CN205464723U - IGBT single tube industrial grade contravariant manual metal -arc welding machine - Google Patents
IGBT single tube industrial grade contravariant manual metal -arc welding machine Download PDFInfo
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- CN205464723U CN205464723U CN201620031866.3U CN201620031866U CN205464723U CN 205464723 U CN205464723 U CN 205464723U CN 201620031866 U CN201620031866 U CN 201620031866U CN 205464723 U CN205464723 U CN 205464723U
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Abstract
The utility model relates to a IGBT single tube industrial grade contravariant manual metal -arc welding machine, have digital display table, VRD low voltage output on the welding machine front panel and overflow overheat protection pilot lamp, electric current far away / nearly accuse adjusts and VRD change over switch welding, striking and thrust electric current regulator potentiometer, an accuse box socket far away to and just, burden output cable coupler. Have power cable junction terminal and switch, cooling fan on the rear panel, there are parts such as control panel welding machine inside, includes: three phase bridge circuit board, IGBT circuit board PCB3, control little control panel on the big board of big board, control, the control panel of fast extensive diode, between each control panel and the circuit device, according to the utility model discloses a circuit diagram relation links together, accomplishes each item control requirement, the utility model discloses the partial adjustment of some parameters of accessible and spare part forms different rated current and cyclic duration factor's product, have advantages such as low cost and reliability height.
Description
Technical field
Big electric current technical grade electric welding machine product that this utility model relates to a kind of single tube IGBT inversion, that can carry out the operations such as manual metal-arc welding under 380V three phase supply supply voltage, belongs to inverter type welder technical field.
Technical background
At present, the competition in inverter type welder product market is the fiercest, is not only embodied in the competitive advantage of price, the aspect such as circuit function and reliability of also depending greatly on welding machine.
On domestic and international market, the rated current of technical grade IGBT inversion manual arc welder is generally at 300～630A(cyclic duration factors 60%) level.Power supply is all that three-phase 380V powers.High-current output, such as the welding machine of 400～630A, utilize the carbon-point of different-diameter, carbon arc air gouging operation can be carried out with the use of air compressor machine, carbon arc air gouging pincers.
But, this type of welding machine, different circuit design, control principle is different, and the complexity that circuit board connects is different, and the reliability of its product, production process and processing technology etc. also can be entirely different.These all can affect sale and the production cost of product.This type of welding machine of such as on market some, some products are metal-oxide-semiconductor inversions, and some products are IGBT module inversions, have plenty of IGBT single-tube contravariant.No matter being any type, its circuit theory diagrams are different, and manufacturing cost etc. also can be different.How solving big electric current (such as 300～400A(cyclic duration factors 60%)) under output, the design of low cost and product reliability problem, be the technical barrier that faces of research staff.
Utility model content
The purpose of this utility model is to provide a kind of IGBT single tube technical grade inversion manual arc welder, achieve and under three-phase 380V power supply, use single tube IGBT to export 300～400A electric currents, can carry out the requirement of big electric current manual electric arc welding operation, welding machine has the advantage such as low cost and high reliability.
The most by the following technical solutions:
A kind of IGBT single tube technical grade inversion manual arc welder; control circuit plate including shell, front panel, rear board and inside; it is characterized in that: described front panel is provided with digital display meter, the output of VRD low pressure and crosses stream/overtemperature protection display lamp, remote/near control regulation of electric current and VRD permutator, welding striking and push current regulator potentiometer, remote control box socket, and positive and negative output cable bonder；Feed cable is had to connect terminal and on and off switch, cooling fan on rear board；Internal control circuit plate includes three phase rectifier bridge circuit cards, IGBT circuit board, controls big plate, the little panel controlling on big plate, the panel of fast extensive diode, and between each panel and circuit board, electrical relation links together.
Described control circuit plate includes that the single tube IGBT in power supply input switch, BR1 three-phase commutation bridge, the buffer inductance L1 that powers on, filter capacitor C2, semi-bridge inversion main circuit controls PCB3 plate and brachium pontis electric capacity C1, inversion main transformer T1, fast recovery diode group D1 and D2, output current filtering inductance L2, inversion primary current detect the inverter main circuit part that transformer IFB1, output current detector LEM1 collectively constitute；Wherein filter capacitor C2, single tube IGBT control PCB3 plate and brachium pontis electric capacity C1, inversion main transformer T1, fast recovery diode group D1 and D2, output current filtering inductance L2, amperometric LEM1 constitute semi-bridge inversion control circuit.
The parts installed on this utility model welding machine front panel mainly have: have digital display meter on the front panel of welding machine, can show electric current.Also have the output of VRD(low pressure) display lamp, (cross stream and overheated) protection display lamp (yellow), REM be remote/closely control permutator, the output of VRD(low no-load voltage) permutator, welding current regulator potentiometer, striking electric current regulator potentiometer, push current regulator potentiometer, (electric current) far control box socket, and positive and negative polarity output welding cable bonder or output snap joint holder assembly.The output cable bonder of positive and negative electrode or output snap joint holder assembly are for connecting electrode holders welding cable and workpiece clamp welding cable respectively.Polarity (workpiece connects and the most still connects negative polarity output) during connection can determine according to the requirement of the kind of welding rod or welding procedure.Whether (cross stream or overheated) protection display lamp (yellow) is used for indicating overheated or over-current state to occur.Such as, when internal components temperature is too high, exceedes the operating temperature of temperature relay, under the effect of control circuit, on the one hand this display lamp can be made to light.On the other hand, welding machine can be made to stop welding or output.In the case of welding machine does not exports, the cooling effect of blower fan can make the temperature of device reduce.When being reduced to the recovery action temperature of thermal protector, thermal protector recovers, and welding machine superheating phenomenon eliminates.This display lamp extinguishes.Welding machine can weld again；When control circuit generation over-current phenomenon avoidance, this display lamp also can be lighted.Control circuit makes welding machine stop welding or output.Until over-current phenomenon avoidance eliminates, this display lamp extinguishes.Welding machine can weld again.Electric current regulator potentiometer is used for carrying out exporting electric current regulation；Ammeter is then used for showing current parameters；VRD permutator is then energized for welding machine when not working, the conversion and control of output no-load voltage.When needs low no-load voltage exports, carry out selecting to realize by this switch.Under low no-load voltage, VRD display lamp is lighted, and output no-load voltage is tens volts.Safer to operator.When not selecting low no-load voltage to export, the output no-load voltage of welding machine is about 75V.Although this value is more much higher than low no-load voltage, but, it is also fully consistent with the use requirement of electric welding machine national safety standard；REM remote/near control permutator mainly cooperation (electric current) is far controlled box (being connected to the far control box socket of (electric current) below welding machine front panel by its plug) and is carried out remote welding current regulation.Nearly control, it is simply that refer to that welding machine faceplate rheostat controls.
The parts installed on this utility model welding machine rear board mainly have: three phase supply feed cable connects terminal and on and off switch, ground protection terminal, cooling fan section.Power line connects terminal and receives power supply grid by service cable.On and off switch controls the on-off of welding machine electric power.Cooling fan is positioned at the rear portion of welding machine, and the cold wind air inlet from welding machine case rear board rear portion enters.Some heater members within butt welding machine or parts, as IGBT and Heat Sink A heat sink, fast recovery diode and radiator etc. carry out forced air cooling, make them preferably be cooled down, to ensure the reliability that welding machine control circuit works.
This utility model welding machine requiring different current classes and cyclic duration factor, can pass through partial parameters and the adjustment of parts, forms difference output rated current and the product of cyclic duration factor, makes product seriation.Such as, 1) type to 300A output electric current, filter capacitor uses 100 μ F/800VDC；Do not use input inductance；On and off switch uses the air switch of 40A grade；Three-phase commutation bridge uses the single-phase rectification bridge of three 35A/1000V, i.e. the rectifier bridge composition of three small area analysis grades；Brachium pontis electric capacity in semi-bridge inversion main circuit uses the electric capacity of 2 × 10 μ F/400V；IGBT uses 4 40A/1200V's, is divided into two groups, often group 2；Inversion output rectifying part, uses the fast recovery diode device of 8 60A/300V.2) 350A and 400A exports the type of electric current, and filter capacitor uses the electrochemical capacitor of two 2200 μ F/400VDC；Use input inductance；On and off switch uses the air switch of 60A current class, and current level is high；Three-phase commutation bridge uses the three-phase commutation bridge composition of a 50A/1600V；Brachium pontis electric capacity in semi-bridge inversion main circuit uses the electric capacity of 2 × 16 μ F/400V；IGBT uses 8 40A/1200V's, is divided into two groups, often group 4；Inversion output rectifying part, uses the fast recovery diode device of 2 100A/400V.It addition, coordinate the heat sink size changing IGBT device to change inversion main transformer and the specification of output filter reactor and parameter etc., can easily form the series of products of different size.Such as 300A/32V(60% cyclic duration factor), 400A/36V(60% cyclic duration factor) etc. multiple current class and the product of specifications and models.Certainly, these changes, it is therefore an objective to make the cost of manufacture of product match with the specifications parameter of corresponding machine and performance indications.So, the welding machine of every kind of specifications and models could realize optimized cost control.This just improves the market competitiveness of institute's development.
This utility model devises new welding machine control circuit, achieve and under three-phase 380V power supply, use single tube IGBT to export 300～400A(cyclic duration factors 60%) electric current, the requirement of big electric current manual electric arc welding (400A type also can carry out carbon arc air gouging) operation can be carried out, its good circuit and structure design thereof are also advantage places of the present utility model, are also to meet efficiently and low-cost production, high reliability, the important leverage of manufacturing technology advance.The circuit theory of this utility model welding machine is designed with the unique distinction of oneself.The content of this utility model patent application protection is that circuit and the structure design protecting this welding machine.
Accompanying drawing explanation
Accompanying drawing 1 is the control circuit theory diagram of this utility model example welding machine；
Accompanying drawing 2 is the three-phase commutation bridge board design layout of this utility model small area analysis type welding machine；
Accompanying drawing 3 is the IGBT board design layout of this utility model small area analysis type welding machine；
Accompanying drawing 4 is the IGBT board design layout of this utility model big electric current type welding machine；
Accompanying drawing 5 is the panel layout of the fast extensive diode assembly of this utility model small area analysis type welding machine；
Accompanying drawing 6 is the panel layout of the fast extensive diode assembly of this utility model big electric current type welding machine；
Accompanying drawing 7 is the control big plate layout figure of this utility model welding machine；
Accompanying drawing 8 is the little panel layout figure that this utility model welding machine controls on big plate；
Accompanying drawing 9 is that this utility model welding machine controls the circuit theory diagrams of little panel on big plate；
Accompanying drawing 10 is the circuit theory diagrams that this utility model welding machine controls big plate.
Detailed description of the invention
A kind of IGBT single tube technical grade inversion manual arc welder, the key component of welding machine includes:
1) housing portion；Parts mainly have: handle, casing and the part such as base plate, leg.
2) front-facing portion；The parts installed mainly have: digital display meter, can show electric current.Also having the output of VRD(low pressure) display lamp, (cross stream and overheated) protection display lamp (yellow), REM be remote/closely control permutator, VRD permutator, welding current regulator potentiometer, striking electric current regulator potentiometer, push current regulator potentiometer, (electric current) far control box socket, and positive and negative polarity output welding cable bonder or output snap joint holder assembly.The output cable bonder of positive and negative electrode or output snap joint holder assembly are for connecting electrode holders welding cable and workpiece clamp welding cable respectively.Polarity (workpiece connects and the most still connects negative polarity output) during connection can determine according to the requirement of the kind of welding rod or welding procedure.Whether (cross stream or overheated) protection display lamp (yellow) is used for indicating overheated or over-current state to occur.Such as, when internal components temperature is too high, exceedes the operating temperature of temperature relay, under the effect of control circuit, on the one hand this display lamp can be made to light.On the other hand, welding machine can be made to stop welding or output.In the case of welding machine does not exports, the cooling effect of blower fan can make the temperature of device reduce.When being reduced to the recovery action temperature of thermal protector, thermal protector recovers, and welding machine superheating phenomenon eliminates.This display lamp extinguishes.Welding machine can weld again；When control circuit generation over-current phenomenon avoidance, this display lamp also can be lighted.Control circuit makes welding machine stop welding or output.Until over-current phenomenon avoidance eliminates, this display lamp extinguishes.Welding machine can weld again.Electric current regulator potentiometer is used for carrying out exporting electric current regulation；Ammeter is then used for showing current parameters；VRD permutator is then energized for welding machine when not working, the conversion and control of output no-load voltage.When needs low no-load voltage exports, carry out selecting to realize by this switch.Under low no-load voltage, VRD display lamp is lighted, and output no-load voltage is tens volts.Safer to operator.When not selecting low no-load voltage to export, the output no-load voltage of welding machine is about 75V.Although this value is more much higher than low no-load voltage, but, it is also fully consistent with the use requirement of electric welding machine national safety standard；REM remote/near control permutator mainly cooperation (electric current) is far controlled box (being connected to the far control box socket of (electric current) below welding machine front panel by its plug) and is carried out remote welding current regulation.Nearly control, it is simply that refer to that welding machine faceplate rheostat controls.
3) rear board part；The parts installed mainly have: three phase supply feed cable connects terminal and on and off switch, ground protection terminal, cooling fan section.Power line connects terminal and receives power supply grid by service cable.On and off switch controls the on-off of welding machine electric power.Cooling fan is positioned at the rear portion of welding machine, and the cold wind air inlet from welding machine case rear board rear portion enters.Some heater members within butt welding machine or parts, as IGBT and Heat Sink A heat sink, fast recovery diode and radiator etc. carry out forced air cooling, make them preferably be cooled down, to ensure the reliability that welder circuit works.
4) panel part；Including: three phase rectifier bridge circuit cards (small area analysis type, such as 300A and following type, has this circuit board)；IGBT circuit board PCB3(big electric current type, such as 350A and 400A type, this circuit board is different with the board design of small area analysis type.Because the IGBT quantity used is different, therefore PCB design is the most different)；Control big plate, the little panel controlling on big plate, (this circuit board of small area analysis type is different from big electric current type for the panel of fast recovery diode assembly.Because, the fast recovery diode device difference that two kinds of types are used).Between each panel circuit, link together according to circuit theory diagrams relation of the present utility model.Complete every control requirement of electric welding machine.
The operation principle of this utility model welder circuit is summarized as follows:
As shown in Figure 1, the single tube IGBT in power supply input switch, BR1 three-phase commutation bridge, the buffer inductance L1 that powers on, filter capacitor C2, semi-bridge inversion main circuit controls PCB3 plate and brachium pontis electric capacity C1, inversion main transformer T1, fast recovery diode group D1 and D2, output current filtering inductance L2, inversion primary current detection transformer IFB1, output current detector LEM1 etc. collectively constitute inverter main circuit part.In this utility model circuit, filter capacitor C2, single tube IGBT control PCB3 plate and brachium pontis electric capacity C1, inversion main transformer T1, fast recovery diode group D1 and D2, output current filtering inductance L2, amperometric LEM1 etc. form typical semi-bridge inversion control circuit.The major function of inverter main circuit and control circuit is: 1) input current powers on dash-control；2) rectification of input AC, filtering control；3) high voltage direct current of dc bus is converted to intermediate frequency (tens KHz) alternating current by IGBT half-bridge inversion circuit；4) inversion primary current detection transformer IFB1 is for detecting the size of current that inversion main transformer is primary, it is achieved inversion primary or bus cross the feedback control of stream；5) T1 inversion main transformer realizes the conversion of voltage step-down and High-current output；6) D1 and D2 fast recovery diode group is then transformed to unidirectional current the medium frequency alternating current of contravariant transformer output, it is achieved the control to welding output；7) welding current waveform exported due to inversion control is pulsation, is unfavorable for stablizing of welding process, therefore, uses output inductor L2 to carry out current filtering.So, the current waveform of output will become stable, is conducive to obtaining high-quality weld seam；8) output current detector LEM1 is for detecting the size of current of output, it is achieved the negative feedback control of output electric current；Finally, OUT+ positive polarity output terminal and OUT-negative polarity outfan DC voltage and electric current are exported.C3 and the C4 electric capacity that outfan connects respectively is anti-interference capacitor, to ensure that controlling loop is not affected by the interference signal from welding circuit.Below in conjunction with the control circuit schematic diagram of various piece, relevant circuit operation principle is illustrated:
In accompanying drawing 1, three-phase 380V communication power supply is inputted to inverter main circuit by the on and off switch K1 on welding machine rear board.After BR1 three-phase commutation bridge rectification, C2 filtering, as the direct-current input power supplying of semi-bridge inversion control circuit.
In accompanying drawing 1, the circuit of this part of L1 and C2 is referred to as power on buffering and power factor improvement control circuit.Use this utility model control circuit, the welding machine to big electric current (such as 350A and 400A), be provided with the circuit of this part.This partial circuit, is on the one hand to prevent on and off switch from connecting moment, owing to not having voltage on filtering C2 electric capacity, brachium pontis electric capacity C1, is equivalent to short circuit, can form bigger surge current, burn out on and off switch.And the effect of the buffering that powers on be through in circuit going here and there (connection) enter to input inductance L1 and carry out limit inrush currents.On the other hand, coordinating the capacitance size of filter capacitor C2, the circuit of this part may also operate as input waveform correction, improves the effect of welder power factor.(about how improving the problem of power factor (PF), reader can consult other relevant research paper and understand.Here, in view of the relation of length, the most reinflated repeat) but, the welding machine to small area analysis (such as 300A), use this utility model control circuit, do not use L1 inductance, therefore there is no the circuit of this part.This mainly considers that the factors such as welding machine cost are removed.
Seeing accompanying drawing 1, T2, for controlling transformator, is a part of power circuit.Power pack is connected to the A1 interface of PCB1.Its effect is that the DC power supply circuit part on PCB1 circuit board provides double 15VAC and 27V alternating current power supply.Make DC power supply circuit produce+5V ,+12V ,-12V ,+24V supply voltage, supply other control circuit work；FAN1 is cooling fan.It is arranged on the rear board of welding machine.The air inlet of cold wind plate from behind enters.Some heater members within butt welding machine or parts, as IGBT and Heat Sink A heat sink, fast recovery diode and radiator etc. carry out forced air cooling, make device preferably be cooled down, to ensure the reliability that welder circuit works；DT1 is current digital display table.It is arranged on the front panel of welding machine.For showing size of current.Display is attached partially to the A5 interface of PCB1.The power supply of ammeter is+5V.Display numerical value is determined by the signal magnitude of SC；The current signal that output current detector LEM1 detects is connected to the A7 interface of PCB1.Negative feedback control signal as output electric current.Output voltage feedback signal between outfan is then connected to the A12 interface of PCB1；Inversion main transformer primary current high low signal that IFB1 transformer detects and the heat alarm of temperature relay ST1, then be connected to the A8 interface of PCB1.Realize inversion primary respectively or bus crosses the feedback control of stream and the overtemperature protection control of power device；The pwm pulse width control signal of PCB3 plate IGBT is exported by the A9 interface of PCB1.Control break-make or the reversals of CB3 plate IGBT.It is controlled by other control circuit on PCB1.
In accompanying drawing 1, A2 interface is connected to remote/near control permutator K2 of panel hot striking arc current regulator potentiometer VR1 and REM；A3 interface is connected to panel welding current regulator potentiometer VR2 and push current regulator potentiometer VR3；A4 interface be connected to panel overheated/cross stream display lamp LED1 and VRD functional indicator light LED2, and VRD(low no-load voltage output) permutator K1；A6 interface is the connection interface far controlling welding current regulator potentiometer.
Accompanying drawing 2 is the three-phase commutation bridge board design layout of this utility model small area analysis type welding machine.In accompanying drawing 2, AC1～AC3 is the binding post of three-phase 380VAC communication power supply.V1～V3 is three single-phase rectification bridges, by circuit board and some of connecting line, constitutes a three phase full wave rectification bridge.DC-and DC+ is respectively negative polarity and positive polarity output terminal of rectifier bridge.Be connectable to rectifier bridge BR1(in inverter main circuit by terminal connecting line and see accompanying drawing 1) rear class dc bus two ends.
Accompanying drawing 3 is the IGBT board design layout of this utility model small area analysis type welding machine.Namely in accompanying drawing 1, the single tube IGBT in semi-bridge inversion main circuit controls PCB3 plate part.In accompanying drawing 3, Q1～Q4 is 4 single tube IGBT.It is divided into upper and lower brachium pontis IGBT switches set.Often group switch brachium pontis is by 2 IGBT parallel connections, forms the brachium pontis switch in a semi-bridge inversion main circuit.With the part that brachium pontis electric capacity C1, inversion main transformer etc. collectively constitute semi-bridge inversion main circuit.In accompanying drawing 3, the also driving control line plug A1 of IGBT；D1～D4, E1～E2, R1～R2, R3～R4, R7～R8, C2～C3, C6 etc. composition IGBT drive part circuit, and other resistance, electric capacity composition protection circuit and binding post (N, P etc.).
Accompanying drawing 4 is the IGBT board design layout of this utility model big electric current type welding machine.Also it is that in accompanying drawing 1, the single tube IGBT in semi-bridge inversion main circuit controls PCB3 plate part.In accompanying drawing 4, Q1～Q8 is 8 single tube IGBT.It is divided into upper and lower brachium pontis IGBT switches set.Often group switch brachium pontis is by 4 IGBT parallel connections, forms the brachium pontis switch in a semi-bridge inversion main circuit.With the part that brachium pontis electric capacity C1, inversion main transformer etc. collectively constitute semi-bridge inversion main circuit.In accompanying drawing 4, the also driving control line plug X14 of IGBT；The IGBT drive part circuit of the composition such as D25～D28, E15～E16, R58～R69, C42～C43, and the protection circuit of the composition such as other electric capacity and binding post (N, P etc.).Smaller for output electric current, but welding machine bigger than small area analysis type again, still use the IGBT circuit board of this part, but, the quantity of IGBT can reduce two.Often group switch brachium pontis is composed in parallel by 3 IGBT.
Accompanying drawing 5 is the panel layout of the fast extensive diode assembly of this utility model small area analysis type welding machine.In accompanying drawing 5, D29～D30, D33～D34 are fast recovery diode.Be equivalent to D1 and the D2 part in accompanying drawing 1.The parts such as they secondary with inversion main transformer, carry out circuit connection according to the accompanying drawing 1 wiring relation of welding machine, complete inversion output rectification and control.Electric capacity C1 on circuit board and resistance R1 series connection, and it is connected to D29～D30 fast recovery diode.Realize the resistance-capacitance absorption to D29～D30 fast recovery diode or overvoltage protection.Prevent peak voltage from damaging D29～D30 fast recovery diode.Electric capacity C2 on circuit board and the effect of resistance R2, similar, it is achieved resistance-capacitance absorption or the overvoltage protection to D33～D34 fast recovery diode.J1 and J2 is binding post, it is simple to be attached with other circuit part.
Accompanying drawing 6 is the panel layout of the fast extensive diode assembly of this utility model big electric current type welding machine.Big electric current type welding machine, its fast recovery diode uses the device of modular.Therefore accompanying drawing 6 resistance-capacitance absorption that actually fast recovery diode module uses or overvoltage protection.Two big holes on circuit board, with the bolt hole of module, are attached by bolt.R1～R3 is in parallel, and C1 capacitances in series, and is connected to the two ends of fast recovery diode module device.Realize the resistance-capacitance absorption to fast recovery diode module device or overvoltage protection.Prevent peak voltage from damaging fast recovery diode.R4～R6 is also in parallel, and C2 capacitances in series, and is connected to the two ends of recovery diode device in another quick module.Its effect with R1～R3, C1 similar.This partial circuit plate has two pieces, and each module configures one piece.
Accompanying drawing 7 is the control big plate layout figure of this utility model welding machine.Accompanying drawing 8 is the little panel layout figure that this utility model welding machine controls on big plate.Accompanying drawing 9 is that this utility model welding machine controls the circuit theory diagrams of little panel on big plate.Accompanying drawing 10 is the circuit theory diagrams that this utility model welding machine controls big plate.
See accompanying drawing 10, control the power supply part of transformator, the most double 15VAC and 27V alternating current power supplys from T2, be connected to A1 interface.In accompanying drawing 10, mid portion, U3 is LM317 manostat, the device of its periphery, forms+24V mu balanced circuit；U5 is LM7805 manostat, the device of its periphery, forms+5V mu balanced circuit；U6 is LM7812 manostat, the device of its periphery, forms+12V mu balanced circuit；U1 is LM7912 manostat, the device of its periphery, forms-12V mu balanced circuit.DC power supply circuit produces+5V ,+12V ,-12V ,+24V supply voltage, supplies other control circuit work.
Seeing accompanying drawing 10, A5 interface connects ammeter part.I.e. DT1 part in accompanying drawing 1.The size changing SC signal can change the numerical value that ammeter shows.RT4 is that video data corrects trimmer potentiometer.A6 interface is the connection socket far controlling potentiometer.When in socket, connection has the potentiometer that remote electric current controls, the remote control/machine control coordinating A2 interface (is exactly far control/closely to control." closely " refers to that welding machine faceplate rheostat controls；" far " refers to the remote control mode controlling electric current damper box) switch, welding machine output current regulation control can be realized.The W1 potentiometer that A2 interface connects, it is simply that the VR1 potentiometer in accompanying drawing 1, it is achieved hot striking arc current regulates.The W2 potentiometer that A3 mouth connects, it is simply that the VR2 potentiometer in accompanying drawing 1, it is achieved welding output electric current regulation.The W3 potentiometer that A3 mouth connects, it is simply that the VR3 potentiometer in accompanying drawing 1, it is achieved push current regulates.According to circuit theory, A2-5(WO) signal end be actually welding machine output electric current given Ug signal end.RT3 is the correcting potential device of output size of current.
As shown in accompanying drawing 10 upper left circuit, T1 is that the pwm pulse of IGBT in inverter main circuit drives isolating transformer.In accompanying drawing 9, owing to 11 feet and the 14 foot output pwm signals of U2 chip drive power little, therefore needing through Q1～Q4, stabilivolt Z1～Z2, electric capacity C1～C2 and C8, resistance R2, R3, R5, R6, M1～the M4 field effect transistor in accompanying drawing 10, R1 and R28, electric capacity C1 and C2, T1 drive the driving control circuit of the device compositions such as isolating transformer to carry out Pulse Power Magnification and isolation.Isolating transformer is driven to go to control the on-off duty of upper and lower two groups of IGBT pipes of brachium pontis in semi-bridge inversion main circuit finally by T1.From circuit theory diagrams it can be seen that driving circuit section, the form of the driving control circuit of two-way IGBT is substantially coincident.
In accompanying drawing 9,11 feet of U2 chip and 14 feet output control signal are two groups of PWM square-wave pulse signals.The frequency of its square wave is fixing, has tens KHz.Resistance and capacitance parameter (such as R4, R7 and electric capacity C7) that it is connected by RT, CT foot of this chip determine.Two prescription wave pulse signals have a regular time poor in time, and specialty is also referred to as Dead Time.It is one of important parameter ensureing IGBT two groups switch alternation.This time is that peripheral components (such as R4, R7 and the electric capacity C7) parameter by U2 chip (SG3525) arranges and determines.As to how determine, check that the data used in connection with of U2 chip or explanation i.e. can be appreciated that.It is not repeated herein.Needing exist for explanation: in accompanying drawing 9, the pwm pulse bandwidth modulation signals that U2 chip (SG3525) exports is to determine welding machine inverter main circuit output voltage and the signal of size of current.Its pulse width by welding current Setting signal Ug(accompanying drawing 10, A2-5 end signal W0) with in the output current negative feedback signal Ufi(accompanying drawing 10 of LEM1, A7-4 end signal) together decide on.The object controlled or target are output size of current.Time unloaded, from LEM1 negative-feedback signal Ufi the least.Control circuit produces the pwm pulse signal that a dutycycle is bigger, makes two groups of IGBT pipes of upper and lower brachium pontis in semi-bridge inversion main circuit be in alternating conductive state, finally makes inverter main circuit output no-load voltage.When operator regulates the potentiometer of welding current on front panel, and when welding, control circuit detects output current signal Ufi by LEM1.It compares with welding current Setting signal Ug.Difference signal after Bi compare, in other control circuit (the mainly U7 operational amplifier CA3140 in accompanying drawing 10 etc. constitute PI(proportional+integral) output characteristics control circuit) effect under, result GV of operational amplifier U7 output goes to control U2(SG3525 in accompanying drawing 9) the output pwm pulse width of PWM chip or certain frequency and the signal of dutycycle.This signal pulse driving circuit by IGBT, the final output electric current determining welding machine inverter main circuit and voltage swing, it is achieved the accurate control of output current parameters.And to make the output characteristics of welding machine be the dropping characteristic dragged outside constant current band.Say further, when welding current Setting signal Ug is constant, the Current Negative Three-Point Capacitance Ufi signal detected along with welding machine LEM1 increases, and after reaching given setting value, the difference of welding current Setting signal Ug and LEM1 current feedback control signal Ufi can increase with electric current and reduce, after being controlled by the PI of U7 circuit, making the pulse width of welding machine output PWM chip or dutycycle reduce, the output voltage of welding machine reduces.This process, the most so-called Current cut-off negative feedback controls, the feedback control i.e. only just worked after electric current reaches the setting value of welding current potentiometer.Hereafter, along with the small increase of output electric current, output voltage can reduce a lot.When voltage drops to below 16V, along with the reduction of voltage, control circuit can make the pulse width of welding machine output PWM chip or dutycycle increase, and makes welding current increase according to the parameter set, ultimately forms the dropping characteristic dragged outside constant current band.When welding current Setting signal Ug changes, the setting value of Current cut-off negative feedback is different, but other control process is similar.So, between Ugmin minimum and maximum Ugmax that potentiometer sets, so that it may obtain without several negative characteristic curves.Such control output characteristics is also to meet the basic demand of manual arc welding.
See that, in accompanying drawing 9 and accompanying drawing 10, A9 interface is connected to the PCB3 plate in accompanying drawing 1.U2(SG3525) the control circuit part such as inversion PWM and IGBT driving, isolating transformer is driven by T1, it exports G1 and E1(or B1 and E1), G2 and E2(or B2 and E2) be respectively two groups of pwm pulse signals, go to control the on-off duty of upper and lower two groups of IGBT pipes of brachium pontis in semi-bridge inversion main circuit.U2(SG3525) pulse width of the PWM output signal of chip is controlled by Ug input Setting signal and LEM1 current negative feedback signal Ufi.Export with or without pwm signal, then depend on that the primary inversion bus current of IFB1 output crosses stream feedback signal and the control signal of the temperature protection relay from ST1.In accompanying drawing 1, IFB1 is an amperometric, can detect the size of current on inverter main circuit dc bus, the namely primary current signal of inversion main transformer T1.The primary of IFB1 only has 1 circle, and secondary generally has 200 circles.It is connected to left side A8-1 and A8-2 terminal in accompanying drawing 10.The secondary output of IFB1, after D23～D26 rectification and resistance R29, R41～R42 and electric capacity C24, stabilivolt Z4 process, is crossed stream feedback signal by the primary inversion bus current of OA output.This signal goes to control the Q6 SCR IGCT in accompanying drawing 9 or controllable silicon, finally controls U2(SG3525) 10 foot level states.This member control circuit mainly checks whether inverter main circuit occurs over-current phenomenon avoidance, and controls accordingly.If there is cross stream, the Z4 in accompanying drawing 9 can puncture, Q6 SCR turn on thyristors, U2(SG3525) 10 foot level be pulled to high level.The pwm signal of U2 chip 11 and 14 foot output is closed, and the drive control signal of welding machine semi-bridge inversion main circuit IGBT is closed, and welding machine cuts out output.Meanwhile, cross stream/overheated indication LED light emitting diode and also can light, carry out stream instruction.
In accompanying drawing 1, ST1 is the temperature relay of open type.It is connected between A8-3 and A8-4 in accompanying drawing 10.And temperature relay is close on the aluminium alloy heat radiator of IGBT or D1～D2 output fast recovery diode group.When temperature relay action, show main power device generation superheating phenomenon.Now, in accompanying drawing 10, OT signal end is pulled to relatively low level by D10.Simultaneously, the circuit formed by operational amplifier U1A and U1B in accompanying drawing 9 and peripheral components thereof, U2(SG3525) 8 foot level also can be pulled to low level, the pwm signal of U2 chip 11 and 14 foot output is closed, the drive control signal of welding machine inverter main circuit IGBT is closed, and welding machine cuts out output.Prevent welding machine from burning out because of overheated.Meanwhile, the stream/overheated LED excessively on welding machine front panel is luminous, carries out stream/overheated instruction.Afterwards, under the effect of cooling blower, after dropping to a certain degree at a temperature of aluminium alloy heat radiator, the superheating phenomenon within welding machine eliminates, and when thermal protector returns to normally open, control circuit just can continue to put out pwm control signal.Cross stream/overheating indicator lamp (yellow) to extinguish simultaneously.Welding machine can export again again.
In accompanying drawing 10, the U+ of A12 interface is welding machine output voltage sampled signal.In A4 interface, VRD is low no-load voltage output selector switch.During non-selected VRD function, the floating voltage that welding machine output is higher.It is usually between 50～90VDC.When selecting VRD function, VRD switch closes, and connects+24V power supply.Now, the lumination of light emitting diode in U4 photoelectrical coupler, its internal triode ON.Meanwhile, Z5 stabilivolt punctures, voltage stabilizing, and the LED light of VRD is lighted.By the clamping action of D12, OT signal end level is made to be pulled to low level.As previously described, when this signal end is low level, 2(SG3525) 8 foot level also can be pulled to low level, the pwm signal of U2 chip 11 and 14 foot output is closed, and the drive control signal of welding machine inverter main circuit IGBT is closed, and welding machine cuts out output.When welding rod and absorption surface prepare to weld, U+ voltage sample point and circuit " " contact, D5 diode can turn on.There will be Z5 stabilivolt will not puncture, the situation of voltage stabilizing.Now, OT signal end level can become again high level, U2 chip 11 and 14 foot output pwm signal, and the drive control signal of welding machine inverter main circuit IGBT produces, makes welding machine output voltage and electric current, it is achieved striking and welding.The when of welding, U+ current potential is higher, and D5 diode can end, be not turned on.Z5 stabilivolt can puncture again, voltage stabilizing.The most repeatedly, welding machine output VRD low no-load voltage or the conversion and control of welding process are finally realized.
Additionally, this utility model welding machine that different current classes and cyclic duration factor are required, parts specifications parameter that can be a small amount of by adjusting circuit, form difference output rated current and the product of cyclic duration factor, make product seriation.Such as, 1) type to 300A output electric current, filter capacitor C2 uses the CBB16 electric capacity of 100 μ F/800VDC；L1 is not used to input inductance；On and off switch K1 uses the air switch of 40A grade；BR1 three-phase commutation bridge uses the single-phase rectification bridge of three 35A/1000V, i.e. the rectifier bridge composition of three small area analysis grades；Brachium pontis electric capacity C1 in semi-bridge inversion main circuit uses the electric capacity of 2 × 10 μ F/400V；IGBT uses 4 40A/1200V's, is divided into two groups, often group 2；Inversion output rectifying part, uses the fast recovery diode device of 8 60A/300V.2) 350A and 400A exports the type of electric current, and filter capacitor C2 uses the electrochemical capacitor of two 2200 μ F/400VDC；L1 is used to input inductance；On and off switch K1 uses the air switch of 60A current class, and current level is high；BR1 three-phase commutation bridge uses the three-phase commutation bridge composition of a 50A/1600V；Brachium pontis electric capacity C1 in semi-bridge inversion main circuit uses the electric capacity of 2 × 16 μ F/400V；IGBT uses 8 40A/1200V's, is divided into two groups, often group 4；Inversion output rectifying part, uses the fast recovery diode device of 2 100A/400V.It addition, coordinate the heat sink size changing IGBT device to change inversion main transformer and the specification of output filter reactor and parameter etc., can easily form the series of products of different size.Such as 300A/32V(60% cyclic duration factor), 400A/36V(60% cyclic duration factor) etc. multiple current class and the product of specifications and models.Big electric current manual electric arc welding (400A type also can carry out carbon arc air gouging) operation can be carried out.These changes, it is therefore an objective to make the cost of manufacture of product match with the specifications parameter of corresponding machine and performance indications.So, the welding machine of every kind of specifications and models could realize optimized cost control.This just improves the market competitiveness of institute's development.
Be above each circuit part of this utility model and welding method briefly controls procedure declaration.More complicated because illustrating circuit theory.Below some main method, thought and the result of control are only given.But give detailed circuit theory diagrams due to this utility model, therefore for having the people of circuit reading ability (or possessing interlock circuit knowledge), can understand completely.Circuit diagram is also a kind of noiseless language.But for not having the people of circuit reading ability (or not possessing interlock circuit knowledge), even if that explains is the most, they are also elusive.In view of the relation of length, patent specification can only illustrate main part, so that patent specification reader better understood when operation principle and the process being correlated with.
Visible by described above, this utility model circuit design is novel, has mentality of designing and the method for oneself uniqueness.Can realize under three-phase 380V power supply, using single tube IGBT to export 300～400A(cyclic duration factors 60%) electric current, the requirement of big electric current manual electric arc welding (400A type also can carry out carbon arc air gouging) operation can be carried out.Welding machine has the advantage such as low cost and high reliability.The circuit theory of this utility model manual arc welder is designed with the unique distinction of oneself.This is also the basic goal place of application this patent protection.
Above content is to combine concrete machine structure and circuit board and control the detailed description that this utility model is made by function, it is impossible to assert that of the present utility model being embodied as is only limited to these explanations.For the others skilled in the art of technical field described in the utility model, without departing from the inventive concept of the premise, it is also possible to make some other deduction and conversion, these all should be considered as belonging to this utility model protection category.
Claims (2)
1. an IGBT single tube technical grade inversion manual arc welder; control circuit plate including shell, front panel, rear board and inside; it is characterized in that: described front panel is provided with digital display meter, the output of VRD low pressure and crosses stream/overtemperature protection display lamp, remote/near control regulation of electric current and VRD permutator, welding striking and push current regulator potentiometer, remote control box socket, and positive and negative output cable bonder；Feed cable is had to connect terminal and on and off switch, cooling fan on rear board；Internal control circuit plate includes three phase rectifier bridge circuit cards, IGBT circuit board, controls big plate, the little panel controlling on big plate, the panel of fast extensive diode, and between each panel and circuit board, electrical relation links together.
2. a kind of IGBT single tube technical grade inversion manual arc welder as claimed in claim 1, it is characterised in that: described control circuit plate includes that the single tube IGBT in power supply input switch, BR1 three-phase commutation bridge, the buffer inductance L1 that powers on, filter capacitor C2, semi-bridge inversion main circuit controls PCB3 plate and brachium pontis electric capacity C1, inversion main transformer T1, fast recovery diode group D1 and D2, output current filtering inductance L2, inversion primary current detect the inverter main circuit part that transformer IFB1, output current detector LEM1 collectively constitute；Wherein filter capacitor C2, single tube IGBT control PCB3 plate and brachium pontis electric capacity C1, inversion main transformer T1, fast recovery diode group D1 and D2, output current filtering inductance L2, amperometric LEM1 constitute semi-bridge inversion control circuit.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113579420A (en) * | 2021-06-15 | 2021-11-02 | 宁波欧罗巴科技有限公司 | Argon arc welding machine control circuit through IGBT contravariant |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113579420A (en) * | 2021-06-15 | 2021-11-02 | 宁波欧罗巴科技有限公司 | Argon arc welding machine control circuit through IGBT contravariant |
| CN113579420B (en) * | 2021-06-15 | 2023-12-12 | 宁波欧罗巴科技有限公司 | Argon arc welding machine control circuit through IGBT contravariant |
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