CN111408817A - Short-period arc discharge inversion stud welding machine system - Google Patents

Short-period arc discharge inversion stud welding machine system Download PDF

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Publication number
CN111408817A
CN111408817A CN201910017212.3A CN201910017212A CN111408817A CN 111408817 A CN111408817 A CN 111408817A CN 201910017212 A CN201910017212 A CN 201910017212A CN 111408817 A CN111408817 A CN 111408817A
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module
igbt
voltage
circuit
diode
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黄永志
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Suzhou Yuehe Intelligent Technology Co ltd
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Suzhou Yuehe Intelligent Technology Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/10Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1006Power supply
    • B23K9/1043Power supply characterised by the electric circuit
    • B23K9/1056Power supply characterised by the electric circuit by using digital means
    • B23K9/1062Power supply characterised by the electric circuit by using digital means with computing means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/095Monitoring or automatic control of welding parameters
    • B23K9/0953Monitoring or automatic control of welding parameters using computing means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/20Stud welding

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Arc Welding Control (AREA)
  • Inverter Devices (AREA)

Abstract

The invention provides a short-period arc-discharge inversion stud welding machine system which comprises an EMI filtering module, a three-phase rectification module, an IGBT full-bridge inversion module, an IGBT driving module, a PWM wave control module, a transformer module, an output rectification module and a P L C parameter setting and reading module, wherein the EMI filtering module is used for passing power-frequency three-phase alternating current, the three-phase rectification module is used for rectifying the power-frequency three-phase alternating current into high-voltage direct current, the IGBT full-bridge inversion module is used for converting the high-voltage direct current into high-voltage high-frequency pulse voltage, the IGBT driving module is used for outputting driving signals of an IGBT, the PWM wave control module is used for transmitting the PWM signals to the IGBT driving module, the transformer module is used for converting the high-voltage high-frequency pulse voltage into low-voltage pulse voltage, the output rectification module is used for converting the low-voltage high-voltage pulse voltage into direct current, and the P L.

Description

Short-period arc discharge inversion stud welding machine system
Technical Field
The invention relates to the field of arc stud welding, in particular to a short-period arc discharge inverter stud welding machine system.
Background
Stud welding is to contact one end of a stud with the surface of a workpiece, and after the contact surface is melted, the stud is pressed into a molten pool by certain pressure through arc striking and arc burning, and then the stud is cooled to finish welding. Arc stud welding is widely used in automobiles, buildings, highways, bridges, towers, energy sources, crane machinery and other steel structures. Screw threadThe stud welding can be classified into short-cycle stud welding and long-cycle stud welding according to the length of a welding cycle. The welding period of the short-period stud welding is less than 100ms, and the short-period stud welding is mainly used for welding
Figure BDA0001939502690000011
The stud of (2). Although the arc stud welding technology is widely applied in various industries after the introduction of the arc stud welding technology in 80 s of the 20 th century, the arc stud welding technology still belongs to a primary application stage and has a larger gap with the stud welding technology in developed countries. The method mainly shows that the stability of the equipment is not high, the fluctuation of welding current is large, the number of air holes of a welding joint is increased, the strength of the joint is not high, and the base metal near the joint is seriously oxidized.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a short-period arc discharge inverter stud welding machine system.
The invention provides a short-period arc discharge inversion stud welding machine system which comprises the following modules:
an EMI filtering module: the power frequency three-phase alternating current power supply is used for inhibiting high-frequency interference and outputting power frequency three-phase alternating current;
three-phase rectifier module: the IGBT full-bridge inversion module is used for rectifying the power frequency three-phase alternating current into high-voltage direct current to supply to the IGBT full-bridge inversion module;
IGBT full-bridge contravariant module: the high-voltage direct current is converted into high-voltage high-frequency pulse voltage according to the driving signal of the IGBT and transmitted to the transformer module;
the IGBT driving module: the IGBT full-bridge inversion module is used for inputting PWM signals and outputting IGBT driving signals to the IGBT full-bridge inversion module;
a PWM wave control module: the IGBT driving module is used for transmitting the PWM signal to the IGBT driving module;
a transformer module: the high-voltage high-frequency pulse voltage is converted into low-voltage pulse voltage;
an output rectifying module: the low-voltage pulse voltage is converted into direct current voltage as a welding power supply.
Preferably, the IGBT full-bridge inverter module includes a full-bridge circuit which is mainly formed by a transistor IGBT _ G1, a transistor IGBT _ G2, a transistor IGBT _ G3, and a transistor IGBT _ G4 in a bridge connection, wherein: the emitter of the transistor IGBT _ G1 is connected with the emitter of the transistor IGBT _ G3 to form a first bridge arm, the emitter of the transistor IGBT _ G2 is connected with the emitter of the transistor IGBT _ G4 to form a second bridge arm, the collector of the transistor IGBT _ G1 and the collector of the transistor IGBT _ G2 are connected with the three-phase rectifier module, the collector of the transistor IGBT _ G3 and the collector of the transistor IGBT _ G4 are grounded, the full-bridge circuit is provided with a short-circuit protection function, and if two transistors on the same bridge arm are conducted simultaneously, the full-bridge circuit performs the short-circuit protection function to cut off the two transistors on the bridge arm.
Preferably, the transformer module is a high-frequency pulse transformer, and the input end of the high-frequency pulse transformer is high-voltage high-frequency pulse voltage;
the output rectifying module comprises a diode D1, a diode D2, a diode D3, a diode D4, a capacitor C, an inductor L and a load, wherein one voltage output end of the transformer module is connected with the anode of a diode D1 and the anode of a diode D2, the other voltage output end of the transformer module is connected with the anode of a diode D3 and the anode of a diode D4, one end of the inductor L is connected with the cathode of the diode D1 and the cathode of a diode D3, the other end of the inductor L is connected with one end of the capacitor C, the other end of the capacitor C is connected with the cathode of the diode D2 and the cathode of the diode D4, and two ends of the load are connected with two.
Preferably, the IGBT driving module includes an IGBT driving circuit mainly built by MOSFETs, the IGBT driving circuit is connected to the PWM wave control module through a standard interface, the IGBT driving circuit is provided with a restart function and an error signal feedback function, and if the IGBT driving circuit is abnormal, the IGBT driving module actively sends a signal to the PWM wave control module.
Preferably, the PWM wave control module includes a PWM wave controller, a memory unit, a communication interface USART, a communication interface I2C, a communication interface SPI, a communication interface CAN, a PWM signal isolation output circuit, an analog signal isolation sampling circuit, and a digital signal isolation sampling circuit; wherein:
the PWM signal isolation output circuit comprises an optical coupler, a transformer and a solid-state relay, and in the PWM signal isolation output circuit, a PWM signal is isolated by the optical coupler, the transformer and the solid-state relay and then output to the IGBT driving module;
the PWM wave controller comprises an analog-to-digital converter, and the analog signal isolation sampling circuit is used for inputting analog signals into the analog-to-digital converter of the PWM wave controller after the analog signals are isolated by a linear optical coupler to sample the analog signals;
the digital signal isolation sampling circuit is used for isolating a digital signal through an optical coupler and a transformer and then inputting the isolated digital signal into an IO port of the controller.
Preferably, the method further comprises the following steps:
and the P L C parameter setting and reading module is used for man-machine interaction and communication expansion.
Preferably, the human-computer interaction, specifically, the welding parameters including welding current and welding time are set through a P L C parameter setting and reading module;
the communication extension is specifically that the P L C parameter setting and reading module can communicate with a welding gun and a nailing machine, and can perform the extension of multiple nailing machines and multiple welding gun applications according to the requirements of users.
Preferably, the connecting assembly is also included, and the module of the connecting assembly is used for installation and connection with other modules by using standard industrial specifications.
Compared with the prior art, the invention has the following beneficial effects:
1. the consumption of the robot system in the interface and protocol part is reduced, and the installation and the maintenance are convenient;
2. the transformer not only ensures stable heat productivity, but also ensures small volume, the loss of the transformer is reduced, and the efficiency is improved;
3. the short-period arc discharge inversion stud welding system has improved stability and stable welding current fluctuation.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a system block diagram of a short cycle arc discharge inverter stud welding system;
FIG. 2 is an IGBT drive circuit diagram;
FIG. 3 is a circuit diagram of an output rectifying module;
fig. 4 is a schematic diagram of a PWM wave control module.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
The invention provides a short-period arc discharge inversion stud welding system which comprises an EMI filtering module, a three-phase rectification module, an IGBT full-bridge inversion module, a transformer module, an output rectification module, an IGBT driving module, a PWM wave control module, a P L C parameter setting and reading module and a connecting assembly, wherein the connecting assembly is connected through a screw and a lead to form a welding equipment frame, and the EMI filtering module, the three-phase rectification module, the IGBT full-bridge inversion module, the transformer module, the output rectification module, the PWM wave control module and the P L C parameter setting and reading module are fixedly arranged on the connecting assembly to form a welding equipment entity;
the PWM wave control module is connected with the IGBT driving module and the P L C parameter setting and reading module through a standard communication interface, and the EMI filtering module, the three-phase rectifying module, the IGBT full-bridge inverting module, the transformer module and the output rectifying module are connected through a standard wire.
As shown in figure 1, a three-phase main switch is turned on, three-phase alternating current is filtered by an EMI filtering module and then passes through a three-phase rectifying circuit to obtain high-voltage direct current, the high-voltage direct current controls a three-phase inverting circuit through an inverting control signal output by a controller such as a DSP (digital signal processor) of a PWM (pulse width modulation) wave control module to form a high-frequency pulse wave, the high-frequency pulse wave is converted into a low-voltage pulse wave through a high-frequency main transformer, the low-voltage pulse wave passes through an output rectifying circuit to form a low-voltage high-current welding power supply, the controller controls a thyristor output rectifying circuit, and the P L C is used for communicating with a welding gun, a nailing machine and the controller so as to read states and set parameters.
The EMI filtering module is a low-pass filter consisting of a capacitor and an inductor, and can allow industrial alternating current signals of power frequency to pass through and has an inhibiting effect on high-frequency interference; the EMI filtering module inhibits high-frequency interference of a power grid from entering equipment and also inhibits the high-frequency interference generated when the three-phase inverter circuit is switched on and switched off from entering the power grid to cause pollution to the power grid.
The three-phase rectification circuit rectifies the three-phase alternating current filtered by the EMI filtering module into high-voltage direct current to be supplied to the three-phase inverter circuit.
As shown in fig. 2, the IGBT driving module inputs a PWM control signal and outputs an IGBT driving signal, and the main function is to ensure that the IGBT switches at a predetermined frequency. The three-phase inverter circuit shown in fig. 1 comprises a full bridge inverter circuit of IGBTs, which are insulated gate bipolar transistors and are typical fully controlled devices, and combines the advantages of GTRs and MOSFETs. The IGBT full-bridge inverter module comprises a full-bridge circuit which is mainly formed by a transistor IGBT _ G1, a transistor IGBT _ G2, a transistor IGBT _ G3 and a transistor IGBT _ G4 in a bridge connection mode, wherein: an emitter of the transistor IGBT _ G1 is connected with an emitter of the transistor IGBT _ G3 to form a first bridge arm, an emitter of the transistor IGBT _ G2 is connected with an emitter of the transistor IGBT _ G4 to form a second bridge arm, a collector of the transistor IGBT _ G1 and a collector of the transistor IGBT _ G2 are connected with a three-phase rectification circuit, a large capacitor is further connected to the direct current side of the IGBT full-bridge inverter circuit, and the transformer is connected between the two bridge arms of the IGBT full-bridge inverter circuit. The input of the PWM driving signal controls the transistor IGBT _ G1, the transistor IGBT _ G2, the transistor IGBT _ G3 and the transistor IGBT _ G4, so that pulse alternating current is formed on the alternating current side of the IGBT full-bridge inverter circuit and is transmitted to the high-frequency main transformer. The output end of the full-bridge inverter circuit is connected with a capacitor C1 in series for smoothing filtering.
The IGBT driving module comprises HC L P-316J chips.
The high-frequency main transformer converts high-amplitude pulse voltage into low-amplitude pulse voltage, the IGBT inversion frequency is as high as 50KHZ, and the high-frequency main transformer not only ensures stable heat productivity, but also ensures small volume.
As shown in fig. 3, the output rectifying circuit is used to convert a low-voltage pulse voltage into a direct-current voltage, which is used for the welding power supply.
As shown in fig. 4, the PWM wave control module further includes a processor unit, a memory unit, USART, I2C, SPI, CAN, a PWM signal isolation output circuit, an analog signal isolation sampling circuit, and a digital signal isolation sampling circuit;
the PWM isolation output circuit connects a PWM output port of the controller with an optocoupler, a transformer or a solid-state relay for signal transmission, prevents the interference of a rear stage on the controller, and can prevent the damage of the controller caused by the overvoltage of the rear stage circuit.
The analog signal isolation sampling circuit is used for isolating an external analog signal through a linear optical coupler and then inputting the isolated external analog signal into the ADC;
the digital isolation sampling circuit isolates digital signals by using an optical coupler, a transformer or a solid-state relay and then inputs the isolated digital signals into an IO port of the controller so as to prevent an external circuit from interfering a main controller circuit and causing operation errors or damage of the controller.
The PWM wave is composed of four paths of signals, and each two paths are one group and used for controlling the switch of the IGBT full-bridge inverter. The analog signal comprises bus voltage and is used for representing whether the welding power supply is normal or not;
the welding current is used for realizing current closed-loop feedback to obtain stable welding current; and arc voltage is a parameter index for representing whether welding is normal or not.
The P L C parameter setting and reading module is used for man-machine interaction and communication extension, the man-machine interaction means that welding parameters including welding current and welding time can be set through P L C, and the communication extension means that the P L C parameter setting and reading module can communicate with a welding gun and a nailing machine.
In summary, the present invention relates to the IGBT inversion technology and the PWM control technology, by modularizing the entire system, the system is divided into an EMI filter module, a three-phase rectifier module, an IGBT full-bridge inverter module, a transformer module, an output rectifier module, an IGBT driver module, a PWM wave control module, a P L C parameter setting and reading module, and a connection module.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.

Claims (8)

1. Short cycle arc discharge contravariant stud welding machine system, its characterized in that includes the following module:
an EMI filtering module: the power frequency three-phase alternating current power supply is used for inhibiting high-frequency interference and outputting power frequency three-phase alternating current;
three-phase rectifier module: the IGBT full-bridge inversion module is used for rectifying the power frequency three-phase alternating current into high-voltage direct current to supply to the IGBT full-bridge inversion module;
IGBT full-bridge contravariant module: the high-voltage direct current is converted into high-voltage high-frequency pulse voltage according to the driving signal of the IGBT and transmitted to the transformer module;
the IGBT driving module: the IGBT full-bridge inversion module is used for inputting PWM signals and outputting IGBT driving signals to the IGBT full-bridge inversion module;
a PWM wave control module: the IGBT driving module is used for transmitting the PWM signal to the IGBT driving module;
a transformer module: the high-voltage high-frequency pulse voltage is converted into low-voltage pulse voltage;
an output rectifying module: the low-voltage pulse voltage is converted into direct current voltage as a welding power supply.
2. The short-cycle arc discharge inverter stud welder system according to claim 1, wherein the IGBT full-bridge inverter module comprises a full-bridge circuit mainly built by a bridge connection method of a transistor IGBT _ G1, a transistor IGBT _ G2, a transistor IGBT _ G3 and a transistor IGBT _ G4, wherein: the emitter of the transistor IGBT _ G1 is connected with the emitter of the transistor IGBT _ G3 to form a first bridge arm, the emitter of the transistor IGBT _ G2 is connected with the emitter of the transistor IGBT _ G4 to form a second bridge arm, the collector of the transistor IGBT _ G1 and the collector of the transistor IGBT _ G2 are connected with the three-phase rectifier module, the collector of the transistor IGBT _ G3 and the collector of the transistor IGBT _ G4 are grounded, the full-bridge circuit is provided with a short-circuit protection function, and if two transistors on the same bridge arm are conducted simultaneously, the full-bridge circuit performs the short-circuit protection function to cut off the two transistors on the bridge arm.
3. The short cycle drawn arc inverter stud welder system of claim 1,
the transformer module is specifically a high-frequency pulse transformer, and the input end of the high-frequency pulse transformer is high-voltage high-frequency pulse voltage;
the output rectifying module comprises a diode D1, a diode D2, a diode D3, a diode D4, a capacitor C, an inductor L and a load, wherein one voltage output end of the transformer module is connected with the anode of a diode D1 and the anode of a diode D2, the other voltage output end of the transformer module is connected with the anode of a diode D3 and the anode of a diode D4, one end of the inductor L is connected with the cathode of the diode D1 and the cathode of a diode D3, the other end of the inductor L is connected with one end of the capacitor C, the other end of the capacitor C is connected with the cathode of the diode D2 and the cathode of the diode D4, and two ends of the load are connected with two.
4. The short-cycle arc discharge inverter stud welding machine system according to claim 1, wherein the IGBT driving module comprises an IGBT driving circuit which is mainly built by MOSFETs, the IGBT driving circuit is connected with the PWM wave control module through a standard interface, the IGBT driving circuit is provided with a restarting function and an error signal feedback function, and if the IGBT driving circuit is abnormal, the IGBT driving module actively sends a signal to the PWM wave control module.
5. The short-cycle arc discharge inverter stud welding machine system according to claim 1, wherein the PWM wave control module comprises a PWM wave controller, a memory unit, a communication interface USART, a communication interface I2C, a communication interface SPI, a communication interface CAN, a PWM signal isolation output circuit, an analog signal isolation sampling circuit, and a digital signal isolation sampling circuit; wherein:
the PWM signal isolation output circuit comprises an optical coupler, a transformer and a solid-state relay, and in the PWM signal isolation output circuit, a PWM signal is isolated by the optical coupler, the transformer and the solid-state relay and then output to the IGBT driving module;
the PWM wave controller comprises an analog-to-digital converter, and the analog signal isolation sampling circuit is used for inputting analog signals into the analog-to-digital converter of the PWM wave controller after the analog signals are isolated by a linear optical coupler to sample the analog signals;
the digital signal isolation sampling circuit is used for isolating a digital signal through an optical coupler and a transformer and then inputting the isolated digital signal into an IO port of the controller.
6. The short cycle drawn arc inverter stud welder system of claim 1, further comprising:
and the P L C parameter setting and reading module is used for man-machine interaction and communication expansion.
7. The short cycle drawn arc inverter stud welder system of claim 6,
the man-machine interaction is to specifically set welding parameters including welding current and welding time through a P L C parameter setting and reading module;
the communication extension is specifically that the P L C parameter setting and reading module can communicate with a welding gun and a nailing machine, and can perform the extension of multiple nailing machines and multiple welding gun applications according to the requirements of users.
8. The short cycle drawn arc inverter stud welder system according to claim 1, further comprising a connection assembly, the module of the connection assembly using standard industry specifications for installation, connecting to other modules.
CN201910017212.3A 2019-01-08 2019-01-08 Short-period arc discharge inversion stud welding machine system Pending CN111408817A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112620880A (en) * 2020-12-04 2021-04-09 成都斯达特焊接研究所 Circuit structure of double-channel short-period arc stud welding machine

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US20140209586A1 (en) * 2013-01-29 2014-07-31 Shenzhen Jasic Technology Development Co., Ltd Portable igbt arc welding machine
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CN101386098A (en) * 2008-10-28 2009-03-18 上海沪工电焊机制造有限公司 Micro-controller control method of soft-switch invert welding source of electric welding machine
US20140209586A1 (en) * 2013-01-29 2014-07-31 Shenzhen Jasic Technology Development 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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