CN113843479B - Welding power supply energy saving method and system - Google Patents
Welding power supply energy saving method and system Download PDFInfo
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- CN113843479B CN113843479B CN202111198185.8A CN202111198185A CN113843479B CN 113843479 B CN113843479 B CN 113843479B CN 202111198185 A CN202111198185 A CN 202111198185A CN 113843479 B CN113843479 B CN 113843479B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
- B23K9/1043—Power supply characterised by the electric circuit
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Abstract
The application discloses a welding power supply energy-saving method and a system. By applying the method, when the continuous standby time of the welding power supply exceeds 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 when the welding power supply is required to be reused, the breaker switch NFB is manually restarted. The system comprises a main circuit module, a control module and an auxiliary power module. The control module single-chip microcomputer minimum system is provided with a main program for realizing control logic of the system and achieving the energy-saving function of the welding power supply. The method and the system can fundamentally avoid serious electric energy waste caused by long-time standby of the welding power supply, bring considerable economic benefit to enterprises and create remarkable social benefit.
Description
Technical Field
The application relates to the field of energy-saving control of welding power sources, in particular to a welding power source energy-saving method and a welding power source energy-saving system.
Background
As a general welding apparatus, a welding power source is widely used in the field of welding manufacture, wherein the number and types of welding power sources held by units such as shipyards, automobile factories, steel structure processing factories, pressure vessel factories, and the like are the largest. The more common types of welding power sources include carbon dioxide protected 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.
In general, a welding power source melts a welding wire and a material to be welded by using a high-temperature arc generated when an anode and a cathode are instantaneously short-circuited, so as to achieve the purpose of combining the welding wire and the material to be welded. In order to generate high-temperature electric arcs capable of melting welding wires and materials to be welded, a welding power supply is required to have larger output power, for example, more carbon dioxide arc welding is used in steel structure processing factories, the rated power is mostly more than 20kW, and in the example of loose YD-500ER series welding, the rated power of the welding power supply is 23.3kW. The rated power of the welding power supply is larger in normal operation, the power consumption of the welding power supply in a standby state is not small, such as an inverted manual welding power supply, the no-load loss in the standby state is about 200-400W, and the no-load loss in the standby state is larger in other types of welding power supplies such as a submerged arc welding power supply.
However, when a welder performs a welding operation using a welding power source, the welder is not always in an effective operation state, and generally, after powering up the welding power source, the welder performs the welding operation only after having a welding task or finishing a weldment, and the welding power source is in a standby state at other times. For convenience, the welder does not turn off the welding power supply in a standby state for saving energy, including during noon break, and many welders do not or forget to turn off the welding power supply in time.
The above working scenario causes the welding power supply to be in a standby state for a long time, according to the investigation statistical data of a large shipyard in the north of the author, the working time statistics is counted according to 8 hours per day (excluding noon break), the actual effective working time of a welder is about 4-5 hours, the average value is 4.5 hours, namely the welder has an ineffective working time of about 3.5 hours per day (not only for personal idle reasons, some welding works need to arrange weldments in advance), and then, if the welder does not have or forgets to turn off the welding power supply during noon break (noon break time is generally 1 hour), then, one welding power supply may have a standby state for 4.5 hours in one day, and the no-load loss of one welding power supply in the standby state is about 300W, and the no-load loss of one welding power supply per day is about 1.35kW. A medium-scale steel structure processing plant maintains about 200 welding power supplies, so that the no-load loss of the welding power supplies per day of the plant is about 270kW, and the effective operating days in one year are 300 days, and the no-load loss of the welding power supplies in one year is about 81000kW, that is, the plant wastes about 8 ten thousand degrees of electricity in terms of the standby loss of the welding power supplies each year. According to the analysis data, the welding power supply in the standby state has larger loss power, and the waste electric energy effect in welding manufacturing enterprises with larger scale is more obvious, so that the situation not only brings extra economic cost expense to the enterprises, but also does not accord with the advocates of building energy-saving environment-friendly enterprises and sustainable development society advocated by the state. 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 no-load loss of the welding power source, which has great economic benefit and significant social benefit.
Disclosure of Invention
The application aims to provide an energy-saving method and an energy-saving system for a welding power supply, 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 radically stop the serious waste of electric energy caused by long-time standby of the welding power supply.
In order to achieve the aim, the application provides an energy-saving method for a welding power supply, which realizes energy saving through the mutual coordination 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; a main program and a timer T0 are carried in the minimum system of the singlechip; 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 singlechip, and the control port of the minimum system of the singlechip 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 the secondary side windings T22 and 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 workflow comprises the following steps:
step 1, closing a breaker switch NFB, enabling a control module to be reset, enabling a minimum system control port of a singlechip in the control module to output low level, and enabling a welding power supply and the control module to operate normally;
step 2, running a minimum system main program of the singlechip, and executing a while (1) function;
step 3, when the time corresponding to the count value of the timer T0 reaches T, automatically triggering the interrupt function of the timer T0;
step 4, interrupting function intervention to cause power failure of the welding power supply, and stopping operation; the main program continues to run but is in a dead-loop state.
Further, the specific flow of controlling the normal operation of the welding power supply by the low level output by the control port in the step 1 is as follows:
step 1-1, a control port outputs a low level;
step 1-2, a conduction loop is formed between the control port and the interface unit;
step 1-3, a coil of a control relay KA at the output end of an interface unit is electrified, so that a main contact of the control relay KA deployed on a secondary side winding T21 of a control transformer TR is attracted to form a conduction loop with a coil of an alternating current contactor KM;
step 1-4, the main contact of an alternating current contactor KM deployed on a three-phase alternating current power supply is attracted, and the welding power supply is reset;
and step 1-5, the welding power supply and the control module normally operate.
Further, the execution flow of the 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 a while (1) function; if yes, entering the next step;
step 2-2, reading 10 groups of current measured values converted by the AD conversion unit and storing the current measured 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 rest 8 groups of numerical values to be used as a sampling value;
step 2-4, judging whether the sampling value is larger than a set value C, if so, resetting and closing a timer T0, and returning to a while (1) function; if not, entering step 2-5;
step 2-5, judging whether the count value of the timer T0 is zero, if not, returning to a while (1) function; if yes, enter step 2-6;
step 2-6, starting a timer T0, starting counting, and returning to the while (1) function.
Further, in step 3, the execution flow of the timer T0 interrupt function is as follows:
step 3-1, the control port outputs high level;
step 3-2, clearing and closing a timer T0;
and 3-3, returning to a while (1) function.
Further, the interruption function intervention in the step 4 causes the welding power supply to lose power, and the specific flow of stopping operation is as follows:
step 4-1, the control port outputs high level;
step 4-2, a conduction loop cannot be formed between the control port and the interface unit;
step 4-3, controlling the coil of the relay KA to lose electricity, controlling the main contact of the relay KA to be disconnected, and preventing the main contact from forming a conducting loop with the coil of the alternating current contactor KM;
and 4-4, disconnecting the main contact of the alternating current contactor KM deployed on the three-phase alternating current power supply, and stopping the operation of the welding power supply.
Further, after the execution of step 4 is completed, if the welding power supply needs to be reused, the system is restarted in step 5, and the specific flow is as follows:
step 5-1, the breaker switch NFB is opened;
step 5-2, controlling the power supply to lose electricity and stopping operation;
step 5-3, reclosing the breaker switch NFB;
step 5-4, the control module gets the power reset again;
step 5-5, reclosing the main contact of the alternating current contactor KM;
step 5-6, the welding power supply is powered on and reset;
and 5-7, the welding power supply and the control module are operated normally again, and the system flow is restarted.
In order to achieve the purpose of the application, the application 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 breaker switch NFB, the main contact of the alternating-current contactor KM and the welding power supply are connected in series to be connected with a three-phase alternating-current power supply, and the three-phase alternating-current power supply outputs DC+ and DC-of a direct-current power supply after passing through the welding power supply; the current sampling sensor is sleeved at the DC+ output end of the positive electrode of the welding power supply, and the output end of the current sampling sensor is connected with 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 a singlechip minimum system, and a control port of the singlechip minimum system is connected with the interface unit; the inside of the minimum system of the singlechip is provided with a main program and a timer T0;
the auxiliary power supply module comprises a control transformer TR, a first rectifying diode D1, an interface power supply, a second rectifying diode D2 and a control power supply; the primary winding T1 of the control transformer TR in the auxiliary power module is connected with a three-phase alternating current power supply; the 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; the secondary side winding T22 is connected in series with the first rectifying diode D1 and the interface power supply and then is connected into the control module, and the reference ground of the interface power supply is GND2; the secondary side winding T23 is connected in series with a second rectifying diode D2 and a control power supply and then is connected into a control module, and the reference ground of the control power supply is GND1;
the main circuit module is used for realizing the conversion from three-phase alternating current to direct current, controlling the welding power supply and the control module to be electrified, and the current sampling sensor is used for realizing the current sampling of the DC+ output end of the positive electrode of the welding power supply; the control module is used for providing a carrier for the system main program operation and control logic implementation, 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 and the control power supply are electrically isolated.
Further, the phase lines of the three-phase alternating current power supply in the main circuit module are L1, L2 and L3 respectively, and the voltage between any two phases is 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 GND1; the interface unit in the control module is provided with 4 pins; the minimum system of the singlechip is connected to a pin 2 of the interface unit through a control port and a second resistor R2; 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 ground GND2 via the coil of control relay KA; pin 4 of the interface unit is connected to a 24V DC power supply via a third resistor R3.
Further, a primary winding T1 of a control transformer TR in the auxiliary power module is connected with a phase line L2 and a phase line L3 of a three-phase alternating current power supply, and rated voltage is 380V; the rated voltage of the secondary side winding T21 of the control transformer TR is 36V; the control relay KA controls the on-off 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 on, and when the coil of the alternating-current contactor KM is in power failure, the main contact of the alternating-current contactor KM is off; the AC contactor KM controls whether a 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 powered off; the rated voltage of the secondary side winding T22 of the control transformer TR is alternating current 48V, and an interface power supply provides 24V power for the output side of an interface unit in the control module and is used for driving a coil of the control relay KA; the rated voltage of the secondary side winding T23 of the control transformer TR is 12V, and the control power supply provides 3.3V and 5.5V direct current power for the minimum system of the singlechip, the AD conversion unit and the input side of the interface unit in the control module.
Further, when the control port outputs a low level, the 3.3V direct current power supply forms a conducting loop through the pin 1, the pin 2, the second resistor R2 and the control port of the interface unit; the 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 the ground GND2, and controls the main contact of the relay KA to be attracted; the 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 attracted, and a welding power supply is powered and operates normally; 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, the pin 2, the second resistor R2 and the control port of the interface unit; 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 ground GND2, and the main contact of the control relay KA is disconnected; a conduction loop cannot be formed among the secondary side winding T21 of the control transformer TR, the coil of the alternating current contactor KM and the main contact of the control relay KA, the main contact of the alternating current contactor KM is disconnected, the welding power supply is in power failure, and the operation is stopped.
Compared with the prior art, the application has the following advantages:
1) The application adopts a discrete design mode, firstly, an alternating current contactor KM is connected in series with three-phase alternating current power supplies L1, L2 and L3 of a welding power supply, then a primary 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, finally, a Hall current sensor CT is sleeved on a positive DC 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 supporting plate, so that the application is easy to apply.
2) The system cost is controllable, the application adopts a universal design mode, and the cost of an alternating current contactor, a transformer, a current sensor, a control module and the like is lower, so that the whole cost of the system is controllable, and the application is beneficial to popularization and application.
3) The energy-saving system of the welding power supply has obvious energy-saving effect, can radically stop the serious waste of electric energy caused by long-time standby of the welding power supply, has obvious energy-saving effect and has wide popularization and application prospects.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute a limitation on the application. In the drawings:
FIG. 1 is an electrical schematic of the present application;
FIG. 2 is a flow chart illustrating the operation of the control logic of the present application;
FIG. 3 is a flowchart of the restart operation of the present application;
FIG. 4 is a flowchart of a main process of the present application;
FIG. 5 is a flowchart of the interrupt function of the timer T0 according to the present application.
Detailed Description
The following description of the embodiments of the present application will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the application; all other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
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 breaker switch NFB, the main contact of the alternating-current contactor KM and the welding power supply are connected in series to be connected with a three-phase alternating-current power supply, and the three-phase alternating-current power supply outputs DC+ and DC-of a direct-current power supply after passing through the welding power supply; the current sampling sensor is sleeved at the DC+ output end of the positive electrode of the welding power supply, and the output end of the current sampling sensor is connected with the control module; the control module K1 comprises an AD conversion unit, a singlechip minimal 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 singlechip; the auxiliary power supply module comprises a control transformer TR, a first rectifying diode D1, an interface power supply, a second rectifying diode D2 and a control power supply; the primary winding T1 of the control transformer TR in the auxiliary power module is connected with a three-phase alternating current power supply; the 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; the secondary side winding T22 is connected in series with the first rectifying diode D1 and the interface power supply and then is connected into the control module, and the reference ground of the interface power supply is GND2; the secondary side winding T23 is connected in series with the second rectifying diode D2 and the control power supply and then is connected into the control module, and the reference ground of the control power supply is GND1.
The phase lines of the three-phase alternating current power supply in the main circuit module are L1, L2 and L3 respectively, and the voltage between any two phases is 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 GND1. The interface unit J1 in the control module is provided with 4 pins; the minimum system of the singlechip 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 interface unit J1 is connected with a 3.3V DC power supply; pin 3 of interface unit J1 is connected to ground GND2 via the coil of control relay KA; pin 4 of interface unit J1 is connected to 24V DC power supply via third resistor R3. The primary winding T1 of the control transformer TR in the auxiliary power module is connected with the phase line L2 and the phase line L3 of the three-phase alternating current power supply, and the rated voltage is 380V; the rated voltage of the secondary side winding T21 of the control transformer TR is 36V; the control relay KA controls the on-off 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 on, and when the coil of the alternating-current contactor KM is in power failure, the main contact of the alternating-current contactor KM is off; the AC contactor KM controls whether a 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 powered off; the rated voltage of the secondary side winding T22 of the control transformer TR is alternating current 48V, and an interface power supply provides 24V power for the output side of an interface J1 unit in the control module and is used for driving and controlling a coil of a relay KA; the rated voltage of the secondary side winding T23 of the control transformer TR is 12V, and the control power supply provides 3.3V and 5.5V direct current power for the input side of the single chip microcomputer minimum system, the AD conversion unit and the interface J1 unit in the control module.
When the control port P1.0 outputs a low level, a 3.3V direct current 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; the 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 the ground GND2, and controls the main contact of the relay KA to be attracted; the 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 attracted, and a welding power supply is powered and operates normally; when the control port P1.0 outputs a high level, a conduction loop cannot be formed among the 3.3V direct current power supply, the pin 1, the pin 2, the second resistor R2 and the port P1.0 of the interface J1 unit; a loop cannot be formed among the 24V direct current power supply, the pin 4 of the interface J1 unit, the pin 3, the coil of the control relay KA and the ground GND2, and the main contact of the control relay KA is disconnected; a conduction loop cannot be formed among the secondary side winding T21 of the control transformer TR, the coil of the alternating current contactor KM and the main contact of the control relay KA, the main contact of the alternating current contactor KM is disconnected, the welding power supply is in power failure, and the operation is stopped.
Specifically, in the circuit system of the application, the model of the control transformer TR is TSMU0077, the model of the alternating current contactor KM is LC1D80CC7C, the model of the control relay KA is RXM2CB2BD, and the model of the Hall current sensor CT is CHCS-EKBA-1000A.
As shown in fig. 2, the control logic implementing the energy saving function of the welding power supply has the following operation flow:
step a1, closing a breaker switch NFB;
step a2, the control module is powered on for resetting;
step a3, closing a KM main contact of the alternating-current contactor;
step a4, power-on reset of welding power supply
Step a5, the welding power supply normally operates, and the control module normally operates;
step a6, the control module judges whether the welding power supply is in a standby state, if so, the step a7 is entered; if not, returning to the step a5;
step a7, the control module judges whether the continuous standby time of the welding power supply exceeds T, if so, the step a8 is entered; if not, returning to the step a5;
step a8, disconnecting the main contact of the alternating current contactor KM;
step a9, the welding power supply is powered off and stops running;
step a10, the control module continues to operate, but is in a dead-loop state;
in the present system, the time T is set to 10 minutes.
As shown in fig. 3, when the welding power supply is forced to be powered off and stopped due to the fact that the continuous standby time exceeds T, the control module continues to operate, but is in a dead-cycle state, and when the welding power supply needs to be reused at this time, the system is restarted, and the restarting operation flow of the system is as follows:
step b1, the breaker switch NFB is opened;
step b2, controlling the power supply to lose electricity, and stopping operation;
step b3, reclosing the breaker switch NFB;
step b4, the control module is reset again;
step b5, reclosing the main contact of the alternating-current contactor KM;
step b6, power-on reset of the welding power supply;
and b7, the welding power supply is operated normally again, and the control module is operated normally again, so that the system flow is restarted.
As shown in fig. 4, the minimum system of the singlechip of the system provides a carrier for the operation of a main program, the main program is used for realizing the control logic of the system, and the execution flow of the main program is as follows:
step c1, the control module is powered on for resetting, and a main program starts to run;
step c2, the control port p1.0 outputs a low level, i.e. p1.0=0;
step c3, executing a while (1) function;
step c4, judging whether the output level state of the port P1.0 is 0, if not, returning to a while (1) function; if yes, enter step c5;
step c5, reading AD values, reading 10 groups of current measured values after AD conversion and storing the current measured 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 rest 8 groups of numerical values as a sampling value;
step C7, judging whether the sampling value is larger than a set value C, if so, resetting and closing a timer T0, returning to a while (1) function, and if not, entering a step C8; the step is used for judging whether the welding power supply is in a standby state or not;
step c8, judging whether the count value of the timer T0 is zero, and if not, returning to a while (1) function; if yes, go to step c9;
step c9, starting a timer T0 and returning to a 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 interrupt function is automatically triggered, and the execution flow of the timer T0 interrupt function is as follows:
step d1, the control port p1.0 outputs a high level, i.e., p1.0=1;
d2, clearing and closing a timer T0;
step d3, returning to the 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 restarted manually, so that the system can fundamentally stop the serious electric energy waste caused by long-time standby of the welding power supply, bring considerable economic benefit to enterprises and create remarkable social benefit.
It is noted that relational terms such as first and second, and the like are 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. Moreover, 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 application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the application, the scope of which is defined in the appended claims and their equivalents.
Claims (6)
1. The energy-saving method for the welding power supply is characterized in that energy saving is realized 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; a main program and a timer T0 are mounted in the minimum system of the singlechip; 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 a singlechip minimum system, and a control port of the singlechip minimum system is connected with 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 with a coil of an alternating current contactor KM and a control relay KA main contact in series, and the secondary side windings T22 and T23 are respectively connected with the interface power supply and the control power supply in series and are used for supplying power to the interface unit; the specific workflow comprises the following steps:
step 1, closing a breaker switch NFB, and obtaining power-on reset of a control module, wherein a minimum system control port of a singlechip in the control module outputs low level, and a welding power supply and the control module normally operate;
step 2, running a minimum system main program of the singlechip, and executing a while (1) function;
step 3, when the time corresponding to the count value of the timer T0 reaches T, automatically triggering the interrupt function of the timer T0;
step 4, interrupting function intervention to cause power failure of the welding power supply, and stopping operation; the main program continues to run, but is in a dead-loop state;
the specific flow of controlling the normal operation of the welding power supply by the low level output of the control port in the step 1 is as follows:
step 1-1, a control port outputs a low level;
step 1-2, a conduction loop is formed between the control port and the interface unit;
step 1-3, a coil of a control relay KA at the output end of an interface unit is electrified, so that a main contact of the control relay KA deployed on a secondary side winding T21 of a control transformer TR is attracted to form a conduction loop with a coil of an alternating current contactor KM;
step 1-4, the main contact of an alternating current contactor KM deployed on a three-phase alternating current power supply is attracted, and the welding power supply is reset;
step 1-5, the welding power supply and the control module normally operate;
the execution flow of the while (1) function in the 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 a while (1) function; if yes, entering the next step;
step 2-2, reading 10 groups of current measured values converted by the AD conversion unit and storing the current measured 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 rest 8 groups of numerical values as a sampling value;
step 2-4, judging whether the sampling value is larger than a set value C, if so, resetting and closing a timer T0, and returning to a while (1) function; if not, entering step 2-5;
step 2-5, judging whether the count value of the timer T0 is zero, if not, returning to a while (1) function; if yes, enter step 2-6;
step 2-6, starting a timer T0, starting counting, and returning to a while (1) function;
the execution flow of the timer T0 interrupt function in step 3 is as follows:
step 3-1, the control port outputs high level;
step 3-2, clearing and closing a timer T0;
step 3-3, returning a while (1) function;
step 4, interruption function intervention causes power failure of the welding power supply, and the specific flow of stopping operation is as follows:
step 4-1, the control port outputs high level;
step 4-2, a conduction loop cannot be formed between the control port and the interface unit;
step 4-3, controlling the coil of the relay KA to lose electricity, controlling the main contact of the relay KA to be disconnected, and preventing the main contact from forming a conducting loop with the coil of the alternating current contactor KM;
and 4-4, disconnecting the main contact of the alternating current contactor KM deployed on the three-phase alternating current power supply, and stopping the operation of the welding power supply.
2. The method for saving energy of a welding power supply according to claim 1, wherein after the step 4 is performed, if the welding power supply needs to be reused, the system is restarted in 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 electricity and stopping operation;
step 5-3, reclosing the breaker switch NFB;
step 5-4, the control module gets the power reset again;
step 5-5, reclosing the main contact of the alternating current contactor KM;
step 5-6, the welding power supply is powered on and reset;
and 5-7, the welding power supply and the control module are operated normally again, and the system flow is restarted.
3. A welding power supply energy saving system for implementing the welding power supply energy saving method of any one of claims 1-2, 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 breaker switch NFB, the main contact of the alternating-current contactor KM and the welding power supply are connected in series to be connected with a three-phase alternating-current power supply, and the three-phase alternating-current power supply outputs DC+ and DC-of a direct-current power supply after passing through the welding power supply; the current sampling sensor is sleeved at the DC output end DC+ of the positive electrode of the welding power supply, and the output end of the current sampling sensor is connected with 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 the control port of the singlechip minimum system is connected with the interface unit; the single chip microcomputer minimum system is internally provided with a main program and a timer T0;
the auxiliary power supply module comprises a control transformer TR, a first rectifying diode D1, an interface power supply, a second rectifying 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 an alternating current contactor KM and a main contact of a control relay KA; the secondary side winding T22 is connected in series with a first rectifying diode D1 and an interface power supply and then connected into the control module, and the reference ground of the interface power supply is GND2; the secondary side winding T23 is connected in series with a second rectifying diode D2 and a control power supply and then connected into the control module, and the reference ground of the control power supply is GND1;
the main circuit module is used for realizing the conversion from three-phase alternating current to direct current, controlling the welding power supply and the control module to be electrified, and the current sampling sensor is used for realizing the current sampling of the DC+ output end of the positive electrode of the welding power supply; the control module is used for providing a carrier for the system main program operation and control logic implementation, 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 and the control power supply are electrically isolated.
4. A welding power supply economizer system as recited in claim 3, wherein,
the phase lines of the three-phase alternating current power supply in the main circuit module are L1, L2 and L3 respectively, and the voltage between any two phases is 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 GND1;
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 and a second resistor R2; the pin 1 of the interface unit is connected with a 3.3V direct current power supply; the pin 3 of the interface unit is connected to the ground GND2 through a coil of the control relay KA; and a pin 4 of the interface unit is connected with a 24V direct current power supply through a third resistor R3.
5. A welding power supply economizer system as defined in claim 4 wherein,
the primary winding T1 of the control transformer TR in the auxiliary power module is connected with the phase line L2 and the phase line L3 of the three-phase alternating current power supply, and the rated voltage is 380V;
the rated voltage of the secondary side winding T21 of the control transformer TR is 36V; the control relay KA controls the on-off 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 on, and when the coil of the alternating-current contactor KM is in power failure, the main contact of the alternating-current contactor KM is off; the alternating current contactor KM controls whether a 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 deenergized;
the rated voltage of the secondary side winding T22 of the control transformer TR is alternating current 48V, and an interface power supply provides 24V power for the output side of an interface unit in the control module and is used for driving a coil of the control relay KA;
the rated voltage of the secondary side winding T23 of the control transformer TR is 12V, and the control power supply provides 3.3V and 5.5V direct current power for the minimum system of the singlechip, the AD conversion unit and the input side of the interface unit in the control module.
6. A welding power supply economizer system as defined in claim 5 wherein,
when the control port outputs a low level, the 3.3V direct current power supply forms a conducting loop through the pin 1, the pin 2, the second resistor R2 and the control port of the interface unit; the 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 the ground GND2, and controls the main contact of the relay KA to be attracted; the 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 attracted, and a welding power supply is powered and operates normally;
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, the pin 2, the second resistor R2 and the control port of the interface unit; 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 ground GND2, and the main contact of the control relay KA is disconnected; a conduction loop cannot be formed among the secondary side winding T21 of the control transformer TR, the coil of the alternating current contactor KM and the main contact of the control relay KA, the main contact of the alternating current contactor KM is disconnected, the welding power supply is in power failure, and the operation is stopped.
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