CN203933438U - A kind of high-power single inversion stud welding machine - Google Patents
A kind of high-power single inversion stud welding machine Download PDFInfo
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- CN203933438U CN203933438U CN201420340549.0U CN201420340549U CN203933438U CN 203933438 U CN203933438 U CN 203933438U CN 201420340549 U CN201420340549 U CN 201420340549U CN 203933438 U CN203933438 U CN 203933438U
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Abstract
The utility model relates to a kind of high-power single inversion stud welding machine; comprise EMI filter circuit, rectified three-phase circuit, parallel great power inverter circuit, high frequency transformer, fast-recovery commutation circuit, inverse changing driving circuit, protective circuit etc.; in parallel great power inverter circuit wherein, four brachium pontis form by the inverse switch pipe of some parallel connections, and high frequency transformer secondary winding output links together and exports respectively after fast recovery diode.The utility model solved inversion stud welding machine under an inversion system, the high-power difficult problem of output of operating voltage within the scope of three-phase AC180V～AC600V, wide accommodation not only, and can realize under Same Efficieney, have that volume is less, the lighter advantage of weight; In addition, the utility model welding machine also has the plurality of advantages such as security and stability is good, manufacturing process is simple, production cost is low, has conspicuousness using value.
Description
Technical field
The utility model relates to a kind of high-power single inversion stud welding machine, belongs to inversion stud welding machine technical field.
Background technology
Stud welding machine is mainly divided into: capacitance energy storage type stud welding machine, arcing capacitor stud welding machine, short period stud welding machine, and above stud welding machine can only weld Φ 10mm left and right weldering nail on thin plate; Also has a kind of long period arc stud welding machine, for Φ 3mm～Φ 36mm stud welding.Long period stud welding machine weld time is at 100ms～2000ms, and what have uses 5000ms, and the maximum 2000A of welding current is to 4000A.
Long period arc stud welding is mainly used in the major projects such as construction steel structure welding WELDING STUDS (peg), high-speed railway built-in fitting, large bridge, machinery.Long period arc stud welding machine has thyristor type: volume is large, weight very heavy (2500A welding machine weight is at 300KG～400KG), electrical efficiency is not high, input power is large.Another kind is inversion stud welding machine.
Because welding machine industry switching tube module is generally at 75A～600A, more high-current module is expensive, drives complexity and reaction speed to be not suitable for welding machine.Because P (power)=I (electric current) * U (voltage), under equal bonding power, when voltage becomes three-phase AC180V～AC280V from three-phase AC380V～AC600V, its electric current just entering is large, inverse switch pipe will be larger, therefore now also there is no the above high power contravariant stud welding machine of 2000A of three-phase AC180V～AC280V.Inversion large power welding machine more than 380V (as carbon arc gas welding, submerged-arc welding, arc stud welding) is all that 2 or 3 inversion systems combine on the market.Its total current in parallel and discrete inversion system are difficult for regulating, and many inversion systems work together easy phase mutual interference and have that manufactured parts is many, the problem such as complex manufacturing, production efficiency are low, bulky, Heavy Weight, failure rate height so that stud welding machine quality is unstable.
Welding arc is a dynamic load altering a great deal, and has a lot of transition states: as short circuit, bulky grain, molten drop instantaneous short circuit, can blow up welding machine inverse switch pipe and the damage of secondary fast recovery rectifier diode, cause loss of personal property.It on built-in fitting, large bridge, is all Φ 22mm～Φ 32mm weldering nail, on steel construction building site, contour plate penetrates that welding WELDING STUDS task is large, engineering anxious especially, play first floor every day, welding machine utilization rate is high, and power line is drawn in some building sites temporarily, and various other welding machines, crane inter-working have interference, supply voltage is stable not, in several seconds, bonding power is more than 100KW in arc stud welding, and 3 phase electric line inductance reverse voltages are high, easily damage equipment.Building site WELDING STUDS distributes wide, and welding gun need to be lengthened to 50m～150m (100m rifle line drop 25V～30V) welder power more to be needed to strengthen.The transformer of a fabrication of iron core for welding machine, power is little, hot very soon, and the pressure drop of power supply line length is high, no current compensating action when voltage is low, long welding gun line cannot weld, and impact construction, cannot finish the work.
Utility model content
Technical problem to be solved in the utility model is, overcome the above-mentioned defect of prior art, a kind of high-power single inversion stud welding machine is provided, solve inversion stud welding machine under an inversion system, the high-power difficult problem of output of operating voltage within the scope of three-phase AC180V～AC600V, improve the security and stability of high power contravariant stud welding machine, realize under Same Efficieney, make that welding machine volume is less, weight is lighter, the objects such as convenient transportation and use.
In order to solve above technical problem, the technical solution adopted in the utility model is as follows:
A kind of high-power single inversion stud welding machine, comprise the rectified three-phase circuit connecting successively, inverter circuit, high frequency transformer, fast-recovery commutation circuit, described rectified three-phase circuit is transformed into direct current by three-phase alternating current, inverter circuit converts direct current to high-frequency alternating current, after high frequency transformer step-down and fast recovery diode rectification, obtain direct current welding current, described inverter circuit is the full bridge inverter with four brachium pontis, four brachium pontis of described inverter circuit form by the inverse switch pipe of some parallel connections, the first output of inverter circuit is through switched inductors, capacitance connects the first end of high frequency transformer armature winding, the second end of the second output termination high frequency transformer armature winding of inverter circuit, described high frequency transformer has some secondary winding, the two ends of each secondary winding link together respectively as the cathode power supply output of welding machine after fast recovery diode, and the mid point lead-out wire of each secondary winding connects the negative power supply output as welding machine by filter reactor successively.
High-power single inversion stud welding machine described in the utility model also has following improvement:
1, the front end of described rectified three-phase circuit is provided with EMI filter circuit, and described EMI filter circuit forms a LC filter that comprises that electric capacity adopts triangle to connect, and the inductance of a described LC filter is differential mode inductance; Electric capacity adopts the 2nd LC filter of Y-connection, and the inductance of described the 2nd LC filter is common mode inductance, on the circuit between a described LC filter and the 2nd LC filter, adopts delta connection to be connected with three piezo-resistances.
2, between described rectified three-phase circuit and inverter circuit, be connected to DC filtering circuit, described DC filtering circuit comprises the ground capacity, passive filter of filtering discharge resistance, two series connection, some nonpolarity high frequency capacitance in parallel successively, described passive filter is connected on the positive terminal of direct current, inductance in parallel, diode, electric capacity, consist of, described diode is that reverse parallel connection connects in succession.
3, high-power single inversion stud welding machine described in the utility model also has for driving separately brachium pontis on inverter circuit the first half-bridge, the first drive circuit of each inverse switch pipe in brachium pontis under the second half-bridge, for driving separately brachium pontis under inverter circuit the first half-bridge, the second drive circuit of each inverse switch pipe in brachium pontis on the second half-bridge, and to described first, the second drive circuit sends the inversion pulse-generating circuit of inversion pulse signal, described drive circuit comprises the DC power supply connecting successively, driving tube module, with the driving transformer that in each brachium pontis of inverter circuit, inverse switch pipe quantity equates, described driving transformer has an armature winding and two secondary winding, driving transformer secondary winding Same Name of Ends in the first drive circuit, different name end connects respectively in inverter circuit brachium pontis on the first half-bridge, inverse switch pipe under the second half-bridge in brachium pontis, driving transformer secondary winding Same Name of Ends in the second drive circuit, different name end connects respectively in inverter circuit brachium pontis on the second half-bridge, inverse switch pipe under the first half-bridge in brachium pontis, one end of described driving transformer armature winding is connected to capacitance in parallel and resistance.
4, described driving tube module is the full-bridge inverting drive circuit or the integrated drive chips that 4 driving tubes, consist of, and described driving tube is a kind of in field effect transistor, triode, IGBT pipe.
5, high-power single inversion stud welding machine described in the utility model also has for identifying the protective circuit of Pulse by Pulse overcurrent and down pulse, described protective circuit comprises that several are for responding to the first coil instrument transformer of each inverse switch tube current, several are for responding to the second coil mutual inductance device of each fast recovery diode electric current, and first, second, the 3rd, the 4th comparator, the output of described the first instrument transformer connects diode by sample resistance after full-bridge rectification, then connect together, send into first simultaneously, the electrode input end of the second comparator, the output of described the second instrument transformer connects diode by sample resistance after full-bridge rectification, then connect together, send into the 3rd simultaneously, the electrode input end of the 4th comparator, described first, the negative pole input voltage of the 3rd comparator is Pulse by Pulse protection voltage, described second, the negative pole input voltage of the 4th comparator is down pulse protection voltage, first, the output of the 3rd comparator respectively after triode as the output of Pulse by Pulse overcurrent protection signal, second, the output of the 4th comparator respectively after controllable silicon as the output of down pulse guard signal.
6, the finite both that described inversion pulse-generating circuit is comprised of loop Current-type PWM Controller and time-base circuit is controlled ZVZCS-PWM full-bridge impulse waveform.
7, voltage-stabiliser tube or triode or optocoupler or integrated circuit replacement for described comparator.。
8, Pulse by Pulse overcurrent protection signal is connected on the waveform arithmetic unit of inversion pulse-generating circuit; Down pulse guard signal is connected on the pulse-off pin of inversion pulse-generating circuit.
8, described high frequency transformer has the same specification magnetic core of several merging, and each secondary winding is formed by the enamelled wire plying of equal number root.
In inverter circuit of the present utility model, be designed with the brachium pontis of a plurality of parallel connections, utilize some common inverse switch pipes can realize the output of carrying out large electric current (high-power) under three-phase AC180V～AC280V low-voltage environment, thereby avoided use great-current inversion switching tube, greatly reduce manufacturing cost, can obtain desirable effect simultaneously; And high frequency transformer secondary winding separates multiply, after connecting fast recovery diode, the positive pole as welding machine in parallel is exported, further improved welder power, make the power-performance of this welding machine can reach the requirement of stud welding machine, because it can normally work under environment under low pressure, also can work at three-phase AC380V～AC600V, so adaptability is stronger.
The front end of the utility model rectified three-phase circuit is provided with EMI filter circuit, has and suppresses common mode disturbances and differential mode interference effect, can suppress interference from the electrical network infringement to inverter itself, also can suppress the interference that inverter feeds back to electrical network; In addition, in EMI filter circuit, added varistor, can replace Transient Suppression Diode, discharging tube for anti-thunderstriking, Zener diode to the voltage surge of external environment condition, thunderbolt, extraneous radiation inhibitory action, anti-tampering reliability is high.
In the drive circuit of the utility model inverter circuit, by special driving transformer, design, can realize the independent driving to all inverse switch pipes, and do not interfere with each other, belong to the suffered triggering waveform of the inverse switch pipe of same group the same, can the damage of other inverse switch pipes of image because of one of them inverse switch pipe fault.Therefore the related drive circuit of the utility model has reduced the failure rate of welding machine electric power, has improved product quality, and then has guaranteed user's production efficiency.
The utility model utilizes coil mutual inductance device to obtain the electric current of inverse switch in inverter circuit and the electric current of high frequency transformer output fast recovery diode, and after rectification, output in parallel respectively after sampling, sends into comparator and carry out voltage ratio; Because the waveform all-pass after sampling is crossed diode merging together, therefore the high pulse meeting of voltage manifests, the pulse meeting that voltage is low is submerged, so the pulse high by voltage can judge whether Pulse by Pulse overcurrent, realized Pulse by Pulse protection, main power source can be stablized output in false short circuit or while welding complicated ohmic load; When having due to artificial origin's welding machine, damage or during true fault, be connected on the down pulse guard signal that inversion pulse-generating circuit turn-offs pin, can directly turn-off drive circuit, and without internal circuit, turn-offing more reliable, and rapid.The utility model protective circuit can be prevented transformer and welding overcurrent, more can prevent switching tube shoot through.
To sum up, the beneficial effects of the utility model are as follows:
1, paralleled power switches technology has solved switching tube capacity problem.
2, adopt the utility model technology can realize under Same Efficieney, have that volume is less, the lighter advantage of weight, facilitated transportation, particularly when outlet transportation, freight charges are more economized.
3, cost is low by 20%, and manufacturing process is simple, and workman is difficult for makeing mistakes, with short production cycle.
4, all inverse switch pipes, fast recovery diode have protection, and its quality is more reliable.
5, paralleled power switches technology has solved the large problem of switching tube electric current, can make primary current when three-phase AC180V～AC280V be twice, and has realized the compensation effect that has larger power output when voltage is low, and low voltage operating is more stable.
6, the high power contravariant welding machine that has solved an independent inversion system, its stability is better.
7, adopt a plurality of paralleled power switches and fast quick-recovery diode in parallel, if there have outer member to damage its loss to be less.If any artificial damage, welding machine is smashed by steel pipe in building site, and one of them damage parts is pulled down bad part, and other just can work on.
8, main transformer adopts magnetic core to merge, and power is large, and loss is little, does not waste.
9, protective circuit is divided Pulse by Pulse protection and error protection, effective.This circuit is for protections such as paralleling switch pipe, secondary fast recoveries in parallel.Also be applicable to not wanting inverter circuit in parallel in case shoot through is protected, overcurrent protection.
10, power saving and power factor improve more than 95%.
11, secondary parallel connection and protection, solve the fault that originally can all burn out.
12, special driving, paralleled power switches and protection, solved switching tube and can one group entirely do not blown up.
In a word, the utility model solved inversion stud welding machine under an inversion system, the high-power difficult problem of output of operating voltage within the scope of three-phase AC180V～AC600V, wide accommodation not only, and can realizing under Same Efficieney, has that volume is less, the lighter advantage of weight; In addition, the utility model welding machine also has the plurality of advantages such as security and stability is good, manufacturing process is simple, production cost is low, has conspicuousness using value.
In addition; the utility model welding machine also has phase shortage, overvoltage/undervoltage protection; control the auxiliary circuits such as power supply, fan, anticorrosion, program board, demonstration, control, welding gun, temperature control and waveform generation, falling characteristic control, but owing to all adopting prior art, do not do relevant improvement.Technique effect of the present utility model is all realized by the improvement of the electric circuit constitute and structure.
Accompanying drawing explanation
Fig. 1 is the electric theory diagram of the utility model welding machine.
Fig. 2 is the electrical schematic diagram of EMI filter circuit.
Fig. 3 is the utility model welding machine electric power part electrical schematic diagram.
Fig. 4-a is the electrical schematic diagram of the first drive circuit.
Fig. 4-b is the electrical schematic diagram of the second drive circuit.
Fig. 4-c is triggering signal sequential chart.
Fig. 5 is protective circuit schematic diagram.
Fig. 6-a is high frequency transformer end view.
Fig. 6-b is high frequency transformer armature winding winding schematic diagram.
Fig. 6-c, Fig. 6-d are high frequency transformer secondary winding winding schematic diagrames.
Fig. 7 is the electrical schematic diagram of inversion pulse-generating circuit.
Embodiment
For making object, technical scheme and the advantage of the utility model embodiment clearer, below in conjunction with accompanying drawing, the technical scheme in the utility model embodiment is clearly and completely described.
Figure 1 shows that the schematic block circuit diagram of a kind of high-power single inversion stud welding machine that the present embodiment provides; mainly comprise the EMI filter circuit, rectified three-phase circuit, inverter circuit, high frequency transformer, fast-recovery commutation circuit, welding gun, the mother metal that connect successively; in addition; also comprise inversion pulse driving circuit; phase shortage, overvoltage/undervoltage protection sample circuit; program board, fan etc.This stud welding machine basic functional principle is, EMI filter circuit carries out after filtering three-phase alternating current, through rectified three-phase circuit, be transformed into direct current, through DC filtering, and convert direct current to high-frequency alternating current by inverter circuit, then through high frequency transformer step-down, by the rectification of fast-recovery commutation circuit, produce direct current welding current, the anodal mother metal that connects, negative pole connects welding gun, thereby realizes the welding to double-screw bolt.
As shown in Figure 2, for being arranged at the EMI filter circuit of rectified three-phase circuit front end, described EMI filter circuit forms and comprises: electric capacity adopts a LC filter of triangle connection (by inductance L A, LB, LC, capacitor C 31, C32, C33 form, inductance L A, LB, LC are connected on respectively on A, B, C three-phase inlet wire, and LA, LB, LC are differential mode inductances; Capacitor C 31, C32, C33 are connected on respectively between AB phase, BC mutually between, AC mutually between), electric capacity adopts the 2nd LC filter (inductance L D of Y-connection, capacitor C 34, C35, C36, inductance L D is three-phase common mode inductance, capacitor C 34, C35, C36 are ground capacity), on circuit between the one LC filter and the 2nd LC filter, adopt delta connection to be connected with three piezo-resistance R1, R2, R3, three piezo-resistance R1, R2, R3 are attempted by respectively three capacitor C 31, C32, the C33 two ends of a LC filter.Three-phase electricity ABC carries out EMI filtering after by mains switch, EMI filtering has the common mode disturbances of inhibition and differential mode interference effect, can suppress interference from the electrical network infringement to inverter itself, also can suppress inverter to the interference of electrical network feedback, separately increase varistor.Varistor is a kind of element with transient voltage inhibit feature, can replace Transient Suppression Diode, discharging tube for anti-thunderstriking, Zener diode to the voltage surge of external environment condition, thunderbolt, extraneous radiation inhibitory action.In the present embodiment, the inductance value range of choice of inductance L A, LB, LC is 100mH～700mH; The desirable 1 μ F～10 μ F of the capacitance of capacitor C 31, C32, C33, voltage is more than 1200V; Capacitor C 34, C35, C36 get 0.1 μ F～0.47 μ F, and its voltage is more than 2KV; LD is common mode inductance, more than piezo-resistance R1, R2, R3 adopt peak current 10KA, and the piezo-resistance of voltage 800V～1000V.
As shown in Figure 3, be the utility model welding machine electric power circuit diagram partly.After EMI filtering, three phase mains enters on one side and controls power supply and the protection of phase shortage overvoltage/undervoltage, Yi Bian enter three-phase commutation bridge, rectifier bridge becomes direct current by three-phase alternating current, and its voltage is more than 1.4 times of alternating current, then by DC filtering circuit, direct current is carried out to filtering.In this example, DC filtering circuit comprises filtering discharge resistance R4 (filtering discharge resistance power 3W～10W successively, resistance 50K Ω～100K Ω), the ground capacity C1 of two series connection, C2 is (more than the voltage 2KV of ground capacity, capacitance 0.1 μ F～0.47 μ F), passive filter, 2 nonpolarity high frequency capacitance C3 in parallel, C4 (nonpolarity high frequency capacitance C3, the voltage of C4 is more than 1200V, can a plurality of parallel connections, capacitance is 10 μ F～20 μ F, after in parallel, total capacity is at 40 μ F～150 μ F), passive filter is connected on the positive terminal of direct current, by inductance L in parallel 1 (L1 inductance value 5mH～50mH), diode D9, capacitor C 12 forms, diode D9 is that reverse parallel connection connects in succession.During due to arc stud welding, immediate current is high, so adopt nonpolarity high frequency capacitance in the present embodiment.Also available electrochemical capacitor 450V1000～3300 μ F series connection, adds charging buffer circuit.
Filtered direct current becomes high-frequency alternating current to high frequency transformer T1 by inverter circuit.As shown in Figure 3, in this example, inverter circuit is the full bridge inverter with four brachium pontis, and four brachium pontis of inverter circuit form by 3 inverse switch pipes in parallel, first group of inverse switch pipe G1, G3, G5 form the upper brachium pontis of the first half-bridge, second group of inverse switch pipe G2, G4, G6 form the lower brachium pontis of the second half-bridge, the 3rd group of inverse switch pipe G7, G9, G11 form the upper brachium pontis of the second half-bridge, and the 4th group of inverse switch pipe G8, G10, G12 have formed the lower brachium pontis of the first half-bridge.The first output of inverter circuit connects the first end of high frequency transformer T1 armature winding through switched inductors L2, capacitance C7, C8 in parallel, the second end of the second output termination high frequency transformer T1 armature winding of inverter circuit; High frequency transformer T1 has 4 secondary winding, the two ends of each secondary winding link together respectively as the cathode power supply output of welding machine after fast recovery diode (D1-D8), and the mid point lead-out wire of each secondary winding connects the negative power supply output as welding machine by filter reactor L3 successively.Between both positive and negative polarity output, be also connected to a filter circuit, as shown in Figure 3, this filter circuit comprises ground capacity C9, C10 successively, piezo-resistance R7, and output capacitance C11, unloaded resistance R 6, wherein, piezo-resistance R7 can prevent from welding the circuit voltage butt welding machine of playing a reversed role and damage.The rear side of filter reactor L3 is connected to sampling resistor R5 and carries out current sample, and R5 available current transducer replaces, and sends into program board detect together with the sampled voltage of anodal outlet side.In this example, inverse switch pipe is selected IGBT module, can select in addition TPM module, VMOSFET module, MGT (Mos controls transistor), STT (static sensor transistor) etc.In figure, capacitor C 5, C6 are respectively the leading arm electric capacity of inverse switch pipe G1G3G5, G2G4G6.
In Fig. 3, inverse switch pipe G1-G12, switched inductors L2, capacitance C7, C8, high frequency transformer T1 have formed full bridge soft switch circuit, also available half-bridge, switching tube hard switching circuit.This welding equipment will be exported 44V, 2500A～4000A electric current, the inverse switch tube current of selecting is at 75A～600A, the number of paralleling switch pipe is pressed demanded power output, the quantity (number of fast recovery diode) of high frequency transformation level secondary winding is also calculated according to power requirement, and each switching tube, fast recovery diode model are consistent.Inversion total current is pressed 80% left and right of paralleled power switches total current and is calculated, and secondary total current is pressed 80% left and right of fast recovery diode total current in parallel and calculated.Experimental results show that: adopt the two-tube TGBT module of 200A～300A, in three-phase AC380V～AC600V, 2000A-2500A output, 2 IGBT modules in parallel, be one group, more than 1200V, secondary fast recovery diode total current is at 2500A～3000A, more than 400V; 3000A～4000A in parallel 3 be that one group, voltage 1200V are above, secondary fast recovery pipe total current is at 3600A～4600A, more than 400V; In same power output situation, when input voltage is three-phase AC180V～AC280V, output 2000A～2500A in parallel 4 be one group, voltage more than 600V, secondary fast recovery diode total current 2500A～3000A, more than voltage 400V; Output 3000A～4000A in parallel 6 be one group, voltage more than 600V, secondary fast recovery diode total current is at 3600A～4600A, more than voltage 400V; In all voltage, exporting more than 4000A can multi-parallel switching tube, fast recovery diode, increase protection and drive circuit.Every group of inverse switch pipe main circuit in parallel will evenly connect up, in order to reach each switching tube current-sharing in every group, can adopt resistance-type and inductance type current-sharing, at each switching tube crosstalk resistance or inductance, because switching tube work is high frequency, very little resistance and inductance have positive effect.
As Fig. 4-a, shown in Fig. 4-b, be the drive circuit electrical schematic diagram of inverter circuit in the utility model welding machine.It comprises for driving separately brachium pontis inverse switch pipe G1 on inverter circuit the first half-bridge, G3, G5, inverse switch pipe G2 in brachium pontis under the second half-bridge, G4, the first drive circuit of G6 (Fig. 4-a), for driving separately brachium pontis inverse switch pipe G8 under inverter circuit the first half-bridge, G10, inverse switch pipe G7 in brachium pontis on G12 and the second half-bridge, G9, the second drive circuit (Fig. 4-b) of G11, and to first, the second drive circuit sends the inversion pulse-generating circuit (seeing Fig. 7) of inversion pulse signal, and two driving circuit structures are identical, and the first drive circuit shown in Fig. 4-a of take is example, and this drive circuit comprises the DC power supply (V+ connecting successively, V-), driving tube module, 3 driving transformer T2, T3, T4, take driving transformer T2 as example, it has an armature winding and two secondary winding, one end of armature winding is connected to capacitance C15 in parallel and resistance R 15, brachium pontis inverse switch pipe G1 on the first half-bridge in secondary winding termination inverter circuit of the same name, inverse switch pipe G2 in brachium pontis under different name termination the second half-bridge.The armature winding of corresponding driving transformer T3, T4 is connected to respectively the capacitance C17 resistance R 17 of capacitance C16 resistance R 16 in parallel, parallel connection, secondary winding Same Name of Ends meets respectively inverse switch pipe G3, G5, and different name end meets respectively inverse switch pipe G4, G6.Driving transformer T5, T6, T7 for the second drive circuit, its armature winding is connected to the capacitance C19 resistance R 19 of capacitance C18 resistance R 18 in parallel, parallel connection, capacitance C20 resistance R 20 in parallel, secondary winding termination inverse switch of the same name pipe G7, G9, G11, different name termination inverse switch pipe G8, G10, G12.Driving transformer magnetic core is ferrite and amorphous, also can be (Fig. 4-a) T2, T3, T4, (Fig. 4-b) T5, T6, T7 make respectively two transformers.But secondary separately, each is secondary connects a switching tube.In figure, VF1-VF8 is driving tube, plays the effect that drives T2-T7 driving transformer, what in the present embodiment, use is effect pipe, also available triode or little electric current I GBT pipe belt are replaced, and RG1-RG12 is the control electrode resistance of inverse switch pipe G1-G12, and R7-R14 is the controlling resistance of driving tube VF1-VF8.A, b, c, d are the interlocking signals that inversion pulse-generating circuit (Fig. 7) is sent, but must each control the utmost point separately, and multichip integrated circuit or optocoupler drive separately each inverse switch pipe G1-G12.In experiment if by each switch controlled utmost point not separately, if adopt the direct RG resistance Parallel Control utmost point in parallel of driver, if there is a switch to have problem, collector electrode with control utmost point short circuit, whole group of switching tube all can all be blown up by controlled stage voltage height; And adopt to separate, control separately after utmost point driving, collector electrode and the short circuit of the control utmost point, be own fault, switching tube of artificial damage, and other does not also affect, and welding machine can be protected, and reaches design effect.
As shown in Fig. 4-c, it is triggering signal sequential chart.When a and d trigger, b and c are zero.When a has triggering, driving tube VF1, VF4 conducting, driving tube VF2, VF3 cut-off, drive first group of inverse switch pipe G1, G3, G5 open-minded, when d has triggering, driving tube VF6, VF7 conducting, driving tube VF5, VF8 cut-off, drives the 4th group of inverse switch pipe G8, G10, G12 open-minded.Principal current is by G1, G3, G5 by L2, C7, C8, T1, G8, G10, G12 generation current, and transformer T1 produce power is exported after D1-D4 rectification.When a and d have triggered the Dead Time by tf; B and c start to trigger, a, d are zero, c triggers the 3rd group of inverse switch pipe G7, G9, G11 are open-minded, b triggers second group of inversion G2, G4, G6 is open-minded, principal current is by G7, G9, G11, T1, C7, C8, L2, G2, G4, G6 generation current, transformer T1 produce power is exported after D5-D8 rectification, and after b and c have triggered, by tf Dead Time, a and b trigger again.Trigger rate is 18KHZ-60KHZ.
As shown in Figure 7, the finite both that inversion pulse-generating circuit is comprised of loop Current-type PWM Controller and time-base circuit is controlled ZVZCS-PWM full-bridge impulse waveform.Triggering signal can be coordinated by chip UC3846 and chip NE556, when No. 11 pins and No. 14 pins of UC3846 are exported leading arm signal, lagging leg is by NE556 time delay, the leading arm waveform of broadening, No. 10 pins shutoffs by UC3846 realize finite both control ZVZCS-PWM waveform (seeing Fig. 4-c), a b c d also available UC3846 and CD4013 is used in conjunction with, and also can produce pwm signal by MCU, DSP, FBGA.
As shown in Figure 5; protective circuit for the present embodiment welding machine; be used for identifying Pulse by Pulse overcurrent and down pulse; this protective circuit comprises that 12 for responding to the first coil instrument transformer L5-L16 of each inverse switch tube current, and 8 for responding to the second coil mutual inductance device La-Lh of each fast recovery diode electric current.Coil available current transducer or the resistance detection function of current.And first to fourth comparator IC1-IC4.As shown in Figure 3, the first coil instrument transformer L5-L16 is connected on respectively on the circuit of inverse switch pipe G1-G12, and the second coil mutual inductance device La-Lh is connected on respectively on the circuit of fast recovery diode D1-D8.As shown in Figure 5, the output of the first instrument transformer L5-L16 meets diode R51-R62 by sample resistance after full-bridge rectification, then connect together, send into first simultaneously, the second comparator IC1, the electrode input end of IC2, the output of the second instrument transformer La-Lh connects diode by sample resistance Ra-Rh after full-bridge rectification, then connect together, send into the 3rd simultaneously, the 4th comparator IC3, the electrode input end of IC4, first, the 3rd comparator IC1, the negative pole input voltage of IC3 is Pulse by Pulse protection voltage V1, V3, second, the 4th comparator IC2, the negative pole input voltage of IC4 is down pulse protection voltage V2, V4, first, the 3rd comparator IC1, the output of IC3 respectively after triode as the output of Pulse by Pulse overcurrent protection signal, second, the 4th comparator IC2, the output of IC4 respectively after controllable silicon as the output of down pulse guard signal.In figure, capacitor C 41, C42 are anti-interference ground capacity.Pulse by Pulse overcurrent protection signal is connected on the waveform arithmetic unit of inversion pulse-generating circuit (Fig. 7), and as UC3846 series SG3525 series, TL494 series all has this pin position; Down pulse guard signal is connected on the pulse-off pin of inversion pulse-generating circuit, and its turn-off speed directly turn-offs pulse without internal circuit process, turn-offs reliable.As serial in UC3846 series, SG3525, TL494 is serial shutoff pin.
The resistance of sample resistance R51-R62 will be by the 80% left and right Current calculation of each inverse switch pipe G1-G12; The resistance of sample resistance Ra-Rh is by the 80% left and right Current calculation of each fast recovery diode D1-D8, waveform all-pass after sampling is crossed diode and is merged together, the pulse meeting that voltage is high manifests, the pulse meeting that voltage is low is submerged, the pulse that voltage is high makes principal current electric current maximum, controlled the fail safe of maximum current pipe, little electric current more can be not bad.V1, V3 Pulse by Pulse protection voltage, V2, V4 are down pulse protection voltage, and the voltage ratio V2 of V1 is little, and V4 is little for V3 voltage ratio.When merging pulse E, surpass V1 or merge pulse F while surpassing V3 comparator output HIGH voltage paired pulses and produce circuit and turn-off, carried out Pulse by Pulse protection, inverse switch pipe G1-G12 fast recovery diode D1-D8 can overcurrent, does not damage good reliability.Integrated comparator can use voltage-stabiliser tube, triode, optocoupler to replace.In false short circuit or while welding complicated ohmic load, the power supply stable output of the utility model welding machine.If because artificial origin's welding machine has damage, the immediately upper up voltage of coil pickoff, when E voltage surpasses V1, voltage F has surpassed V3, does not have protection, is at this moment true fault; When voltage E surpasses V2, when voltage F surpasses V4, comparator just turn-offs error protection at once.
If do not increase this defencive function; inverse switch pipe G1-G12 can due to moment overcurrent or open circuit make the inverter failure can bombing; secondary fast recovery diode also has breakdown phenomenon after diode open-circuit or short circuit, and remaining pipe is damaged not and all by electric current, causes damage.Increase this protective circuit and can avoid fault.This circuit is also applicable to the not associated switching tube inverter circuit of needs, can play switching tube shoot through and the protection of secondary fast recovery diode.In experimentation: by switch of welding machine output line two termination, just in time welding machine continuous folding switch when welding, forms the unloaded constantly conversion of short circuit and welding; Or electric current potentiometer was lost efficacy, machine also can be normally not bad.In malfunction test: directly people is short circuit transformer, and diode switch pipe machine can be protected, successful.This protective circuit both can have been prevented transformer and welding overcurrent, more can prevent switching tube shoot through.Reached designing requirement.
As shown in Fig. 6-a, 6-b, 6-c, 6-d, be high-frequency transformer structure schematic diagram, design of transformer is mainly considered operating frequency, power capacity and temperature rise, volume of transformer and cost.Magnetic core can adopt ferrite and amorphous magnetic core, can have high frequency 20～60KHz isolation and transformer action.Ferrite shape has E type, EI type, round and U-shaped, adopt round magnetic core coiling easily and quality good, ferrite permeability is medium, saturation flux density BS=500mT, 150 ℃ of left and right Same Efficieney volumes of Curie temperature are slightly large, power use cost is high, and minority adopts.Non-crystalline material permeability is high, 350 ℃～700 ℃ of saturation magnetic induction degree BS=1.25T, Curie temperature, and it is U-shaped, round that shape has, and adopts round coiling easy.High-power magnetic core has Φ 120mm * 60mm * 30mm to Φ 180mm * 110mm * 60mm on the market now; Power is at 10KW～30KW.
Reach 100KW～200KW, welding current has allowance at 2000A～4000A, offset current effect when low voltage.Transformer of the present utility model is that a plurality of magnetic cores of same specification are closed to connection, increases cross-sectional area, and transformer can be not hot, and its leakage inductance is at 2～3 μ H.As shown in Fig. 6-a, main transformer magnetic core is merged and is formed by three magnetic cores of x, y, z, merges quantity according to transformer efficiency, and the larger quantity of power is many.That Φ 130mm * 80mm in welding machine industry * 40mm is used is many, cost is low, winding space enough, do not waste.Experimental results show that: during output 2000A～2500A, with Φ 130mm * 80mm * 40mm, merge 2; Output 3000A～4000A merges 3, more high-powerly adopts a plurality of merging of magnetic core that winding space is large, as Φ 180mm * 110mm * 60mm.
Aluminium or high temperature plastics for iron core shell, the enamelled wire that is 0.05mm～1mm with diameter, less its collection glue effect of diameter is little, line temperature is low, and multiply is merged into a strand, be convenient to cooling, and twined insulating tape (as polytetrafluoroethylene adhesive tape, the broad film of polyester, pi, yellow cured silk fabric, varnished glass cloth), press 6A～20A calculating for every square millimeter that merges line, little by low current calculating transformer copper loss, welding machine efficiency is improved.The turn ratio is pressed 5:1 and is calculated to 6.5:1, as shown in Fig. 6-b, for armature winding, 2. first line is evenly arranged on whole magnetic core, be 1. out-primary, is respectively secondary winding in Fig. 6-c, Fig. 6-d, because of number of secondary turns few, with 2 same alignment magnetic core 2 limits around, make induction evenly, better inverse switch tube wave shape; Secondary winding respectively according to shown in Fig. 6-c, Fig. 6-d around one deck, finally 6. 5. 4. 3. the end of a thread be connected together and become mid-point tap, as welding machine negative pole.At the other end every line enamelled wire quantity separately, separately quantity equally has current balance function, for the end of a thread 7. 8. 9. 10. or more, the end of a thread
or more, separately quantity will determine according to secondary commutation recovery diode quantity, each is lifted one's head and connects a fast recovery diode.Breakout will be worn ferrite magnetosphere, prevents electromagnetic interference, temperature protection is installed on transformer coil, has warning function having under failure condition, experimental results show that: it is inadequate that this transformer has solved magnetic core power, working properly under long-time large electric current.
Finally be necessary described herein: foregoing is only for being described in further detail the technical solution of the utility model; can not be interpreted as the restriction to the utility model protection range, some nonessential improvement that those skilled in the art makes according to foregoing of the present utility model and adjustment all belong to protection range of the present utility model.
Claims (10)
1. a high-power single inversion stud welding machine, comprise the rectified three-phase circuit connecting successively, inverter circuit, high frequency transformer, fast-recovery commutation circuit, described rectified three-phase circuit is transformed into direct current by three-phase alternating current, inverter circuit converts direct current to high-frequency alternating current, after high frequency transformer step-down and the rectification of fast-recovery commutation circuit, obtain direct current welding current, described inverter circuit is the full bridge inverter with four brachium pontis, four brachium pontis of described inverter circuit form by the inverse switch pipe of some parallel connections, the first output of inverter circuit is through switched inductors, capacitance connects the first end of high frequency transformer armature winding, the second end of the second output termination high frequency transformer armature winding of inverter circuit, described high frequency transformer has some secondary winding, the two ends of each secondary winding link together respectively as the cathode power supply output of welding machine after fast recovery diode, and the mid point lead-out wire of each secondary winding connects the negative power supply output as welding machine by filter reactor successively.
2. high-power single inversion stud welding machine according to claim 1, it is characterized in that: the front end of described rectified three-phase circuit is provided with EMI filter circuit, described EMI filter circuit forms a LC filter that comprises that electric capacity adopts triangle to connect, and the inductance of a described LC filter is differential mode inductance; Electric capacity adopts the 2nd LC filter of Y-connection, and the inductance of described the 2nd LC filter is common mode inductance, on the circuit between a described LC filter and the 2nd LC filter, adopts delta connection to be connected with three piezo-resistances.
3. high-power single inversion stud welding machine according to claim 1, it is characterized in that: between described rectified three-phase circuit and inverter circuit, be connected to DC filtering circuit, described DC filtering circuit comprises the ground capacity, passive filter of filtering discharge resistance, two series connection, some nonpolarity high frequency capacitance in parallel successively, described passive filter is connected on the positive terminal of direct current, inductance in parallel, diode, electric capacity, consist of, described diode is that reverse parallel connection connects in succession.
4. high-power single inversion stud welding machine according to claim 1, it is characterized in that: also have for driving separately brachium pontis on inverter circuit the first half-bridge, the first drive circuit of each inverse switch pipe in brachium pontis under the second half-bridge, for driving separately brachium pontis under inverter circuit the first half-bridge, the second drive circuit of each inverse switch pipe in brachium pontis on the second half-bridge, and to described first, the second drive circuit sends the inversion pulse-generating circuit of inversion pulse signal, described drive circuit comprises the DC power supply connecting successively, driving tube module, with the driving transformer that in each brachium pontis of inverter circuit, inverse switch pipe quantity equates, described driving transformer has an armature winding and two secondary winding, driving transformer secondary winding Same Name of Ends in the first drive circuit, different name end connects respectively in inverter circuit brachium pontis on the first half-bridge, inverse switch pipe under the second half-bridge in brachium pontis, driving transformer secondary winding Same Name of Ends in the second drive circuit, different name end connects respectively in inverter circuit brachium pontis on the second half-bridge, inverse switch pipe under the first half-bridge in brachium pontis, one end of described driving transformer armature winding is connected to capacitance in parallel and resistance.
5. high-power single inversion stud welding machine according to claim 4, it is characterized in that: described driving tube module is the full-bridge inverting drive circuit or the integrated drive chips that 4 driving tubes, consist of, described driving tube is a kind of in field effect transistor, triode, IGBT pipe.
6. high-power single inversion stud welding machine according to claim 4, it is characterized in that: also have for identifying the protective circuit of Pulse by Pulse overcurrent and down pulse, described protective circuit comprises that several are for responding to the first coil instrument transformer of each inverse switch tube current, several are for responding to the second coil mutual inductance device of each fast recovery diode electric current, and first, second, the 3rd, the 4th comparator, the output of described the first instrument transformer connects diode by sample resistance after full-bridge rectification, then connect together, send into first simultaneously, the electrode input end of the second comparator, the output of described the second instrument transformer connects diode by sample resistance after full-bridge rectification, then connect together, send into the 3rd simultaneously, the electrode input end of the 4th comparator, described first, the negative pole input voltage of the 3rd comparator is Pulse by Pulse protection voltage, described second, the negative pole input voltage of the 4th comparator is down pulse protection voltage, first, the output of the 3rd comparator respectively after triode as the output of Pulse by Pulse overcurrent protection signal, second, the output of the 4th comparator respectively after controllable silicon as the output of down pulse guard signal.
7. high-power single inversion stud welding machine according to claim 4, is characterized in that: the limited ambipolar ZVZCS-PWM full-bridge impulse waveform that described inversion pulse-generating circuit is comprised of loop Current-type PWM Controller and time-base circuit.
8. high-power single inversion stud welding machine according to claim 6, is characterized in that: voltage-stabiliser tube or triode or optocoupler or integrated circuit replacement for described comparator.
9. high-power single inversion stud welding machine according to claim 6, is characterized in that: Pulse by Pulse overcurrent protection signal is connected on the waveform arithmetic unit of inversion pulse-generating circuit; Down pulse guard signal is connected on the pulse-off pin of inversion pulse-generating circuit.
10. high-power single inversion stud welding machine according to claim 1, is characterized in that: described high frequency transformer has the same specification magnetic core of several merging, and each secondary winding is formed by the enamelled wire plying of equal number root.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201420340549.0U CN203933438U (en) | 2014-06-24 | 2014-06-24 | A kind of high-power single inversion stud welding machine |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201420340549.0U CN203933438U (en) | 2014-06-24 | 2014-06-24 | A kind of high-power single inversion stud welding machine |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104052326A (en) * | 2014-06-24 | 2014-09-17 | 胡长建 | High-power single inversion stud welding machine |
| CN106787832A (en) * | 2016-11-29 | 2017-05-31 | 北京北广科技股份有限公司 | A kind of radio-frequency power supply power supply circuit without Switching Power Supply |
| CN107020441A (en) * | 2017-04-24 | 2017-08-08 | 四川玛瑞焊业发展有限公司 | Multiple power supplies high intensity arc stud welding system in parallel |
-
2014
- 2014-06-24 CN CN201420340549.0U patent/CN203933438U/en not_active Withdrawn - After Issue
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104052326A (en) * | 2014-06-24 | 2014-09-17 | 胡长建 | High-power single inversion stud welding machine |
| CN106787832A (en) * | 2016-11-29 | 2017-05-31 | 北京北广科技股份有限公司 | A kind of radio-frequency power supply power supply circuit without Switching Power Supply |
| CN107020441A (en) * | 2017-04-24 | 2017-08-08 | 四川玛瑞焊业发展有限公司 | Multiple power supplies high intensity arc stud welding system in parallel |
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