CN206605137U - A kind of general IGBT single-tube contravariant manual arc welders of whole power - Google Patents
A kind of general IGBT single-tube contravariant manual arc welders of whole power Download PDFInfo
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- CN206605137U CN206605137U CN201720305601.2U CN201720305601U CN206605137U CN 206605137 U CN206605137 U CN 206605137U CN 201720305601 U CN201720305601 U CN 201720305601U CN 206605137 U CN206605137 U CN 206605137U
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Abstract
The utility model is related to a kind of general IGBT single-tube contravariant formula manual arc welders of whole power voltage; the control board of welding machine is designed as four pieces; one piece of PCB1 power panel; one piece of PCB2 power control board; one piece of PCB3 control panel; it is mainly switching power source control circuit part on one piece of PCB4 bus protection plate circuit control panel, PCB1 control panels；PCB2 function controls plate part includes drive control circuit, output rectification circuit, supply voltage automatic identification and conversion control circuit, upper electric buffer control circuit part；It is microprocessor and its charactron, the circuit part of given value of current potentiometer composition on PCB3 control panels, and output characteristics control circuit portion；On PCB4 control panels, then mainly bus protection controls circuit part；The utility model have 220V and 380V power supplys can automatic identification and conversion and control, with very wide voltage adaptation and stronger anti-voltage ripple of power network ability.
Description
Technical field
The utility model is related to the IGBT single-tube contravariant formula manual arc welders that a kind of single-phase 220V and 380V power supplys can be used
Circuit and structure, belong to inverter type welder technical field.
Technical background
At present, the competition in plasma cutting inverter product market is very fierce, is not only embodied in the advance and advantage of technology,
In terms of the function and design that also depend greatly on welding machine.
On domestic and international market, the rated current of the dual-purpose machine of small-sized IGBT pipes Inverter Hand arc-welding is generally in 80 ~ 200A（Load
Water holdup 100 ~ 15%）Level.Power supply is typically single-phase 220V.The production that single-phase 220V and 380V power supplys can be used
Product, are commonly called as " welding machine of whole power ", or " twin voltage welding machine ".Such like product, in the market also has.But it is many this
Class product, fault rate is very high, and repair rate reaches more than 20%.Major failure point is 220V and 380V power supplys automatic identification and conversion
Control circuit work unreliable.To different products, its control circuit theory diagrams, board structure of circuit and complete machine structure design etc. are
Different.In terms of the performance of product, reliability, manufacture craft and cost, larger otherness is also had.Therefore, how
The exploitation welding machine that performance is good, reliability is high has certain technical difficulty.This is also the problem of the utility model needs solution.
Utility model content
The purpose of this utility model is to provide a kind of whole power voltage general IGBT single-tube contravariant formula manual arc welders,
Function with manual arc soldering method, its power supply is single-phase 220V or 380V；220V and 380V power supplys can automatic identification
And conversion and control, welding machine can be in 150V~260V（Correspondence access 220V power networks）, or 300V~500V（Correspondence access 380V electricity
Net）Welding is used under the conditions of supply voltage, with very wide voltage adaptation, anti-voltage ripple of power network energy stronger in other words
Power.
Following technical scheme is used to achieve the above object：
A kind of general IGBT single-tube contravariant formula manual arc welders of whole power, it is characterised in that：Including shell, rear board,
Cooling fan, front panel, output snap joint holder assembly, working power and guard mode indicator lamp, electric current output regulation current potential
Device, control board and internal connecting wire；The control board of welding machine is designed as four pieces, one piece of PCB1 power panel, one piece
On PCB2 power control boards, one piece of PCB3 control panel, one piece of PCB4 bus protection plate circuit control panel, PCB1 control panels mainly
Switching power source control circuit part；PCB2 control plate parts include IGBT and its radiator and drive control circuit, recover two soon
Output rectification circuit, supply voltage automatic identification and conversion control circuit, the upper electric cushioning control of pole pipe and its radiator composition
Circuit part；It is microprocessor and its charactron, the circuit part of given value of current potentiometer composition on PCB3 control panels, and it is defeated
Go out characteristic controling circuit part, the core of output characteristics control circuit part is 3846 pwm pulse width modulated chips and its outer
The circuit of peripheral device composition；On PCB4 control panels, then mainly bus protection controls circuit part；Above-mentioned each control panel passes through
Switch, fan, the inversion main transformer of connecting wire and welding machine are connected as an entirety, and whole control circuit is mainly in completion
Electric buffer circuit, 220V and 380V supply voltages automatic identification and conversion control circuit, inverter main circuit, switching power circuit,
IGBT drive circuit, current detecting and rectification transformating circuit, under-voltage and overtemperature protection detection and control circuit, bus protection control
System, given value of current circuit, output characteristics control circuit composition.
Described supply voltage automatic identification and conversion control circuit part, by optocoupler, triode, voltage-stabiliser tube, diode,
The resistor- capacitor composition of IGCT, relay and these device peripheries, the supply voltage inputted for automatic detection passes through
Puncturing and voltage stabilizing for voltage-stabiliser tube, makes a triode ON, and then goes to make the output stage triode ON of optocoupler；Meanwhile, make crystalline substance
Brake tube is turned on, and the IGCT controls the action of another triode and relay, is automatically switched by the actuating of relay electric
380V or 220V inputs.
Described under-voltage protection control circuit includes diode, optocoupler, resistance, triode composition, under-voltage protection control electricity
Whether road is used to detect supply voltage, lighted by the diode in optocoupler, to control whether the triode of output stage turns on,
Again by the clamping action by triode and diode, make voltage-stabiliser tube be not in puncture, the situation of voltage stabilizing, cause other one
Individual triode cut-off, while multiplication of voltage control relay is failure to actuate.
Described bus protection control circuit is by diode, voltage-stabiliser tube, triode, optocoupler and the device group of their peripheries
Into bus protection controls circuit by plug, the output end of rear class optocoupler is connected in parallel on overheat protector, different
Input voltage, different VCC bus DC voltages can be produced, controlled by detecting VCC voltages, and accordingly
The parts installed on the front panel of the utility model welding machine mainly have：Two groups of output snap joint holder assemblies, works
Make power supply indicator（White）, overheat etc. protection indicator lamp（Yellow）, electric current output regulation potentiometer, the part such as ammeter.
Guard mode indicator lamp（Yellow）Then indicate whether overheat, under-voltage condition occur.The high power device inside welding machine
Radiator temperature it is too high, more than temperature protection relay operating temperature when, control circuit in the presence of, on the one hand can make
The indicator lamp is lighted；On the other hand, welding machine can be made to stop welding or export.In the case where welding machine is not exported, the cooling of blower fan
Effect can make the temperature reduction of high power device inside welding machine.When being reduced to the recovery action temperature of temperature protection relay,
Welding machine superheating phenomenon is eliminated.Overheating indicator lamp extinguishes.Meanwhile, welding machine can be welded again.Either in 220V, or it is defeated in 380V
Enter under supply voltage, when there is under-voltage phenomenon, i.e., in access 220V power networks, and input voltage is less than 150V, or in access
380V power networks, and input voltage between 300V~260V when, the guard mode indicator lamp of welding machine（Yellow）It can light, indicate
Welding machine occurs under-voltage.After only under-voltage phenomenon is eliminated, the indicator lamp can just extinguish, and welding machine can be welded and used.Namely
Say, this welding machine can be in 150V~260V（Correspondence access 220V power networks）, or 300V~500V（Correspondence access 380V power networks）Electricity
Worked under the voltage conditions of source.From the point of view of above-mentioned data, this welding machine also has good anti-voltage ripple of power network ability simultaneously.It is welded
Input supply voltage fluctuation range workable for connecing has exceeded specified as defined in Electric welding machine standards（220V or 380V）Power supply electricity
± 10 ℅ of pressure.Certainly, the need for according to production, on the front panel of welding machine also can be set voltmeter, striking electric current and
The parts such as push current regulation potentiometer, with the function or performance of extended products.
The parts installed on the rear board of the utility model welding machine mainly have：Power switch, power supply line, cooling wind
The parts such as machine.Cold wind is carried out from the air admission hole at welding machine case rear portion.Can have some heater members or parts on circuit board
Good cooling effect.
On the circuit anti-interference measure of the utility model welding machine, mainly there is the following aspects：1）Input filter.Input
Filtered electrical routing resistance and filter capacitor composition.Mainly the interference signal from power network is filtered, reduces or reduce dry
Disturb the adverse effect that signal controls this welding machine circuit work.2）Output filtering.It is made up of filter capacitor.It can suppress in waveform
Burr is mutated or interference signal.Above-mentioned measure is ensure the welding machine product functional reliability that the utility model circuit is made one
Important prerequisite.
, can be by a small amount of on adjustment circuit plate to different current classes and the utility model welding machine of cyclic duration factor requirement
Amount of parts and specifications parameter, formed it is different output rated current and cyclic duration factor products, make product seriation.Example
Such as, the number of big electrochemical capacitor is changed；Change rectifier bridge parameter；Change the current class and heat sink size of IGBT device；Change
Become the model and parameter of fast recovery diode；Change specification and parameter of inversion main transformer and output filter reactor etc.,
The series of products of different size can easily be formed.Such as 200A/28V, 180A/27.2V, 160A/26.4V, 140A/25.6V
The product of a variety of current classes and specifications and models.Certainly, these change, it is therefore an objective to make the cost of manufacture and corresponding machine of product
Specifications parameter and performance indications match.So, the welding machine of every kind of specifications and models could realize the cost control of optimization.This is just
Improve the market competitiveness of institute's development.
The utility model welding machine, in terms of specific circuit design, employs the control circuit of maturation, is also provided with simultaneously
The measure of some circuit anti-interferences, thus ensured the reliability of welding machine work.
In addition, the utility model welding machine, according to production the need for, voltage also can be set on the front panel of welding machine
The parts such as table, striking electric current and push current regulation potentiometer, with the function or performance of extended products.
The utility model welding machine, due to having preferably with good control performance, safety and reliability, thus welding machine
Market adaptability；Its good circuit and its structure design are also advantage place of the present utility model, are also to meet efficiently and low
The advanced important leverage of cost production, high reliability, manufacturing technology.The circuit theory of the utility model welding machine, circuit board and
Complete machine structure is designed with the unique distinction of oneself；The content of the utility model patent application protection is that this welding machine of protection
Circuit and structure design.
The utility model welding machine, due to having preferably with good control performance, safety and reliability, thus welding machine
Market adaptability.Its good circuit and its structure design are also advantage place of the present utility model, are also to meet efficiently and low
The advanced important leverage of cost production, high reliability, manufacturing technology.The circuit theory of the utility model welding machine, circuit board and
Complete machine structure is designed with the unique distinction of oneself.
Brief description of the drawings
Fig. 1 is decomposition texture schematic diagram of the present utility model；
Fig. 2 is the PCB2 power amplifier board circuit theory diagrams of the utility model welding machine；
Fig. 3 is the PCB1 power panel circuit theory diagrams of the utility model welding machine；
Fig. 4 is the PCB3 control panel circuit theory diagrams of the utility model welding machine；
Fig. 5 is the PCB4 bus protection plate circuit theory diagrams of the utility model welding machine；
The title of name part is as follows in accompanying drawing：1st, screw；2nd, handle；3rd, shell, 4, PCB1 power panels；5th, IGBT and its dissipate
Hot device；6th, transformer I；7th, voltage-stablizer and its radiator；8th, resistance；9th, plastic protective box I；10th, radiator I；11st, radiator
II；12nd, electrochemical capacitor；13rd, radiator III；14th, transformer II；15th, radiator IV；16th, overheat protector；17、IGBT；
18th, rectifier bridge；19th, transformer III；20th, relay；21st, PCB2 power control boards；22nd, plastic protective box II；23rd, deep bead；
24th, rear plastic front board；25th, power switch；26th, power line；27th, fan；28th, bottom plate；29th, plastic support bar I；30th, plastics branch
Stay II；31st, PCB3 control panels；32nd, foreboard；33rd, electric current output regulation potentiometer；34th, positive polarity output snap joint；35、
Negative polarity exports snap joint；36th, preceding plastic front board；37th, inversion main transformer；38th, PCB4 bus protections plate circuit control panel.
Embodiment
As shown in figure 1, being a kind of structural representation for the IGBT inversions manual arc welder being made using the utility model, it is welded
The chief component of machine includes：
1）Casing part, including shell 3, handle 2, bottom plate 28, shell screw etc..
2）The parts installed on rear board part, rear board mainly have：Power switch 25, power line 26, power line are drawn
Do not take off, the part such as rear plastic front board 24, cooling fan 27；Power line 26 is connected to power supply grid.Power switch 25 controls welding machine
The on-off of power supply.Cooling fan 27 is located at the rear portion of welding machine, and cold wind is carried out from the air admission hole at welding machine rear portion.Left side circuit can be made
Some partial heater members or parts, such as IGBT and Heat Sink A heat sink, fast recovery diode and zero, radiator
Part is preferably cooled down.Such air channel and type of cooling design, are conducive to ensureing the reliability of welder circuit work, are also
The utility model welding machine realizes one of larger current and the major reason of high capacity water holdup.
3）Front-facing portion.The parts installed on welding machine front panel mainly have：Preceding plastic front board 36, positive polarity output are fast
Quick coupling 34, negative polarity output snap joint 35, PCB3 control panels 31, foreboard 32, working power indicator lamp（White）And heat is protected
Protect status indicator lamp（Yellow）, electric current output regulation potentiometer 33 etc. part.Two groups of output snap joint holder assemblies are used for by hand
Welding clamp cable and workpiece clamp cable are connected during arc welding respectively；Working power indicator lamp（White）Indicate power on.Protection
Status indicator lamp（Yellow）Then indicate whether overheat, under-voltage condition occur.The radiator temperature of high power device inside welding machine
It is too high, more than temperature protection relay operating temperature when, control circuit in the presence of, on the one hand can make the indicator lamp point
It is bright；On the other hand, welding machine can be made to stop welding or export.In the case where welding machine is not exported, the cooling effect of blower fan can make weldering
The temperature reduction of high power device inside machine.When being reduced to the recovery action temperature of temperature protection relay, welding machine overheat is existing
As eliminating.Overheating indicator lamp extinguishes.Meanwhile, welding machine can be welded again.Either in 220V, or in 380V input supply voltages
Under, when there is under-voltage phenomenon, i.e., in access 220V power networks, and input voltage is less than 150V, or is accessing 380V power networks, and defeated
When entering voltage between 300V~260V, the guard mode indicator lamp of welding machine（Yellow）It can light, indicate that welding machine occurs under-voltage.
After only under-voltage phenomenon is eliminated, the indicator lamp can just extinguish, and welding machine can be welded and used.That is, this welding machine can be
150V~260V（Correspondence access 220V power networks）, or 300V~500V（Correspondence access 380V power networks）Work under the conditions of supply voltage
Make.From the point of view of above-mentioned data, this welding machine also has good anti-voltage ripple of power network ability simultaneously.It welds workable input
Mains fluctuations scope has exceeded specified as defined in Electric welding machine standards（220V or 380V）± 10 ℅ of supply voltage.When
So, the need for according to production, ammeter, voltmeter, striking electric current and thrust also can be set on the front panel 32 of welding machine
The parts such as electric current regulation potentiometer, with the function or performance of extended products.
4）Control section, including PCB1 power panels 4, PCB2 power control boards 21, PCB3 control panels 31 and PCB4 buses are protected
Backplate circuit control panel 38.On these control panels, also many parts or component are specifically the visible phase of those devices
The circuit theory diagrams and circuit board element layout of pass.
Circuit board control section and the component in welding machine front and back panels, such as electric current adjust potentiometer 33, fan 27, referred to
Show lamp, power switch 25 etc., carrying out mutual circuit by some pilots connects.Between each circuit board, device or zero
Between part, according to the circuit theory diagrams relation of the utility model welding machine（See 2~accompanying drawing of accompanying drawing 5）Link together.It can meet
The circuit output Characteristics Control of manual welding method function.
Accompanying drawing 2, accompanying drawing 3, accompanying drawing 4 and accompanying drawing 5 are the circuit theory diagrams of the utility model welding machine.Welder circuit plate is designed as
Four pieces.One piece of PCB1 power panel, one piece of PCB2 power control board, one piece of PCB3 control panel, one piece of PCB4 bus protection plate circuit
Control panel.Part on PCB2 control panels, mainly include IGBT and its radiator and drive control circuit, fast recovery diode and
Output rectification circuit, supply voltage automatic identification and conversion control circuit, the upper electric buffer control circuit of the compositions such as its radiator
Deng part.On PCB3 control panels, the mainly circuit part of the composition such as microprocessor and its charactron, given value of current potentiometer,
And output characteristics control circuit part.The core of output characteristics control circuit part is 3846 pwm pulse width modulated chips
And its circuit of peripheral components composition.On PCB1 control panels, mainly switching power source control circuit part.On PCB4 control panels,
Then it is mainly bus protection control circuit part.Above-mentioned each control panel passes through connecting wire and other parts of welding machine（Such as open
Pass, fan, inversion main transformer etc.）An entirety is connected as according to circuit theory diagrams.Whole control circuit is mainly in completion
It is electric cushioning control, power input voltage automatic identification and conversion and control, rectifying and wave-filtering, inversion, output rectification, anti-interference, each straight
Flow generation, pwm pulse width adjusting, IGBT pipes drive control, the inverter circuit output of manual metal-arc welding welding method of operating voltage
Parameter（Electric current）Negative feedback control, overheat, overvoltage and under-voltage protection control etc. work.Finally in the presence of control circuit,
Automatic identification 220V or 380V supply voltage is realized, and automatic conversion is controlled, the items for meeting the control of manual metal-arc welding output characteristics will
Ask.Related functional circuit is illustrated below：
See accompanying drawing 2, inversion full-bridge main circuit is by power switch, input rectifying bridge BR1, RT1 thermistor, JDQ1A relays
Device and its contact JDQ1B, JDQ2A relay and its big electrochemical capacitor filter circuits of contact JDQ2B, EC1 ~ EC4, IGBT1 ~
IGBT4 pipes, B inversions main transformer, DD1 ~ D6 fast recovery diodes etc. are constituted.DD1 ~ DD6 fast recovery diodes constitute welding machine
Output rectification circuit.By OUT（+）Positive polarity and OUT（-）Negative polarity output exports welding current and voltage.
See accompanying drawing 2, AC1 is connected to the power supplies such as 220V or 380V, 50/60Hz with AC2 ends.Power switch connects power network
After power supply, welding machine is powered.White power supply indicator on front panel is lighted.The alternating current come from power network, before rectification, is first passed through
RT1 thermistors, after BR1 rectifier bridge rectifications, are changed into Rectified alternating current.The big electrochemical capacitors of EC1 ~ EC4 are charged, voltage
Gradually rise, eventually become relatively stable direct current VCC, then be output to late-class circuit.
See accompanying drawing 2, JDQ1A relays and its control circuit（Q7 containing triode, diode D13, voltage-stabiliser tube D, resistance R28
Deng）Electric buffer control circuit on composition.JDQ1A relays can be connected in power switch, be acted after the certain time-delay time, its contact
JDQ1B is closed or short circuit RT1 thermistors.JDQ1A pull up times lag behind power switch and closed the moment, i.e.,
JDQ1A relays are deferred action.The delay of JDQ1A relays is controlled by it circuit to realize.The big electrolysis of EC1 ~ EC4
The charging of electric capacity, first passes through RT1 thermistors, afterwards short circuit RT1 thermistors again.When filling on the big electrochemical capacitors of EC1 ~ EC4
After piezoelectric voltage is stable, the relay is just acted, its contact closure RT1 thermistors, makes the normal inversion work of the utility model welding machine
When making, high current is flowed through from the contact of relay.Such control circuit is referred to as electric buffer circuit.Mainly prevent electricity
Source switch connects moment, due to not having voltage on the big electrochemical capacitors of EC1 ~ EC4, equivalent to short circuit, can form larger surge electricity
Stream, burns out power switch.And the effect of upper electric buffer circuit, RT1 thermistors are exactly sealed in by moment of closing a floodgate, to limit wave
Gush electric current.Also, the resistance of RT1 thermistors, is to rise with its temperature and increase.Therefore, upper electric buffer circuit can rise
To preferable protective effect.
See accompanying drawing 2, EC1 ~ EC4 is big, and electrochemical capacitor plays a part of filtering.VCC direct currents supply by IGBT1 ~ IGBT4 pipe,
The bridge inverter main circuit of the composition such as B inversions main transformer and D5 ~ D9 fast recovery diodes.Its function is mainly：High straightening
Stream electricity is converted to intermediate frequency（Tens KHz）Alternating current.B contravariant transformers realize the conversion of voltage step-down and High-current output.D5~D9
Fast recovery diode is then that the medium frequency alternating current that contravariant transformer is exported is transformed to direct current.
See accompanying drawing 2, input supply voltage automatic identification and conversion control circuit are by resistance R18~R21 and R22~R27, two
Pole pipe D9~D10, voltage-stabiliser tube Z5 and Z8, optocoupler U3（Containing U3A and U3B）And U4（Containing U4A and U4B）, triode Q6 and Q8, brilliant lock
Pipe U5, relay JDQ2（Coil containing JDQ2A and its JDQ2B contacts）, the electric capacity C3~component such as C5 and EC8 composition.It is acted on
It is the supply voltage of automatic detection input, judgement belongs to 220V, or 380V.Certainly, in the range of 150V~260V
When, circuit is judged as belonging to 220V normal power voltage categories；And when in the range of 300V~500V, circuit is judged as
Belong to 380V normal power voltage categories.
See accompanying drawing 2, when the supply voltage detected belongs to 380V power supply categories, because input voltage is higher, can make steady
Pressure pipe Z5 punctures, voltage stabilizing, triode Q5 conductings, and then the U3A diodes in U3 optocouplers can light, the triode of its output stage
U3B is turned on.IGCT U5 is in the conduction state.Meanwhile, Z8 voltage-stabiliser tubes be not in puncture, the situation of voltage stabilizing, cause triode
Q8 ends, and relay JDQ2 is failure to actuate.
See accompanying drawing 2, when the supply voltage detected belongs to 220V power supply categories, because input voltage is relatively low, will not make
Voltage-stabiliser tube Z5 punctures, voltage stabilizing, and triode Q5 is not turned on, and then the U3A diodes in U3 optocouplers will not light, and the three of its output stage
Pole pipe U3B is not turned on.IGCT U5 is in cut-off state.Meanwhile, Z8 voltage-stabiliser tubes can due to have high voltage and occur puncturing, voltage stabilizing
Situation, cause triode Q8 turn on, relay JDQ2 action.
See accompanying drawing 2, the composition under-voltage protection control such as diode D10, optocoupler U4, resistance R/24~R25 and R22, triode Q6
Circuit processed.When the supply voltage detected is less than 70V, because input voltage is very low, then the U4A diodes in U4 optocouplers are not
It can light, the triode U4B of its output stage is not turned on.Triode Q6 is turned on.Pass through diode D12 and D11 clamping action.One
Aspect, make Z8 voltage-stabiliser tubes be not in puncture, the situation of voltage stabilizing, cause triode Q8 to end, relay JDQ2 is failure to actuate.It is another
Aspect, also causes triode Q7 to end, and relay JDQ1 is failure to actuate.Because relay JDQ1 is failure to actuate, such RT1 is just connected on
In input circuit.This can cause welding machine to weld output.When welding rod frequently contacts workpiece, power supply instruction lantern festival frequently flashes.
Which achieves " under-voltage " the protection control of welding machine.
See accompanying drawing 2, when the supply voltage detected is higher than 70V, the U4A diodes in U4 optocouplers can be lighted, and it is exported
The triode U4B conductings of level.Triode Q6 will be in cut-off state.Diode D12 and D11 will be in not on-state.
The problem of being not in clamp.Therefore, control will not be naturally also caused to triode Q7 and Q8, relay JDQ1 and JDQ2 not
Good influence.
In accompanying drawing 2 and accompanying drawing 4, B1（Containing B1A, B1B, B1C）And B2（Containing B2A, B2B, B2C）Driving transformer, Q1 ~ Q4
Triode, D1 ~ D8 diodes, Z1 ~ Z4 voltage-stabiliser tubes, U1 and U2 driving chips, and their peripheries the device group such as resistance, electric capacity
Into IGBT driving circuit section.4 IGBT, each IGBT drive circuit form are consistent.The partial circuit, input
Control signal is introduced by 2,3 pin of J2 plugs in accompanying drawing 2, and they control the U5 in circuit from output characteristics in accompanying drawing 4
Pwm pulse width modulated chip（UC3846）A and B output ends.Because the signal driving power that U5 chips are exported is small, therefore need
To be amplified by driving power circuit, then go 4 IGBT's of control by the drive circuit of driving transformer and its periphery
Working condition.U5 pulse width modulations（PWM）Chip（UC3846）The control signal of output is two prescription wave pulse signals.Two groups
Square-wave pulse signal has in time is also referred to as dead time in a regular time difference, specialty.It is to ensure that two groups of IGBT is opened
Close one of important parameter of alternation.The time is the peripheral components by UC3846 chips（The resistance at RT ends；The electricity at CT ends
Hold）Parameter setting and determine.As to how determining, it is necessary to check UC3846 data used in connection with or explanation.Here no longer
Repeat.Need exist for explanation be：Pwm pulse bandwidth modulation signals are to determine that welding machine inverter main circuit output voltage and electric current are big
Small signal.And pwm pulse bandwidth modulation signals are then adjusted Setting signal Ug and current negative feedback signal Ufi by the electric current of welding machine
Determine.
See accompanying drawing 3, switch power supply route T1 switching mode power supply transformers, VT1 metal-oxide-semiconductors, U1（UC3842）Pwm pulse is wide
Spend modulator, D1 ~ D4 diodes, D5 ~ D9 fast diodes, U3（7815）Integrated regulator, and resistance, electricity around them
The device such as appearance, voltage-stabiliser tube D8, IGCT Q1 is constituted.Switching power circuit generation+15V ,+24V supply voltages, the corresponding control of supply
The live line works such as circuit processed.For switching power circuit part, due to VT1 metal-oxide-semiconductors and T1 switching mode power supply transformers it is primary around
Group, and the composition such as voltage-stabiliser tube D8, D1 around them ~ D4 diodes, D5 ~ D9 fast diodes, many resistance and electric capacity
Circuit, belongs to high tension loop.To ensure the safety for controlling circuit, in fig 2, U2 is employed（817）Photoelectrical coupler
Isolated.The kernel control chip of Switching Power Supply PWM control panels is U1, i.e. UC3842 pwm pulses width adjustor.Outside it
Resistance, the electric capacity enclosed can set the relevant parameter of its work.As to how determining, it is necessary to check UC3842 data used in connection with
Or explanation.It is not repeated herein.In a word, the pulse of U1 outputs is the driving pulse of certain working frequency, can be made in accompanying drawing 2
VT1 metal-oxide-semiconductors are in break-make working condition.In T1 voltage follower circuit part, acquisition+15V ,+24V, supply voltage respectively.
The different device of supply and circuit are used.For example ,+24V supplies fan work by J1 plugs；+ 15V power supply voltage supplying computings
Amplifier control circuit etc..On the operation principle of this part of Switching Power Supply, above section is to have carried out simple illustration.Such as
Fruit is it should be understood that the detailed working condition of this circuit part, is related to many knowledge of Switching Power Supply.Reader can inquire about correlation
On-off circuit books or data make further understanding.Here no longer describe in detail.
From the circuit and principle of switching power supply parts, the utility model does not use general control transformer and phase
The voltage conversion circuit of pass produces above-mentioned 2 supply voltages.The volume and size of switch transformer, be significantly less weight than it is general
Transformer is controlled, this just reduces the cost of the utility model welding machine, improves the technical value added of welding machine.
See accompanying drawing 2 and accompanying drawing 4, current detecting and rectification transformating circuit by current detecting ring DLH or T5 current transformer,
（In accompanying drawing 4）D1 ~ D4 diodes, resistance（In accompanying drawing 4）R22 ~ R24 etc. is constituted.It is last defeated by current detecting, rectifying conversion
Go out current negative feedback signal Ufi.It is connected in output characteristics control circuit.
See accompanying drawing 4, temperature relay WJ, the protection instruction OT of Thermal protection detection and control circuit by open type（Yellow）
The device such as lamp, triode Q2, resistance R15 and R16 is constituted.The temperature relay WJ connections of the open type upper left corner in figure 4
BH interfaces.The radiator that temperature relay WJ is close to IGBT is installed.
See accompanying drawing 4, given value of current circuit adjusts potentiometer RP1, current correction current potential by operational amplifier U3, output current
Device RP3 and RP4, and periphery the device such as resistance, electric capacity composition.By given value of current circuit, by operational amplifier IC3A's
Output end, obtains electric current regulation Setting signal Ug.Current correction potentiometer RP3 and RP4, recoverable welding machine output maximum and most
Low current.By the cooperation with given potentiometer, the output current of welding machine can be made to meet the requirement of curent change scope in nameplate.
AD end signals are then connected to the display circuit of microprocessor control, and final welding current is shown by charactron SMG.
See accompanying drawing 4, output characteristics controls circuit by U5 pwm pulse width modulated chips（UC3846）, U3 operation amplifiers
Device, and these device peripheries the device such as many resistance, electric capacity and diode composition.
See accompanying drawing 4, output voltage suppression circuit is by resistance R20, R40 and R43, electric capacity C25 and EC2, optocoupler U4, voltage-stabiliser tube
The devices such as Z3, triode Q1 are constituted.VF interfaces, the output of welding machine is connected to by wire.When the output voltage of welding machine is too high,
Voltage-stabiliser tube Z3 can puncture, voltage stabilizing.Light emitting diode U4A in optocoupler U4 can be lighted, then, and the triode U4B of its output stage is led
It is logical, turn on triode Q1.So as to by resistance R20, go U5 pwm pulse width modulateds in control output characteristics control circuit
Chip（UC3846）Output pwm pulse width, the output voltage of final limitation welding machine.
See accompanying drawing 4, the display of output current and control circuit are by microprocessor U2（STM8）, charactron SMG and its periphery
The device such as some resistance, electric capacity composition.+ 15V from switching power circuit passes through U1（78M05）Voltage regulator circuit generation+
5V power supplys, supply microcontroller circuit work is used.J3 interfaces, are the program burn writing interface of microprocessor.By it, using journey
Sequence fever writes, the control software of microprocessor are write in single-chip microcomputer.Under the control of microprocessor system circuit, it can sample and
From AD given value of current signal.According to given signal magnitude, in the presence of control software, corresponding current value is passed through number
Code pipe SMG is shown.Because the current value of given current value and reality output can be by potentiometer calibration accuracy,
Therefore, the given value of current value of regulation is actually also output current value.Further, since employing microcontroller circuit control system
System, therefore, it is very easy to realize the preset of welding machine output current.That is, in no welded, adjusting and being shown in electricity
Current value in flow table is exactly actual current when welding.Without determining output current by test weld.It is thus greatly convenient
The operation of user.
See accompanying drawing 5, bus protection circuit by diode 1D2, voltage-stabiliser tube 1D1, Z1~Z2 and 1Z1~1Z3, triode 1Q1,
Q1 and Q2, optocoupler U1 and U2, and the device of their peripheries are constituted.By BHQ1 and BHQ2 plugs, optocoupler U2 output can be made
End is connected in the BH protection circuits in accompanying drawing 4.Different input voltages, passes through the rectification and electrolysis of rectifier bridge BR1 in accompanying drawing 2
The filtering of electric capacity, can produce different VCC bus DC voltages.That is rectifier bridge BR1 of the VCC voltages in accompanying drawing 2 output
End.24V power supplys, from switching power circuit.The circuit is controlled by detecting VCC voltages, and accordingly.Either exist
220V, or under 380V input supply voltages, when there is under-voltage phenomenon, i.e., in access 220V power networks, and input voltage is less than
150V, or in access 380V power networks, and input voltage between 300V~260V when, the OT guard modes in welding machine accompanying drawing 4
Indicator lamp（Yellow）It can light, indicate that welding machine occurs under-voltage.After only under-voltage phenomenon is eliminated, the indicator lamp can just extinguish, and
And welding machine can be welded and used.Puncture 1D1,1Z1 voltage-stabiliser tube when corresponding VCC voltages, voltage stabilizing, when triode 1Q1 is turned on,
Light emitting diode in optocoupler U1 does not light, the triode cut-off of its output stage.Now, triode Q1 is turned on, Q2 cut-offs, similar
Ground, can make the triode ON of output stage in optocoupler U2.Because BHQ1 and BHQ2 plugs are to be connected in parallel（Open type）Overheat
On protector, therefore, now equivalent to overheat protector operating state, that is, its normally opened contact is transformed to closed form
State, therefore the control circuit of welding machine can close pwm pulse.Welding machine stops output current；When corresponding VCC voltages make 1Z2,1Z3
Voltage-stabiliser tube punctures, voltage stabilizing, the lumination of light emitting diode in optocoupler U1, during the triode ON of its output stage, triode Q1 cut-offs,
Q2 is turned on, and can end the triode of output stage in optocoupler U2.Now, welding machine can just have output current.
The control process of the utility model welding machine manual electric arc welding output characteristics is summarized as follows：
The switch of welding machine rear board, which closes, to be connected after the power supply extremely short time（During this, welder circuit carries out upper electricity
Cushioning control, JDQ1A relays have certain delays time to control）, above-mentioned each control panel live line work inside welding machine.Front panel
On white power supply instruction LED it is bright, indicate welding machine it is powered.
In the presence of control circuit, it is larger that the U5 pwm pulses Width Control circuit inside welding machine produces a dutycycle
Pulse signal, make IGBT drive circuit works, make two groups of IGBT be in alternating conductive state, finally make inverter main circuit defeated
Go out floating voltage.When operator regulates the given potentiometer signal Ug of welding current on front panel, and when being welded, pass through
Current detecting ring DLH or T5 current transformer, the change in inverter main circuit is can detect by current detecting and rectification transformating circuit
Depressor primary current signal, i.e. current negative feedback signal Ufi.Current negative feedback signal Ufi, with welding current Setting signal Ug
It is compared.Difference signal after comparing, circuit is controlled by the output characteristics in accompanying drawing 4, carries out PI（Ratio and integration）Adjust
Section control.Pulse width or the dutycycle output of its output control U5 PWM chip exported.Pass through IGBT drive circuit, control
IGBT make-and-break time in inverter main circuit processed, it is final to determine welding machine output current and the size of voltage, realize that output current is joined
Several accurate control.And make the output characteristics of welding machine for the dropping characteristic dragged outside constant current band.Further say, when welding current is given
Determine signal Ug it is constant when, the negative-feedback Ufi current signals increase detected with welder circuit, also, reach given setting
After value, welding current, which gives Ug signals and the difference of Ufi current feedback control signals, can increase and reduce with electric current, pass through PI
After control, reduce pulse width or dutycycle that welding machine exports PWM chip, the output voltage reduction of welding machine.This process,
It is exactly so-called Current cut-off negative feedback control.Only just worked after electric current reaches the setting value of welding current potentiometer
Feedback control.Hereafter, with the small increase of electric current, voltage reduction can be a lot.When welding machine output voltage drops to below 16V
When, with the reduction of voltage, control circuit can make pulse width or the dutycycle increase of U5 PWM chips, make welding current according to
The parameter increase of setting, ultimately forms the dropping characteristic dragged outside constant current band.When welding current Setting signal changes, current cut-off
Negative-feedback setting value is different, but other control process are similar.So, between the minimum and maximum that potentiometer is set,
It is achieved with without several negative characteristic curves.Such control, is also the basic demand for meeting manual arc welding.
On the course of work of welding machine other parts circuit, because many explanations have been carried out in above section.Here
No longer it is described in detail.
On overtemperature protection control, some explanations are carried out below.The temperature relay WJ connections of open type are left in figure 4
The BH interfaces at upper angle.The radiator that temperature relay WJ is close to IGBT is installed.In welding machine output procedure, when IGBT radiator
During generation superheating phenomenon, temperature relay WJ closures.Overtemperature protection indicates OT（Yellow）Lamp is lighted, and indicates that welding machine occurs overheat and protected
Shield.Meanwhile, triode Q2 conductings can close the pulse output of U5 PWM chips, welding machine is stopped output current.In cooling blower
In the presence of, when superheating phenomenon is eliminated, control circuit can just continue to output pwm control signal.Overheat simultaneously and indicate that OT lamps put out
Go out.Which achieves welding machine overtemperature protection.
On the circuit anti-interference measure of the utility model welding machine, mainly there is the following aspects：
1）Input filter.See accompanying drawing 2, input filter circuit is made up of resistance R and filter capacitor CC1, CC2.Mainly pair
Interference signal from power network is filtered, and reduces or reduce the adverse effect that interference signal controls this welding machine circuit work.
2）Output filtering.See accompanying drawing 2, output filter circuit is made up of filter capacitor CC3 and CC4.It can suppress in waveform
Burr is mutated or interference signal.
Above-mentioned measure is to ensure one of important measures of welding machine product functional reliability that this welder circuit is made.
Above is the brief control process explanation of each circuit part of the utility model welding machine and manual metal-arc welding method.Due to
The utility model has been presented for the detailed circuit schematic diagram of accompanying drawing 2, accompanying drawing 3 and accompanying drawing 4, therefore, for there is circuit to read energy
Power（Or possess interlock circuit knowledge）People for, can understand completely.Circuit diagram is exactly a kind of noiseless language.But
It is, for not having circuit reading ability（Or do not possess interlock circuit knowledge）People for, even if explain it is many again, they are also
It is elusive.In view of the relation of length, can only illustrate main part herein, so that reader better understood when correlation
Operation principle and process.
Visible by described above, the utility model circuit has oneself unique mentality of designing and method.It can not only realize
Welding machine manual metal-arc welding method output control, moreover, designed control circuit and the complete machine structure of welding machine, are all to make the utility model
Welding machine product meets security credential requirement, where the basic reason with technical advantages such as good control performances, is also to meet
The advanced important leverage of the efficient and inexpensive production of product, high reliability, manufacturing process technology.The utility model patent application
The content of protection is that the structure design for protecting this welding machine.
In addition, connecting simple between circuit board of the present utility model, device is much to use automatic placement machine on circuit board
Processing is completed with inserter, its production process and production technology are greatly simplified, reduction product weight, production and transportation cost.
Above content be with reference to specific machine structure and circuit board and control function the utility model is made it is detailed
Explanation, it is impossible to assert that specific implementation of the present utility model is only limited to these explanations.To its of technical field described in the utility model
For his technical staff, without departing from the concept of the premise utility, some other deductions can also be made and converted,
These should all be considered as belonging to the category of the utility model protection.
Claims (4)
1. a kind of general IGBT single-tube contravariant formula manual arc welders of whole power, it is characterised in that：Including shell, rear board, cold
But fan, front panel, output snap joint holder assembly, working power and guard mode indicator lamp, electric current output regulation potentiometer,
Control board and internal connecting wire；The control board of welding machine is designed as four pieces, one piece of PCB1 power panel, one piece of PCB2 work(
Electricity is mainly switched on rate control panel, one piece of PCB3 control panel, one piece of PCB4 bus protection plate circuit control panel, PCB1 control panels
Source control circuit part；PCB2 control plate parts include IGBT and its radiator and drive control circuit, fast recovery diode and
Output rectification circuit, supply voltage automatic identification and the conversion control circuit of its radiator composition, upper electric buffer control circuit portion
Point；It is microprocessor and its charactron, the circuit part of given value of current potentiometer composition, and output characteristics on PCB3 control panels
Circuit part is controlled, the core of output characteristics control circuit part is 3846 pwm pulse width modulated chips and its peripheral components
The circuit of composition；On PCB4 control panels, then mainly bus protection controls circuit part；Above-mentioned each control panel is led by connection
Switch, fan, the inversion main transformer of line and welding machine are connected as an entirety, and whole control circuit is mainly the upper electricity buffering of completion
Circuit, 220V and 380V supply voltages automatic identification and conversion control circuit, inverter main circuit, switching power circuit, IGBT drive
Dynamic circuit, current detecting and rectification transformating circuit, under-voltage and overtemperature protection detection and control circuit, bus protection control, electric current
Given circuit, output characteristics control circuit composition.
2. a kind of general IGBT single-tube contravariant formula manual arc welders of whole power as claimed in claim 1, it is characterised in that：Institute
The supply voltage automatic identification stated and conversion control circuit part, by optocoupler, triode, voltage-stabiliser tube, diode, IGCT, after
Electrical equipment and the resistor- capacitor of these device peripheries composition, the supply voltage inputted for automatic detection, pass through voltage-stabiliser tube
Puncture and voltage stabilizing, make a triode ON, and then go to make the output stage triode ON of optocoupler；Meanwhile, make turn on thyristors,
And the IGCT controls the action of another triode and relay, pass through actuating of relay automatic switchover electricity 380V or 220V
Input.
3. a kind of general IGBT single-tube contravariant formula manual arc welders of whole power as claimed in claim 1, it is characterised in that：Institute
The under-voltage protection control circuit stated includes diode, optocoupler, resistance, triode composition, and under-voltage protection control circuit is used to detect
Whether supply voltage, lighted by the diode in optocoupler, to control whether the triode of output stage turns on, then by passing through
The clamping action of triode and diode, make voltage-stabiliser tube be not in puncture, the situation of voltage stabilizing, cause another triode cut
Only, while multiplication of voltage control relay is failure to actuate.
4. a kind of general IGBT single-tube contravariant formula manual arc welders of whole power as claimed in claim 1, it is characterised in that：Institute
The bus protection control circuit stated includes diode, voltage-stabiliser tube, triode, optocoupler and peripheral components, bus protection control electricity
Road makes the output end of rear class optocoupler be connected in parallel on overheat protector by plug, and different input voltages can be produced
Different VCC bus DC voltages, are controlled by detecting VCC voltages, and accordingly.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN106944717A (en) * | 2017-03-27 | 2017-07-14 | 朱宣东 | A kind of general IGBT single-tube contravariant manual arc welders of whole power |
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| GR01 | Patent grant | ||
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Effective date of registration: 20180404 Address after: Taizhou City, Zhejiang province Luqiao District 318050 Luqiao Shugang Avenue No. 2299 Patentee after: ZHEJIANG KENDE MECHANICAL & ELECTRICAL Co.,Ltd. Address before: 318050 West Road Bridge Road, Lubei street, Luqiao District, Taizhou City, Zhejiang Province, No. 973-975 Patentee before: Zhu Xuandong |
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Granted publication date: 20171103 |
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