CN111601447A - Dc等离子体焰炬电力设计方法和设备 - Google Patents

Dc等离子体焰炬电力设计方法和设备 Download PDF

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CN111601447A
CN111601447A CN202010430441.0A CN202010430441A CN111601447A CN 111601447 A CN111601447 A CN 111601447A CN 202010430441 A CN202010430441 A CN 202010430441A CN 111601447 A CN111601447 A CN 111601447A
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J·J·莫斯
B·T·诺埃尔
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Monolith Materials Inc
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    • H05H1/32—Plasma torches using an arc
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Abstract

一种用于使DC等离子体焰炬工作的方法和设备。所使用的电源至少是所使用的平均工作电压的两倍，从而使所述焰炬更稳定工作。所述焰炬可以包括两个同心圆柱电极，所述电极可以是石墨，并且等离子体合成气体可以是氢气。所提供的电源还具有以至少20千伏的脉冲电压点燃所述焰炬的能力。

Description

DC等离子体焰炬电力设计方法和设备
本申请是申请日为2016年07月26日、申请号为201680056461.8、发明名称为“DC等离子体焰炬电力设计方法和设备”的中国专利申请(其对应PCT申请的申请日为2016年07月26日、申请号为PCT/US2016/044039)的分案申请。
相关申请的交叉引用
本申请要求2015年7月29日提交的美国临时申请62/198,431的优先权，上述申请通过引用而全文并入于此。
技术领域
本发明一般涉及的技术领域是利用电能来实现化学变化的方法和设备。
背景技术
无论产品或过程如何独特，随着时间的推移，所有的制造过程都在寻找更高效且更有效的方式。这可以采用原材料成本、能量成本、或过程稳定性和效率的简单改进等的形式。一般来说，作为大部分制造过程(如果不是全部的话)的成本的主要部分的原材料成本和能量资源实际上趋向于随时间而增加，这是因为如果没有其它原因，则规模会扩大并且产量会增加。出于这些和其它原因，在本领域不断搜索不仅改进过程和生产的产品而且还以更高效率且有效的方式生产产品的方式。
这里描述的系统满足上述的挑战，同时还实现附加的改进。
发明内容
描述了一种方法，其使用等离子体合成气体和工作电压电源来使DC等离子体电弧焰炬工作，其中，所述电源至少是所使用的平均工作电压的两倍，从而使得所述焰炬更稳定地工作，该更稳定地工作包括电压波动减少以及所述电弧基本上不熄灭。
附加实施例包括：在上述方法中，所述焰炬在功率调节模式下工作，其中在该功率调节模式下，所述电源在给定功率设定点处工作，并且所述电源调节输出电压和电流这两者以使输出功率保持在所述设定点处；在上述方法中，所述焰炬利用电流设定点进行工作，其中在该电流设定点处，所述电源切换为电流调节模式以保持所述电弧不熄灭，然后使所述电流设定点升高并且在电流高到足以保持所述电弧不熄灭的情况下切换回所述功率调节模式，从而使得电压波动被基本上消除并且电弧熄灭被基本上消除；在上述方法中，所述焰炬包括同心圆柱电极；在上述方法中，所述电源具有以至少20千伏的脉冲电压点燃所述焰炬的能力；在上述方法中，所述电极包括石墨；在上述方法中，所述等离子体合成气体是氢气。
描述了一种设备，其包括DC等离子体焰炬和工作电压电源，其中，所述电源至少是所使用的平均工作电压的两倍，从而使得所述焰炬更稳定地工作。
附加实施例包括：在上述设备中，所述焰炬包括同心圆柱电极；在上述设备中，所述电源具有以至少20千伏的脉冲电压点燃所述焰炬的能力；在上述设备中，所述电源包含感应滤波器，所述感应滤波器分布在调节器的正极腿和负极腿之间以防止所述等离子体焰炬和/或点燃器所引起的传导发射反馈回敏感电子部件；在上述设备中，还包括滤波元件，所述滤波元件用于使所述敏感电子部件在瞬时测量或累积测量中暴露于电压或电流形式的能量的50％以下；在上述设备中，所述电源包含斩波调节器的输出处的滤波元件以对高频能量进行分流；在上述设备中，所述电源包含并联配置的斩波调节器以实现冗余；在上述设备中，所述电源包含串并联配置的斩波调节器以允许使用较低的阻断电压；在上述设备中，所述电极包括石墨。
根据以下说明，这些和附加实施例将变得显而易见。
附图说明
图1示出如这里所述的典型焰炬的示意性表示。
图2示出如这里所述的典型系统的示意性表示。
具体实施方式
这里所示的详情利用示例的方式并且仅用于说明性地讨论本发明的实施例，并且是为了提供被认为是对本发明的原理和概念方面最有用且最容易理解的描述而呈现的。在这方面，没有尝试比对本发明的基本理解所必需的更详细地示出本发明的详情，该描述使得关于可以如何在实践中实现本发明的多个形式对于本领域技术人员而言是显而易见的。
现将参考更详细的实施例来描述本发明。然而，本发明能够以不同形式实现，并且不应当被理解为受限于这里阐述的实施例。相反，这些实施例被提供以使得本公开将是全面且完整的，并且将向本领域技术人员充分传达本发明的范围。
除非另有定义，这里所使用的所有技术和科学术语具有与本发明所属领域的普通技术人员通常理解的含义相同的含义。这里在本发明的描述中所使用的术语仅用于描述特定实施例，并且不意在限制本发明。如在本发明的描述和所附权利要求书中所使用的，除非上下文另有明确指示，单数形式“a”、“an”和“the”还包括复数形式。这里所提及的所有公布、专利申请、专利和其它引用文献明确地通过引用而全文并入于此。
除非另有指示，说明书和权利要求书中所使用的所有表示成分数量的数字、以及反应条件等被理解为在所有情况下通过术语“约”来修饰。因此，除非有相反指示，以下说明书和所附权利要求书中阐述的数值参数是可以根据旨在通过本发明获得的期望属性而变化的近似值。至少不应认为是尝试将等同原则的应用限制到权利要求书的范围，各数值参数应该根据有效数字的数量和一般舍入方法来进行解释。
尽管阐述本发明的宽范围的数值范围和参数是近似值，但可以尽可能精确地报告具体示例中所阐述的数值。然而，任何数值固有地包含由它们各自的测试测量中发现的标准偏差所必然导致的某些误差。在该说明书中给出的每个数值范围将包括落在这种更宽数值范围内的每个较窄数值范围，就如同这种较窄数值范围都在这里明确写出一样。
本发明的附加优点将在以下的描述中部分阐述，并且其中一部分将根据以下描述而变得显而易见，或者可以通过实践本发明而获悉。应当理解，前面的一般描述和以下的详细描述仅仅是示例性和说明性的，而不限制所要求保护本发明。
DC等离子体电弧焰炬所用的典型DC(direct current，直流)电源的大小通常被设计为使得该DC电源的最大电压比焰炬的预期工作电压高35％。对于采用同心圆柱作为电极的焰炬设计(例如参见美国专利4,289,949和5,481,080，其公开内容通过引用而并入于此)，电弧行为可能是不稳定的，例如表现为针对电弧的大的电压波动、或者甚至是电弧的熄灭。为了获得这种焰炬的稳定工作，应该使用比平均工作电压大两倍的最大电源电压。这样将使得针对电弧的电压波动减少或最小化并且电弧熄灭被基本上消除。
另外，出于相同的目的，与更常用的较低电压(例如，6kV～12kV)相反，需要较高的电压脉冲(例如，20千伏(kV))来点燃焰炬。由于需要较高的电压，因此还需要适当的电容滤波器来防止对用于控制电力电子开关装置的敏感电子部件的损坏。此外，如果使用同心圆柱石墨杆，则在电源的大小没有如这里所述被适当设计(例如，为大于通常用于传统DC等离子体焰炬的电源的大小)的情况下，过程完全不能稳定地运行。
使焰炬在功率调节模式下工作还有助于减少电压波动。通常，大部分焰炬在电流调节模式下运行，其中电源被赋予电流设定点，然后该电源调节其输出电压以使电流保持在设定点处，而与负载电压无关。在功率调节模式中，电源被赋予功率设定点，然后该电源调节输出电压和电流这两者以使输出功率保持在设定点处。
在功率调节模式下运行将大大减少电压波动，但是如果电流和电压漂移得太远并且电流太低、则可能导致电弧熄灭更为频繁。这可以通过如下来克服：利用电源将切换回电流调节模式以保持电弧活动的阈值来进行工作，然后使电流设定点升高并且一旦电流足够高就切换回功率调节模式。通过具有电源在默认情况下以功率模式运行、但是如果电流下降得太低则切换至电流模式的系统，来实现电压波动的基本上消除以及电弧熄灭的基本上消除。换句话说，不仅可以满足所设定的电压波动标准，同时还可以保持电弧活动。
图1中示意性地示出对本发明有用的典型焰炬。同心的阴极(10)和阳极(11)形成环，其中可以通过该环在电极(10和11)之间供应传统的等离子体合成气体。图2示意性地示出连接至单独的焰炬启动器(22)并且用于向DC等离子体焰炬(23)提供电力的电源(21)。
所使用的功率范围将根据诸如电抗器的大小、电极之间的距离等的事物而变化。并且虽然典型的工作电压可以处于600～1000伏的范围内，但是这也可以根据诸如电极间隙、气体组分、所使用的压力和/或流速等的事物而变化。
通过使用如这里所述的滤波器来保护敏感电子部件。通常通过滤波器来对能量进行分流，以使得敏感电子部件受到较低的总电压或电流、或者较低的电压或电流的变化率。适当的滤波器包括电容器、LCL(感应滤波器)、或共模滤波器或任何其它的滤波器等。
定义
等离子体电压：等离子体电弧的瞬时电压，其作为等离子体电弧瞬时阻抗和电源的瞬时电流输出的函数而变化。
工作电压：电源的最终输出电压能力。
滤波器：可包括电阻分量的电感器和/或电容器的配置，用于对电能进行分流或者阻断电能从而不影响敏感电子部件。
敏感电子部件：与电源的电气设计及电源的各种子系统集成一体的任意装置，其易受到过度的电压、电流和/或热量的影响。该装置可以包括诸如绝缘栅极双极型晶体管、功率金属氧化物半导体场效应晶体管、集成门极换流晶闸管、门极关断晶闸管、硅控整流器等的电力电子开关装置；用于对电力电子开关装置进行切换或“门控”的控制电流；瞬变电压浪涌抑制装置；电容器、电感器和变压器。
斩波调节器(chopper regulator)：降压调节器(buck regulator)的替代项，包括传统的拓扑结构和所有变形，其中使用PWM(脉冲宽度调制)控制的电子开关将针对转换器的输入DC电压“斩波”至某个较低的输出电压。
缓冲电路：与电力电子开关装置并联放置的保护电路，其目的在于限制跨装置的电压和/或通过装置的电流的高变化率。
平波电抗器：指在传统的降压/斩波调节器中用作存储元件的电感器、或者用于在DC-DC转换器的输出处限制电流纹波的电感器。
示例1
DC同心圆柱、石墨电极、等离子体焰炬使用300～500伏的平均工作电压进行工作。用以使等离子体焰炬工作的电源具有至少为所需平均工作电压的两倍的电压生成能力(即，1000伏)。这使得这里所述的焰炬更稳定地工作。单独的启动器电源还具有以至少20千伏的脉冲电压点燃焰炬的能力。启动器电源包含适当量的电容滤波，以将不想要的能量从敏感电子部件分流出去。
示例2
用于实现示例1中所述的系统的拓扑结构如下所述。使用6脉冲、12脉冲、18脉冲或24脉冲整流器作为前端AC-DC转换器。该整流器可以利用电容输出滤波器、以及利用或不利用换流输出扼流圈来进行相位控制的或自然换流。包括电力电子开关装置、缓冲电路和门控电路的多个斩波调节器用于控制要施加给负载的电流。这些斩波调节器可以放置在并联配置中以添加冗余，或者放置在串并联配置中以还允许使用具有较低阻断电压的装置。平波电抗器(smoothingreactor)用作电流调节器(current regulator)中的主能量存储装置，并且分布在该调节器的正极腿和负极腿之间以添加针对敏感电力电子器件的附加保护。电容器用作在电流调节器的输出上的滤波器，以吸收可能由等离子体焰炬负载的混沌性质引起的高频能量。
因此，本发明的范围应当包括可落在所附权利要求书的范围内的所有修改和变形。考虑到这里公开的本发明的说明书和实践，本发明的其它实施例对于本领域技术人员将变得显而易见。说明书和示例旨在仅被认为是示例性的，本发明的真实范围和精神由所附权利要求书指示出。

Claims (10)

1.一种方法，其使用等离子体合成气体和工作电压电源来使DC等离子体电弧焰炬工作，其中，所述电源至少是所使用的平均工作电压的两倍，从而使得所述焰炬更稳定地工作，该更稳定地工作包括电压波动减少以及所述电弧基本上不熄灭。
2.根据权利要求1所述的方法，其中，所述焰炬在功率调节模式下工作，其中在该功率调节模式下，所述电源在给定功率设定点处工作，并且所述电源调节输出电压和电流这两者以使输出功率保持在所述设定点处。
3.根据权利要求2所述的方法，其中，所述焰炬利用电流设定点进行工作，其中在该电流设定点处，所述电源切换为电流调节模式以保持所述电弧不熄灭，然后使所述电流设定点升高并且在电流高到足以保持所述电弧不熄灭的情况下切换回所述功率调节模式，从而使得电压波动被基本上消除并且电弧熄灭被基本上消除。
4.根据权利要求1所述的方法，其中，所述焰炬包括同心圆柱电极。
5.根据权利要求1所述的方法，其中，所述电源具有以至少20千伏的脉冲电压点燃所述焰炬的能力。
6.根据权利要求4所述的方法，其中，所述电极包括石墨。
7.根据权利要求1所述的方法，其中，所述等离子体合成气体是氢气。
8.一种设备，其包括DC等离子体焰炬和工作电压电源，其中，所述电源至少是所使用的平均工作电压的两倍，从而使得所述焰炬更稳定地工作。
9.根据权利要求8所述的设备，其中，所述焰炬包括同心圆柱电极。
10.根据权利要求8所述的设备，其中，所述电源具有以至少20千伏的脉冲电压点燃所述焰炬的能力。
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