CN111299756A - High-pressure environment self-adaptive arc striking system - Google Patents
High-pressure environment self-adaptive arc striking system Download PDFInfo
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- CN111299756A CN111299756A CN202010094133.5A CN202010094133A CN111299756A CN 111299756 A CN111299756 A CN 111299756A CN 202010094133 A CN202010094133 A CN 202010094133A CN 111299756 A CN111299756 A CN 111299756A
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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
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
- B23K9/067—Starting the arc
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Abstract
A high-pressure environment self-adaptive arc ignition system comprises a high-frequency oscillator (1), a linear sliding table (2), a control unit (3), an air pressure sensor (4) and a welding power supply loop (8). The high-frequency oscillator (1) comprises a primary high-voltage transformer (T1) and a secondary high-frequency coupling transformer (T2), a linear sliding table (2) is in slidable contact with a secondary coil (L2) of the secondary high-frequency coupling transformer (T2), a control unit (3) is electrically connected with the linear sliding table (2) and the air pressure sensor (4), and the high-frequency oscillator (1) is connected into a welding power supply loop (8) in a series connection mode. The two-stage transformer boosts and couples the AC input voltage respectively. The gas pressure sensor transmits a gas pressure signal of the closed pressure environment to the control unit, the control unit analyzes and calculates the pressure signal and drives the linear sliding table to move for a corresponding distance, and the welding power supply loop applies the corresponding high-frequency high voltage determined by the linear sliding table between the welding gun (6) and the workpiece (7) in the closed pressure environment, so that self-adaptive arc striking is realized. The invention has simple structure and good environmental adaptability.
Description
Technical Field
The invention relates to a high-pressure environment self-adaptive arc striking system. The high-pressure environment self-adaptive arc striking system can realize self-adaptive sensing of the environmental pressure and output high-frequency high pressure matched with the environmental pressure, thereby realizing arc striking between an electrode and a workpiece.
Background
In the construction and maintenance of some important projects, welding and cutting are often required to be carried out in an environment other than one atmosphere. An environment above one atmosphere is referred to as a high pressure environment and an environment below one atmosphere is referred to as a low pressure environment. The most representative low-pressure environment is space welding, and space station maintenance is mainly carried out in a high-vacuum environment. The high-pressure environment is widely applied, and mainly comprises the welding maintenance of underwater structures such as ocean platforms, pipelines and the like in the ocean, rivers and lakes, the welding maintenance of components in boric acid water environment of a reactor pressure vessel and a general fuel storage pool of a nuclear power station, and the welding maintenance of cutter heads and cutters in a cutter head cabin of a tunnel shield machine with protruded underground water.
Arc welding and arc cutting are both adaptable and economical repair processes for high gas pressure environment repairs, such as argon arc welding, plasma cutting, and gas metal arc welding. For these welding and cutting methods, a high frequency oscillator is the basic device for achieving arc initiation between the electrode and the workpiece.
The current commercial welding and cutting power supply is applied in an atmosphere pressure environment. The degree of ionization of a gas is related to the ambient pressure, and decreases as the ambient pressure increases. When the pressure in the high-pressure environment is higher than one atmosphere, because of the increased gas density, the energy provided by the existing high-frequency oscillator of the welding and cutting power supply may not be sufficient to achieve the breakdown of the high-density air between the electrode and the workpiece, thereby making it difficult to successfully strike the arc.
The high-frequency oscillator should be able to provide energy corresponding to different ambient air pressures to break down the high-density air between the electrode and the workpiece to achieve arc striking, so that there is a strong need to develop an adaptive arc striking system in high-air pressure environment.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a high-pressure environment self-adaptive arc striking system which can self-adaptively sense the environmental pressure and output high-frequency high voltage matched with the environmental pressure, thereby realizing the arc striking between an electrode and a workpiece.
The arc ignition process is to break down the air gap between the electrode and the workpiece, essentially ionizing the air by the applied energy. For gases at sufficiently high temperatures, collisions between atoms will ionize some of the atoms. One or more electrons, which are typically bound to an atom, will be emitted from the atom, forming a cluster of electron gas, which coexists with the ionized atom and neutral atom gas, a condition known as plasma. The degree of ionization of the plasma is described as a function of temperature, gas pressure (gas density) and ionization energy of the atoms, which is the following saha equation:
in the above equation (1), x is the ionization degree (%) of the gas, P is the gas pressure (Pa), T is the gas temperature (K), e is the electric quantity (C) of electrons, and K is the boltzmann constant (1.38 × 10)－23J/K), Ui is the ionization voltage (i.e., ionization energy) of the gas (V).
The above equation (1) illustrates: the ionization degree x of the gas is related to the temperature T and the pressure P, and the ionization degree x is reduced as the temperature T is reduced, the pressure P is increased and the ionization energy Ui is increased.
Non-contact arc ignition, i.e. ionization of gas by high frequency and high voltage, is commonly used for welding and cutting power sources. The high-frequency high-voltage (about 1MHz and 11250V) signal generated by the oscillation of the high-frequency arc striking circuit of the welding and cutting power supply sold in the market at present breaks down the air gap between the electrode and the workpiece, thereby generating high-temperature plasma arc.
However, the high-frequency high-voltage arc striking circuit of the value can only realize the air gap breakdown of 1 atmospheric pressure environment in common occasions, but cannot realize the air gap breakdown of the high-pressure environment. The specific value of the air pressure in the high-pressure environment is determined by engineering operation. The water depth of the nuclear power station maintenance project is within 15m (the corresponding relative air pressure is within 0.15 MPa), the water depth of the tunnel shield machine maintenance project is within 150m (the corresponding relative air pressure is within 1.5 MPa), and the water depth of the offshore oil maintenance project can reach 3000m (the corresponding relative air pressure is 30 MPa). Obviously, for welding and cutting in a high-pressure environment, if the high-frequency high-voltage arc striking circuit has enough self-adaptive capacity, namely, on the basis of automatically sensing the ambient pressure, the high-frequency high voltage adaptive to the high-frequency high-voltage arc striking circuit is provided, so that great flexibility is brought to engineering operation.
The high-pressure environment self-adaptive arc ignition system is realized by the following technical scheme:
the utility model provides a high atmospheric pressure environment self-adaptation striking system, includes high frequency oscillator, sharp slip table, the control unit, baroceptor and welding power return circuit, its characterized in that: the high-frequency oscillator comprises a primary high-voltage transformer and a secondary high-frequency coupling transformer, the secondary output voltage of the primary high-voltage transformer is high voltage, the linear sliding table is in slidable contact with the secondary coil of the secondary high-frequency coupling transformer, the control unit is electrically connected with the linear sliding table and an air pressure sensor arranged in an airtight pressure environment, the high-frequency oscillator is connected with a welding power supply loop in a series connection mode, wherein the air pressure sensor measures the gas pressure in the airtight pressure environment and transmits a pressure signal to the control unit, the control unit analyzes and calculates the pressure signal and drives the linear sliding table to move, high-frequency high voltage corresponding to the pressure signal is obtained, and the welding power supply loop applies the high-frequency high voltage to be arranged between a welding gun and a workpiece in the airtight pressure environment.
Therefore, the high-frequency oscillator boosts the voltage through the two-stage booster transformer, the input alternating current power supply signal is converted into a high-frequency high-voltage signal corresponding to the control quantity of the linear sliding table, and the welding power supply loop punctures air between the electrode and the workpiece through the high-frequency high voltage to achieve welding arc striking.
Drawings
FIG. 1 is a schematic diagram of a high pressure environment adaptive arc ignition system of the present invention;
fig. 2 is a circuit diagram of the control unit of the present invention.
In the figure: the device comprises a high-frequency oscillator 1, a high-frequency oscillator T1, a primary high-voltage transformer T2, a secondary high-frequency coupling transformer, a linear sliding table 2, a control unit 3, an air pressure sensor 4, a sealed pressure environment 5, a welding gun 6, a workpiece 7, a welding power supply circuit 8, a spark gap discharger P and an oscillation capacitor C.
Detailed Description
The technical solution, principle and effect of the present invention will be described and explained with reference to the accompanying drawings.
As shown in fig. 1, a high-pressure environment adaptive arc ignition system includes a high-frequency oscillator 1, a linear sliding table 2, a control unit 3, an air pressure sensor 4, and a welding power supply circuit 8. Wherein, the high-frequency oscillator 1 comprises a primary high-voltage transformer T1 and a secondary high-frequency coupling transformer T2, the secondary output voltage of the primary high-voltage transformer T1 is high voltage, the linear sliding table 2 is in sliding contact with a secondary coil L2 of the secondary high-frequency coupling transformer T2, the control unit 3 is electrically connected with the linear sliding table 2 and an air pressure sensor 4 arranged in a closed pressure environment 5, the high-frequency oscillator 1 is connected with a welding power supply loop 8 in a series connection way, the air pressure sensor 4 measures the air pressure in the closed pressure environment 5 and transmits a pressure signal to the control unit 3, the control unit 3 analyzes and calculates the pressure signal and drives the linear sliding table 2 to linearly move for a corresponding moving distance to obtain a high-frequency high voltage corresponding to the pressure signal, and the welding power supply loop 8 applies the high-frequency high voltage between the welding gun 6 and the workpiece 7 in the closed pressure environment 5.
Wherein the driving of the linear sliding table 2 by the control unit 3 is realized based on the corresponding control quantity. The control quantity is used for controlling the rotation direction and the rotation angle of the small servo motor, the rotation direction determines whether the motor rotates forwards or backwards according to the linear movement direction required by the linear sliding table, the rotation angle is determined according to the movement distance required by the linear sliding table, and the numerical value of the rotation angle is fed back by the code disc.
As shown in fig. 1, the input of the high-frequency oscillator 1 is an ac power supply signal (e.g., 120V). The secondary side of a primary high-voltage transformer T1 of the high-frequency oscillator 1 is connected in parallel with a spark gap discharger P, and the secondary side of a primary high-voltage transformer T1 is connected in series with an oscillation capacitor C and then connected to the primary side of a secondary high-frequency coupling transformer T2, and the secondary side of the secondary high-frequency coupling transformer T2 is connected in series to a welding power supply circuit 8.
As shown in fig. 2, the control unit 3 includes a computer, a data acquisition card, a driver, a small servo motor and a reducer, wherein the data acquisition card is installed on a computer motherboard, the driver is connected with a computer serial port, and the pressure signal processing and the linear sliding table moving distance calculation are completed by corresponding control programs.
Referring to fig. 1 again, the secondary coil L2 of the secondary high-frequency coupling transformer T2 is a sliding coil, the linear sliding table 2 is provided with a sliding block, and the sliding block is connected with a moving sliding sheet which is in sliding contact with the secondary coil L2. Firstly, a driver of the control unit 3 drives the small servo motor to rotate according to the required rotation direction and rotation angle, then the small servo motor is decelerated by the speed reducer, and then the slide block of the linear sliding table 2 is driven to move linearly.
The effective output turns of the secondary coil L2 of the secondary high-frequency coupling transformer T2 are determined by the moving distance of the slider of the linear slide 2, which is determined by the analysis and calculation of the control unit 3 based on the ambient gas pressure measured by the gas pressure sensor 4
The number of turns of a primary coil and a secondary coil of the secondary high-frequency coupling transformer T2 is set to be N1 and N2 respectively, the alternating voltage of the primary coil is U1, the induced voltage U2 is generated at two ends of the secondary coil, and the number relation meets the following equation (2):
the secondary high-frequency coupling transformer T2 is a step-up transformer, namely N2 > N1, and the specific value of U2 depends on N2/N1, namely the ratio of turns.
The secondary coil of the secondary high-frequency coupling transformer T2 is a sliding coil, the effective output coil number can be changed by the movement of the linear sliding table, so that the induced voltage U2 of the secondary coil is changed, and the requirements of arc striking under different pressures on different voltages can be met. And (3) arc striking under the working condition of one atmosphere pressure, wherein N2/N1 is required to be 2.25, N1 is required to be 100 circles, the number of effective output circles of N2 is 225 circles, and the length of a coil which is connected into 225 circles is 54mm if the diameter of a lead of N2 is 0.24 mm.
When the ambient air pressure rises to 0.5MPa (5 atmospheric pressures), the moving distance of the linear sliding table is increased by 216mm, the effective output turn number of N2 is increased by 900 turns to 1125 turns, and at the moment, the N2/N1 is 11.25, so that the induced voltage U2 of the secondary coil L2 is increased to 5 times under one atmospheric pressure. In order to meet the requirement of arc striking voltage under 0.5MPa (5 atmospheric pressures), the stroke requirement of the linear sliding table reaches 270 mm.
The control program of the control unit 3 calculates the moving distance of the linear sliding table 2 corresponding to the environmental pressure acquired by the air pressure sensor 4, then outputs the rotating direction and the rotating angle of the motor corresponding to the environmental pressure to the driver, and accesses the number of turns of the effective coil corresponding to the environmental pressure through the movement of the linear sliding table 2, thereby inducing and generating the arc striking voltage U2 corresponding to the environmental pressure.
The working principle of the invention is as follows:
when the input terminal of the high-frequency oscillator 1 is connected to an ac power supply, the ac voltage is boosted by the primary high-voltage transformer T1 and charges the oscillating capacitor C, so that the terminal voltage of the spark gap discharger P gradually rises and is finally broken down. After the spark gap discharger P is broken down, on the one hand, the secondary circuit of the primary high-voltage transformer T1 is short-circuited to terminate charging of the oscillating capacitor C, and on the other hand, the already charged oscillating capacitor C and the primary coil L1 of the secondary high-frequency coupling transformer T2 form an oscillating circuit.
The oscillating voltage (high frequency and high voltage) generated by the oscillating circuit is coupled by a secondary high frequency coupling transformer T2 and then input to the welding power supply circuit 8. The oscillation frequency is calculated by the following equation (3), and the oscillation is damped, and the sustain time is several ms each time, and when the input power is a sine wave, the oscillation is performed once every half cycle.
The high-frequency oscillator 1 is connected with the welding power supply loop 8 in a series connection mode, a shunt loop is not arranged, arc striking is reliable, and the influence of high frequency on the welding power supply is greatly reduced.
The arc ignition between the welding torch 6 and the workpiece 7 is realized by the high frequency and high voltage generated by the high frequency oscillator 1. The high-frequency high-voltage arc striking method comprises the following steps: a tungsten electrode of a welding gun 6 is close to a workpiece 7, but is not in direct contact with the workpiece, a gap of 2-5 mm is reserved, after an arc striking switch on the welding gun 6 is pulled, a high no-load voltage is immediately added between the tungsten electrode of the welding gun 6 and the workpiece 7, and air between the gaps is directly punctured and ionized by utilizing the high voltage to initiate electric arcs.
However, since the high voltage brings danger to the safety of the operator, it is necessary to increase the frequency of the current to a very high frequency, i.e. to avoid the harm of the high voltage to the human body by using the strong skin effect of the high frequency current.
The degree of ionization of a gas is related to the ambient pressure, and decreases as the ambient pressure increases. When the pressure in the closed high-pressure environment 5 rises, the gas density increases, and the no-load voltage output by the high-frequency oscillator 1 must be correspondingly increased, so that the arc striking between the welding gun 6 and the workpiece 7 can be realized.
The pressure in the closed pressure environment 5 is measured through the air pressure sensor 4, the control unit 3 analyzes and calculates an environmental gas pressure signal measured by the air pressure sensor 4, and the linear sliding table 2 moves a distance corresponding to the environmental gas pressure according to a calculation result under the control and driving of the control unit 3, so that the secondary high-frequency coupling transformer T2 outputs a no-load voltage corresponding to the environmental gas pressure, and arc striking is successfully realized. Namely, the moving distance of the linear sliding table is adaptively adjusted through the control unit according to the actual environmental gas pressure in the closed pressure environment, so that the secondary high-frequency coupling transformer outputs high-frequency high voltage adaptive to the environmental gas pressure, and adaptive arc striking is realized.
For a welding and cutting power supply, if the working current is set to be 270A, in order to form an arc smoothly under one atmospheric pressure, the arc striking voltage is required to be higher than 3kV, and the arc striking frequency is required to be higher than 200kHz, so that the neutral medium gas can be broken down smoothly to form the arc.
Example 1
Under the working condition of atmospheric pressure, the coil turns of the two-stage transformer can be configured, so that the 120V alternating current is boosted to 5kV by the first-stage high-voltage transformer T1, and the output voltage of the first-stage high-voltage transformer T1 is boosted to 11.25kV by the second-stage high-frequency coupling transformer T2. The withstand voltage of the high-voltage ceramic parallel capacitor C is 25kV, the equivalent capacitance is 4200pF, the inductance of a primary coil L1 of the secondary high-frequency coupling transformer T2 is 6uH, the oscillation frequency is 1MHz according to equation (3) calculation, and the arc striking requirement is met.
Example 2
When the ambient air pressure rises to 0.5MPa (5 atmospheres), the moving slide sheet connected with the slide block of the linear sliding table 2 moves, so that the secondary coil of the secondary high-frequency coupling transformer T2 is connected with a coil (effective output coil) which is 5 times of the original coil, thereby increasing the output voltage of the secondary high-frequency coupling transformer T2 to 56.25kV and realizing 0.5MPa arc striking. Of course, the withstand voltage class of the high-voltage ceramic parallel capacitor C should be selected to be high enough to be compatible with the output voltage corresponding to the highest ambient pressure.
Claims (8)
1. The utility model provides a high atmospheric pressure environment self-adaptation striking system, includes high frequency oscillator (1), sharp slip table (2), the control unit (3), baroceptor (4) and welding power return circuit (8), its characterized in that: the high-frequency oscillator (1) comprises a primary high-voltage transformer (T1) and a secondary high-frequency coupling transformer (T2), wherein the secondary output voltage of the primary high-voltage transformer (T1) is high voltage, a linear sliding table (2) is in sliding contact with a secondary coil (L2) of the secondary high-frequency coupling transformer (T2), a control unit (3) is electrically connected with the linear sliding table (2) and an air pressure sensor (4) arranged in a sealed pressure environment (5), the high-frequency oscillator (1) is connected with a welding power supply loop (8) in a series connection mode, the air pressure sensor (4) measures the air pressure in the sealed pressure environment (5) and transmits a pressure signal to the control unit (3), the control unit (3) analyzes and calculates the pressure signal and drives the linear sliding table (2) to move to obtain high-frequency high voltage corresponding to the pressure signal, and the welding power supply loop (8) applies the high-frequency high voltage to a welding gun (6) and a welding gun arranged in the sealed pressure environment (5) Between the workpieces (7).
2. The high-pressure environment adaptive arc ignition system according to claim 1, wherein: the secondary side of the primary high-voltage transformer (T1) is connected in parallel with a spark gap arrester (P), and the secondary side of the primary booster transformer (T1) is connected in series with an oscillating capacitor (C) and then connected to the primary side of the secondary high-frequency coupling transformer (T2), and the secondary side of the secondary high-frequency coupling transformer (T2) is connected in series to the welding power supply loop (8).
3. The high-pressure environment adaptive arc ignition system according to claim 1 or 2, wherein: the secondary coil (L2) of the secondary high-frequency coupling transformer (T2) is a sliding coil, and the effective output circle number of the sliding coil is determined by the moving distance of the linear sliding table (2).
4. The high atmospheric pressure environment adaptive arc ignition system of any one of claims 1-3, characterized in that: the moving distance of the linear sliding table (2) is determined by analyzing and calculating the environmental gas pressure measured by the air pressure sensor (4) through the control unit (3).
5. The high atmospheric pressure environment adaptive arc ignition system of any one of claims 1-4, characterized in that: and a sliding block is arranged on the linear sliding table (2), a movable sliding sheet is connected onto the sliding block, and the movable sliding sheet is in sliding contact with a secondary coil of the secondary high-frequency coupling transformer (T2).
6. The high atmospheric pressure environment adaptive arc ignition system of any one of claims 1-5, characterized in that: the control unit (3) comprises a computer, a data acquisition card, a driver, a small servo motor and a reducer, wherein the data acquisition card is arranged on a computer mainboard, and the driver is connected with a serial port of the computer; the control unit (3) drives the linear sliding table (2) to move through a driver, a small servo motor and a speed reducer.
7. The high-pressure environment adaptive arc ignition system according to claim 6, wherein: under the working condition of atmospheric pressure, the primary high-voltage transformer (T1) boosts the 120V alternating current to 5kV, the output voltage of the secondary high-frequency coupling transformer (T2) is 11.25kV, and the oscillation frequency is 1 MHz.
8. The high-pressure environment adaptive arc ignition system according to claim 6, wherein: under 5 atmospheric pressure working conditions, the output voltage of the secondary high-frequency coupling transformer (T2) is 56.25 kV.
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| CN202010094133.5A CN111299756B (en) | 2020-02-15 | 2020-02-15 | High-pressure environment self-adaptive arc striking system |
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| CN202010094133.5A CN111299756B (en) | 2020-02-15 | 2020-02-15 | High-pressure environment self-adaptive arc striking system |
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2179227Y (en) * | 1993-09-06 | 1994-10-12 | 徐世荣 | High frequency electric spark generator |
| US6388232B1 (en) * | 2000-11-27 | 2002-05-14 | Lincoln Global, Inc. | Starting and welding device for DC TIG welder and method of operating same |
| CN2684345Y (en) * | 2003-12-01 | 2005-03-09 | 陈仁富 | A step up transformer for arc generating of argon welder |
| CN205184011U (en) * | 2015-12-08 | 2016-04-27 | 昆山瑞凌焊接科技有限公司 | High pressure striking circuit and welding machine |
| CN106513934A (en) * | 2016-12-29 | 2017-03-22 | 浙江联洋机电科技有限公司 | High-frequency high-voltage arc ignition circuit |
| CN207431471U (en) * | 2017-09-29 | 2018-06-01 | 苏州天奇安激光设备有限公司 | Micro- arc welding machine high-frequency arc ignition circuit |
-
2020
- 2020-02-15 CN CN202010094133.5A patent/CN111299756B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2179227Y (en) * | 1993-09-06 | 1994-10-12 | 徐世荣 | High frequency electric spark generator |
| US6388232B1 (en) * | 2000-11-27 | 2002-05-14 | Lincoln Global, Inc. | Starting and welding device for DC TIG welder and method of operating same |
| CN2684345Y (en) * | 2003-12-01 | 2005-03-09 | 陈仁富 | A step up transformer for arc generating of argon welder |
| CN205184011U (en) * | 2015-12-08 | 2016-04-27 | 昆山瑞凌焊接科技有限公司 | High pressure striking circuit and welding machine |
| CN106513934A (en) * | 2016-12-29 | 2017-03-22 | 浙江联洋机电科技有限公司 | High-frequency high-voltage arc ignition circuit |
| CN207431471U (en) * | 2017-09-29 | 2018-06-01 | 苏州天奇安激光设备有限公司 | Micro- arc welding machine high-frequency arc ignition circuit |
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