CN210587616U - System for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power - Google Patents
System for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power Download PDFInfo
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Abstract
The utility model provides a system for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power, its characterized in that: the high-frequency secondary rectifying device comprises a resistance welding power supply, a high-frequency transformer, a high-frequency secondary rectifying unit, an electrode unit, a pressure monitoring unit, a voltage feedback unit and a current feedback unit; the pressure monitoring unit is connected with the main control board to realize the detection feedback of the pressure and control the welding clamp servo motor to pressurize the workpiece according to the set pressure; the main control board is connected with the pressure monitoring unit, the voltage feedback unit and the current feedback unit, and therefore collection of welding pressure, secondary voltage and secondary current is achieved. The inversion frequency is 10KHz, 20000 groups of data points can be collected per second according to the collected secondary current output waveform, the collection rate of the system is improved, and the welding process can be controlled more accurately.
Description
Technical Field
The utility model relates to a resistance welds the field, concretely relates to system for be used for aluminium spot welding based on high frequency contravariant direct current resistance welds power.
Background
With the increasing demands of people on environmental protection, energy conservation and emission reduction in the current society, the light weight of automobiles becomes the trend of automobile manufacturing in the world as the most effective and direct method for reducing oil consumption and gas emission. Aluminum alloys, with their outstanding properties and advantages, have a high brilliance in lightweight materials, are favored by numerous manufacturers and are used in some vehicle models. Resistance spot welding is one of the connection processes of automobile bodies, and is widely applied due to the characteristics of reliable quality, high efficiency, economy, easiness in automatic welding by using a robot and the like. However, because the aluminum alloy has physical and chemical characteristics such as high electrical conductivity, high thermal conductivity, low melting point and easy oxidation, the resistance spot welding of the aluminum alloy has great difference compared with the resistance spot welding of traditional steel materials, which mainly shows that short welding time, large welding current, high welding pressure and the like are needed, although relevant research is carried out on the resistance spot welding of the aluminum alloy from different directions at home and abroad, most of the resistance spot welding of the aluminum alloy still stays in a laboratory stage, the technical effect of the aluminum spot welding entering a practical stage is not ideal, the transformer has large volume, the electrode holder has higher requirements on the load structure design of the electrode holder due to the fact that the electrode holder needs to bear large pressure, and a controller or a welding power supply has high power and cost, the electrode grinding frequency is high, and a special electrode belt or an electrode structure is needed.
SUMMERY OF THE UTILITY MODEL
To the problem, the utility model discloses a method and system that DC resistance welding power source carries out aluminium spot welding based on high frequency contravariant that the purpose provided, contravariant frequency is 10KHz, can realize gathering 20000 group data points every second according to gathering secondary current output waveform, has improved the collection speed of system, control welding current that can be more accurate.
The utility model provides a technical scheme that above-mentioned technical problem adopted is: the utility model provides a system for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power, its characterized in that: the high-frequency secondary rectifying device comprises a resistance welding power supply, a high-frequency transformer, a high-frequency secondary rectifying unit, an electrode unit, a pressure monitoring unit, a voltage feedback unit and a current feedback unit; the pressure monitoring unit is connected with the main control board to realize the detection feedback of the pressure and control the welding clamp servo motor to pressurize the workpiece according to the set pressure; the main control board is connected with the pressure monitoring unit, the voltage feedback unit and the current feedback unit, and therefore collection of welding pressure, secondary voltage and secondary current is achieved.
Further, the resistance welding power supply comprises a main control board, a driving board and a power unit.
Further, the power unit comprises a primary rectifying module, a filter capacitor and an IGBT.
Furthermore, the MCU model on the main control board is STM32F103, and accurate control of secondary signal acquisition time is realized.
Furthermore, the upper electrode and the lower electrode of the electrode unit are made of chromium-zirconium-copper materials, the diameter d1 of the electrode is 12-18mm of the electrode cap, and the end face of the electrode is an arc with the radius R1 larger than 40 mm.
Further, the IGBT and the high-frequency secondary rectifier unit of the power unit 10 are a high-frequency IGBT module and a high-frequency rectifier module adapted to the high-frequency inversion frequency.
Furthermore, the resistance welding power supply is a high-frequency inverter resistance welding power supply, the drive board is a high-frequency IGBT drive board, the main control board is connected with the drive board to control the drive board to carry out high-frequency on-off control on the IGBT, and the inverter frequency reaches 10 KHz.
Further, the high-frequency transformer adopts a middle tap mode, and an iron core is made of ferrite materials; the current feedback unit adopts an annular Rogowski coil and is sleeved at the output end of the high-frequency secondary rectifying unit.
A method for carrying out aluminum spot welding by a direct current resistance welding power supply based on high-frequency inversion is characterized by comprising the following steps: comprises the following steps
(1) According to the secondary current fluctuation curve, in a welding period, the welding current can pass through the effective value of the welding current for 2 times, and a signal at the moment when the current passes through the effective value is connected into an interrupt pin of a main control board;
(2) sampling output signals of the pressure monitoring unit, the voltage feedback unit and the current feedback unit at the terminal moment of the over-effective value;
(3) calculating a secondary resistance according to ohm's law by the collected secondary voltage and the secondary current, and adjusting the weighted value epsilon 1 of the resistance of the output current according to the comparison difference value of the secondary resistance and the set resistance curve;
(4) adjusting the weight value epsilon 2 of the output current pressure according to the comparison difference value of the collected secondary pressure data and the set pressure;
(5) multiplying the resistance weight value epsilon 1 by the resistance adjustment coefficient
And multiplying the pressure weighted value epsilon 2 by the resistance adjustment coefficient
As a result, a current adjustment coefficient is obtained
(6) Adjusting coefficient according to current
Through a PID control strategy, the Pulse Width Modulation (PWM) waveform output by the drive plate 9 is controlled to change and adjust by adjusting the PWM combined waveform on the main control plate (8), so that high-frequency accurate control of the output magnitude of the welding current is realized.
The utility model has the advantages that:
1. the current is adjusted more rapidly and finely
The secondary current output waveform is a pulsating waveform as shown in fig. 2, the pulsating cycle keeps unanimous with the contravariant cycle, secondary current and voltage are gathered when the pulsating waveform is effectual, can see out every cycle from the waveform and can gather 2 times, gather constantly at the effective value and can guarantee at every turn data acquisition constantly uniformity and accurate definite, contravariant intermediate frequency welding machine collection frequency is subject to contravariant frequency, usually 1KHz or 2KHz, adopt the utility model provides a method and system that DC resistance welding power source carries out aluminium spot welding based on high frequency contravariant, contravariant frequency is 10KHz, can realize gathering 20000 group data points per second according to gathering secondary current output waveform, has improved the collection rate of system, control welding current that can be more accurate.
2. The transformer can be lighter and smaller
According to the induction potential formula of the transformer:
in the formula: e-effective value of induced potential f-frequency N-number of turns
-main flux maximum; the effective value of the induced potential can be analyzed to be definite according to a formula, when the frequency is high, the number of turns and the main flux can be less, the iron core can be small, the volume of the natural transformer can be small, and the weight can be reduced. Therefore, the transformer in the high-frequency direct current-based resistance welding system has smaller volume and lighter weight than a common inverter medium-frequency welding machine under the same capacity, and is more suitable for robot welding.
3. The welding current is smaller, the volume of the welding power supply is smaller, and the welding pressure is smaller
The aluminum alloy coefficient of heat conductivity is high, specific heat capacity is big, and current aluminum alloy spot welding technology is realized through heavy current, big pressure, and the electric current generally needs 40 ~ 100KA, has proposed higher requirement to the control of resistance welding power and cooling from this, need adopt powerful rectification and IGBT module, causes control system design cost high, and the volume is also bigger, adopts the utility model provides a method can realize good welding under the condition that welding current is 35KA, pressure are 4-6KN, has effectively reduced the power and the volume of resistance welding power, has reduced the payload of soldering turret, has simplified the soldering turret design.
4. Can realize aluminum spot welding by using conventional electrode and reduce electrode grinding frequency
The aluminum alloy has fast heat dissipation, and the metal melted by the aluminum alloy after welding can generate electrochemical reaction with the copper alloy of the copper electrode, so that the electrode is adhered, the welding quality is affected, and generally, one-time grinding is needed at 40-70 points; in addition aluminum alloy metal surface forms the oxide film easily, and this oxide film resistivity is big, the melting point is high, therefore aluminum alloy spot welding technology has higher requirement to the welding electrode, the utility model provides a method and system that DC resistance welding power based on high frequency contravariant carries out aluminum spot welding, this system is the pulsating direct current of high frequency in electrode end output, can form a conical pulse beam through this high frequency current on the oxide, the oxide film on aluminum alloy surface can be got rid of with quick and steady mode to this pulse beam to preferentially form the energy concentration district at the work piece contact surface, form the nugget, consequently the electrode terminal surface adopt ordinary terminal surface flat electrode cap can, and can improve the number of times interval of electrode coping.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the technical solutions in the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a block diagram of a high-frequency inverted direct-current resistance welding power supply aluminum spot welding system
FIG. 2 is a waveform diagram of the secondary current of the inverter DC resistance welding power supply
FIG. 3 is a flow chart of a method for performing aluminum spot welding by using a high-frequency inverted direct-current resistance welding power supply
FIG. 4 electrode cross-sectional view
Wherein: the device comprises a resistance welding power supply 1, a high-frequency transformer 2, a high-frequency secondary rectifying unit 3, an electrode unit 4, a pressure monitoring unit 5, a voltage feedback unit 6 and a current feedback unit 7; wherein the resistance welding power supply 1 comprises a main control board 8, a drive board 9 and a power unit 10
Detailed Description
The technical solution of the present invention will be described clearly and completely with reference to the accompanying drawings, and obviously, the described embodiments are some, but not all embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplification of description, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
A system for aluminum spot welding based on a high-frequency inversion direct current resistance welding power supply comprises a resistance welding power supply 1, a high-frequency transformer 2, a high-frequency secondary rectifying unit 3, an electrode unit 4, a pressure monitoring unit 5, a voltage feedback unit 6 and a current feedback unit 7; the resistance welding power supply 1 comprises a main control board 8, a driving board 9 and a power unit 10; the power unit 10 comprises a primary rectifying module, a filter capacitor, an IGBT and other devices; the pressure monitoring unit is connected with the main control board to realize the detection feedback of the pressure and control the welding clamp servo motor to pressurize the workpiece according to the set pressure; the main control board is connected with the pressure monitoring unit, the voltage feedback unit and the current feedback unit, and therefore collection of welding pressure, secondary voltage and secondary current is achieved.
The resistance welding power supply 1 is a high-frequency inverter resistance welding power supply, the drive plate 9 is a high-frequency IGBT drive plate, the main control plate 8 is connected with the drive plate 9 to control the drive plate 9 to carry out high-frequency on-off control on the IGBT, and the inverter frequency reaches 10 KHz; the system works in an inversion high-frequency band, so that the high-frequency transformer 2 and the high-frequency secondary rectifying unit 3 are designed and selected according to the high-frequency band;
the main control board 8 is connected with the pressure monitoring unit 5, the voltage feedback unit 6 and the current feedback unit 7, so that the collection of welding pressure, secondary voltage and secondary current is realized, the sampling frequency is 2 times of high-frequency inversion frequency, and 20000 data points can be collected every second when the inversion frequency is 10KHz, so that the control of a welding process is more refined.
The IGBT and the high-frequency secondary rectifying unit 3 of the power unit 10 are a high-frequency IGBT module and a high-frequency rectifying module which are adaptive to high-frequency inversion frequency;
the high-frequency transformer 2 adopts a middle tap form, as shown in a secondary transformer 2 in fig. 1, an iron core is made of ferrite material; the current feedback unit 7 adopts an annular Rogowski coil and is sleeved at the output end of the high-frequency secondary rectifying unit 3, namely the positive electrode or the negative electrode end of the output loop;
the mainboard board 8 controls the drive board 9 to carry out on-off control on the IGBT component by outputting a Pulse Width Modulation (PWM) wave, and the inversion frequency is not the intermediate frequency of 1KHz, but is in the inversion high frequency band, and can reach 10 KHz;
furthermore, the model of the main control board is STM32F103, and accurate control over secondary signal acquisition time is achieved.
Furthermore, the upper electrode and the lower electrode of the electrode unit are made of chromium-zirconium-copper materials, the diameter d1 of the electrode is 12-18mm of the electrode cap, and the end face of the electrode is an arc with the radius R1 larger than 40 mm.
Further, the IGBT and the high-frequency secondary rectifier unit of the power unit 10 are a high-frequency IGBT module and a high-frequency rectifier module adapted to the high-frequency inversion frequency.
Furthermore, the resistance welding power supply is a high-frequency inverter resistance welding power supply, the drive board is a high-frequency IGBT drive board, the main control board is connected with the drive board to control the drive board to carry out high-frequency on-off control on the IGBT, and the inverter frequency reaches 10 KHz.
Further, the high-frequency transformer adopts a middle tap mode, and an iron core is made of ferrite materials; the current feedback unit adopts an annular Rogowski coil and is sleeved at the output end of the high-frequency secondary rectifying unit.
A method for carrying out aluminum spot welding by a direct current resistance welding power supply based on high-frequency inversion,
1. according to the secondary current fluctuation curve in the graph of fig. 2, in a welding period, the welding current can pass through the effective value of the welding current for 2 times, and a signal at the moment when the current passes through the effective value is connected into an MCU interrupt pin of a main control board, wherein the MCU is STM32F103 in model number, so that the accurate control of the secondary signal acquisition time is realized;
2. sampling output signals of the pressure monitoring unit 5, the voltage feedback unit 6 and the current feedback unit 7 at the terminal time of the over-effective value, wherein the sampling frequency can reach 20KHz at the time of t1, t2, t3, t4, t5, t6, t7, t8, t9, t10 and the like, namely collecting 20000 groups of data points per second;
3. calculating a secondary resistance according to ohm's law by the collected secondary voltage and the secondary current, and adjusting the weighted value epsilon 1 of the resistance of the output current according to the comparison difference value of the secondary resistance and the set resistance curve;
4. adjusting the weight value epsilon 2 of the output current pressure according to the comparison difference value of the collected secondary pressure data and the set pressure;
5. multiplying the resistance weight value epsilon 1 by the resistance adjustment coefficient
And multiplying the pressure weighted value epsilon 2 by the resistance adjustment coefficient
As a result, a current adjustment coefficient is obtained
6. Adjusting coefficient according to current
Through a PID control strategy, the PWM combined waveform is adjusted on the main control board 8 so as to control the PWM waveform output by the drive board 9, and butt welding power connection is realizedThe high-frequency accurate control of the flow output size, and the PID adjusting frequency can reach 10 KHz;
at present, companies mainly monitor the three parameters and carry out output control of resistance spot welding according to respective algorithms, and the inverter frequency of the inverter medium-frequency direct-current resistance welding machine is basically a fixed value within the range of 800 plus one 1200Hz for inverter welding, wherein the inverter frequency of 1KHz is most widely applied.
The utility model provides a method and system that direct current resistance welding power source carries out aluminium spot welding based on high frequency contravariant, this system work in contravariant high frequency band, consequently high frequency transformer 2, high frequency secondary rectifier unit 3 are all to the design and the lectotype that the high frequency channel goes on.
Working process
After welding, the main control board calls corresponding welding standard parameters according to input signals, welding is carried out according to set welding parameters, the inverter frequency is 10KHz, and the parameters mainly comprise welding current of each section, welding time, pressure values and pressure time related to pressure, such as prepressing time, pressurizing time, pressure maintaining time and the like.
The main control board 9 controls a welding clamp servo motor to clamp the workpiece and apply set pressure through the pressure monitoring unit 5 in the prepressing time and the pressurizing time;
after welding starts, data acquisition is carried out on the pressure monitoring unit 5, the voltage feedback unit 6 and the current feedback unit 7 at the interruption moment when the acquisition current passes through the effective value, and as inversion reaches 10KHz, high-frequency data acquisition with the sampling rate reaching 20KHz is realized;
according to ohm's law, the data collected by the voltage feedback unit 6 and the current feedback unit 7 are calculated in real time to obtain a secondary resistance value, the secondary resistance value is compared with a set resistance curve to obtain a deviation value, and an output current resistance weight value epsilon 1 is adjusted according to the deviation value;
obtaining a deviation value by comparing the data of the pressure monitoring unit 5 acquired in real time with the set pressure, and adjusting the weight value epsilon 2 of the output current pressure according to the deviation value;
multiplying the resistance weight value epsilon 1 by the resistance adjustment coefficient
And multiplying the pressure weighted value epsilon 2 by the resistance adjustment coefficient
As a result, a current adjustment coefficient is obtained
Adjusting coefficient according to current
Through a PID control strategy, the PWM combined waveform is adjusted on the main control board 8 so as to control the PWM waveform output by the drive board 9, high-frequency accurate control on the output magnitude of welding current is realized, and the PID adjusting frequency can reach 10 KHz;
finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the present invention.
Claims (8)
1. The utility model provides a system for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power, its characterized in that: the device comprises a resistance welding power supply (1), a high-frequency transformer (2), a high-frequency secondary rectifying unit (3), an electrode unit (4), a pressure monitoring unit (5), a voltage feedback unit (6) and a current feedback unit (7); the pressure monitoring unit (5) is connected with the main control board (8) to realize the detection feedback of pressure and control the welding clamp servo motor to pressurize the workpiece according to the set pressure; the main control board (8) is connected with the pressure monitoring unit (5), the voltage feedback unit (6) and the current feedback unit (7) to realize collection of welding pressure, secondary voltage and secondary current.
2. The system for aluminum spot welding based on the high-frequency inversion direct current resistance welding power supply according to claim 1, characterized in that: the resistance welding power supply (1) comprises a main control board (8), a driving board (9) and a power unit (10).
3. The system for aluminum spot welding based on the high-frequency inversion direct current resistance welding power supply according to claim 2, wherein: the power unit (10) comprises a primary rectifying module, a filter capacitor and an IGBT.
4. The system for aluminum spot welding based on the high-frequency inversion direct current resistance welding power supply according to claim 1, characterized in that: and the MCU model on the main control board (8) is STM32F103, so that the accurate control of the secondary signal acquisition time is realized.
5. The system for aluminum spot welding based on the high-frequency inversion direct current resistance welding power supply according to claim 1, characterized in that: the upper electrode and the lower electrode of the electrode unit (4) are made of chromium-zirconium-copper materials, the diameter d1 of the electrode is 12-18mm of an electrode cap, and the end face of the electrode is an arc with the radius R1 larger than 40 mm.
6. The system for aluminum spot welding based on the high-frequency inverter direct current resistance welding power supply according to claim 3, wherein: the IGBT and the high-frequency secondary rectifying unit (3) of the power unit 10 are a high-frequency IGBT module and a high-frequency rectifying module which are adaptive to high-frequency inversion frequency.
7. The system for aluminum spot welding based on the high-frequency inverter direct current resistance welding power supply according to claim 3, wherein: the resistance welding power supply (1) is a high-frequency inversion resistance welding power supply, the drive plate (9) is a high-frequency IGBT drive plate, the main control plate (8) is connected with the drive plate (9) to control the drive plate (9) to carry out high-frequency on-off control on the IGBT, and the inversion frequency reaches 10 KHz.
8. The system for aluminum spot welding based on the high-frequency inverter direct current resistance welding power supply according to claim 3, wherein: the high-frequency transformer (2) adopts a middle tap form, and an iron core is made of ferrite material; the current feedback unit (7) adopts an annular Rogowski coil and is sleeved at the output end of the high-frequency secondary rectifying unit (3).
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| Application Number | Priority Date | Filing Date | Title |
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| CN201921146050.5U CN210587616U (en) | 2019-07-18 | 2019-07-18 | System for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power |
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| CN201921146050.5U CN210587616U (en) | 2019-07-18 | 2019-07-18 | System for be used for aluminium spot welding based on high frequency contravariant direct current resistance welding power |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110253129A (en) * | 2019-07-18 | 2019-09-20 | 天津七所高科技有限公司 | The system and method for spot welding aluminum is used for based on high-frequency inversion direct current resistance welding power source |
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2019
- 2019-07-18 CN CN201921146050.5U patent/CN210587616U/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110253129A (en) * | 2019-07-18 | 2019-09-20 | 天津七所高科技有限公司 | The system and method for spot welding aluminum is used for based on high-frequency inversion direct current resistance welding power source |
| CN110253129B (en) * | 2019-07-18 | 2024-01-30 | 天津七所高科技有限公司 | System and method for aluminum spot welding based on high-frequency inversion direct-current resistance welding power supply |
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