限公司 | Single-tube IGBT inversion electric-arc welding machine |
| CN202224811U (en) * | 2011-08-25 | 2012-05-23 | 深圳市鸿栢科技实业有限公司 | High-frequency stud welder with two transformers |
| CN202344104U (en) * | 2011-09-29 | 2012-07-25 | 熊猫电子集团有限公司 | Multifunctional digital welding machine |
| US9199327B2 (en) * | 2013-01-29 | 2015-12-01 | Shenzhen Jasic Technology Co., Ltd. | Portable IGBT arc welding machine |
| CN203621708U (en) * | 2013-11-29 | 2014-06-04 | 深圳市鸿栢科技实业有限公司 | Drawn-arc inverter stud welding machine |
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Application publication date: 20200204 |