CN113843479A - Energy-saving method and system for welding power supply - Google Patents
Energy-saving method and system for welding power supply Download PDFInfo
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- CN113843479A CN113843479A CN202111198185.8A CN202111198185A CN113843479A CN 113843479 A CN113843479 A CN 113843479A CN 202111198185 A CN202111198185 A CN 202111198185A CN 113843479 A CN113843479 A CN 113843479A
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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
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Abstract
The invention discloses a welding power supply energy-saving method and system. By applying the method, when the continuous standby time of the welding power supply is detected to exceed the set time T, the welding power supply is automatically powered off and shut down, so that the electric energy loss is effectively saved, and the NFB of the circuit breaker can be manually restarted when the welding power supply needs to be reused. The system comprises a main circuit module, a control module and an auxiliary power supply module. And a main program is arranged in the minimum system of the control module singlechip and is used for realizing the control logic of the system and achieving the energy-saving function of the welding power supply. The method and the system can fundamentally avoid the situation of serious electric energy waste caused by long-time standby of the welding power supply, bring considerable economic benefits to enterprises and create remarkable social benefits.
Description
Technical Field
The invention relates to the field of energy-saving control of welding power supplies, in particular to a welding power supply energy-saving method and system.
Background
The welding power supply is a common welding device, and is widely applied in the field of welding manufacturing, wherein the number and the types of the welding power supplies kept by units such as a shipyard, an automobile manufacturing factory, a steel structure processing factory, a pressure vessel manufacturing factory and the like are the largest. The types of welding power sources commonly used include carbon dioxide shield welding power sources, submerged arc welding power sources, argon arc welding power sources, direct current welding power sources, alternating current manual arc welding power sources, and the like.
Generally, a welding power source melts a welding wire and a material to be welded by using a high-temperature arc generated when a positive electrode and a negative electrode are instantaneously short-circuited, so that the purpose of combining the welding wire and the material to be welded is achieved. In order to generate a high-temperature arc that can melt the wire and the material to be welded, the welding power source needs to have a large output power, for example, a large amount of carbon dioxide arc welding is used in a steel structure processing factory, the rated power of the welding power source is mostly above 20kW, and the rated power of the welding power source is 23.3kW as an example of loose YD-500ER series welding. The rated power of the welding power supply is larger when the welding power supply works normally, the power consumption of the welding power supply in the standby state is not small, for example, the inverter manual welding power supply has no-load loss of about 200-400W in the standby state, and the no-load loss of other types of welding power supplies such as submerged arc welding power supplies in the standby state is larger.
However, the welder is not always in an active working state when using the welding power source to perform the welding operation, and generally, after the welder powers on the welding power source, the welder only performs the welding operation after having a welding task or having finished the weldment, and the welding power source is in a standby state at other times. In order to facilitate use, welders cannot turn off the welding power supply in a standby state for energy conservation, and many welders cannot or forget to turn off the welding power supply in time during noon break.
According to the statistical data of investigation of a certain large shipbuilding factory in the north by an author, the welding power supply is in a standby state for a long time, the working time of each welder is counted according to 8 hours each day (except for noon break), the actual effective working time of one welder is about 4-5 hours, the average value is 4.5 hours, namely, the ineffective working time of about 3.5 hours each day is provided for one welder (not only personal idle reasons but also weldments need to be finished in advance), and then the welder does not or forgets to turn off the welding power supply during the noon break (the noon break time is generally 1 hour), so that 4.5 hours of one welding power supply may be in the standby state in one day, and the idle loss in the standby state is 300W, so the idle loss of one welding power supply per day is about 1.35 kW. The number of welding power supplies in a medium-scale steel structure processing plant is about 200, so that the no-load loss of the welding power supplies in the plant is about 270kW every day, the effective operation days in one year is 300 days, and the no-load loss of the welding power supplies in one year is about 81000kW, namely, about 8 ten thousand degrees of electricity is wasted in the standby loss of the welding power supplies in the plant every year. According to the analysis data, the welding power supply in the standby state has larger power loss, and the effect of wasting electric energy in welding manufacturing enterprises with larger scale is more obvious, so that the condition not only brings extra economic cost expense to the enterprises, but also does not meet the advocates of building energy-saving and environment-friendly enterprises and sustainable development society advocated by the nation vigorously. However, there is no better method or system for improving the current situation in the market, so that a system is proposed or designed to reduce the standby time or idle loss of the welding power supply, which has great economic and social benefits.
Disclosure of Invention
The invention aims to provide a welding power supply energy-saving method and a welding power supply energy-saving system, which can automatically force the welding power supply to lose power and stop running after detecting that the continuous standby time of the welding power supply exceeds the set time, and can fundamentally avoid the serious waste of electric energy caused by the long-time standby of the welding power supply.
In order to realize the aim of the invention, the invention provides an energy-saving method for a welding power supply, which realizes energy saving through the mutual matching of a main circuit module, a control module and an auxiliary circuit module;
the main circuit module comprises a breaker switch NFB, an alternating current contactor KM main contact, a welding power supply and a current sampling sensor which are all connected in series with a three-phase alternating current power supply;
the control module comprises an AD conversion unit, a singlechip minimum system and an interface unit; the minimum system of the single chip microcomputer is internally provided with a main program and a timer T0; the input end of the AD conversion unit is connected with the current sampling sensor, the output end of the AD conversion unit is connected with the minimum system of the single chip microcomputer, and the control port of the minimum system of the single chip microcomputer is connected with the interface unit; the output end of the interface unit is connected with a coil of the control relay KA;
the auxiliary power supply module comprises a control transformer TR, an interface power supply and a control power supply, wherein a primary side winding of the control transformer TR is connected with a three-phase alternating current power supply, a secondary side winding T21 is connected in series with a coil of an alternating current contactor KM and a main contact of a control relay KA, and a secondary side winding T22 and a secondary side winding T23 are respectively connected in series with the interface power supply and the control power supply to supply power for an interface unit;
the specific work flow comprises the following steps:
Further, the specific process of controlling the port to output low level to control the welding power supply to normally operate in step 1 is as follows:
step 1-1, controlling a port to output a low level;
step 1-2, a conduction loop is formed between the control port and the interface unit;
step 1-3, electrifying a coil of a control relay KA at the output end of the interface unit to enable a main contact of the control relay KA arranged on a secondary side winding T21 of a control transformer TR to be attracted and form a conducting loop with a coil of an alternating current contactor KM;
step 1-4, attracting a main contact of an alternating current contactor KM deployed in a three-phase alternating current power supply, and resetting a welding power supply after power is on;
and 1-5, normally operating the welding power supply and the control module.
Further, the execution flow of while (1) function in step 2 is as follows:
step 2-1, judging whether the output level state of the control port is a low level, if not, returning to the while (1) function; if yes, entering the next step;
step 2-2, reading 10 current measurement values converted by the AD conversion unit and storing the current measurement values in an array A;
step 2-3, discarding the maximum value and the minimum value in the array A, and calculating the average value of the remaining 8 arrays of values as a sampling value;
step 2-4, judging whether the sampling value is larger than a set value C, if so, clearing and closing a timer T0, and returning to the while (1) function; if not, entering the step 2-5;
step 2-5, judging whether the count value of the timer T0 is zero, if not, returning to the while (1) function; if yes, entering step 2-6;
step 2-6, start timer T0, start counting, and return to while (1) function.
Further, the execution flow of the timer T0 interrupt function in step 3 is as follows:
step 3-1, controlling a port to output a high level;
step 3-2, clearing and closing a timer T0;
and 3-3, returning to the while (1) function.
Further, step 4, interrupting the function intervention to cause the welding power source to lose power, and the specific process of stopping the operation is as follows:
step 4-1, controlling the port to output high level;
step 4-2, a conduction loop cannot be formed between the control port and the interface unit;
4-3, controlling the coil of the relay KA to lose power, and controlling the main contact of the relay KA to be disconnected, so that a conduction loop cannot be formed with the coil of the alternating current contactor KM;
and 4-4, disconnecting the main contact of the alternating current contactor KM deployed in the three-phase alternating current power supply, and stopping the operation of the welding power supply.
Further, after the step 4 is completed, if the welding power supply needs to be reused, the system should be restarted in the step 5, and the specific process is as follows:
step 5-1, the breaker switch NFB is opened;
step 5-2, controlling the power supply to lose power and stopping running;
step 5-3, the breaker switch NFB is reclosed;
5-4, the control module is powered on again for resetting;
5-5, reclosing the main contact of the alternating current contactor KM;
5-6, the welding power supply is powered on and reset;
and 5-7, the welding power supply and the control module normally operate again to complete the system restarting process.
In order to realize the aim of the invention, the invention also discloses a welding power supply energy-saving system, which comprises a main circuit module, a control module and an auxiliary power supply module;
the main circuit module comprises a three-phase alternating current power supply, a breaker switch NFB, an alternating current contactor KM, a welding power supply and a current sampling sensor; the circuit breaker switch NFB, the alternating current contactor KM main contact and the welding power supply are connected in series to be connected into a three-phase alternating current power supply, and the three-phase alternating current power supply outputs direct current power supplies DC + and DC-after passing through the welding power supply; the current sampling sensor is sleeved at the DC + of the anode direct-current output end of the welding power supply, and the output end of the current sampling sensor is connected to the control module;
the control module comprises an AD conversion unit, a singlechip minimum system and an interface unit; the input end of an AD conversion unit in the control module is connected with a current sampling sensor, the output end of the AD conversion unit is connected with a singlechip minimum system, and a control port of the singlechip minimum system is connected with an interface unit; a main program and a timer T0 are loaded in the minimum system of the single chip microcomputer;
the auxiliary power supply module comprises a control transformer TR, a first rectifier diode D1, an interface power supply, a second rectifier diode D2 and a control power supply; a primary side winding T1 of a control transformer TR in the auxiliary power supply module is connected with a three-phase alternating current power supply; the secondary side winding T21 is connected in series with a coil of the alternating current contactor KM and a main contact of the control relay KA; the secondary side winding T22 is connected in series with a first rectifier diode D1 and an interface power supply, and then is connected into the control module, and the reference ground of the interface power supply is GND 2; the secondary side winding T23 is connected in series with a second rectifier diode D2 and a control power supply and then connected into the control module, and the reference ground of the control power supply is GND 1;
the main circuit module is used for realizing the conversion from three-phase alternating current to direct current and controlling whether the welding power supply and the control module are electrified or not, and the current sampling sensor is used for realizing the current sampling of a direct current output end DC + of the anode of the welding power supply; the control module is used for providing a carrier for the operation of a main program of the system and the realization of control logic, completing the AD conversion of the output value of the current sampling sensor and controlling the on-off of the alternating current contactor KM; the auxiliary power supply module is used for providing an interface power supply and a control power supply for the control module, and the interface power supply is electrically isolated from the control power supply.
Furthermore, the three-phase alternating current power supply lines in the main circuit module are respectively L1, L2 and L3, and the voltage between any two phases is alternating current 380V; the current sampling sensor is a Hall current sensor CT, the output end of the Hall current sensor CT is connected to the input end of an AD conversion unit in the control module through a first resistor R1, the first resistor R1 is a pull-down resistor, and the reference ground is GND 1; the interface unit in the control module is provided with 4 pins; the minimum system of the single chip microcomputer is connected to a pin 2 of the interface unit through a control port through a second resistor R2; a pin 1 of the interface unit is connected with a 3.3V direct-current power supply; pin 3 of the interface unit is connected to the ground reference GND2 through a coil of the control relay KA; pin 4 of the interface unit is connected to a 24V dc supply via a third resistor R3.
Further, a primary side winding T1 of a control transformer TR in the auxiliary power supply module is connected with a phase line L2 and a phase line L3 of a three-phase alternating-current power supply, and the rated voltage is alternating current 380V; the rated voltage of a secondary side winding T21 of the control transformer TR is alternating current 36V; the control relay KA controls the attraction and disconnection of the main contact of the alternating current contactor KM by controlling whether the coil of the alternating current contactor KM is electrified or not, when the coil of the alternating current contactor KM is electrified, the main contact of the alternating current contactor KM is attracted, and when the coil of the alternating current contactor KM is not electrified, the main contact of the alternating current contactor KM is disconnected; the AC contactor KM controls whether the welding power supply is electrified or not through the attraction and disconnection of the main contact, when the main contact of the AC contactor KM is attracted, the welding power supply is electrified, and when the main contact of the AC contactor KM is disconnected, the welding power supply is not electrified; the rated voltage of a secondary side winding T22 of the control transformer TR is AC 48V, and the interface power supply provides 24V power supply for the output side of an interface unit in the control module to drive a coil of the control relay KA; the rated voltage of a secondary winding T23 of the control transformer TR is 12V alternating current, and a control power supply provides 3.3V and 5.5V direct current power supplies for the input sides of a minimum system of a singlechip, an AD conversion unit and an interface unit in the control module.
Further, when the control port outputs a low level, the 3.3V dc power supply forms a conduction loop through the pin 1, the pin 2, the second resistor R2 and the control port of the interface unit; a 24V direct current power supply forms a conducting loop through a pin 4 and a pin 3 of the interface unit, a coil of the control relay KA and a reference ground GND2, and the main contact of the control relay KA is attracted; a secondary side winding T21 of the control transformer TR forms a conduction loop through a coil of the alternating current contactor KM and a main contact of the control relay KA, the main contact of the alternating current contactor KM is closed, a welding power supply is electrified, and the normal operation is realized; when the control port outputs a high level, a conduction loop cannot be formed among the 3.3V direct-current power supply, the pin 1 and the pin 2 of the interface unit, the second resistor R2 and the control port; a loop cannot be formed among the 24V direct-current power supply, the pin 4 and the pin 3 of the interface unit, the coil of the control relay KA and the reference ground GND2, and the main contact of the control relay KA is disconnected; and a conduction loop cannot be formed among a secondary side winding T21 of the control transformer TR, a coil of the alternating current contactor KM and a main contact of the control relay KA, the main contact of the alternating current contactor KM is disconnected, and the welding power supply loses power and stops running.
Compared with the prior art, the invention has the following advantages:
1) the invention adopts a discrete design mode, firstly, the alternating current contactor KM is connected in series into three-phase alternating current power supplies L1, L2 and L3 of a welding power supply, then, a primary side winding T1 of a control transformer TR is connected with a phase line L2 and a phase line L3 of the three-phase alternating current power supply, and finally, a Hall current sensor CT is sleeved on a positive electrode direct current output end DC + of the welding power supply, and a control module, an auxiliary power supply and related cables are arranged in a welding power supply support plate.
2) The system has controllable cost, adopts a universal design mode, has lower cost of the alternating current contactor, the transformer, the current sensor, the control module and the like, ensures that the overall cost of the system is controllable, and is beneficial to popularization and application.
3) The welding power supply energy-saving system designed by the invention can fundamentally avoid the serious waste of electric energy caused by long-time standby of the welding power supply, has obvious energy-saving effect and wide popularization and application prospects.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention without limiting the invention. In the drawings:
FIG. 1 is an electrical schematic of the present invention;
FIG. 2 is a flow chart of the operation of the control logic of the present invention;
FIG. 3 is a restart operation flow diagram of the present invention;
FIG. 4 is a flowchart of a main process of the present invention;
FIG. 5 is a flow chart of the interrupt function of the timer T0 according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments; all other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, the main circuit module includes a three-phase ac power supply, a breaker switch NFB, an ac contactor KM, a welding power supply, and a current sampling sensor; the circuit breaker switch NFB, the alternating current contactor KM main contact and the welding power supply are connected in series to be connected into a three-phase alternating current power supply, and the three-phase alternating current power supply outputs direct current power supplies DC + and DC-after passing through the welding power supply; the current sampling sensor is sleeved at the DC + of the anode direct-current output end of the welding power supply, and the output end of the current sampling sensor is connected to the control module; the control module K1 comprises an AD conversion unit, a singlechip minimum system and an interface unit J1; the input end of an AD conversion unit in the control module is connected with a current sampling sensor, the output end of the AD conversion unit is connected with a singlechip minimum system, and a control port P1.0 of the singlechip minimum system is connected with an interface unit J1; a timer T0 is arranged in the minimum system of the single chip microcomputer; the auxiliary power supply module comprises a control transformer TR, a first rectifier diode D1, an interface power supply, a second rectifier diode D2 and a control power supply; a primary side winding T1 of a control transformer TR in the auxiliary power supply module is connected with a three-phase alternating current power supply; the secondary side winding T21 is connected in series with a coil of the alternating current contactor KM and a main contact of the control relay KA; the secondary side winding T22 is connected in series with a first rectifier diode D1 and an interface power supply, and then is connected into the control module, and the reference ground of the interface power supply is GND 2; the secondary winding T23 is connected in series with a second rectifier diode D2 and a control power supply, and then connected to the control module, wherein the reference ground of the control power supply is GND 1.
Three-phase alternating current power supply lines in the main circuit module are respectively L1, L2 and L3, and the voltage between any two phases is alternating current 380V; the current sampling sensor is a Hall current sensor CT, the output end of the Hall current sensor CT is connected to the input end of an AD conversion unit in the control module through a first resistor R1, the first resistor R1 is a pull-down resistor, and the reference ground is GND 1. The interface unit J1 in the control module is provided with 4 pins; the minimum system of the single chip microcomputer is connected to a pin 2 of the interface unit J1 through a control port P1.0 and a second resistor R2; pin 1 of the interface unit J1 is connected with a 3.3V direct-current power supply; pin 3 of the interface unit J1 is connected to the ground GND2 through a coil of the control relay KA; pin 4 of the interface unit J1 is connected to a 24V dc power supply via a third resistor R3. A primary side winding T1 of a control transformer TR in the auxiliary power supply module is connected with a phase line L2 and a phase line L3 of a three-phase alternating-current power supply, and the rated voltage is alternating current 380V; the rated voltage of a secondary side winding T21 of the control transformer TR is alternating current 36V; the control relay KA controls the attraction and disconnection of the main contact of the alternating current contactor KM by controlling whether the coil of the alternating current contactor KM is electrified or not, when the coil of the alternating current contactor KM is electrified, the main contact of the alternating current contactor KM is attracted, and when the coil of the alternating current contactor KM is not electrified, the main contact of the alternating current contactor KM is disconnected; the AC contactor KM controls whether the welding power supply is electrified or not through the attraction and disconnection of the main contact, when the main contact of the AC contactor KM is attracted, the welding power supply is electrified, and when the main contact of the AC contactor KM is disconnected, the welding power supply is not electrified; the rated voltage of a secondary winding T22 of the control transformer TR is AC 48V, and the interface power supply provides 24V power supply for the output side of an interface J1 unit in the control module to drive a coil of the control relay KA; the rated voltage of a secondary winding T23 of the control transformer TR is 12V alternating current, and a control power supply provides 3.3V and 5.5V direct current power supplies for the input sides of a minimum system of a single chip microcomputer in the control module, the AD conversion unit and the interface J1 unit.
When the control port P1.0 outputs low level, the 3.3V DC power supply forms a conducting loop through the pin 1, the pin 2, the second resistor R2 and the port P1.0 of the interface J1 unit; a 24V direct-current power supply forms a conducting loop through a pin 4 and a pin 3 of the interface J1 unit, a coil of the control relay KA and a reference ground GND2, and the main contact of the control relay KA is attracted; a secondary side winding T21 of the control transformer TR forms a conduction loop through a coil of the alternating current contactor KM and a main contact of the control relay KA, the main contact of the alternating current contactor KM is closed, a welding power supply is electrified, and the normal operation is realized; when the control port P1.0 outputs a high level, a conduction loop cannot be formed among the 3.3V dc power supply, the pin 1 and the pin 2 of the interface J1 unit, the second resistor R2, and the port P1.0; a loop cannot be formed among a 24V direct-current power supply, a pin 4 and a pin 3 of the interface J1 unit, a coil of the control relay KA and the reference ground GND2, and the main contact of the control relay KA is disconnected; and a conduction loop cannot be formed among a secondary side winding T21 of the control transformer TR, a coil of the alternating current contactor KM and a main contact of the control relay KA, the main contact of the alternating current contactor KM is disconnected, and the welding power supply loses power and stops running.
Specifically, in the circuit system, the control transformer TR is TSMU0077, the alternating current contactor KM is LC1D80CC7C, the control relay KA is RXM2CB2BD, and the Hall current sensor CT is CHCS-EKBA-1000A.
As shown in fig. 2, the operation flow of the control logic for realizing the energy saving function of the welding power supply is as follows:
step a1, closing the breaker switch NFB;
step a2, the control module is reset by power;
step a3, closing a main contact of an alternating current contactor KM;
step a4, welding power supply power-on reset
Step a5, the welding power supply operates normally, and the control module operates normally;
step a6, the control module judges whether the welding power supply is in a standby state, if so, the control module enters step a 7; if not, return to step a 5;
step a7, the control module judges whether the continuous standby time of the welding power supply exceeds T, if yes, the control module enters step a 8; if not, return to step a 5;
step a8, disconnecting the main contact of the alternating current contactor KM;
step a9, stopping operation when the welding power supply loses power;
step a10, the control module continues to operate but is in a dead-cycle state;
in the present system, the time T is set to 10 minutes.
As shown in fig. 3, the welding power supply is forced to power off and stop running because the continuous standby time exceeds T, the control module continues running but is in a dead cycle state, and at this time, when the welding power supply needs to be reused, the system is restarted, and the restart running process of the system is as follows:
step b1, opening the breaker switch NFB;
step b2, controlling the power supply to lose power and stopping running;
step b3, reclosing of the breaker switch NFB;
step b4, the control module is powered on again and reset;
step b5, reclosing the main contact of the alternating current contactor KM;
step b6, the welding power supply is powered on and reset;
and b7, the welding power supply normally operates again, the control module normally operates again, and the system restarting process is completed.
As shown in fig. 4, the system provides a carrier for the operation of a main program, the main program is used for implementing the control logic of the system, and the main program executes the following processes:
step c1, the control module is electrified and reset, and the main program starts to run;
step c2, controlling port P1.0 to output low level, that is, P1.0 is 0;
step c3, executing while (1) function;
step c4, judging whether the output level state of the port P1.0 is 0, if not, returning to while (1) function; if so, go to step c 5;
step c5, reading the AD value, reading 10 current measurement values after AD conversion and storing the current measurement values in an array A;
step c6, discarding the maximum value and the minimum value in the array A, and calculating the average value of the remaining 8 arrays of values as a sampling value;
step C7, judging whether the sampling value is larger than a set value C, if so, clearing and closing a timer T0, returning to the while (1) function, and if not, entering the step C8; the step is used for judging whether the welding power supply is in a standby state;
step c8, judging whether the count value of the timer T0 is zero, if not, returning to the while (1) function; if so, go to step c 9;
step c9, starting a timer T0 and returning to while (1) function;
in the present system, the set value C is 20A.
As shown in fig. 5, when the time corresponding to the count value of the timer T0 reaches T, the timer T0 is automatically triggered to interrupt the function, and the execution flow of the timer T0 interrupt function is as follows:
step d1, controlling port P1.0 to output high level, i.e. P1.0 equals 1;
step d2, clearing and closing the timer T0;
step d3, return to while (1) function.
When the system detects that the continuous standby time of the welding power supply exceeds the set time T, the welding power supply is forced to be powered off and shut down, the electric energy loss is effectively saved, and when the welding power supply is reused, the breaker switch NFB is manually restarted, so that the system can fundamentally avoid the serious electric energy waste caused by the long-time standby of the welding power supply, bring considerable economic benefits to enterprises and create remarkable social benefits.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (10)
1. A welding power supply energy-saving method is characterized in that energy conservation is realized through mutual matching of a main circuit module, a control module and an auxiliary circuit module;
the main circuit module comprises a breaker switch NFB, an alternating current contactor KM main contact, a welding power supply and a current sampling sensor which are all connected in series with a three-phase alternating current power supply;
the control module comprises an AD conversion unit, a singlechip minimum system and an interface unit; the single chip microcomputer minimum system is internally provided with a main program and a timer T0; the input end of the AD conversion unit is connected to the current sampling sensor, the output end of the AD conversion unit is connected to a single chip microcomputer minimum system, and a single chip microcomputer minimum system control port is connected to an interface unit; the output end of the interface unit is connected with a coil of the control relay KA;
the auxiliary power supply module comprises a control transformer TR, an interface power supply and a control power supply, wherein a primary side winding of the control transformer TR is connected with a three-phase alternating current power supply, a secondary side winding T21 is connected in series with a coil of an alternating current contactor KM and a main contact of a control relay KA, and secondary side windings T22 and T23 are respectively connected in series with the interface power supply and the control power supply and used for supplying power to an interface unit; the specific work flow comprises the following steps:
step 1, closing a breaker switch NFB, enabling a control module to be powered on and reset, outputting a low level through a minimum system control port of a singlechip in the control module, and enabling a welding power supply and the control module to normally operate;
step 2, the minimum system main program of the single chip microcomputer runs and executes while (1) function;
step 3, when the time corresponding to the count value of the timer T0 reaches T, automatically triggering a timer T0 interrupt function;
step 4, interrupting the function to cause the welding power supply to lose power, and stopping running; the main routine continues to run, but is in a loop-locked state.
2. The energy-saving method for the welding power supply according to claim 1, wherein the specific process of controlling the port to output the low level to control the normal operation of the welding power supply in the step 1 is as follows:
step 1-1, controlling a port to output a low level;
step 1-2, a conduction loop is formed between the control port and the interface unit;
step 1-3, electrifying a coil of a control relay KA at the output end of an interface unit to pull a main contact of the control relay KA arranged on a secondary side winding T21 of a control transformer TR into a conduction loop with a coil of an alternating current contactor KM;
step 1-4, attracting a main contact of an alternating current contactor KM deployed in a three-phase alternating current power supply, and resetting a welding power supply after power is on;
and 1-5, normally operating the welding power supply and the control module.
3. The method for saving energy of the welding power supply according to claim 1, wherein the while (1) function in step 2 is executed by:
step 2-1, judging whether the output level state of the control port is a low level, if not, returning to the while (1) function; if yes, entering the next step;
step 2-2, reading 10 current measurement values converted by the AD conversion unit and storing the current measurement values in an array A;
step 2-3, discarding the maximum value and the minimum value in the array A, and calculating the average value of the remaining 8 arrays of values as a sampling value;
step 2-4, judging whether the sampling value is larger than a set value C, if so, clearing and closing a timer T0, and returning to the while (1) function; if not, entering the step 2-5;
step 2-5, judging whether the count value of the timer T0 is zero, if not, returning to the while (1) function; if yes, entering step 2-6;
step 2-6, start timer T0, start counting, and return to while (1) function.
4. The welding power supply energy saving method according to claim 1, wherein the timer T0 interruption function in step 3 is executed by:
step 3-1, controlling a port to output a high level;
step 3-2, clearing and closing a timer T0;
and 3-3, returning to the while (1) function.
5. The energy-saving method for the welding power supply as claimed in claim 1, wherein the step 4 interrupt function intervention causes the welding power supply to lose power, and the specific process of stopping the operation is as follows:
step 4-1, controlling the port to output high level;
step 4-2, a conduction loop cannot be formed between the control port and the interface unit;
4-3, controlling the coil of the relay KA to lose power, and controlling the main contact of the relay KA to be disconnected, so that a conduction loop cannot be formed with the coil of the alternating current contactor KM;
and 4-4, disconnecting the main contact of the alternating current contactor KM deployed in the three-phase alternating current power supply, and stopping the operation of the welding power supply.
6. The energy-saving method for the welding power supply according to claim 1, wherein after step 4 is completed, if the welding power supply needs to be reused, step 5 is performed to restart the system, and the specific process is as follows:
step 5-1, the breaker switch NFB is opened;
step 5-2, controlling the power supply to lose power and stopping running;
step 5-3, the breaker switch NFB is reclosed;
5-4, the control module is powered on again for resetting;
5-5, reclosing the main contact of the alternating current contactor KM;
5-6, the welding power supply is powered on and reset;
and 5-7, the welding power supply and the control module normally operate again to complete the system restarting process.
7. A welding power supply energy-saving system is characterized by comprising a main circuit module, a control module and an auxiliary power supply module;
the main circuit module comprises a three-phase alternating current power supply, a breaker switch NFB, an alternating current contactor KM, a welding power supply and a current sampling sensor; the circuit breaker switch NFB, the alternating current contactor KM main contact and the welding power supply are connected in series to be connected into a three-phase alternating current power supply, and the three-phase alternating current power supply outputs direct current power supplies DC + and DC-after passing through the welding power supply; the current sampling sensor is sleeved at a DC + output end of the anode of the welding power supply, and the output end of the current sampling sensor is connected to the control module;
the control module comprises an AD conversion unit, a singlechip minimum system and an interface unit; the input end of an AD conversion unit in the control module is connected with the current sampling sensor, the output end of the AD conversion unit is connected with the singlechip minimum system, and a control port of the singlechip minimum system is connected with the interface unit; a main program and a timer T0 are mounted in the minimum system of the single chip microcomputer;
the auxiliary power supply module comprises a control transformer TR, a first rectifier diode D1, an interface power supply, a second rectifier diode D2 and a control power supply; a primary side winding T1 of the control transformer TR in the auxiliary power supply module is connected with a three-phase alternating current power supply; the secondary side winding T21 is connected in series with a coil of the alternating current contactor KM and a main contact of the control relay KA; the secondary side winding T22 is connected in series with a first rectifier diode D1 and an interface power supply, and then is connected into the control module, and the reference ground of the interface power supply is GND 2; the secondary side winding T23 is connected in series with a second rectifier diode D2 and a control power supply, and then is connected into the control module, and the reference ground of the control power supply is GND 1;
the main circuit module is used for realizing the conversion from three-phase alternating current to direct current and controlling whether the welding power supply and the control module are electrified or not, and the current sampling sensor is used for realizing the current sampling of a direct current output end DC + of the anode of the welding power supply; the control module is used for providing a carrier for the operation of a main program of the system and the realization of control logic, completing the AD conversion of the output value of the current sampling sensor and controlling the on-off of the alternating current contactor KM; the auxiliary power supply module is used for providing an interface power supply and a control power supply for the control module, and the interface power supply is electrically isolated from the control power supply.
8. The welding power supply energy saving system of claim 7,
three-phase alternating current power supply lines in the main circuit module are respectively L1, L2 and L3, and the voltage between any two phases is alternating current 380V; the current sampling sensor is a Hall current sensor CT, the output end of the Hall current sensor CT is connected to the input end of an AD conversion unit in the control module through a first resistor R1, the first resistor R1 is a pull-down resistor, and the reference ground is GND 1;
the interface unit in the control module is provided with 4 pins; the singlechip minimum system is connected to a pin 2 of the interface unit through a control port through a second resistor R2; a pin 1 of the interface unit is connected with a 3.3V direct-current power supply; pin 3 of the interface unit is connected to a ground reference GND2 through a coil of a control relay KA; pin 4 of the interface unit is connected to a 24V dc power supply via a third resistor R3.
9. The welding power supply energy saving system of claim 8,
a primary side winding T1 of a control transformer TR in the auxiliary power supply module is connected with a phase line L2 and a phase line L3 of a three-phase alternating-current power supply, and the rated voltage is alternating current 380V;
the rated voltage of a secondary side winding T21 of the control transformer TR is alternating current 36V; the control relay KA controls the attraction and disconnection of the main contact of the alternating current contactor KM by controlling whether the coil of the alternating current contactor KM is electrified or not, when the coil of the alternating current contactor KM is electrified, the main contact of the alternating current contactor KM is attracted, and when the coil of the alternating current contactor KM is not electrified, the main contact of the alternating current contactor KM is disconnected; the alternating current contactor KM controls whether the welding power supply is electrified or not through the attraction and disconnection of the main contact, when the main contact of the alternating current contactor KM is attracted, the welding power supply is electrified, and when the main contact of the alternating current contactor KM is disconnected, the welding power supply is not electrified;
the rated voltage of a secondary side winding T22 of the control transformer TR is AC 48V, and the interface power supply provides 24V power supply for the output side of an interface unit in the control module to drive a coil of the control relay KA;
the rated voltage of a secondary winding T23 of the control transformer TR is 12V alternating current, and a control power supply provides 3.3V and 5.5V direct current power supplies for the input sides of a minimum system of a singlechip, an AD conversion unit and an interface unit in the control module.
10. The welding power supply energy saving system of claim 9,
when the control port outputs a low level, the 3.3V dc power supply forms a conduction loop through pin 1, pin 2, the second resistor R2 and the control port of the interface unit; a 24V direct current power supply forms a conducting loop through a pin 4 and a pin 3 of the interface unit, a coil of the control relay KA and a reference ground GND2, and the main contact of the control relay KA is attracted; a secondary side winding T21 of the control transformer TR forms a conduction loop through a coil of the alternating current contactor KM and a main contact of the control relay KA, the main contact of the alternating current contactor KM is closed, a welding power supply is electrified, and the normal operation is realized;
when the control port outputs a high level, a conduction loop cannot be formed among the 3.3V direct-current power supply, the pin 1 and the pin 2 of the interface unit, the second resistor R2 and the control port; a loop cannot be formed among the 24V direct-current power supply, the pin 4 and the pin 3 of the interface unit, the coil of the control relay KA and the reference ground GND2, and the main contact of the control relay KA is disconnected; and a conduction loop cannot be formed among a secondary side winding T21 of the control transformer TR, a coil of the alternating current contactor KM and a main contact of the control relay KA, the main contact of the alternating current contactor KM is disconnected, and the welding power supply loses power and stops running.
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