CN117697079B - Welding power supply suitable for continuous uninterrupted welding of ultra-long welding seam - Google Patents
Welding power supply suitable for continuous uninterrupted welding of ultra-long welding seam Download PDFInfo
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Abstract
The application discloses a welding power supply suitable for continuous uninterrupted welding of overlength welding seam relates to welding equipment technical field. The power supply comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balance module, a first single-pole double-throw switch, a second single-pole double-throw switch, a double-way driving module, a standby double-way driving module, a double-way IGBT module, a standby double-way IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation state feedback module, wherein the probability value of an arc stopping event occurring at the end of the next period can be periodically estimated after successful arcing through the connection relation and functional cooperation of the modules, and when the probability value is judged to be larger than or equal to a preset threshold value, the standby double-way driving module and the standby double-way IGBT module are switched and started to output direct current for maintaining an arc, so that the purpose of continuous uninterrupted welding can be realized in the ultra-long welding seam welding process.
Description
Technical Field
The invention belongs to the technical field of welding equipment, and particularly relates to a welding power supply suitable for continuous and uninterrupted welding of ultra-long welding seams.
Background
TIG (Tungsten Inert Gas Welding), also known as non-consumable inert gas arc welding, is a well-established welding method and has wide application in the field of welding carbon steel, stainless steel, aluminum alloys and nonferrous materials. The common TIG welding arc is stable, the welding quality is good, but the penetration depth is shallow, the welding speed is slow, the efficiency is low, and the welding method is generally used for sheet welding or bottom penetration bead backing welding of thick-wall important components.
Titanium alloy welding is a difficult problem of traditional welding, particularly continuous uninterrupted welding with a weld length of 6000-12000 m is carried out, which means that continuous uninterrupted welding is carried out for more than 250-500 hours, and the ultra-long weld and ultra-long titanium alloy welding have no precedent for one time completion, mainly because a module for maintaining an arc in a welding power supply can malfunction due to ultra-long use, and further an arc stopping event is accidentally triggered, and secondary arc starting is needed. In addition, external unavoidable factors such as unexpected power failure and the like can cause unexpected arc stopping accidents and influence welding yield.
Disclosure of Invention
The invention aims to provide a welding power supply suitable for continuous and uninterrupted welding of an ultra-long welding line, which is used for solving the problem that the conventional welding power supply is difficult to realize continuous and uninterrupted welding in the welding process of the ultra-long welding line.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
in a first aspect, a welding power supply suitable for continuous and uninterrupted welding of an ultra-long welding seam is provided, and the welding power supply comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balance module, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use double-way driving module, a standby double-way driving module, an in-use double-way IGBT module, a standby double-way IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation state feedback module, wherein the power supply output negative electrode is used for being connected with a welding gun head, and the power supply output positive electrode is used for being connected with a workpiece to be welded;
the first output end of the welding power supply control module is connected with the controlled end of the control switch module, the second output end of the welding power supply control module is connected with the first input end of the current balance module, the third output end of the welding power supply control module is respectively connected with the controlled ends of the first single-pole double-throw switch and the second single-pole double-throw switch, the control switch module is connected with the high-frequency arcing module, and the output end of the high-frequency arcing module is connected with the power supply output cathode;
The first PWM pulse signal output end of the current balance module is connected with the common end of the first single-pole double-throw switch, the second PWM pulse signal output end of the current balance module is connected with the common end of the second single-pole double-throw switch, the normally closed end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit in the using double-path driving module, the output end of the first path current driving unit in the using double-path driving module is connected with the input end of the first path IGBT unit in the using double-path IGBT module, the normally open end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit in the standby double-path driving module, the output end of the first path current driving unit in the standby double-path driving module is connected with the input end of the first path IGBT unit in the standby double-path driving module, the output end of the second normally closed end of the second single-pole double-throw switch is connected with the input end of the first path IGBT unit in the standby double-path driving module, the normally open end of the second single-pole double-throw switch is connected with the input end of the first path IGBT unit in the standby double-path driving module, the output end of the second IGBT unit in the in-use double-path IGBT module and the output end of the second IGBT unit in the standby double-path IGBT module are respectively connected with the power supply output anode;
The output end of the running state feedback module is connected with the input end of the welding power supply control module;
the welding power supply control module is used for executing starting/stopping actions on the high-frequency arcing module through the control switch module according to welding control time sequence data, and outputting excitation control signals to the current balance module so as to enable the current balance module to output two paths of balanced PWM pulse signals through two paths of current constant-frequency PWM pulse generator circuits which are connected in a master-slave mode and run in parallel, and further enable the in-use double-path driving module and the in-use double-path IGBT module to output direct current and to be overlapped with high-frequency pulse high-voltage signals generated by the high-frequency arcing module to be input into a welding gun;
and the welding power supply control module is also used for periodically extracting and processing the real-time operation state data from the operation state feedback module to obtain multi-dimensional operation state characteristics after successful arcing, then guiding the multi-dimensional operation state characteristics into an arc stopping event occurrence prediction model which is based on a machine learning algorithm and is trained in advance, outputting a probability value of the arc stopping event when the next period is finished, and finally controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a normally open end and a public end corresponding to the cut-off of the first single-pole double-throw switch and a normally closed end when the probability value is judged to be more than or equal to a preset threshold value, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch so as to enable the standby double-way driving module and the standby double-way IGBT module to output the direct current.
Based on the above summary, a novel welding power supply scheme capable of automatically switching and using an arc maintenance module is provided, namely, the novel welding power supply scheme comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balance module, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use double-way driving module, a standby double-way driving module, an in-use double-way IGBT module, a standby double-way IGBT module, a power supply output cathode, a power supply output anode and an operation state feedback module, and through the connection relation and function cooperation of the modules, the probability value of an arc stopping event occurring at the end of the next period can be periodically estimated after successful arcing, and when the probability value is judged to be greater than or equal to a preset threshold value, the standby double-way driving module and the standby double-way IGBT module are switched and started to output direct current for maintaining the arc, so that the novel welding power supply scheme can be timely stopped before the in-use arc maintenance module fails, the unexpected triggering of the arc stopping event is avoided, and the aim of continuous and uninterrupted welding can be realized in the ultra-long welding process, so that the actual application and popularization are facilitated.
In one possible design, the power supply system further comprises a UPS uninterruptible power supply, wherein a power supply end of the UPS uninterruptible power supply is respectively connected to the welding power supply control module, the control switch module, the high-frequency arcing module, the current balancing module, the first single-pole double-throw switch, the second single-pole double-throw switch, the in-use dual-path driving module, the standby dual-path driving module, the in-use dual-path IGBT module, the standby dual-path IGBT module and the running state feedback module.
In one possible design, the power supply circuit further comprises a first electric control switch, a second electric control switch, a first capacitor and a second capacitor, wherein one end of the first electric control switch is connected with the power supply output cathode, the other end of the first electric control switch is connected with one end of the first capacitor, the other end of the first capacitor is grounded, one end of the second electric control switch is connected with the power supply output anode, the other end of the second electric control switch is connected with one end of the second capacitor, and the other end of the second capacitor is grounded;
the fourth output end of the welding power supply control module is respectively connected with the controlled ends of the first electric control switch and the second electric control switch;
controlling the common end corresponding to the first single-pole double-throw switch to be conducted and the common end corresponding to the normally open end to be cut off and the normally closed end, and controlling the common end corresponding to the second single-pole double-throw switch to be conducted and the common end corresponding to the normally open end to be cut off and the normally closed end, comprising:
the first electric control switch and the second electric control switch are controlled to be switched from the off state to the on state respectively, and a timer is started;
when the timing of the timer reaches a preset duration threshold, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a normally-open end and a public end corresponding to the cut-off of the first single-pole double-throw switch and a normally-closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and a normally-open end and a public end corresponding to the cut-off of the second single-pole double-throw switch and a normally-closed end, wherein the preset duration threshold is shorter than half of the period duration of the next period;
And controlling the first electric control switch and the second electric control switch to recover to an off state from an on state respectively.
In one possible design, the first electronically controlled switch or the second electronically controlled switch employs a thyristor or a relay.
In one possible design, the welding power supply control module is further configured to, after successful arcing:
when the continuous use time of the on-use double-circuit driving module and the on-use double-circuit IGBT module reaches M period time, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a public end corresponding to the normally open end and the normally closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch and the normally closed end, so as to enable the standby double-circuit driving module and the standby double-circuit IGBT module to output the direct current, wherein M represents a positive integer greater than or equal to 5;
and when the continuous use time of the standby double-circuit driving module and the standby double-circuit IGBT module reaches N period time, controlling the public end and the normally open end corresponding to cut-off of the first single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, and controlling the public end and the normally open end corresponding to cut-off of the second single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, so as to enable the in-use double-circuit driving module and the in-use double-circuit IGBT module to resume outputting the direct current, wherein N represents a positive integer greater than or equal to 5.
In one possible design, the machine learning algorithm employs a linear regression algorithm based on the Python sklearn library.
In one possible design, the arc-stopping event occurrence prediction model is pre-trained as follows:
acquiring a plurality of pieces of normal running state data and a plurality of pieces of previous running state data which are in one-to-one correspondence with a plurality of historical arc stopping events, wherein the normal running state data are real-time running state data acquired by the running state feedback module at the starting moment of a K-hour historical period when no arc stopping event occurs, K represents a positive integer, the previous running state data are real-time running state data acquired by the running state feedback module at the moment when the corresponding event occurs at the moment of determining, and the moment of determining is equal to the moment of the corresponding event occurrence minus one period duration;
extracting multidimensional operation state characteristics from corresponding data as corresponding model input items and taking a value 0 as a corresponding model output item aiming at each piece of normal operation state data in the plurality of pieces of normal operation state data to obtain a corresponding negative sample containing the model input items and the model output items;
Extracting multidimensional operation state characteristics from corresponding data as corresponding model input items aiming at each previous operation state data in the previous operation state data, and taking a numerical value 1 as a corresponding model output item to obtain a corresponding positive sample containing the model input item and the model output item;
and performing calibration verification modeling on the artificial intelligent model based on the machine learning algorithm by applying a plurality of negative samples and a plurality of positive samples to obtain the arc stopping event occurrence prediction model, wherein the confidence coefficient of the arc stopping event occurrence prediction model with the output value of 1 is used as a probability value of the arc stopping event at the end of the next period.
In one possible design, the first single pole double throw switch or the second single pole double throw switch employs a single pole double throw CMOS analog switch model LN 3657.
In one possible design, the running state feedback module comprises a welding current feedback unit, an arc voltage feedback unit, a temperature signal feedback unit, a chiller running state feedback unit and a two-way IGBT output feedback unit.
In one possible design, the control switch module includes a gun protection gas valve switch, a chiller start-stop switch, and an arc start-stop switch.
The beneficial effect of above-mentioned scheme:
(1) The invention creatively provides a novel welding power supply scheme capable of automatically switching and using an arc maintenance module, which comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balance module, a first single-pole double-throw switch, a second single-pole double-throw switch, a double-way driving module, a standby double-way driving module, a double-way IGBT module, a power supply output cathode, a power supply output anode and an operation state feedback module, wherein the probability value of an arc stopping event occurring at the end of the next period can be periodically estimated after successful arcing through the connection relation and function cooperation of the modules, and when the probability value is judged to be more than or equal to a preset threshold value, the standby double-way driving module and the standby double-way IGBT module are switched and started to output direct current for maintaining the arc, so that the arc maintenance module can be timely stopped before faults occur, the arc stopping event is prevented from being accidentally triggered, the continuous uninterrupted welding purpose can be realized in the ultra-long welding process, and the actual application and popularization are convenient;
(2) The uninterrupted power supply of the UPS can be adopted to avoid unexpected arc stopping accidents caused by unexpected power failure, and further ensure that continuous uninterrupted welding is realized in the ultra-long welding seam welding process;
(3) By adopting the time-delay power-off scheme, the welding machine and the welding gun can be cooled down when the commercial power is abnormal, the welding power supply and the welding gun are effectively protected, the long-term stability of welding is further effectively ensured, and the loss is reduced.
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In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic structural diagram of a welding power supply suitable for continuous and uninterrupted welding of ultra-long welding seams according to an embodiment of the present application.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the present invention will be briefly described below with reference to the accompanying drawings and the description of the embodiments or the prior art, and it is obvious that the following description of the structure of the drawings is only some embodiments of the present invention, and other drawings can be obtained according to these drawings without inventive effort to a person skilled in the art. It should be noted that the description of these examples is for aiding in understanding the present invention, but is not intended to limit the present invention.
It should be understood that although the terms first and second, etc. may be used herein to describe various objects, these objects should not be limited by these terms. These terms are only used to distinguish one object from another. For example, a first object may be referred to as a second object, and similarly a second object may be referred to as a first object, without departing from the scope of example embodiments of the invention.
It should be understood that for the term "and/or" that may appear herein, it is merely one association relationship that describes an associated object, meaning that there may be three relationships, e.g., a and/or B, may represent: three cases of A alone, B alone or both A and B exist; as another example, A, B and/or C, can represent the presence of any one of A, B and C or any combination thereof; for the term "/and" that may appear herein, which is descriptive of another associative object relationship, it means that there may be two relationships, e.g., a/and B, it may be expressed that: the two cases of A and B exist independently or simultaneously; in addition, for the character "/" that may appear herein, it is generally indicated that the context associated object is an "or" relationship.
Examples
As shown in fig. 1, the welding power supply provided in the first aspect of the present embodiment and suitable for continuous and uninterrupted welding of ultra-long welding seams includes, but is not limited to, a welding power supply control module, a control switch module, a high-frequency arcing module, a current balancing module, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use dual-drive module, a standby dual-drive module, an in-use dual-IGBT (insulated gate bipolar transistor) module, a standby dual-IGBT module, a power output negative electrode, a power output positive electrode and an operation state feedback module, wherein the power output negative electrode is used for connecting a welding gun head, and the power output positive electrode is used for connecting a workpiece to be welded.
The first output end of the welding power supply control module is connected with the controlled end of the control switch module, the second output end of the welding power supply control module is connected with the first input end of the current balance module, the third output end of the welding power supply control module is respectively connected with the controlled ends of the first single-pole double-throw switch and the second single-pole double-throw switch, the control switch module is connected with the high-frequency arcing module, and the output end of the high-frequency arcing module is connected with the power supply output cathode. The control switch module is used for completing the arc starting of the welding gun by controlling the high-frequency arc starting module to work; specifically, the control switch module comprises, but is not limited to, a welding gun protecting gas valve switch, a cold water machine start-stop switch and an arc start-stop switch, wherein the welding gun protecting gas valve switch is used for controlling the opening/closing of the welding gun protecting gas valve so as to enable the protecting gas to continuously flow out of a welding gun nozzle when the gas valve is opened and stop flowing out of the protecting gas when the gas valve is closed; the cold water machine start-stop switch is used for controlling the cold water machine to start/stop so as to cool a welding gun when the cold water machine is started, in particular, the welding power supply control module can also monitor the temperature of a welding gun in real time through a conventional temperature measurement means, and trigger the cold water machine start-stop switch to start the cold water machine when the temperature of the welding gun is higher than a first preset temperature (for example, 10 ℃ is added on the basis of room temperature, namely, 35 ℃), and trigger the cold water machine start-stop switch to stop the cold water machine when the temperature of the welding gun is continuously lower than a second preset temperature (which is lower than the first preset temperature, for example, room temperature) within a preset time period (for example, within 30 minutes), so as to realize intelligent start-stop of the cold water machine and facilitate saving of electric energy; the arcing start-stop switch is used for controlling the high-frequency arcing module to start/stop so as to realize arcing when starting.
The first PWM pulse signal output end of the current balancing module is connected with the common end of the first single-pole double-throw switch, the second PWM pulse signal output end of the current balancing module is connected with the common end of the second single-pole double-throw switch, the normally closed end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit (namely, the current driving unit A in figure 1) in the using double-path driving module, the output end of the first path current driving unit in the using double-path driving module is connected with the input end of the first path IGBT unit (namely, the IGBT unit A in figure 1) in the using double-path IGBT module, the normally open end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit (namely, the current driving unit C in figure 1) in the standby double-path driving module, the output end of the first path current driving unit in the standby double-path IGBT module is connected with the input end of the first path IGBT unit B in figure 1 in the standby double-path IGBT module, the normally closed end of the first path current driving unit in the standby double-path IGBT module is connected with the output end of the first path IGBT unit B in the standby double-path IGBT module in figure 1, the normally open end of the second single pole double throw switch is connected with the input end of a second path current driving unit (i.e. a current driving unit D in fig. 1) in the standby double-path driving module, the output end of the second path current driving unit in the standby double-path driving module is connected with the input end of a second path IGBT unit (i.e. an IGBT unit D in fig. 1) in the standby double-path IGBT module, and the output end of the second path IGBT unit in the standby double-path IGBT module are respectively connected with the power output anode.
And the output end of the running state feedback module is connected with the input end of the welding power supply control module. The running state feedback module is used for monitoring signals such as welding current, welding voltage, temperature of a power device, running state of a water chiller and the like when the system runs, and feeding back the signals to the welding power supply control module after necessary electrical isolation, so that the welding power supply control module can obtain real-time running state data based on analog-to-digital conversion of the signals in real time; specifically, the operation state feedback module includes, but is not limited to, a welding current feedback unit, an arc voltage feedback unit, a temperature signal feedback unit, a cold water machine operation state feedback unit, and two paths of IGBT output feedback units, where the welding current feedback unit is used to collect and feedback a welding current state, the arc voltage feedback unit is used to collect and feedback an arc voltage state (i.e. a welding voltage state), the temperature signal feedback unit is used to collect and feedback a temperature state of a power device, the cold water machine operation state feedback unit is used to collect and feedback an operation state of the cold water machine, and the two paths of IGBT output feedback units are used to collect and feedback states of output parameters such as an output voltage, an output current or an output power of the in-use double-path IGBT module or the standby double-path IGBT module, and they can all implement corresponding functions by adopting an existing circuit structure.
The welding power supply control module is used for executing starting/stopping actions on the high-frequency arcing module through the control switch module according to welding control time sequence data, and outputting excitation control signals to the current balance module, so that the current balance module outputs two paths of balanced PWM pulse signals through two paths of current constant-frequency PWM pulse generator circuits which are connected in a master-slave mode and run in parallel, and the in-use double-path driving module and the in-use double-path IGBT module output direct current and are overlapped with high-frequency pulse high-voltage signals generated by the high-frequency arcing module to be input into a welding gun. The foregoing functions are basic functions of existing welding power sources, and may be conventionally implemented based on the prior art, including, but not limited to: according to accurate welding control time sequence data, the start-stop switch of the cold water machine and the protection gas valve switch of the welding gun are sequentially controlled to be started, circulating cooling water of the welding gun is enabled to run, protection gas continuously flows out of a welding gun nozzle, after a certain time, a space between a tungsten needle and a workpiece to be welded is filled with the protection gas, then arc striking excitation current is output to the current balancing module, two paths of balanced PWM (Pulse width modulation ) pulse signals are generated by the arc striking excitation current to drive the on-use double-path driving module and the on-use double-path IGBT module to work, stable direct current voltage is formed between the tip of a tungsten electrode of the welding gun and the surface of the workpiece, then the arc striking start-stop switch is started, the high-frequency arc striking module is controlled to output a high-frequency high-voltage signal and load the high-frequency high-voltage signal to the power output cathode to excite an arc, the power output cathode is enabled to be conducted with the power output anode, finally, the high-frequency arc striking module is controlled to stop working immediately after the arc is generated, and the on-use double-path IGBT module outputs basic value current (namely the direct current) to maintain the arc.
And the welding power supply control module is also used for periodically extracting and processing the real-time running state data from the running state feedback module to obtain multi-dimensional running state characteristics after successful arcing, then guiding the multi-dimensional running state characteristics into an arc stopping event occurrence prediction model which is based on a machine learning algorithm and is trained in advance, outputting a probability value of the arc stopping event when the next period is finished, and finally controlling a public end and a normally closed end which correspond to the conduction of the first single-pole double-throw switch and a public end and a normally closed end which correspond to the conduction of the second single-pole double-throw switch when the probability value is more than or equal to a preset threshold (for example, 62.8%) and controlling the public end and the normally closed end which correspond to the conduction of the second single-pole double-throw switch so as to enable the standby double-way driving module and the standby double-way IGBT module to output the direct current. The period duration of the foregoing period may be, but is not limited to, 1 minute, for example. The specific mode of the characteristic extraction processing is an existing conventional mode, for example, a welding current value, a welding voltage value, a temperature value of a power device, an operation condition value of a water chiller and the like are extracted as multidimensional operation state characteristics. The machine learning algorithm is an artificial intelligent core algorithm which specially researches how a computer simulates or realizes the learning behavior of human beings so as to acquire new knowledge or skills, reorganizes the existing knowledge structure to continuously improve the self performance, and is a fundamental way for making the computer have intelligence; in particular, the machine learning algorithm preferably employs a linear regression algorithm based on a Python sklearn library to quickly and accurately find rules in the data. The prediction model of the occurrence of the arc stopping event can be obtained by training in advance according to the following steps S101-S104.
S101, acquiring a plurality of pieces of normal running state data and a plurality of pieces of previous running state data corresponding to a plurality of historical arc stopping events one by one, wherein the normal running state data is real-time running state data acquired by the running state feedback module at the starting time of a K-hour historical period when no arc stopping event occurs, K represents a positive integer, the previous running state data is real-time running state data acquired by the running state feedback module at the previous determining time when the corresponding event occurs, and the determining time is equal to the corresponding event occurrence time minus one period duration.
In the step S101, for example, if no arc interruption event occurs within 4 hours from 8 to 12 points (i.e., K has a value of 4), the real-time running state data collected at 8 points 00 minutes may be used as a part of the normal running state data; if the arc interruption event occurs at the point 12, 01, the real-time operation state data collected at the point 12, 00 minutes (i.e. the determined time, the period duration is 1 minute) can be used as a part of the previous operation state data.
S102, extracting multidimensional operation state features from corresponding data as corresponding model input items and taking a value 0 as a corresponding model output item aiming at each piece of normal operation state data in the plurality of pieces of normal operation state data to obtain a corresponding negative sample containing the model input items and the model output items.
S103, extracting multidimensional operation state characteristics from corresponding data as corresponding model input items and taking a numerical value 1 as a corresponding model output item aiming at each previous operation state data in the previous operation state data to obtain a positive sample which corresponds to and comprises the model input item and the model output item.
S104, applying a plurality of negative samples and a plurality of positive samples, and performing calibration verification modeling on an artificial intelligent model based on a machine learning algorithm to obtain the arc stopping event occurrence prediction model, wherein the confidence coefficient of the arc stopping event occurrence prediction model, which is output as 1, is used as a probability value of the arc stopping event at the end of the next period.
In the step S104, the specific process of calibration verification modeling includes a calibration process and a checking process of the model, that is, the simulation result and the actually measured data of the model are compared, and then the model parameters are adjusted according to the comparison result, so that the simulation result and the actual process of matching can be achieved, and therefore, the arc-stopping event occurrence prediction model can be obtained through a conventional calibration verification modeling mode. Preferably, in the calibration verification modeling process of the artificial intelligent model, a Bayesian optimization algorithm based on a tree structure is adopted to perform optimization on model parameters. In addition, the artificial intelligence model may also be implemented, but is not limited to, using machine learning algorithms such as support vector machines, K-nearest neighbor methods, random gradient descent methods, multi-layer perceptron, decision trees, back-propagation neural networks, or radial basis function networks.
The novel welding power supply scheme comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balancing module, a first single-pole double-throw switch, a second single-pole double-throw switch, an on-line driving module, a standby double-way driving module, an on-line IGBT module, a standby double-way IGBT module, a power output negative electrode, a power output positive electrode and an operation state feedback module, wherein the connection relation and the function cooperation of the modules can periodically estimate the probability value of an arc stopping event occurring at the end of the next period after successful arcing, and when the probability value is larger than or equal to a preset threshold value, the on-line driving module and the standby double-way IGBT module are switched to output direct current for maintaining the arc.
Preferably, the power supply system further comprises a UPS (Uninterruptible Power Supply) uninterruptible power supply, wherein a power supply end of the UPS uninterruptible power supply is respectively connected with the welding power supply control module, the control switch module, the high-frequency arcing module, the current balancing module, the first single-pole double-throw switch, the second single-pole double-throw switch, the on-use double-way driving module, the standby double-way driving module, the on-use double-way IGBT module, the standby double-way IGBT module, the running state feedback module and the like. The UPS uninterrupted power supply is an uninterrupted power supply with an energy storage device, and can provide uninterrupted power supply for equipment with high requirements on power stability. Therefore, by adopting the UPS uninterrupted power supply, the accident of stopping the arc due to unexpected power failure can be effectively avoided. Specifically, the UPS uninterruptible power supply may, but is not limited to, a passive backup UPS power supply (i.e., an inverter is connected in parallel between the utility power and the load and is simply used as a backup power supply; such UPS power supply, when the utility power is normal, is powered by the modified utility power and is charged by the charger, the inverter does not perform any power conversion, the battery is powered by an independent charger; when the utility power is abnormal, the load is completely powered by the inverter), an online interactive UPS power supply (i.e., an inverter is connected in parallel between the utility power and the load and functions as a backup power supply, while the inverter is charged by the charger, and thus is referred to as an interactive UPS power supply, when the utility power is normal, the load is powered by the modified utility power and is charged by the charger, and when the utility power is failed, the load is completely powered by the inverter and is functioning as a DC/AC converter), or a dual-conversion UPS power supply (i.e., an inverter is connected in parallel between the utility power supply and the load, and is powered by the inverter, and is not powered by the load, and is continuously connected in series to the load, when the utility power is supplied by the load and is not powered by the inverter). In addition, considering that the UPS uninterruptible power supply has limited energy storage and larger welding electric quantity, the UPS uninterruptible power supply cannot supply power permanently, and preferably, the welding power supply control module is further configured to monitor a working state of the UPS uninterruptible power supply, and when the UPS uninterruptible power supply is found to start up the inverter to supply power due to abnormal mains supply according to a monitoring result, the control switch module and/or the current balancing module is controlled to enable the welding machine to enter an arc-receiving process or create a welding seam which is convenient to use for a lap-top next (a specific control process can be conventionally implemented based on the prior art), and delay running for a preset period (for example, 10 minutes) after completion, and then monitor a welding gun temperature in real time through a conventional temperature measurement means, and then stop the welding gun when the welding gun temperature is restored to a third preset temperature (for example, 10 degrees celsius is added on a room temperature basis) or other preset temperature conditions are reached, so as to avoid problems such as to effectively protect the power supply and the welding gun from being formally stopped due to overlarge gap between the power-off temperature and the room temperature. Through the scheme of the time-delay power-off, the welding machine and the welding gun can be cooled down when the commercial power is abnormal, the welding power supply and the welding gun are effectively protected, the long-term stability of welding is effectively ensured, and the loss is reduced.
Preferably, the power supply circuit further comprises a first electric control switch K1, a second electric control switch K2, a first capacitor C1 and a second capacitor C2, wherein one end of the first electric control switch K1 is connected with the power supply output cathode, the other end of the first electric control switch K1 is connected with one end of the first capacitor C1, the other end of the first capacitor C1 is grounded, one end of the second electric control switch K2 is connected with the power supply output anode, the other end of the second electric control switch K2 is connected with one end of the second capacitor C2, and the other end of the second capacitor C2 is grounded; the fourth output end of the welding power supply control module is respectively connected with the controlled ends of the first electric control switch K1 and the second electric control switch K2; the method comprises the steps of controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a public end corresponding to the normally open end and the cut-off of the first single-pole double-throw switch and a normally closed end, and controlling the public end corresponding to the conduction of the second single-pole double-throw switch and the public end corresponding to the normally open end and the cut-off of the second single-pole double-throw switch and the normally closed end, and comprises the following steps of, but is not limited to: s201, controlling the first electric control switch K1 and the second electric control switch K2 to be respectively switched from an off state to an on state, and starting a timer; s202, when the timing of the timer reaches a preset duration threshold, controlling the public end corresponding to the conduction and the normally open end of the first single-pole double-throw switch and the public end corresponding to the cut-off and the normally closed end of the first single-pole double-throw switch, and controlling the public end corresponding to the conduction and the normally open end of the second single-pole double-throw switch and the public end corresponding to the cut-off and the normally closed end of the second single-pole double-throw switch, wherein the preset duration threshold is shorter than half of the period duration of the next period; s203, controlling the first electric control switch K1 and the second electric control switch K2 to be respectively recovered from an on state to an off state. Therefore, before the standby double-circuit driving module and the standby double-circuit IGBT module are used for switching and starting, the power output negative electrode and the first capacitor C1 and the power output positive electrode and the second capacitor C2 are respectively connected in a conducting mode, the first capacitor C1 and the second capacitor C2 can be used for charging, and then the first single-pole double-throw switch and the second single-pole double-throw switch are used for discharging at the switching moment of the two capacitors, so that the output stability of direct current is maintained, the arc stopping event in the switching process can be completely avoided, and the purpose of continuous uninterrupted welding is further ensured. In addition, after the standby double-circuit driving module and the standby double-circuit IGBT module are used in switching starting, the connection between the power output negative electrode and the first capacitor C1 and the connection between the power output positive electrode and the second capacitor C2 are disconnected, so that adverse effects of capacitance and electric quantity on the stability of direct current can be avoided. Specifically, the first electronically controlled switch K1 or the second electronically controlled switch K2 may, but is not limited to, use a thyristor or a relay.
Preferably, the welding power supply control module is further configured to, after successful arcing: when the continuous use time of the on-use double-circuit driving module and the on-use double-circuit IGBT module reaches M period time, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a public end corresponding to the normally open end and the normally closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch and the normally closed end, so as to enable the standby double-circuit driving module and the standby double-circuit IGBT module to output the direct current, wherein M represents a positive integer greater than or equal to 5; and when the continuous use time of the standby double-circuit driving module and the standby double-circuit IGBT module reaches N period time, controlling the public end and the normally open end corresponding to cut-off of the first single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, and controlling the public end and the normally open end corresponding to cut-off of the second single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, so as to enable the in-use double-circuit driving module and the in-use double-circuit IGBT module to resume outputting the direct current, wherein N represents a positive integer greater than or equal to 5. The foregoing M and N may be respectively exemplified by 60, that is, the in-use two-way driving module and the in-use two-way IGBT module are turned on every 60 minutes, and the standby two-way driving module and the standby two-way IGBT module are turned on, so that the two-way driving module and the two-way IGBT module are turned on by turns, and the two-way driving module and the two-way IGBT module can be prevented from being broken down due to long-term use, thereby further ensuring continuous and uninterrupted welding.
Preferably, the first single pole double throw switch or the second single pole double throw switch may be, but is not limited to, a single channel single pole double throw CMOS (Complementary Metal Oxide Semiconductor ) analog switch of model LN 3657.
In summary, the welding power supply suitable for continuous and uninterrupted welding of ultra-long welding seams provided by the embodiment has the following technical effects:
(1) The embodiment provides a novel welding power supply scheme capable of automatically switching and using an arc maintenance module, namely the novel welding power supply scheme comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balance module, a first single-pole double-throw switch, a second single-pole double-throw switch, a double-way driving module, a standby double-way driving module, a double-way IGBT module, a standby double-way IGBT module, a power supply output cathode, a power supply output anode and an operation state feedback module, wherein the probability value of an arc stopping event occurring at the end of the next period can be periodically estimated after successful arcing through the connection relation and function cooperation of the modules, and when the probability value is judged to be larger than or equal to a preset threshold value, the standby double-way driving module and the standby double-way IGBT module are switched and started to output direct current for maintaining the arc, so that the novel welding power supply scheme can be timely stopped before the current arc maintenance module fails, an unexpected triggering arc stopping event is avoided, and continuous uninterrupted welding can be realized in the ultra-long welding process, and practical application and popularization are facilitated;
(2) The uninterrupted power supply of the UPS can be adopted to avoid unexpected arc stopping accidents caused by unexpected power failure, and further ensure that continuous uninterrupted welding is realized in the ultra-long welding seam welding process;
(3) By adopting the time-delay power-off scheme, the welding machine and the welding gun can be cooled down when the commercial power is abnormal, the welding power supply and the welding gun are effectively protected, the long-term stability of welding is further effectively ensured, and the loss is reduced.
Finally, it should be noted that: the foregoing description is only of the preferred embodiments of the invention and is not intended to limit the scope of the invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. The welding power supply is characterized by comprising a welding power supply control module, a control switch module, a high-frequency arcing module, a current balancing module, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use double-way driving module, a standby double-way driving module, an in-use double-way IGBT module, a standby double-way IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation state feedback module, wherein the power supply output negative electrode is used for being connected with a welding gun head, and the power supply output positive electrode is used for being connected with a workpiece to be welded;
The first output end of the welding power supply control module is connected with the controlled end of the control switch module, the second output end of the welding power supply control module is connected with the first input end of the current balance module, the third output end of the welding power supply control module is respectively connected with the controlled ends of the first single-pole double-throw switch and the second single-pole double-throw switch, the control switch module is connected with the high-frequency arcing module, and the output end of the high-frequency arcing module is connected with the power supply output cathode;
the first PWM pulse signal output end of the current balance module is connected with the common end of the first single-pole double-throw switch, the second PWM pulse signal output end of the current balance module is connected with the common end of the second single-pole double-throw switch, the normally closed end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit in the using double-path driving module, the output end of the first path current driving unit in the using double-path driving module is connected with the input end of the first path IGBT unit in the using double-path IGBT module, the normally open end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit in the standby double-path driving module, the output end of the first path current driving unit in the standby double-path driving module is connected with the input end of the first path IGBT unit in the standby double-path driving module, the output end of the second normally closed end of the second single-pole double-throw switch is connected with the input end of the first path IGBT unit in the standby double-path driving module, the normally open end of the second single-pole double-throw switch is connected with the input end of the first path IGBT unit in the standby double-path driving module, the output end of the second IGBT unit in the in-use double-path IGBT module and the output end of the second IGBT unit in the standby double-path IGBT module are respectively connected with the power supply output anode;
The output end of the running state feedback module is connected with the input end of the welding power supply control module;
the welding power supply control module is used for executing starting/stopping actions on the high-frequency arcing module through the control switch module according to welding control time sequence data, and outputting excitation control signals to the current balance module so as to enable the current balance module to output two paths of balanced PWM pulse signals through two paths of current constant-frequency PWM pulse generator circuits which are connected in a master-slave mode and run in parallel, and further enable the in-use double-path driving module and the in-use double-path IGBT module to output direct current and to be overlapped with high-frequency pulse high-voltage signals generated by the high-frequency arcing module to be input into a welding gun;
and the welding power supply control module is also used for periodically extracting and processing the real-time operation state data from the operation state feedback module to obtain multi-dimensional operation state characteristics after successful arcing, then guiding the multi-dimensional operation state characteristics into an arc stopping event occurrence prediction model which is based on a machine learning algorithm and is trained in advance, outputting a probability value of the arc stopping event when the next period is finished, and finally controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a normally open end and a public end corresponding to the cut-off of the first single-pole double-throw switch and a normally closed end when the probability value is judged to be more than or equal to a preset threshold value, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch so as to enable the standby double-way driving module and the standby double-way IGBT module to output the direct current.
2. The welding power supply of claim 1, further comprising a UPS uninterruptible power supply, wherein a power supply end of the UPS uninterruptible power supply is connected to the welding power supply control module, the control switch module, the high frequency arcing module, the current balancing module, the first single pole double throw switch, the second single pole double throw switch, the on-use two-way drive module, the standby two-way drive module, the on-use two-way IGBT module, the standby two-way IGBT module, and the operational status feedback module, respectively.
3. The welding power supply according to claim 1, further comprising a first electrically controlled switch (K1), a second electrically controlled switch (K2), a first capacitor (C1) and a second capacitor (C2), wherein one end of the first electrically controlled switch (K1) is connected to the power output negative electrode, the other end of the first electrically controlled switch (K1) is connected to one end of the first capacitor (C1), the other end of the first capacitor (C1) is grounded, one end of the second electrically controlled switch (K2) is connected to the power output positive electrode, the other end of the second electrically controlled switch (K2) is connected to one end of the second capacitor (C2), and the other end of the second capacitor (C2) is grounded;
The fourth output end of the welding power supply control module is respectively connected with the controlled ends of the first electric control switch (K1) and the second electric control switch (K2);
controlling the common end corresponding to the first single-pole double-throw switch to be conducted and the common end corresponding to the normally open end to be cut off and the normally closed end, and controlling the common end corresponding to the second single-pole double-throw switch to be conducted and the common end corresponding to the normally open end to be cut off and the normally closed end, comprising:
controlling the first electric control switch (K1) and the second electric control switch (K2) to be respectively switched from an off state to an on state, and starting a timer;
when the timing of the timer reaches a preset duration threshold, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a normally-open end and a public end corresponding to the cut-off of the first single-pole double-throw switch and a normally-closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and a normally-open end and a public end corresponding to the cut-off of the second single-pole double-throw switch and a normally-closed end, wherein the preset duration threshold is shorter than half of the period duration of the next period;
and controlling the first electric control switch (K1) and the second electric control switch (K2) to respectively recover from an on state to an off state.
4. A welding power supply according to claim 3, characterized in that the first electrically controlled switch (K1) or the second electrically controlled switch (K2) employs a thyristor or a relay.
5. The welding power supply of claim 1, wherein the welding power supply control module is further configured to, upon successful arcing:
when the continuous use time of the on-use double-circuit driving module and the on-use double-circuit IGBT module reaches M period time, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a public end corresponding to the normally open end and the normally closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch and the normally closed end, so as to enable the standby double-circuit driving module and the standby double-circuit IGBT module to output the direct current, wherein M represents a positive integer greater than or equal to 5;
and when the continuous use time of the standby double-circuit driving module and the standby double-circuit IGBT module reaches N period time, controlling the public end and the normally open end corresponding to cut-off of the first single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, and controlling the public end and the normally open end corresponding to cut-off of the second single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, so as to enable the in-use double-circuit driving module and the in-use double-circuit IGBT module to resume outputting the direct current, wherein N represents a positive integer greater than or equal to 5.
6. The welding power supply of claim 1, wherein the machine learning algorithm employs a linear regression algorithm based on a Python sklearn library.
7. The welding power supply of claim 1, wherein the arc-stopping event occurrence prediction model is pre-trained in the following manner:
acquiring a plurality of pieces of normal running state data and a plurality of pieces of previous running state data which are in one-to-one correspondence with a plurality of historical arc stopping events, wherein the normal running state data are real-time running state data acquired by the running state feedback module at the starting moment of a K-hour historical period when no arc stopping event occurs, K represents a positive integer, the previous running state data are real-time running state data acquired by the running state feedback module at the moment when the corresponding event occurs at the moment of determining, and the moment of determining is equal to the moment of the corresponding event occurrence minus one period duration;
extracting multidimensional operation state characteristics from corresponding data as corresponding model input items and taking a value 0 as a corresponding model output item aiming at each piece of normal operation state data in the plurality of pieces of normal operation state data to obtain a corresponding negative sample containing the model input items and the model output items;
Extracting multidimensional operation state characteristics from corresponding data as corresponding model input items aiming at each previous operation state data in the previous operation state data, and taking a numerical value 1 as a corresponding model output item to obtain a corresponding positive sample containing the model input item and the model output item;
and performing calibration verification modeling on the artificial intelligent model based on the machine learning algorithm by applying a plurality of negative samples and a plurality of positive samples to obtain the arc stopping event occurrence prediction model, wherein the confidence coefficient of the arc stopping event occurrence prediction model with the output value of 1 is used as a probability value of the arc stopping event at the end of the next period.
8. The welding power supply of claim 1, wherein the first single pole double throw switch or the second single pole double throw switch is a single pole double throw CMOS analog switch model LN 3657.
9. The welding power supply of claim 1, wherein the operating state feedback module comprises a welding current feedback unit, an arc voltage feedback unit, a temperature signal feedback unit, a chiller operating state feedback unit and a two-way IGBT output feedback unit.
10. The welding power supply of claim 1, wherein the control switch module comprises a gun protection gas valve switch, a chiller start-stop switch, and an arc start-stop switch.
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