CN115395802A - Ultrasonic power supply circuit and ultrasonic welding device - Google Patents

Ultrasonic power supply circuit and ultrasonic welding device Download PDF

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Publication number
CN115395802A
CN115395802A CN202211041273.1A CN202211041273A CN115395802A CN 115395802 A CN115395802 A CN 115395802A CN 202211041273 A CN202211041273 A CN 202211041273A CN 115395802 A CN115395802 A CN 115395802A
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China
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capacitor
circuit
igbt tube
ultrasonic
diode
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CN202211041273.1A
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CN115395802B (en
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不公告发明人
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Guangdong Lyric Robot Automation Co Ltd
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Guangdong Lyric Robot Intelligent Automation Co Ltd
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Priority to CN202211041273.1A priority Critical patent/CN115395802B/en
Publication of CN115395802A publication Critical patent/CN115395802A/en
Priority to PCT/CN2022/139633 priority patent/WO2024045420A1/en
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/02—Conversion of ac power input into dc power output without possibility of reversal
    • H02M7/04—Conversion of ac power input into dc power output without possibility of reversal by static converters
    • H02M7/06—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes without control electrode or semiconductor devices without control electrode
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0048—Circuits or arrangements for reducing losses
    • H02M1/0054—Transistor switching losses
    • H02M1/0058—Transistor switching losses by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/12—Arrangements for reducing harmonics from ac input or output
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208—Arrangements for improving power factor of AC input
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/44—Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/01—Resonant DC/DC converters
    • H02M3/015—Resonant DC/DC converters with means for adaptation of resonance frequency, e.g. by modification of capacitance or inductance of resonance circuit
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • H02M7/5387—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration
    • H02M7/53871—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration with automatic control of output voltage or current
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

The invention discloses an ultrasonic power supply circuit and an ultrasonic welding device. The ultrasonic power supply circuit comprises a rectifying filter circuit, a power factor correction circuit, a phase-shifted full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor and an output load which are sequentially connected, wherein the LLCCL circuit part forms a band-pass filter aiming at required ultrasonic frequency, a filter inductor is placed at the primary side of a transformer of the transformer isolation circuit, and the secondary side of the transformer can be directly connected with the two ends of the transducer. In addition, the invention also discloses an ultrasonic welding device which comprises an ultrasonic power supply circuit. After the ultrasonic stop command is sent out, the attenuation oscillation of the residual energy stored in the inductor and the capacitor of the LLCCL circuit cannot reach the set frequency again, and cannot be transmitted to the welding head; the energy stored in the transducer can only be consumed in a loop formed by the secondary inductance of the transformer and the transducer, and cannot form ultrasonic frequency oscillation.

Description

Ultrasonic power supply circuit and ultrasonic welding device
Technical Field
The invention relates to the technical field of ultrasonic power supplies, in particular to an ultrasonic power supply circuit and an ultrasonic power supply.
Background
An ultrasonic power supply, also called an ultrasonic generator, is a device for converting electrical energy into a high frequency alternating current signal matched with an ultrasonic transducer, and is used for generating and providing ultrasonic energy to the ultrasonic transducer. Ultrasonic welding is a technique in which high-frequency vibration waves are transmitted to the surfaces of two objects to be welded, and the surfaces of the two objects are rubbed against each other under pressure to fuse the molecular layers. With the development of new energy industries, ultrasonic metal welding is gradually applied to industries such as lithium batteries and semiconductors, the ultrasonic welding process of the industries is very important, and if defects or hidden dangers exist in welding quality, safety risks are certainly caused when welded parts are applied to new energy products.
The ultrasonic welding quality depends on the ultrasonic generator to accurately control ultrasonic energy, the ultrasonic generator on the market at present adopts a traditional circuit framework of 'inverter bridge + LC filtering', the circuit framework is in an ultrasonic stopping stage, energy stored in a static capacitor of a transducer and an inductor of an LC circuit can form oscillation between the inductor and the capacitor, the oscillation of the residual energy can still cause an uncontrollable self-oscillation ultrasonic energy output after an ultrasonic stopping command is obtained, and the uncontrollable self-oscillation ultrasonic energy output happens in a pressure maintaining time when a welding head presses a welded piece, so the uncontrollable self-oscillation ultrasonic energy can cause uncontrollable damage to the welding quality, and when the ultrasonic welding quality defect is applied to a new energy product, the risk of causing a serious accident exists.
Disclosure of Invention
The invention provides an ultrasonic power supply circuit and an ultrasonic power supply, which are used for solving the technical problems that the existing ultrasonic power supply adopts a circuit framework of an inverter bridge and LC filtering, and the static capacitor of a transducer and the energy stored in the inductor of an LC circuit can form oscillation between the inductor and the capacitor in the ultrasonic stop stage, so that a section of uncontrollable self-oscillation ultrasonic energy is still output after an ultrasonic stop command is obtained, and the welding quality is influenced.
In view of this, the first aspect of the present invention provides an ultrasonic power circuit, which includes a rectifying filter circuit, a power factor correction circuit, a phase-shifted full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor, and an output load, which are connected in sequence;
the rectification filter circuit is used for rectifying and filtering the alternating current signal of the commercial power and outputting a direct current signal;
the power factor correction circuit is used for carrying out reactive power local compensation on the direct current signal output by the rectifying filter circuit;
the phase-shifted full-bridge circuit is used for inverting the direct current signal output by the power factor correction circuit and outputting an inverted alternating current signal;
the LLCCL circuit is used for being switched on at zero voltage and switched off at zero current with four IGBTs of the phase-shifted full-bridge circuit, filtering high-frequency components and low-frequency components in square waves output by the phase-shifted full-bridge circuit, and forming series resonance with equivalent capacitance of a transducer in the ultrasonic vibration system;
the input end of the transformer isolation circuit is connected with the LLCCL circuit, and the output end of the transformer isolation circuit is directly connected with the transducer and used for electrically isolating the input and the output of the ultrasonic power supply and converting the impedance of the ultrasonic vibration system into equivalent impedance equal to the internal impedance of the ultrasonic power supply;
the filter capacitor is used for filtering high-frequency harmonic waves in signals output by the transformer isolation circuit and adjusting the output voltage;
and the output load is used for stabilizing the voltage output to two ends of the transducer.
Optionally, the LLCCL circuit includes a first inductor, a second inductor, a first capacitor, a second capacitor, a third capacitor, a fourth capacitor, and a third inductor;
one end of the first inductor is connected with the common end of the collector and the emitter of the two IGBT tubes of the left half bridge of the phase-shifted full bridge circuit, and the other end of the first inductor is connected with the second inductor in series;
the first capacitor is connected with the second capacitor in parallel, and the third capacitor is connected with the fourth capacitor in parallel;
the other end of the second inductor is connected with first common ends of the first capacitor and the second capacitor, the first common ends of the first capacitor and the second capacitor are connected with one primary tap of a transformer of the transformer isolation circuit, second common ends of the first capacitor and the second capacitor are connected with first common ends of the third capacitor and the fourth capacitor, and second common ends of the third capacitor and the fourth capacitor are connected with the other primary tap of the transformer isolation circuit;
one end of the third inductor is connected with the common ends of the collector electrodes and the emitter electrodes of the two IGBT tubes of the right half bridge of the phase-shifted full-bridge circuit, and the other end of the third inductor is connected with the first common ends of the third capacitor and the fourth capacitor.
Optionally, the transformer isolation circuit comprises a transformer and a grounded load, the secondary of the transformer being grounded through the grounded load.
Optionally, the ground load is a ground resistor.
Optionally, the filter capacitor includes a fifth capacitor and a sixth capacitor connected in series, one end of the fifth capacitor is connected to one tap of the secondary of the transformer isolation circuit, and one end of the sixth capacitor is grounded.
Optionally, the rectifier filter circuit comprises a bridge rectifier circuit and a second electrolytic capacitor;
a second electrolytic capacitor is connected between the positive electrode and the negative electrode of the direct current output end of the bridge rectifier circuit;
the anode of the second electrolytic capacitor is connected with the input end of the power factor correction circuit, and the cathode of the second electrolytic capacitor is grounded;
the positive and negative poles of the AC input end of the bridge rectifier circuit are connected with the positive and negative poles of the commercial power.
Optionally, the power factor correction circuit comprises a fourth inductor, a first IGBT tube, a second IGBT tube, a first diode, a second diode and a first electrolytic capacitor;
one end of a fourth inductor is connected with the rectifying and filtering circuit, the other end of the fourth inductor is connected with the common ends of the first IGBT tube and the second IGBT tube, the emitting electrode of the first IGBT tube is grounded, the collecting electrode of the second IGBT tube is connected with the collecting electrode of the first IGBT tube, the emitting electrode of the second IGBT tube is connected with the positive electrode of the first electrolytic capacitor and the phase-shifted full-bridge circuit, and the negative electrode of the first electrolytic capacitor is grounded;
the cathode of the first diode is connected with the collector of the first IGBT tube, and the anode of the first diode is connected with the emitter of the first IGBT tube;
the cathode of the second diode is connected with the collector of the second IGBT tube, and the anode of the second diode is connected with the emitter of the second IGBT tube;
and the gate electrodes of the first IGBT tube and the second IGBT tube are suspended.
Optionally, the phase-shifted full-bridge circuit comprises a third IGBT, a fourth IGBT, a fifth IGBT, a sixth IGBT, a third diode, a fourth diode, a fifth diode, a sixth diode, a seventh capacitor, an eighth capacitor, a ninth capacitor and a tenth capacitor;
the collector of the third IGBT tube, the cathode of the third diode, one end of the seventh capacitor, the collector of the fifth IGBT tube and one end of the ninth capacitor are connected with the output end of the power factor correction circuit;
gate poles of a third IGBT tube, a fourth IGBT tube, a fifth IGBT tube and a sixth IGBT tube are suspended;
an emitting electrode of the third IGBT tube is connected with a collector electrode of the fourth IGBT tube, the other end of the seventh capacitor and the anode of the third diode are connected with the emitting electrode of the third IGBT tube, an emitting electrode of the fifth IGBT tube is connected with a collector electrode of the sixth IGBT tube, and the other end of the ninth capacitor and the anode of the fifth diode are connected with the emitting electrode of the sixth IGBT tube;
one end of an eighth capacitor and the anode of the fourth diode are connected with the collector of the fourth IGBT, and the other end of the eighth capacitor and the anode of the fourth diode are connected with the emitter of the fourth IGBT;
one end of a tenth capacitor and the negative electrode of the sixth diode are connected with the collector of the sixth IGBT tube, and the other end of the tenth capacitor and the positive electrode of the sixth diode are connected with the emitter of the sixth IGBT tube;
and the emitter of the fourth IGBT tube and the emitter of the sixth IGBT tube are grounded.
Optionally, the output load is a single fixed-value resistor or a series resistor or an adjustable resistor.
The invention provides an ultrasonic welding device in a second aspect, which comprises the ultrasonic power supply circuit in any one of the first aspect, a transducer and a welding head;
the transformer secondary of the transformer isolation circuit of the ultrasonic power supply circuit is directly connected with the positive end and the negative end of the transducer, and the transducer is connected with the welding head.
According to the technical scheme, the ultrasonic power circuit and the ultrasonic welding device provided by the invention have the following advantages:
the ultrasonic power circuit and the ultrasonic welding device provided by the invention fully utilize the characteristics of high power control precision of the phase-shifted full-bridge circuit and good selection characteristic of the LLCCL circuit, form a band-pass filter aiming at the required ultrasonic frequency at the LLCCL circuit part, form high impedance for the unnecessary frequency components, and form a low impedance channel for the required ultrasonic frequency energy. The filter inductor is arranged at the primary side of the transformer isolation circuit, and the secondary side of the transformer is used for being directly connected with the positive end and the negative end of the energy converter. After the ultrasonic stop command is sent out, under the condition of no excitation energy driving, the attenuation oscillation of the residual energy stored in the inductor and the capacitor of the LLCCL circuit part cannot reach the set frequency again, and cannot be transmitted to the welding head through a band-pass filter with a high Q value; similarly, a small amount of energy stored in the transducer can only be slowly consumed in a loop formed by the secondary inductance of the transformer and the transducer, and ultrasonic frequency oscillation cannot be formed. Therefore, after the ultrasonic stop command is obtained, residual energy stored in all energy storage components does not affect a welding head, so that the damage of the residual energy to welding quality is avoided, the circuit framework that an inverter bridge and an LC filter are adopted by the conventional ultrasonic power supply is solved, and in the ultrasonic stop stage, energy stored in a static capacitor of a transducer and an inductor of an LC circuit can form oscillation between the inductor and the capacitor, so that the ultrasonic energy output of one section of uncontrollable self-oscillation is still obtained after the ultrasonic stop command is obtained, and the technical problem of affecting the welding quality is solved.
Meanwhile, the transformer secondary in the transformer isolation circuit of the ultrasonic power supply circuit is not connected with an inductor in series, so that the problem that the voltage at two ends of the transducer cannot change in real time along with a control instruction due to the blocking effect of the large inductor on the change of an electric field when the transformer secondary of the traditional ultrasonic generating circuit is subjected to LC filtering is solved, and the control precision of output power and the response speed of starting and stopping ultrasonic commands are improved. The problems that the output power linear adjustment precision of the ultrasonic welding machine is low, the dynamic response characteristic is poor, and the consistency of the welding quality is difficult to guarantee are solved.
According to the ultrasonic power supply circuit provided by the invention, the function of band-pass filtering of high-power ultrasonic frequency electric energy is realized through the LLCCL circuit, and the band-pass filter with a high Q value can be obtained under the condition that the parameters of the LLCCL circuit components are reasonably designed. The electrical energy below and above the selected frequency is filtered out entirely in the primary loop of the output matching transformer, passing only ultrasonic energy at the selected frequency to the load. Not only is the purity of the generated ultrasonic driving signal ensured, but also the loss of the transformer and the driven transducer is reduced.
According to the ultrasonic power supply circuit provided by the invention, by reasonably designing the component parameters of the LLCCL circuit, a plurality of resonant cavities can be formed, and the soft switching functions of zero-voltage opening and zero-current closing of four switching tubes of the phase-shifted full bridge can be realized by matching with the control of the phase-shifted full bridge while energy is transmitted by band-pass filtering, so that the loss and the switching noise are further reduced, and the efficiency and the stability are improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other related drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic diagram of a modular structure of an ultrasonic power circuit provided in the present invention;
fig. 2 is a schematic circuit diagram of an ultrasonic power circuit provided in the present invention;
fig. 3 is a schematic circuit structure diagram of an ultrasonic power supply provided in the present invention.
Detailed Description
In order to make the technical solutions of the present invention better understood, 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.
For easy understanding, referring to fig. 1, the present invention provides an embodiment of an ultrasonic power circuit, which includes a rectifying filter circuit, a power factor correction circuit, a phase-shifted full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor, and an output load, which are connected in sequence;
the rectification filter circuit is used for rectifying and filtering the alternating current signal of the commercial power and outputting a direct current signal;
the power factor correction circuit is used for carrying out reactive power local compensation on the direct current signal output by the rectifying filter circuit;
the phase-shifted full-bridge circuit is used for inverting the direct current signal output by the power factor correction circuit and outputting an inverted alternating current signal;
the LLCCL circuit is used for being switched on at zero voltage and switched off at zero current with four IGBTs of the phase-shifted full-bridge circuit, filtering high-frequency components and low-frequency components in square waves output by the phase-shifted full-bridge circuit, and forming series resonance with equivalent capacitance of a transducer in the ultrasonic vibration system;
the input end of the transformer isolation circuit is connected with the LLCCL circuit, and the output end of the transformer isolation circuit is directly connected with the transducer and used for electrically isolating the input and the output of the ultrasonic power supply and converting the impedance of the ultrasonic vibration system into equivalent impedance equal to the internal impedance of the ultrasonic power supply;
the filter capacitor is used for filtering high-frequency harmonic waves in signals output by the transformer isolation circuit and adjusting the output voltage;
and the output load is used for stabilizing the voltage output to two ends of the transducer.
It should be noted that the ultrasonic power circuit provided in the present invention includes a rectification filter circuit, a power factor correction circuit, a phase-shifted full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor, and an output load, which are connected in sequence, wherein an input terminal of the rectification filter circuit is connected to 220VAC, and the rectification filter circuit rectifies an input ac power into a dc power and performs a filtering process on the dc power. The power factor correction circuit is used for reducing harmonic current pollution and carrying out in-situ compensation on reactive power, ensures that power supply fluctuation does not influence the stability of a load, and can avoid the impact of pulse energy requirements of intermittent work of ultrasonic welding on a power grid. The phase-shifted full-bridge circuit is used for inverting alternating current with ultrasonic frequency and controllable voltage and current. The LLCCL circuit is used for realizing a resonant soft switching function in cooperation with the phase-shifted full-bridge circuit, so that four IGBTs forming the inverter bridge are switched on at zero voltage and switched off at zero current; on the other hand, the ultrasonic transducer has a band-pass filtering function, namely, high-frequency components and low-frequency components in square waves output by the phase-shifted full bridge are filtered, so that sine wave energy of selected ultrasonic frequency passes through; on the other hand, the ultrasonic vibration amplitude control circuit can form series resonance with the equivalent capacitance of the transducer in the ultrasonic vibration system, so that the ultrasonic amplitude output by the ultrasonic vibration system is ensured to reach the maximum value. The transformer isolation circuit is used for realizing the functions of input and output isolation and impedance transformation; the electrical isolation of the input and the output ensures the electricity utilization safety of the ultrasonic vibration system; the impedance of the ultrasonic vibration system is converted into equivalent impedance equal to the internal impedance of the ultrasonic power supply, so that the energy of the ultrasonic power supply can be transmitted with the maximum efficiency. In the ultrasonic power supply circuit provided by the invention, the LLCCL circuit part forms a band-pass filter aiming at the required ultrasonic frequency, forms high impedance for the unnecessary frequency components and forms a low impedance channel for the required ultrasonic frequency energy. The filter inductor is arranged at the primary side of the transformer isolation circuit, and the secondary side of the transformer is used for being directly connected with the positive end and the negative end of the transducer, so that the condition that the inductor is connected in series at the input end of the transducer is avoided, and the condition that the energy stored in the static capacitor of the transducer and the inductor of the LC circuit is oscillated between the inductor and the capacitor in the ultrasonic stop stage is also avoided. Through the combined action of the rectification filter circuit, the power factor correction circuit, the phase-shifted full-bridge circuit, the LLCCL circuit and the transformer isolation circuit, a stable ultrasonic driving signal can be output, and the quick response to an ultrasonic starting command and the accurate control to output energy are realized.
In one embodiment, as shown in fig. 2, the LLCCL circuit includes a first inductor L1, a second inductor L2, a first capacitor C4, a second capacitor C5, a third capacitor C11, a fourth capacitor C12, and a third inductor L4;
one end of a first inductor L1 is connected with the common end of the collector and the emitter of the two IGBT tubes of the left half-bridge of the phase-shifted full-bridge circuit, and the other end of the first inductor L1 is connected with a second inductor L2 in series;
the first capacitor C4 is connected with the second capacitor C5 in parallel, and the third capacitor 11 is connected with the fourth capacitor C12 in parallel;
the other end of the second inductor L2 is connected to first common ends of a first capacitor C4 and a second capacitor C5, the first common ends of the first capacitor C4 and the second capacitor C5 are connected to a primary tap of a transformer TR1 of the transformer isolation circuit, second common ends of the first capacitor C4 and the second capacitor C5 are connected to first common ends of a third capacitor C11 and a fourth capacitor C12, and second common ends of the third capacitor C11 and the fourth capacitor C12 are connected to another primary tap of the transformer TR1 of the transformer isolation circuit;
one end of a third inductor L4 is connected with the common end of the collector and the emitter of the two IGBT tubes of the right half bridge of the phase-shifted full-bridge circuit, and the other end is connected with the first common end of a third capacitor C11 and a fourth capacitor C12. The third capacitor C11 and the fourth capacitor C12 have the function of isolating the dc component.
The transformer isolation circuit includes a transformer TR1 and a ground load R5, and the secondary of the transformer TR1 is grounded EGND through the ground load R5. The grounding load R5 is a grounding resistor.
The filter capacitor comprises a fifth capacitor C3 and a sixth capacitor C8 which are connected in series, one end of the fifth capacitor C3 is connected with one tap of the secondary side of the transformer TR1 of the transformer isolation circuit, and one end of the sixth capacitor C8 is grounded EGND.
The output load can be selected as a single constant-value resistor, can be selected as a series resistor, such as R1, R2, R3, R4 and R6 in fig. 2, which are connected in series, and can also be selected as an adjustable resistor.
The rectification filter circuit comprises a bridge rectifier circuit D1 and a second electrolytic capacitor C7, the second electrolytic capacitor C7 is connected between the positive pole and the negative pole of the direct current output end of the bridge rectifier circuit D1, the positive pole of the second electrolytic capacitor C is connected with the input end of the power factor correction circuit, the negative pole of the second electrolytic capacitor C is grounded PGND, and the positive pole and the negative pole of the alternating current input end of the bridge rectifier circuit D1 are connected with the positive pole and the negative pole of the commercial power 220VAC (namely P1 in figures 2 and 3).
The power factor correction circuit comprises a fourth inductor L3, a first IGBT tube Q4, a second IGBT tube Q1, a first diode, a second diode and a first electrolytic capacitor C6, one end of the fourth inductor L3 is connected with a rectification filter circuit, the other end of the fourth inductor L3 is connected with the common end of the first IGBT tube Q4 and the common end of the second IGBT tube Q1, the emitting electrode of the first IGBT tube Q4 is grounded PGND, the collecting electrode of the second IGBT tube Q1 is connected with the collecting electrode of the first IGBT tube Q4, the emitting electrode of the second IGBT tube Q1 is connected with the positive electrode of the first electrolytic capacitor C6 and a full-bridge phase-shifting circuit, the negative electrode of the first electrolytic capacitor C6 is grounded PGND, the negative electrode of the first diode is connected with the collecting electrode of the first IGBT tube Q4, the positive electrode is connected with the emitting electrode of the first IGBT tube Q4, the negative electrode of the second diode is connected with the collecting electrode of the second IGBT tube Q1, the positive electrode is connected with the emitting electrode of the second IGBT tube Q1, and the gate electrodes of the first IGBT tube Q4 and the second IGBT tube Q1 are suspended. After the input 220VAC passes through a rectifier bridge D1 and a power factor correction circuit composed of L3, Q4, and Q1, a dc bus voltage of 400V can be obtained.
The phase-shift full-bridge circuit comprises a third IGBT tube Q2, a fourth IGBT tube Q5, a fifth IGBT tube Q3, a sixth IGBT tube Q6, a third diode, a fourth diode, a fifth diode, a sixth diode, a seventh capacitor C1, an eighth capacitor C9, a ninth capacitor C2 and a tenth capacitor C10, wherein the collector electrode of the third IGBT tube Q2, the cathode of the third diode, one end of the seventh capacitor C1, the collector electrode of the fifth IGBT tube Q3 and one end of the ninth capacitor C2 are connected with the output end of the power factor correction circuit (namely the emitter electrode of the second IGBT tube Q1), the gate electrodes of the third IGBT tube Q2, the fourth IGBT tube Q5, the fifth IGBT tube Q3 and the sixth IGBT tube Q6 are suspended, the emitter electrode of the third IGBT tube Q2 is connected with the collector electrode of the fourth IGBT tube Q5, the other end of the seventh capacitor C1 and the anode of the third diode are connected to the emitter of the third IGBT Q2, the emitter of the fifth IGBT Q3 is connected to the collector of the sixth IGBT Q6, the other end of the ninth capacitor C10 and the anode of the fifth diode are connected to the emitter of the sixth IGBT Q6, one end of the eighth capacitor C9 and the anode of the fourth diode are connected to the collector of the fourth IGBT Q5, the other end of the eighth capacitor C10 and the anode of the fourth diode are connected to the emitter of the fourth IGBT Q5, one end of the tenth capacitor C10 and the cathode of the sixth diode are connected to the collector of the sixth IGBT Q6, the other end of the tenth capacitor C10 and the anode of the sixth diode are connected to the emitter of the sixth IGBT Q6, and the emitter of the fourth IGBT Q5 and the emitter of the sixth IGBT Q6 are grounded EGND.
The ultrasonic power supply circuit provided by the embodiment of the invention fully utilizes the characteristics of high power control precision of the phase-shifted full-bridge circuit and good selection characteristic of the LLCCL circuit, forms a band-pass filter aiming at the required ultrasonic frequency at the LLCCL circuit part, forms high impedance for the unnecessary frequency components, and forms a low impedance channel for the required ultrasonic frequency energy. The filter inductor is arranged at the primary side of the transformer isolation circuit, and the secondary side of the transformer is used for being directly connected with the positive end and the negative end of the energy converter. After the ultrasonic stop command is sent out, under the condition of no excitation energy driving, the attenuation oscillation of the residual energy stored in the inductor and the capacitor of the LLCCL circuit part cannot reach the set frequency again, and cannot be transmitted to the welding head through a band-pass filter with a high Q value; similarly, a small amount of energy stored in the transducer can only be slowly consumed in a loop formed by the secondary inductance of the transformer and the transducer, and ultrasonic frequency oscillation cannot be formed. Therefore, after the ultrasonic stop command is obtained, residual energy stored in all energy storage components does not affect a welding head, so that the damage of the residual energy to welding quality is avoided, the circuit framework that an inverter bridge and an LC filter are adopted by the conventional ultrasonic power supply is solved, and in the ultrasonic stop stage, energy stored in a static capacitor of a transducer and an inductor of an LC circuit can form oscillation between the inductor and the capacitor, so that the ultrasonic energy output of one section of uncontrollable self-oscillation is still obtained after the ultrasonic stop command is obtained, and the technical problem of affecting the welding quality is solved.
Meanwhile, the transformer secondary in the transformer isolation circuit of the ultrasonic power supply circuit is not provided with a series inductor, so that the problem that the voltage at two ends of the transducer cannot change in real time along with a control instruction due to the blocking effect of the large inductor on the change of an electric field when the transformer secondary of the traditional ultrasonic generating circuit is subjected to LC filtering is solved, and the control precision of the output power and the response speed of starting and stopping ultrasonic commands are improved. The problems that the output power linear adjustment precision of the ultrasonic welding machine is low, the dynamic response characteristic is poor, and the consistency of the welding quality is difficult to guarantee are solved.
According to the ultrasonic power supply circuit, the function of band-pass filtering of high-power ultrasonic frequency electric energy is achieved through the LLCCL circuit, and the band-pass filter with the high Q value can be obtained under the condition that the parameters of the components of the LLCCL circuit are reasonably designed. The electrical energy below and above the selected frequency is filtered out entirely in the primary loop of the output matching transformer, passing only ultrasonic energy at the selected frequency to the load. Not only ensures the purity of the generated ultrasonic driving signal, but also reduces the loss of the transformer and the driven transducer.
According to the ultrasonic power supply circuit provided by the invention, the component parameters of the LLCCL circuit are reasonably designed, a plurality of resonant cavities can be formed, the soft switching functions of zero-voltage opening and zero-current closing of four switching tubes of the phase-shifted full bridge can be realized by matching with the control of the phase-shifted full bridge while the energy is transmitted by band-pass filtering, so that the loss and the switching noise are further reduced, and the efficiency and the stability are improved.
For easy understanding, referring to fig. 3, the present invention provides an embodiment of an ultrasonic power supply, which includes the ultrasonic power supply circuit in the foregoing embodiment of the ultrasonic power supply circuit, and further includes a transducer and a welding head;
the secondary of the transformer isolation circuit of the ultrasonic power supply circuit is directly connected with the positive end and the negative end of the transducer, namely the P2 end and the P3 end in the figure 3, and the transducer is connected with the welding head. Ultrasonic power supply circuit is through rectifier filter circuit, power factor correction circuit, phase-shift full bridge circuit, LLCCL circuit, transformer buffer circuit, filter capacitance and output load combined action after, but output stable ultrasonic drive signal, and direct positive and negative both ends with ultrasonic vibration system's transducer are connected, realize energy conversion back through the transducer, give the soldered connection with mechanical vibration transfer with electric energy conversion for the soldered connection realizes the welding.
The ultrasonic welding device provided by the invention fully utilizes the characteristics of high power control precision of the phase-shifted full-bridge circuit and good selective characteristic of the LLCCL circuit, forms a band-pass filter aiming at the required ultrasonic frequency in the LLCCL circuit part, forms high impedance for the unnecessary frequency components, and forms a low impedance channel for the required ultrasonic frequency energy. The filter inductor is arranged at the primary side of the transformer isolation circuit, and the secondary side of the transformer is used for being directly connected with the positive end and the negative end of the energy converter. After the ultrasonic stop command is sent out, under the condition of no excitation energy driving, the attenuation oscillation of the residual energy stored in the inductor and the capacitor of the LLCCL circuit part cannot reach the set frequency again, and cannot be transmitted to the welding head through a band-pass filter with a high Q value; similarly, a small amount of energy stored in the transducer can only be slowly consumed in a loop formed by the secondary inductance of the transformer and the transducer, and ultrasonic frequency oscillation cannot be formed. Therefore, after the ultrasonic stop command is obtained, residual energy stored in all energy storage components does not influence a welding head any more, so that the damage of the residual energy to the welding quality is avoided, the problem that the existing ultrasonic power supply adopts a circuit framework of an inverter bridge and LC filtering is solved, and in the ultrasonic stop stage, energy stored in a static capacitor of a transducer and an inductor of an LC circuit can form oscillation between the inductor and the capacitor, so that the uncontrollable self-oscillation ultrasonic energy output still exists after the ultrasonic stop command is obtained, and the welding quality is influenced is solved.
Meanwhile, the transformer secondary in the transformer isolation circuit of the resonant soft switching circuit of the ultrasonic welding device is not connected with an inductor in series, so that the problem that the voltage at two ends of the transducer cannot change along with a control instruction in real time due to the blocking effect of the inductor on the change of an electric field when the transformer secondary of the traditional ultrasonic generating circuit carries out LC filtering is solved, and the control precision of output power and the response speed of starting and stopping an ultrasonic command are improved. The problems that the ultrasonic welding machine is low in output power linear adjustment precision, poor in dynamic response characteristic and difficult to guarantee the consistency of welding quality are solved.
According to the ultrasonic welding device, the function of band-pass filtering of high-power ultrasonic frequency electric energy is achieved through the LLCCL circuit, and the band-pass filter with the high Q value can be obtained under the condition that the parameters of the components of the LLCCL circuit are reasonably designed. The electrical energy below and above the selected frequency is filtered out entirely in the primary loop of the output matching transformer, passing only ultrasonic energy at the selected frequency to the load. Not only ensures the purity of the generated ultrasonic driving signal, but also reduces the loss of the transformer and the driven transducer.
According to the ultrasonic welding device provided by the invention, the parameters of the elements of the LLCCL circuit are reasonably designed, a plurality of resonant cavities can be formed, the energy is transmitted by band-pass filtering, and meanwhile, the soft switching functions of zero-voltage opening and zero-current closing of four switching tubes of the phase-shifted full bridge can be realized by matching with the control of the phase-shifted full bridge, so that the loss and the switching noise are further reduced, and the efficiency and the stability are improved.
The above-mentioned embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the same; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.

Claims (10)

1. An ultrasonic power supply circuit is characterized by comprising a rectification filter circuit, a power factor correction circuit, a phase-shifted full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor and an output load which are connected in sequence;
the rectification filter circuit is used for rectifying and filtering the alternating current signal of the commercial power and outputting a direct current signal;
the power factor correction circuit is used for carrying out reactive power local compensation on the direct current signal output by the rectifying filter circuit;
the phase-shifted full-bridge circuit is used for inverting the direct current signal output by the power factor correction circuit and outputting an inverted alternating current signal;
the LLCCL circuit is used for being switched on at zero voltage and switched off at zero current with four IGBTs of the phase-shifted full-bridge circuit, filtering high-frequency components and low-frequency components in square waves output by the phase-shifted full-bridge circuit, and forming series resonance with an equivalent capacitor of a transducer in an ultrasonic vibration system;
the input end of the transformer isolation circuit is connected with the LLCCL circuit, and the output end of the transformer isolation circuit is directly connected with the transducer and used for electrically isolating the input and the output of the ultrasonic power supply and converting the impedance of the ultrasonic vibration system into equivalent impedance equal to the internal impedance of the ultrasonic power supply;
the filter capacitor is used for filtering high-frequency harmonic waves in signals output by the transformer isolation circuit and adjusting the output voltage;
and the output load is used for stabilizing the voltage output to two ends of the transducer.
2. The ultrasonic power supply circuit of claim 1, wherein the LLCCL circuit comprises a first inductor, a second inductor, a first capacitor, a second capacitor, a third capacitor, a fourth capacitor, and a third inductor;
one end of the first inductor is connected with the common end of the collector and the emitter of the two IGBT tubes of the left half-bridge of the phase-shifted full-bridge circuit, and the other end of the first inductor is connected with the second inductor in series;
the first capacitor is connected with the second capacitor in parallel, and the third capacitor is connected with the fourth capacitor in parallel;
the other end of the second inductor is connected with a first common end of a first capacitor and a second capacitor, the first common ends of the first capacitor and the second capacitor are connected with one primary tap of a transformer of the transformer isolation circuit, a second common end of the first capacitor and the second capacitor is connected with a first common end of a third capacitor and a fourth capacitor, and a second common end of the third capacitor and the fourth capacitor is connected with the other primary tap of the transformer isolation circuit;
one end of the third inductor is connected with the common ends of the collector electrodes and the emitter electrodes of the two IGBT tubes of the right half bridge of the phase-shifted full-bridge circuit, and the other end of the third inductor is connected with the first common ends of the third capacitor and the fourth capacitor.
3. The ultrasonic power supply circuit of claim 1, wherein the transformer isolation circuit comprises a transformer and a grounded load, the secondary of the transformer being grounded through the grounded load.
4. An ultrasonic power supply circuit according to claim 3, wherein the ground load is a ground resistor.
5. The ultrasonic power supply circuit according to claim 1, wherein the filter capacitor includes a fifth capacitor and a sixth capacitor connected in series, one end of the fifth capacitor is connected to one tap of the secondary side of the transformer isolation circuit, and one end of the sixth capacitor is grounded.
6. The ultrasonic power supply circuit according to claim 1, wherein the rectifying-filtering circuit includes a bridge rectifying circuit and a second electrolytic capacitor;
a second electrolytic capacitor is connected between the positive electrode and the negative electrode of the direct current output end of the bridge rectifier circuit;
the anode of the second electrolytic capacitor is connected with the input end of the power factor correction circuit, and the cathode of the second electrolytic capacitor is grounded;
the positive and negative poles of the AC input end of the bridge rectifier circuit are connected with the positive and negative poles of the commercial power.
7. The ultrasonic power supply circuit according to claim 1, wherein the power factor correction circuit comprises a fourth inductor, a first IGBT tube, a second IGBT tube, a first diode, a second diode, and a first electrolytic capacitor;
one end of a fourth inductor is connected with the rectifying and filtering circuit, the other end of the fourth inductor is connected with the common end of the first IGBT tube and the second IGBT tube, the emitting electrode of the first IGBT tube is grounded, the collecting electrode of the second IGBT tube is connected with the collecting electrode of the first IGBT tube, the emitting electrode of the second IGBT tube is connected with the positive electrode of the first electrolytic capacitor and the phase-shifted full-bridge circuit, and the negative electrode of the first electrolytic capacitor is grounded;
the cathode of the first diode is connected with the collector of the first IGBT tube, and the anode of the first diode is connected with the emitter of the first IGBT tube;
the cathode of the second diode is connected with the collector of the second IGBT tube, and the anode of the second diode is connected with the emitter of the second IGBT tube;
the gate electrodes of the first IGBT tube and the second IGBT tube are suspended.
8. The ultrasonic power supply circuit of claim 1, wherein the phase-shifted full-bridge circuit comprises a third IGBT tube, a fourth IGBT tube, a fifth IGBT tube, a sixth IGBT tube, a third diode, a fourth diode, a fifth diode, a sixth diode, a seventh capacitor, an eighth capacitor, a ninth capacitor and a tenth capacitor;
the collector electrode of the third IGBT tube, the cathode of the third diode, one end of the seventh capacitor, the collector electrode of the fifth IGBT tube and one end of the ninth capacitor are connected with the output end of the power factor correction circuit;
gate poles of a third IGBT tube, a fourth IGBT tube, a fifth IGBT tube and a sixth IGBT tube are suspended;
an emitting electrode of the third IGBT tube is connected with a collector electrode of the fourth IGBT tube, the other end of the seventh capacitor and the anode of the third diode are connected with the emitting electrode of the third IGBT tube, an emitting electrode of the fifth IGBT tube is connected with a collector electrode of the sixth IGBT tube, and the other end of the ninth capacitor and the anode of the fifth diode are connected with the emitting electrode of the sixth IGBT tube;
one end of an eighth capacitor and the anode of the fourth diode are connected with the collector of the fourth IGBT, and the other end of the eighth capacitor and the anode of the fourth diode are connected with the emitter of the fourth IGBT;
one end of a tenth capacitor and the negative electrode of the sixth diode are connected with the collector of the sixth IGBT tube, and the other end of the tenth capacitor and the positive electrode of the sixth diode are connected with the emitter of the sixth IGBT tube;
and the emitter of the fourth IGBT tube and the emitter of the sixth IGBT tube are grounded.
9. The ultrasonic power supply circuit of claim 1, wherein the output load is a single fixed resistor or a series resistor or an adjustable resistor.
10. An ultrasonic welding apparatus comprising the ultrasonic power supply circuit of any one of claims 1 to 9, further comprising a transducer and a welding head;
the secondary side of the transformer isolation circuit of the ultrasonic power supply circuit is directly connected with the positive end and the negative end of the transducer, and the transducer is connected with the welding head.
CN202211041273.1A 2022-08-29 2022-08-29 Ultrasonic power supply circuit and ultrasonic welding device Active CN115395802B (en)

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