CN115395802B - 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
CN115395802B
CN115395802B CN202211041273.1A CN202211041273A CN115395802B CN 115395802 B CN115395802 B CN 115395802B CN 202211041273 A CN202211041273 A CN 202211041273A CN 115395802 B CN115395802 B CN 115395802B
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circuit
capacitor
igbt
ultrasonic
diode
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CN115395802A (en
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请求不公布姓名
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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 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 and filtering circuit, a power factor correction circuit, a phase-shifting 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 the required ultrasonic frequency, the filter inductor is arranged at the primary side of a transformer of the transformer isolation circuit, and the secondary side of the transformer can be directly connected with 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, the damping oscillation of the residual energy stored in the inductance and the capacitance 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 the loop formed by the secondary inductance of the transformer and the transducer, and ultrasonic frequency oscillation cannot be formed.

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 generating and providing ultrasonic energy to an ultrasonic transducer, for converting electrical energy into a high frequency alternating current signal that is matched to the ultrasonic transducer. The ultrasonic welding technology is to transmit high-frequency vibration waves to the surfaces of two objects to be welded, and under the condition of pressurization, the surfaces of the two objects are rubbed with each other to form fusion between molecular layers. With the development of new energy industries, ultrasonic metal welding is gradually applied to industries such as lithium batteries, semiconductors and the like, the ultrasonic welding process of the industries is of great importance, and if welding quality has defects or hidden dangers, the welded parts are applied to new energy products, so that safety risks are always present.
The ultrasonic welding quality depends on the accurate control of ultrasonic energy by an ultrasonic generator, and the ultrasonic generator on the market adopts a traditional circuit architecture of an inverter bridge and an LC filter, and the circuit architecture can generate oscillation between the inductance and the capacitance of a static capacitor of a transducer and the energy stored in the inductance of the LC circuit in an ultrasonic stopping stage, so that after an ultrasonic stopping command is obtained, an uncontrollable self-oscillating ultrasonic energy output still exists, and the uncontrollable self-oscillating ultrasonic energy output happens just within the dwell time of the welding head still pressing on a welded piece, so that the uncontrollable sub-oscillating ultrasonic energy can cause uncontrollable damage to the welding quality, and the welding quality defect has the risk of causing serious accidents when the welding quality is applied to a new energy product.
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 architecture of an inverter bridge and an LC filter, and in the ultrasonic stopping stage, the static capacitance of a transducer and the energy stored in the inductance of the LC circuit can oscillate between the inductance and the capacitance, so that a section of uncontrollable self-oscillating ultrasonic energy output still exists after an ultrasonic stopping command is obtained, and the welding quality is affected.
In view of the above, a first aspect of the present invention provides an ultrasonic power supply circuit, including a rectifying and filtering circuit, a power factor correction circuit, a phase-shifting full-bridge circuit, a LLCCL circuit, a transformer isolation circuit, a filter capacitor, and an output load, which are sequentially connected;
the rectification filter circuit is used for rectifying and filtering the commercial alternating current signal and outputting a direct current signal;
the power factor correction circuit is used for carrying out reactive power on-site compensation on the direct current signal output by the rectification filter circuit;
the phase-shifting 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 switching on at zero voltage and switching off at zero current with four IGBTs of the phase-shifting full-bridge circuit, filtering out high-frequency components and low-frequency components in square waves output by the phase-shifting full-bridge circuit, and forming series resonance with equivalent capacitors of transducers in the ultrasonic vibration system;
the input end of the transformer isolation circuit is connected with the LLCCL circuit, the output end of the transformer isolation circuit is used for being directly connected with the transducer, and the transformer isolation circuit is used for electrically isolating the input and the output of the ultrasonic power supply and transforming the impedance of the ultrasonic vibration system into equivalent impedance equal to the internal resistance 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 an output load for stabilizing the voltage output to both ends of the transducer.
Optionally, the LLCCL circuit includes a first inductance, a second inductance, a first capacitance, a second capacitance, a third capacitance, a fourth capacitance, and a third inductance;
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-shifting full bridge circuit, and the other end of the first inductor is connected with the second inductor in series;
the first capacitor is connected in parallel with the second capacitor, and the third capacitor is connected in parallel with the fourth capacitor;
the other end of the second inductor is connected with a first common end of the first capacitor and the second capacitor, the first common end of the first capacitor and the second capacitor is connected with one primary tap of a transformer of the transformer isolation circuit, the second common end of the first capacitor and the second capacitor is connected with a first common end of the third capacitor and the fourth capacitor, and the 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 end of the collector and the emitter of the two IGBT tubes of the right half-bridge of the phase-shifting 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 includes a transformer and a ground load, the secondary of the transformer being grounded through the ground load.
Optionally, the ground load is a ground resistance.
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 rectifying and filtering circuit comprises 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 alternating current 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 includes 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 the 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 emitter of the first IGBT tube is grounded, the collector of the second IGBT tube is connected with the collector of the first IGBT tube, the emitter of the second IGBT tube is connected with the positive electrode of the first electrolytic capacitor and the phase-shifting 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, and the anode of the first diode is connected with the emitter of the first IGBT;
the cathode of the second diode is connected with the collector of the second IGBT, and the anode of the second diode is connected with the emitter of the second IGBT;
the gates of the first IGBT tube and the second IGBT tube are suspended.
Optionally, the phase-shifting full-bridge circuit includes 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 of the third IGBT, the cathode of the third diode, one end of the seventh capacitor, the collector of the fifth IGBT and one end of the ninth capacitor are connected with the output end of the power factor correction circuit;
the gates of the third IGBT tube, the fourth IGBT tube, the fifth IGBT tube and the sixth IGBT tube are suspended;
the emitter of the third IGBT tube is connected with the collector of the fourth IGBT tube, the other end of the seventh capacitor and the positive electrode of the third diode are connected with the emitter of the third IGBT tube, the emitter of the fifth IGBT tube is connected with the collector of the sixth IGBT tube, and the other end of the ninth capacitor and the positive electrode of the fifth diode are connected with the emitter of the fifth IGBT tube;
one end of the eighth capacitor and the positive electrode of the fourth diode are connected with the collector electrode of the fourth IGBT, and the other end of the eighth capacitor and the positive electrode of the fourth diode are connected with the emitter electrode of the fourth IGBT;
one end of the tenth capacitor and the cathode of the sixth diode are connected with the collector electrode of the sixth IGBT, and the other end of the tenth capacitor and the anode of the sixth diode are connected with the emitter electrode of the sixth IGBT;
the emitter of the fourth IGBT tube and the emitter of the sixth IGBT tube are grounded.
Alternatively, the output load is a single fixed value resistor or a series resistor or an adjustable resistor.
The second aspect of the invention provides an ultrasonic welding device, comprising the ultrasonic power supply circuit of any one of the first aspect, 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, and the transducer is connected with the welding head.
From the above technical scheme, the ultrasonic power supply circuit and the ultrasonic welding device provided by the invention have the following advantages:
the ultrasonic power supply circuit and the ultrasonic welding device fully utilize the characteristics of high power control precision of the phase-shifting full-bridge circuit and good selection characteristic of the LLCCL circuit, a band-pass filter is formed on the LLCCL circuit part aiming at the required ultrasonic frequency, high impedance is formed on unnecessary frequency components, and a low impedance channel is formed on 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 directly connecting the positive end and the negative end of the transducer. After the ultrasonic stop command is sent, under the condition that excitation energy is not used for driving, the damping oscillation of the residual energy stored in the inductance and the capacitance of the LLCCL circuit part cannot reach the set frequency again, and the damping oscillation cannot be transmitted to the welding head through the band-pass filter with a high Q value; as such, a small amount of energy stored in the transducer is only slowly dissipated in the loop formed by the secondary inductance of the transformer and the transducer, and cannot form an ultrasonic oscillation. Therefore, after the ultrasonic stop command is obtained, the residual energy stored in all energy storage components does not influence the welding head any more, so that the damage to welding quality caused by the residual energy is avoided, the technical problems that the welding quality is influenced due to the fact that the existing ultrasonic power supply adopts a circuit architecture of an inverter bridge and an LC filter and oscillation is formed between the inductance and the capacitance by the static capacitance of the transducer and the energy stored in the inductance of the LC circuit in the ultrasonic stop stage are 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 be changed in real time along with a control instruction due to the blocking effect of the large inductor on the electric field change due to the fact that the large inductor is directly connected in series with the transducer when the traditional ultrasonic generating circuit performs LC filtering on the transformer secondary is avoided, and the control accuracy of the output power and the response speed of the ultrasonic command to start and stop are improved. The problems of low linear adjustment precision of the output power of the ultrasonic welding machine, poor dynamic response characteristic and difficult guarantee of consistency of welding quality are solved.
According to the ultrasonic power supply circuit provided by the invention, the function of bandpass filtering of high-power ultrasonic frequency electric energy is realized through the LLCCL circuit, and a bandpass filter with a high Q value can be obtained under the condition of reasonably designing parameters of components of the LLCCL circuit. The power below the selected frequency and above the selected frequency is filtered out in the primary loop of the output matching transformer and only the ultrasonic energy of the selected frequency is transferred to the load. The purity of the generated ultrasonic driving signal is guaranteed, and the loss of the transformer and the driven transducer is reduced.
According to the ultrasonic power supply circuit provided by the invention, through reasonably designing component parameters of the LLCCL circuit, a plurality of resonant cavities can be formed, and the control of the phase-shifting full bridge can be matched while the energy is transmitted through band-pass filtering, so that the soft switching functions of zero-voltage on and zero-current off of four switching tubes of the phase-shifting full bridge are realized, the loss and switching noise are further reduced, and the efficiency and stability are improved.
Drawings
For a clearer description of embodiments of the invention or of solutions according to the prior art, the figures which are used in the description of the embodiments or of the prior art will be briefly described, it being obvious that the figures in the description below are only some embodiments of the invention, from which, without the aid of inventive efforts, other relevant figures can be obtained for a person skilled in the art.
FIG. 1 is a schematic diagram of a modular structure of an ultrasonic power supply circuit provided in the present invention;
fig. 2 is a schematic circuit diagram of an ultrasonic power supply circuit according to the present invention;
fig. 3 is a schematic circuit diagram of an ultrasonic power supply according to the present invention.
Detailed Description
In order to make the present invention better understood by those skilled in the art, the following description will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
For easy understanding, referring to fig. 1, an embodiment of an ultrasonic power supply circuit is provided in the present invention, which includes a rectifying and filtering circuit, a power factor correction circuit, a phase-shifting full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor, and an output load, which are sequentially connected;
the rectification filter circuit is used for rectifying and filtering the commercial alternating current signal and outputting a direct current signal;
the power factor correction circuit is used for carrying out reactive power on-site compensation on the direct current signal output by the rectification filter circuit;
the phase-shifting 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 switching on at zero voltage and switching off at zero current with four IGBTs of the phase-shifting full-bridge circuit, filtering out high-frequency components and low-frequency components in square waves output by the phase-shifting full-bridge circuit, and forming series resonance with equivalent capacitors of transducers in the ultrasonic vibration system;
the input end of the transformer isolation circuit is connected with the LLCCL circuit, the output end of the transformer isolation circuit is used for being directly connected with the transducer, and the transformer isolation circuit is used for electrically isolating the input and the output of the ultrasonic power supply and transforming the impedance of the ultrasonic vibration system into equivalent impedance equal to the internal resistance 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 an output load for stabilizing the voltage output to both ends of the transducer.
The ultrasonic power supply circuit provided by the invention comprises a rectification filter circuit, a power factor correction circuit, a phase-shifting full-bridge circuit, an LLCCL circuit, a transformer isolation circuit, a filter capacitor and an output load which are sequentially connected, wherein the input end of the rectification filter circuit is connected with 220VAC, and the rectification filter circuit rectifies input alternating current into direct current and carries out filtering treatment on the direct current. The power factor correction circuit is used for reducing harmonic current pollution and carrying out reactive power on-site compensation, ensuring that power supply fluctuation does not influence the stability of a load, and simultaneously avoiding impact of pulse energy requirements of intermittent operation of ultrasonic welding on a power grid. The phase-shifting full-bridge circuit is used for inverting alternating current with controllable voltage and current of ultrasonic frequency. The LLCCL circuit is used for realizing a resonance soft switching function by matching with the phase-shifting full-bridge circuit, so that four IGBTs forming an inverter bridge are turned on at zero voltage and turned off at zero current; on the other hand, the device has a band-pass filtering function, namely, the high-frequency component and the low-frequency component in the square wave output by the phase-shifting full bridge are filtered, so that the sine wave energy of the selected ultrasonic frequency passes through; and on the other hand, the ultrasonic vibration system can form series resonance with the equivalent capacitance of the transducer in the ultrasonic vibration system, so that the maximum ultrasonic amplitude output by the ultrasonic vibration system is ensured. The transformer isolation circuit is used for realizing the isolation and impedance transformation functions of input and output; the electrical isolation of the input and the output ensures the electricity safety of the ultrasonic vibration system; the impedance of the ultrasonic vibration system is converted into equivalent impedance equal to the internal resistance of the ultrasonic power supply, so that the energy of the ultrasonic power supply can be transmitted with maximum efficiency. In the ultrasonic power supply circuit provided by the invention, the LLCCL circuit part forms a band-pass filter for 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, the secondary side of the transformer is used for directly connecting the positive end and the negative end of the transducer, the inductance is prevented from being connected in series at the input end of the transducer, and the energy stored in the static capacitance of the transducer and the inductance of the LC circuit in the ultrasonic stop stage is prevented from forming oscillation between the inductance and the capacitance. Through the combined action of the rectification filter circuit, the power factor correction circuit, the phase-shifting full-bridge circuit, the LLCCL circuit and the transformer isolation circuit, stable ultrasonic driving signals 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 inductance L1, a second inductance L2, a first capacitance C4, a second capacitance C5, a third capacitance C11, a fourth capacitance C12, and a third inductance L4;
one end of the 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-shifting full bridge circuit, and the other end of the first inductor L1 is connected with the second inductor L2 in series;
the first capacitor C4 is connected in parallel with the second capacitor C5, and the third capacitor C11 is connected in parallel with the fourth capacitor C12;
the other end of the second inductor L2 is connected with a first common end of a first capacitor C4 and a second capacitor C5, the first common end of the first capacitor C4 and the second capacitor C5 is connected with one primary tap of a transformer TR1 of the transformer isolation circuit, the second common end of the first capacitor C4 and the second capacitor C5 is connected with a first common end of a third capacitor C11 and a fourth capacitor C12, and the second common end of the third capacitor C11 and the fourth capacitor C12 is connected with the other primary tap of the transformer TR1 of the transformer isolation circuit;
one end of the 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-shifting full bridge circuit, and the other end of the third inductor L4 is connected with the first common ends of the third capacitor C11 and the fourth capacitor C12. The third capacitor C11 and the fourth capacitor C12 have the function of isolating the direct current component.
The transformer isolation circuit comprises a transformer TR1 and a grounding load R5, and the secondary side of the transformer TR1 is grounded EGND through the grounding load R5. The ground load R5 is a ground resistance.
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 may be selected as a single constant value resistor, may be selected as a series resistor, such as R1, R2, R3, R4, and R6 in fig. 2, in series, or may be selected as an adjustable resistor.
The rectifying and filtering circuit comprises a bridge rectifying circuit D1 and a second electrolytic capacitor C7, the second electrolytic capacitor C7 is connected between the positive electrode and the negative electrode of the direct current output end of the bridge rectifying circuit D1, the positive electrode of the second electrolytic capacitor C is connected with the input end of the power factor correcting circuit, the negative electrode is grounded PGND, and the positive electrode and the negative electrode of the alternating current input end of the bridge rectifying circuit D1 are connected with the positive electrode and the negative electrode of the commercial power 220VAC (namely P1 in fig. 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, wherein one end of the fourth inductor L3 is connected with the rectification filter circuit, the other end of the fourth inductor L is connected with a common end of the first IGBT tube Q4 and the second IGBT tube Q1, an emitting electrode of the first IGBT tube Q4 is grounded PGND, a collecting electrode of the second IGBT tube Q1 is connected with a collecting electrode of the first IGBT tube Q4, an emitting electrode of the second IGBT tube Q1 is connected with an anode of the first electrolytic capacitor C6 and a phase-shifting full-bridge circuit, a cathode of the first electrolytic capacitor C6 is grounded PGND, a cathode of the first diode is connected with a collecting electrode of the first IGBT tube Q4, an anode of the second diode is connected with a collecting electrode of the second IGBT tube Q1, an anode of the second diode is connected with an emitting electrode of the second IGBT tube Q1, and gates of the first IGBT tube Q4 and the second IGBT tube Q1 are suspended. The input 220VAC is passed through a bridge rectifier D1 and a power factor correction circuit composed of L3, Q4, and Q1, and then a 400V dc bus voltage is obtained.
The phase-shifting full-bridge circuit comprises a third IGBT Q2, a fourth IGBT Q5, a fifth IGBT Q3, a sixth IGBT 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 of the third IGBT Q2, the cathode of the third diode, one end of the seventh capacitor C1, one ends of the collector of the fifth IGBT Q3 and the ninth capacitor C2 are connected with the output end of a power factor correction circuit (namely the emitter of the second IGBT Q1), the emitter of the third IGBT Q2, the fourth IGBT Q5, the gate of the fifth IGBT Q3 and the emitter of the sixth IGBT Q6 are suspended, the emitter of the third IGBT Q2 is connected with the collector of the fourth IGBT Q5, the other end of the seventh capacitor C1 and the positive electrode of the third diode are connected with the emitter of the third IGBT Q2, the emitter of the fifth IGBT Q3 is connected with one end of the sixth IGBT Q6, the positive electrode of the third IGBT Q2 and the negative electrode of the fourth diode Q6 are connected with the positive electrode of the fourth diode Q6 and the negative electrode of the fourth diode Q6, the positive electrode of the third IGBT Q2 and the negative electrode of the positive electrode of the fourth IGBT Q6 are connected with the positive electrode of the fourth diode Q6 and the negative electrode of the fourth IGBT Q6 are connected with the positive electrode of the fourth IGBT Q6.
The ultrasonic power supply circuit provided by the embodiment of the invention fully utilizes the characteristics of high power control precision of the phase-shifting full-bridge circuit and good selection 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 directly connecting the positive end and the negative end of the transducer. After the ultrasonic stop command is sent, under the condition that excitation energy is not used for driving, the damping oscillation of the residual energy stored in the inductance and the capacitance of the LLCCL circuit part cannot reach the set frequency again, and the damping oscillation cannot be transmitted to the welding head through the band-pass filter with a high Q value; as such, a small amount of energy stored in the transducer is only slowly dissipated in the loop formed by the secondary inductance of the transformer and the transducer, and cannot form an ultrasonic oscillation. Therefore, after the ultrasonic stop command is obtained, the residual energy stored in all energy storage components does not influence the welding head any more, so that the damage to welding quality caused by the residual energy is avoided, the technical problems that the welding quality is influenced due to the fact that the existing ultrasonic power supply adopts a circuit architecture of an inverter bridge and an LC filter and oscillation is formed between the inductance and the capacitance by the static capacitance of the transducer and the energy stored in the inductance of the LC circuit in the ultrasonic stop stage are 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 be changed in real time along with a control instruction due to the blocking effect of the large inductor on the electric field change due to the fact that the large inductor is directly connected in series with the transducer when the traditional ultrasonic generating circuit performs LC filtering on the transformer secondary is avoided, and the control accuracy of the output power and the response speed of the ultrasonic command to start and stop are improved. The problems of low linear adjustment precision of the output power of the ultrasonic welding machine, poor dynamic response characteristic and difficult guarantee of consistency of welding quality are solved.
According to the ultrasonic power supply circuit provided by the invention, the function of bandpass filtering of high-power ultrasonic frequency electric energy is realized through the LLCCL circuit, and a bandpass filter with a high Q value can be obtained under the condition of reasonably designing parameters of components of the LLCCL circuit. The power below the selected frequency and above the selected frequency is filtered out in the primary loop of the output matching transformer and only the ultrasonic energy of the selected frequency is transferred to the load. The purity of the generated ultrasonic driving signal is guaranteed, and the loss of the transformer and the driven transducer is reduced.
According to the ultrasonic power supply circuit provided by the invention, through reasonably designing component parameters of the LLCCL circuit, a plurality of resonant cavities can be formed, and the control of the phase-shifting full bridge can be matched while the energy is transmitted through band-pass filtering, so that the soft switching functions of zero-voltage on and zero-current off of four switching tubes of the phase-shifting full bridge are realized, the loss and switching noise are further reduced, and the efficiency and stability are improved.
For ease of understanding, referring to fig. 3, an embodiment of an ultrasonic power supply is provided in the present invention, including the ultrasonic power supply circuit in the foregoing embodiment of the ultrasonic power supply circuit, and further including a transducer and a bonding 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 FIG. 3, and the transducer is connected with the welding head. After the ultrasonic power supply circuit is subjected to combined action of the rectifying and filtering circuit, the power factor correction circuit, the phase-shifting full-bridge circuit, the LLCCL circuit, the transformer isolation circuit, the filter capacitor and the output load, a stable ultrasonic driving signal can be output, the ultrasonic power supply circuit is directly connected with the positive end and the negative end of a transducer of an ultrasonic vibration system, and after energy conversion is realized through the transducer, electric energy is converted into mechanical vibration and transmitted to a welding head, so that the welding head realizes welding.
The ultrasonic welding device provided by the invention fully utilizes the characteristics of high power control precision of the phase-shifting full-bridge circuit and good selection characteristic of the LLCCL circuit, a band-pass filter is formed on the LLCCL circuit part aiming at the required ultrasonic frequency, high impedance is formed on unnecessary frequency components, and a low impedance channel is formed on 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 directly connecting the positive end and the negative end of the transducer. After the ultrasonic stop command is sent, under the condition that excitation energy is not used for driving, the damping oscillation of the residual energy stored in the inductance and the capacitance of the LLCCL circuit part cannot reach the set frequency again, and the damping oscillation cannot be transmitted to the welding head through the band-pass filter with a high Q value; as such, a small amount of energy stored in the transducer is only slowly dissipated in the loop formed by the secondary inductance of the transformer and the transducer, and cannot form an ultrasonic oscillation. Therefore, after the ultrasonic stop command is obtained, the residual energy stored in all energy storage components does not influence the welding head any more, so that the damage to welding quality caused by the residual energy is avoided, the technical problems that the welding quality is influenced due to the fact that the existing ultrasonic power supply adopts a circuit architecture of an inverter bridge and an LC filter and oscillation is formed between the inductance and the capacitance by the static capacitance of the transducer and the energy stored in the inductance of the LC circuit in the ultrasonic stop stage are solved.
Meanwhile, the secondary of the transformer in the transformer isolation circuit of the resonance soft switching circuit of the ultrasonic welding device is not provided with a series inductance, so that the problems that the voltage at two ends of the transducer cannot be changed in real time along with a control instruction due to the blocking effect of the large inductance on the electric field change caused by the fact that the large inductance is directly connected in series with the transducer when the secondary of the transformer is subjected to LC filtering by the traditional ultrasonic generating circuit are avoided, and the control precision of the output power and the response speed of the on-off ultrasonic command are improved. The problems of low linear adjustment precision of the output power of the ultrasonic welding machine, poor dynamic response characteristic and difficult guarantee of consistency of welding quality are solved.
According to the ultrasonic welding device provided by the invention, the function of bandpass filtering of high-power ultrasonic frequency electric energy is realized through the LLCCL circuit, and a bandpass filter with a high Q value can be obtained under the condition of reasonably designing parameters of components of the LLCCL circuit. The power below the selected frequency and above the selected frequency is filtered out in the primary loop of the output matching transformer and only the ultrasonic energy of the selected frequency is transferred to the load. The purity of the generated ultrasonic driving signal is guaranteed, and the loss of the transformer and the driven transducer is reduced.
According to the ultrasonic welding device provided by the invention, through reasonably designing component parameters of the LLCCL circuit, a plurality of resonant cavities can be formed, and the control of the phase-shifting full bridge can be matched while the energy is transmitted through band-pass filtering, so that the soft switching functions of zero-voltage on and zero-current off of four switching tubes of the phase-shifting full bridge are realized, the loss and switching noise are further reduced, and the efficiency and stability are improved.
The above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the 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 scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims (9)

1. An ultrasonic power supply circuit is characterized by comprising a rectifying and filtering circuit, a power factor correction circuit, a phase-shifting full-bridge circuit, a 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 commercial alternating current signal and outputting a direct current signal;
the power factor correction circuit is used for carrying out reactive power on-site compensation on the direct current signal output by the rectification filter circuit;
the phase-shifting 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 realizing that four IGBTs of the phase-shifting full-bridge circuit are turned on at zero voltage and turned off at zero current, filtering high-frequency components and low-frequency components in square waves output by the phase-shifting full-bridge circuit, and forming series resonance with equivalent capacitors of transducers in the ultrasonic vibration system;
the input end of the transformer isolation circuit is connected with the LLCCL circuit, the output end of the transformer isolation circuit is used for being directly connected with the transducer, and the transformer isolation circuit is used for electrically isolating the input and the output of the ultrasonic power supply and transforming the impedance of the ultrasonic vibration system into equivalent impedance equal to the internal resistance 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;
an output load for stabilizing the voltage output to both ends of the transducer;
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-shifting full bridge circuit, and the other end of the first inductor is connected with the second inductor in series;
the first capacitor is connected in parallel with the second capacitor, and the third capacitor is connected in parallel with the fourth capacitor;
the other end of the second inductor is connected with a first common end of the first capacitor and the second capacitor, the first common end of the first capacitor and the second capacitor is connected with one primary tap of a transformer of the transformer isolation circuit, the second common end of the first capacitor and the second capacitor is connected with a first common end of the third capacitor and the fourth capacitor, and the 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 end of the collector and the emitter of the two IGBT tubes of the right half-bridge of the phase-shifting 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.
2. The ultrasonic power supply circuit of claim 1, wherein the transformer isolation circuit comprises a transformer and a ground load, and wherein the secondary of the transformer is grounded through the ground load.
3. The ultrasonic power supply circuit of claim 2, wherein the ground load is a ground resistor.
4. The ultrasonic power supply circuit of claim 1, wherein the filter capacitor comprises a fifth capacitor and a sixth capacitor connected in series, one end of the fifth capacitor being connected to one tap of the secondary side of the transformer isolation circuit, and one end of the sixth capacitor being grounded.
5. The ultrasonic power supply circuit of claim 1, wherein the rectifying and filtering circuit comprises 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 alternating current input end of the bridge rectifier circuit are connected with the positive and negative poles of the commercial power.
6. The ultrasonic power supply circuit of 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 the 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 emitter of the first IGBT tube is grounded, the collector of the second IGBT tube is connected with the collector of the first IGBT tube, the emitter of the second IGBT tube is connected with the positive electrode of the first electrolytic capacitor and the phase-shifting 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, and the anode of the first diode is connected with the emitter of the first IGBT;
the cathode of the second diode is connected with the collector of the second IGBT, and the anode of the second diode is connected with the emitter of the second IGBT;
the gates of the first IGBT tube and the second IGBT tube are suspended.
7. The ultrasonic power supply circuit of claim 1, wherein the phase-shifting 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 capacitance, an eighth capacitance, a ninth capacitance, and a tenth capacitance;
the collector of the third IGBT, the cathode of the third diode, one end of the seventh capacitor, the collector of the fifth IGBT and one end of the ninth capacitor are connected with the output end of the power factor correction circuit;
the gates of the third IGBT tube, the fourth IGBT tube, the fifth IGBT tube and the sixth IGBT tube are suspended;
the emitter of the third IGBT tube is connected with the collector of the fourth IGBT tube, the other end of the seventh capacitor and the positive electrode of the third diode are connected with the emitter of the third IGBT tube, the emitter of the fifth IGBT tube is connected with the collector of the sixth IGBT tube, the other end of the ninth capacitor and the positive electrode of the fifth diode are connected with the emitter of the fifth IGBT tube, the positive electrode of the fifth diode is connected with the collector of the sixth IGBT tube, and the negative electrode of the fifth diode is connected with the collector of the fifth IGBT tube;
one end of the eighth capacitor and the cathode of the fourth diode are connected with the collector electrode of the fourth IGBT, and the other end of the eighth capacitor and the anode of the fourth diode are connected with the emitter electrode of the fourth IGBT;
one end of the tenth capacitor and the cathode of the sixth diode are connected with the collector electrode of the sixth IGBT, and the other end of the tenth capacitor and the anode of the sixth diode are connected with the emitter electrode of the sixth IGBT;
the emitter of the fourth IGBT tube and the emitter of the sixth IGBT tube are grounded.
8. 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.
9. An ultrasonic welding device comprising the ultrasonic power supply circuit of any one of claims 1-8, further comprising 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, and the transducer is connected with the welding head.
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