CN113751833B - Welding circuit and control method thereof - Google Patents
Welding circuit and control method thereof Download PDFInfo
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- CN113751833B CN113751833B CN202111210447.8A CN202111210447A CN113751833B CN 113751833 B CN113751833 B CN 113751833B CN 202111210447 A CN202111210447 A CN 202111210447A CN 113751833 B CN113751833 B CN 113751833B
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- inverter
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- alternating current
- welding
- controller
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- 238000003466 welding Methods 0.000 title claims abstract description 117
- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000010438 heat treatment Methods 0.000 claims abstract description 20
- 230000000694 effects Effects 0.000 claims abstract description 15
- 239000003990 capacitor Substances 0.000 claims description 19
- 230000008569 process Effects 0.000 claims description 19
- 230000004044 response Effects 0.000 claims description 13
- 238000001514 detection method Methods 0.000 claims description 7
- 230000003247 decreasing effect Effects 0.000 claims description 3
- 230000006698 induction Effects 0.000 abstract description 9
- 230000009191 jumping Effects 0.000 description 11
- 238000010586 diagram Methods 0.000 description 6
- 230000005674 electromagnetic induction Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000010485 coping Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
Classifications
-
- 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
Abstract
The invention relates to the field of welding, in particular to a welding circuit and a control method thereof. According to the welding circuit and the control method thereof, the inverter, the welding head and the controller are arranged, the controller is used for adjusting the alternating current frequency output by the inverter according to the preset control method, so that the welding circuit works with the output power of the preset threshold value, the energy of induction heating can be accurately controlled, the welding effect is more stable, the heating effect is consistent for different buses, the circuit is not required to be redesigned, and the design cost is reduced.
Description
Technical Field
The invention relates to the field of welding, in particular to a welding circuit and a control method thereof.
Background
With the progress of society and the development of economy, new clean energy sources are becoming popular. Solar energy is used as a clean energy source, solar photovoltaic panels are main elements for absorbing solar energy, each photovoltaic panel generates current through a photoelectric effect, the current on each panel needs to be collected on a bus through a grid line, and the current on the bus is supplied to families or conveyed to a power grid after passing through power conversion devices such as an inverter and the like. The grid lines and the bus bars are typically physically connected by soldering. Welding is typically performed by means of electromagnetic induction heating. The prior art uses self-exciting circuits to realize electromagnetic induction heating. The self-excited circuit is simple and reliable, but the circuit freely oscillates at the resonance point, each circuit has tolerance, so that the output energy is different when the resonance point oscillates, and the welding effect is different when the output energy is different; meanwhile, the self-excited oscillator cannot accurately control the output energy of electromagnetic induction heating, and a circuit is required to be redesigned for buses with different widths.
Disclosure of Invention
Therefore, the invention aims to provide a welding circuit for busbar magnetic induction heating welding and a control method thereof, which can accurately control the energy of induction heating, so that the welding effect is more stable, and meanwhile, the heating effect of the welding circuit for different busbars is consistent, a circuit is not required to be redesigned, and the design cost is reduced.
The embodiment of the invention provides a welding circuit, which comprises: an inverter; the welding head is connected with the output end of the inverter and comprises a coil and a capacitor; and a controller for adjusting the frequency of the alternating current outputted by the inverter in a predetermined manner after starting until the output power or the input power of the welding circuit reaches a predetermined threshold.
Further, the controller is configured to control the ac frequency output by the inverter according to: in response to receiving the enable operation signal, controlling the inverter to output the alternating current at a highest frequency; the alternating current frequency is stepped down from the highest frequency until the output power or input power of the welding circuit reaches a predetermined threshold.
Further, the controller is further configured to: and controlling the inverter to output the alternating current at the current frequency in response to the output power or the input power reaching a predetermined threshold.
Further, the controller is further configured to perform the steps of: and controlling the inverter to stop outputting the alternating current in response to receiving the stop signal.
Further, the welding circuit further includes: and the detection circuit is connected with the controller and the inverter and is used for detecting the input voltage value and the input current value of the inverter or outputting the voltage value and the output current value and outputting the voltage value and the output current value to the controller.
Further, the controller is configured to: and obtaining the input power value or the output power value according to the input voltage value and the input current value or the output voltage value and the output current value of the inverter.
Further, the controller is further configured to perform the steps of: and in the process of gradually reducing the alternating current frequency from the highest frequency, if the input power or the output power starts to be reduced, controlling the inverter to stop outputting the alternating current.
Further, the controller is further configured to perform the steps of: and controlling the inverter to stop outputting the alternating current in response to the inverter being operated continuously for a predetermined time.
Further, the capacitor includes: a first capacitor; and the first capacitor, the coil and the second capacitor are sequentially connected in series.
Further, the embodiment of the invention also provides a welding circuit control method, which comprises the following steps: in response to receiving the enable operation signal, controlling the inverter to output the alternating current at a highest frequency; gradually reducing the alternating current frequency from the highest frequency until the output power or the input power of the welding circuit reaches a preset threshold value; when the output power or the input power reaches a preset threshold value, controlling the inverter to keep the current frequency to output the alternating current; and controlling the inverter to stop outputting the alternating current in response to receiving a stop signal or the inverter continuously operates for a preset time or the output power or the input power is reduced.
According to the welding circuit and the control method thereof, the inverter, the welding head and the controller are arranged, the controller is used for adjusting the alternating current frequency output by the inverter according to the preset control method, so that the welding circuit works with the output power of the preset threshold value, the energy of induction heating can be accurately controlled, the welding effect is more stable, the heating effect is consistent for different buses, the circuit is not required to be redesigned, and the design cost is reduced.
Drawings
The above and other objects, features and advantages of the present invention will become more apparent from the following description of embodiments of the present invention with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a welding circuit according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a control method of a controller according to an embodiment of the invention;
FIG. 3 is a second schematic diagram of a control method of the controller according to the embodiment of the invention;
FIG. 4 is a third schematic diagram of a control method of the controller according to the embodiment of the invention;
FIG. 5 is a graph showing power versus frequency for a welding circuit according to an embodiment of the present invention;
FIG. 6 is a second diagram illustrating a power versus frequency plot of a welding circuit according to an embodiment of the present invention;
fig. 7 is a schematic diagram of control steps of a welding circuit control method according to an embodiment of the invention.
Detailed Description
The present invention is described below based on examples, but the present invention is not limited to only these examples. In the following detailed description of the present invention, certain specific details are set forth in detail. The present invention will be fully understood by those skilled in the art without the details described herein. Well-known methods, procedures, flows, components and circuits have not been described in detail so as not to obscure the nature of the invention.
Moreover, those of ordinary skill in the art will appreciate that the drawings are provided herein for illustrative purposes and that the drawings are not necessarily drawn to scale.
Meanwhile, it should be understood that in the following description, "circuit" refers to a conductive loop constituted by at least one element or sub-circuit through electrical connection or electromagnetic connection. When an element or circuit is referred to as being "connected to" another element or being "connected between" two nodes, it can be directly coupled or connected to the other element or intervening elements may be present and the connection between the elements may be physical, logical, or a combination thereof. In contrast, when an element is referred to as being "directly coupled to" or "directly connected to" another element, it means that there are no intervening elements present between the two.
Unless the context clearly requires otherwise, the words "comprise," "comprising," and the like in the description are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is, it is the meaning of "including but not limited to".
In the description of the present invention, it should be understood that the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Furthermore, in the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
As shown in fig. 1, the welding circuit of the embodiment of the invention comprises an inverter 1, a welding head 2 and a controller 3, and is mainly used for welding grid lines and bus bars on a solar panel, the inverter 1 converts direct current into alternating current, and the controller 3 controls the frequency of the alternating current converted by the inverter 1. The welding head 2 is connected with the output end of the inverter 1, the inverter 1 can be a bridge type inverter circuit, the welding head 2 comprises a coil L and a capacitor C to form an LC oscillating circuit, an oscillating magnetic field is generated when alternating current is fed into the coil L, so that eddy currents are generated in bus bars of the solar panel through an electromagnetic induction principle, the bus bars are heated, and the bus bars are welded with grid lines. The controller 3 can adopt a singlechip, a PLC programmable controller, a programmable logic circuit and other devices to realize control, and is used for adjusting the alternating current frequency output by the inverter according to a preset mode after starting until the output power or the input power of the welding circuit reaches a preset threshold value. According to the embodiment, the controller 3 is arranged, and the controller 3 is used for adjusting the frequency of the alternating current output by the inverter 1 according to a preset control method, so that the welding circuit works with the output power of the preset threshold value, the energy of induction heating can be accurately controlled, and the welding effect is more stable. When the busbar specification changes, the output power of the welding circuit can be adjusted by adjusting the preset threshold value, so that the heating effect of the welding circuit on different busbars is consistent, the circuit is not required to be redesigned according to the busbar specification change, the universality of the welding circuit is improved, and the design cost is reduced.
Specifically, the capacitor C includes a first capacitor C1 and a second capacitor C2, where the first capacitor C1, the coil L, and the second capacitor C2 are sequentially connected in series. In the embodiment, the series voltage division is performed by adding one series capacitor, so that the voltage stress on each capacitor is reduced, and the safety and stability of the welding circuit are improved. And through the layout mode of respectively connecting two capacitors C1 and C2 in series on two sides of the coil L, electromagnetic interference can be effectively reduced, and the working quality of a welding circuit is improved.
As shown in fig. 2, in one specific embodiment, the workflow of the controller is as follows:
s21: judging whether an enabling working signal is received or not;
if the enabling signal is received, jumping to step S22;
s22: controlling the inverter to output alternating current at the highest frequency;
s23: controlling the inverter to gradually reduce the alternating current frequency from the highest frequency;
s24: judging whether the input or output power is equal to a preset threshold value;
if the output power or the input power of the welding circuit is equal to the preset threshold value, jumping to the step S25;
s25: controlling the inverter to output alternating current at the current frequency;
s26, judging whether a stop signal is received or not;
if a stop signal is received, jumping to the step S27;
s27: controlling the inverter to stop outputting alternating current;
after the step S21, if it is determined that the enable operation signal is not received, the process directly jumps to the step S27;
after the step S24, if the output power or the input power of the welding circuit is not equal to the predetermined threshold value, the step S23 is skipped;
after step S26, if it is determined that the stop signal is not received, the process goes back to step S25.
According to the power versus frequency curve of the welding circuit as shown in fig. 5, the input and output power of the welding circuit is low when the inverter outputs alternating current at the highest frequency. As the ac frequency is stepped down from the highest frequency, the input and output power of the welding circuit is also stepped up along the curve until a predetermined power is reached, at which time the ac frequency is the operating frequency of the welding circuit. According to the embodiment, the controller controls the alternating current frequency output by the inverter, so that the welding circuit can work at a proper frequency, the welding circuit is ensured to work at a preset power, the induction heating energy can be accurately controlled, the welding quality is ensured, and the welding stability is improved.
In some alternative embodiments, the step S26 may be further provided after the steps S22 and/or S23, so as to control the welding circuit to stop working at any time. When the welding is needed to be stopped under some special conditions, a stop signal can be sent to the controller, and after the controller receives the stop signal, the controller controls the inverter to stop outputting alternating current, so that the welding circuit can stop working in time. Through the arrangement, the capacity of the welding circuit for coping with emergency is increased, and the possibility of accidents in the welding process is reduced.
Specifically, through the steps S23 to S25, in the process of controlling the ac frequency output by the inverter to decrease gradually in the manner described above, if the controller detects that the output power or the input power of the welding circuit reaches the predetermined threshold, it indicates that the ac frequency has reached the appropriate operating frequency. At the moment, the controller keeps the inverter to output alternating current at the current frequency, so that the output power of the welding circuit is stabilized at the current threshold value, the energy of induction heating is accurately controlled, and the welding stability is improved.
In a specific embodiment, as shown in fig. 1, the welding circuit further comprises a detection circuit 4. The detection circuit 4 is connected to the controller 3 and the inverter 1, and detects an input voltage value and an input current value, or an output voltage value and an output current value of the inverter 1, and outputs the detected values to the controller 3. Specifically, when the detection circuit 4 detects the input voltage value and the input current value of the inverter 1, the above-mentioned predetermined threshold value is a predetermined threshold value of the input power; when the detection circuit 4 detects the output voltage value and the output current value of the inverter 1, the above-mentioned predetermined threshold value is a predetermined threshold value of the output power. When the detection circuit 4 outputs the detected input voltage value and input current value, or output voltage value and output current value, to the controller 3, the controller 3 calculates the input power or output power according to the received current and voltage value, and compares the input power or output power with a preset input power threshold or output power threshold to complete the control process of the ac frequency. If the calculated input power or output power is not equal to the preset threshold value, the alternating current frequency is reduced, and if the calculated input power or output power is equal to the preset threshold value, the alternating current is controlled to keep the current frequency.
As shown in fig. 3, in some alternative embodiments, the controller may be further configured to perform the steps of:
s31: judging whether an enabling working signal is received or not;
if the enabling signal is received, jumping to step S32;
s32: controlling the inverter to output alternating current at the highest frequency;
s33: controlling the inverter to gradually reduce the alternating current frequency from the highest frequency;
s34: judging whether the input or output power is equal to a preset threshold value;
if the output power or the input power of the welding circuit is equal to the preset threshold value, jumping to the step S35;
s35: controlling the inverter to output alternating current at the current frequency;
s36, judging whether a stop signal is received;
if a stop signal is received, jumping to the step S37;
s37: controlling the inverter to stop outputting alternating current;
after the step S31, if it is determined that the enable operation signal is not received, the process directly jumps to the step S37;
after the step S34, if the output power or the input power of the welding circuit is not equal to the predetermined threshold value, the process goes to the step S38;
s38: judging whether the input or output power is reduced;
if the input or output power is reduced, directly jumping to the step S37;
if the input or output power is not reduced, jumping back to the step S33;
after step S36, if it is determined that the stop signal is not received, the process goes back to step S35.
As shown in the power versus frequency plot of the welding circuit of fig. 6, there is a maximum point of input or output power in the power versus frequency plot, and the power gradually increases with decreasing frequency before the power reaches the maximum point, but also gradually begins to decrease with decreasing frequency after the power reaches the maximum point. If the threshold value of the predetermined power is greater than the power at the maximum point of the power, this means that the input or output power of the welding circuit cannot reach the predetermined threshold value regardless of the frequency change. Therefore, in the process of gradually reducing the alternating current frequency from the highest frequency, if the controller detects that the calculated input power or output power starts to be reduced, the welding circuit is indicated to reach the maximum power value but not reach the preset power threshold, that is, the preset power threshold is too high, and the welding circuit cannot reach the preset power threshold. In this case, it is not significant to continue to reduce the ac frequency, so, in view of energy saving, time saving, safety, and the like, after adding the above step S38, the controller will be able to automatically control the inverter to stop outputting ac, thereby stopping the operation of the welding circuit, and reminding the operator to adjust to reduce the predetermined power threshold or replace the welding head capable of providing higher power for welding.
In particular, in some alternative embodiments, the step S36 may be further configured to control the welding circuit to stop working at any time after the steps S32 and/or S33, so as to increase the capability of the welding circuit to cope with the emergency, and reduce the possibility of accidents occurring in the welding process.
As shown in fig. 4, in some alternative embodiments, the controller may be further configured to perform the steps of:
s41: judging whether an enabling working signal is received or not;
if the enabling signal is received, jumping to step S42;
s42: controlling the inverter to output alternating current at the highest frequency;
s43: controlling the inverter to gradually reduce the alternating current frequency from the highest frequency;
s44: judging whether the input or output power is equal to a preset threshold value;
if the output power or the input power of the welding circuit is equal to the preset threshold value, jumping to the step S45;
s45: controlling the inverter to output alternating current at the current frequency;
s49, judging whether the continuous working time reaches a preset time;
if the continuous operation time reaches the preset time, directly jumping to the step S47;
s47: controlling the inverter to stop outputting alternating current;
after step S41, if it is determined that the enable operation signal is not received, the process goes to step S47;
after the step S44, if the output power or the input power of the welding circuit is not equal to the predetermined threshold value, the process jumps back to the step S43;
after step S49, if it is determined that the continuous operation time has not reached the predetermined time, the process goes to step S46.
S46, judging whether a stop signal is received;
if the stop signal is received, the process jumps to step S47;
if the stop signal is not received, the process goes back to step S45.
In this embodiment, the welding circuit may further advance a predetermined working time, and determine the predetermined working time according to the specification of the busbar to be welded and the predetermined power of welding, and in the welding process, the inverter continues to work for a predetermined time, that is, the welding time for the busbar reaches the predetermined time, and the controller will control the inverter to stop outputting the alternating current, so that the welding circuit stops working. Through the arrangement, the embodiment can ensure that the welding time of the bus bars and each grid line is equal, reduce welding errors and improve welding quality. And can avoid welding time overlength to reduce welding quality, perhaps forget the problem that the long-time heating takes place danger because of the welding circuit that closes of operating personnel.
In particular, in some alternative embodiments, the step S46 may be further provided after the steps S42 and/or S43 and/or S45, so as to control the welding circuit to stop working at any time, so as to increase the capability of the welding circuit to cope with the emergency, and reduce the possibility of accidents occurring in the welding process.
As shown in fig. 7, the embodiment of the invention further provides a control method of the welding circuit, which is used for controlling the welding circuit. The method comprises the following steps:
s10, responding to the received enabling operation signal, controlling the inverter to output the alternating current at the highest frequency;
step 20, starting from the highest frequency, gradually reducing the alternating current frequency until the output power or the input power of the welding circuit reaches a preset threshold value;
s30, controlling the inverter to keep the current frequency to output the alternating current after the output power or the input power reaches a preset threshold value;
and S40, controlling the inverter to stop outputting the alternating current in response to receiving a stop signal or the inverter to continuously operate for a preset time or the output power or the input power to be reduced.
The controller controls the welding circuit to perform welding by executing the steps S10-S40, so that the welding circuit can work with the output power of a preset threshold value, the energy of induction heating is accurately controlled, and the welding effect is more stable. And through adjusting the size of predetermined threshold, the control method of this embodiment can also make welding circuit be applicable to the busbar of different specifications, makes it unanimous to different busbar heating effect, need not to redesign the circuit according to different busbar specifications, has improved welding circuit's commonality.
In summary, according to the welding circuit and the control method thereof provided by the embodiment of the invention, the inverter, the welding head and the controller are arranged, and the controller is utilized to adjust the alternating current frequency output by the inverter according to the preset control method, so that the welding circuit works with the output power of the preset threshold value, the energy of induction heating can be accurately controlled, the welding effect is more stable, the heating effect is consistent for different buses, the circuit is not required to be redesigned, and the design cost is reduced.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, and various modifications and variations may be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (5)
1. A welding circuit for welding a grid line and a busbar of a solar photovoltaic panel, comprising:
an inverter;
the welding head is connected with the output end of the inverter and comprises a coil and a capacitor; and
a controller for adjusting the frequency of the alternating current outputted by the inverter in a predetermined manner after starting until the output power or the input power of the welding circuit reaches a predetermined threshold;
the detection circuit is connected with the controller and the inverter and is used for detecting the input voltage value and the input current value of the inverter or outputting the voltage value and the output current value to the controller;
wherein the controller is configured to control the ac frequency output by the inverter according to:
in response to receiving the enable operation signal, controlling the inverter to output the alternating current at a highest frequency;
gradually reducing the alternating current frequency from the highest frequency until the output power or the input power of the welding circuit reaches a preset threshold value;
the controller is further configured to:
controlling the inverter to maintain a current frequency to output the alternating current in response to the output power or the input power reaching a predetermined threshold;
controlling the inverter to stop outputting the alternating current in response to the inverter continuing to operate for a predetermined time;
the controller is further configured to perform the steps of:
controlling the inverter to stop outputting the alternating current if the input power or the output power starts to decrease in the process of gradually decreasing the alternating current frequency from the highest frequency;
the controller is further configured to perform: when the busbar specification changes, the output power of the welding circuit is adjusted by adjusting the preset threshold value, so that the heating effect of the welding circuit on different busbars is kept consistent.
2. The welding circuit of claim 1, wherein the controller is further configured to perform the steps of:
and controlling the inverter to stop outputting the alternating current in response to receiving the stop signal.
3. The welding circuit of claim 1, wherein the controller is configured to:
and obtaining the input power value or the output power value according to the input voltage value and the input current value or the output voltage value and the output current value of the inverter.
4. The welding circuit of claim 1, wherein the capacitor comprises:
a first capacitor; and
and the first capacitor, the coil and the second capacitor are sequentially connected in series.
5. A control method applied to the welding circuit according to any one of claims 1 to 4 for welding a grid line and a bus bar of a solar photovoltaic panel, characterized by comprising the steps of:
in response to receiving the enable operation signal, controlling the inverter to output alternating current at a highest frequency;
gradually reducing the alternating current frequency from the highest frequency until the output power or the input power of the welding circuit reaches a preset threshold value;
when the output power or the input power reaches a preset threshold value, controlling the inverter to keep the current frequency to output the alternating current;
and controlling the inverter to stop outputting the alternating current in response to receiving a stop signal or the inverter continuously operates for a preset time or the output power or the input power is reduced.
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CN203434871U (en) * | 2013-08-28 | 2014-02-12 | 上海熔易焊接机制造有限公司 | Novel high-frequency induction welding power supply structure |
DE102017123815A1 (en) * | 2017-10-12 | 2019-04-18 | Sma Solar Technology Ag | INVERTER AND METHOD FOR OPERATING AN INVERTER |
CN112928828A (en) * | 2021-02-05 | 2021-06-08 | 郑州轻工业大学 | Frequency-adjustable device for outputting multi-frequency sine waves by single inverter |
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2021
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JPH06284736A (en) * | 1993-03-31 | 1994-10-07 | Kubota Corp | Power-supply for induction welding |
CN1234307A (en) * | 1998-04-02 | 1999-11-10 | 宫地技术株式会社 | Resistance welding control device |
CN101155454A (en) * | 2006-09-30 | 2008-04-02 | 唯冠科技(深圳)有限公司 | Multi-light tube current control method and driving circuit thereof |
CN102035407A (en) * | 2009-09-30 | 2011-04-27 | 雅达电子国际有限公司 | Ac-dc switching power converters with frequency variation in response to load changes |
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