CN212526438U - Multifunctional high-power submerged-arc welding equipment - Google Patents
Multifunctional high-power submerged-arc welding equipment Download PDFInfo
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- CN212526438U CN212526438U CN202021665537.7U CN202021665537U CN212526438U CN 212526438 U CN212526438 U CN 212526438U CN 202021665537 U CN202021665537 U CN 202021665537U CN 212526438 U CN212526438 U CN 212526438U
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Abstract
The utility model provides a multifunctional high-power submerged arc welding device, which comprises an energy supply main circuit, a digital control system, a cooling device, a submerged arc trolley and a man-machine interaction device; the energy supply main circuit comprises at least two main circuits and a pilot arc module; each main circuit comprises a three-phase rectifying and filtering circuit, a high-frequency inverter circuit, a power transformer, a high-frequency rectifying and filtering circuit, a coupling power inductor and a secondary inverter circuit; the secondary inverter circuit comprises a positive secondary inverter unit and a negative secondary inverter unit; the junction of the positive secondary inversion unit and the negative secondary inversion unit is used as the positive electrode output of the main circuit; the middle tap of the secondary side of the power transformer is used as the negative pole output of the main circuit; and the pilot arc module is respectively connected with the negative output of the main circuit and the negative secondary inversion unit. The utility model discloses can realize multiple output mode, can promote the stability when electric arc zero crossing for polarity switching speed to improve energy utilization, promote job stabilization nature.
Description
Technical Field
The utility model relates to a submerged arc welding equipment technical field, more specifically say, relate to a multi-functional high-power submerged arc welding equipment.
Background
The submerged-arc welding has the advantages that due to the advantages of large welding penetration, high deposition speed and the like, the submerged-arc welding has incomparable advantages compared with other welding modes in the field of welding of long welding seams of medium and thick plates; therefore, the method has wide application in the manufacture of nuclear power equipment, engineering machinery, ocean structures and the like. With the advance of industrial technology, the high efficiency of submerged arc welding is an important trend of domestic and foreign welding processing technology research, and the development of domestic high-power digital submerged arc welding equipment is still relatively slow at present.
Limited by the level of power devices and the performance of magnetic materials, many submerged arc welding equipment manufacturers at home and abroad develop in a multi-path parallel connection way in order to increase the output power of equipment. However, the problem of unbalanced current exists in the multi-path parallel connection, and faults are easy to occur. Because the output power is extremely large, once the fault happens, the loss which is difficult to recover is extremely easy to cause. The Chinese utility model patent 'inverter type submerged arc welding power supply double-inverter current-sharing control system' (publication number: CN203851058U) proposes a current-sharing control system with double inverters, but only can realize constant current sharing; the Chinese utility model patent of high-power dual-purpose submerged arc welding machine (publication number: CN205950068U) discloses a dual-purpose submerged arc welding machine with four inverters connected in parallel, but the AC output can not be realized. The existing submerged arc welding equipment technology can only realize multi-path parallel constant current and constant voltage output, and is lack of self-protection design.
In view of the above problems, the utility model provides a submerged arc welding equipment based on multichannel is parallelly connected and can realize the multiple output mode of constant current flow equalizing, constant voltage flow equalizing, alternating current square wave flow equalizing in real time according to actual technological characteristics, adopts full digital control, can be fast, meticulous control output current; the system has perfect fault detection and processing capacity, and can ensure that the equipment is not damaged under extreme conditions; an efficient polarity-changing strategy is provided, with faster polarity switching speed, higher arc stability and lower energy loss than the usual ac square wave output.
SUMMERY OF THE UTILITY MODEL
In order to overcome the defects in the prior art, the utility model aims to provide a multifunctional high-power submerged arc welding device; the utility model discloses can realize multiple output mode, can promote the stability when electric arc zero crossing for polarity switching speed to improve energy utilization, promote job stabilization nature.
In order to achieve the above purpose, the utility model discloses a following technical scheme realizes: a multifunctional high-power submerged arc welding device is characterized in that: the submerged arc welding machine comprises an energy supply main circuit, a digital control system, a cooling device, a submerged arc trolley, a man-machine interaction device and a power supply circuit; the submerged arc trolley and the man-machine interaction device are respectively in signal connection with the digital control system; the three-phase alternating current is respectively and electrically connected with the cooling device, the submerged arc trolley, the human-computer interaction device and the digital control system through the power supply circuit;
the energy supply main circuit comprises at least two main circuits which are connected in parallel and a pilot arc module;
each main circuit comprises a three-phase rectifying and filtering circuit, a high-frequency inverter circuit, a power transformer, a high-frequency rectifying and filtering circuit, a coupling power inductor and a secondary inverter circuit which are connected in sequence; the three-phase rectification filter circuit is connected with three-phase alternating current; the high-frequency inverter circuit is in full-bridge inversion; the secondary side of the power transformer is provided with a middle tap, and two ends of the secondary side of the power transformer are connected with a high-frequency rectifying and filtering circuit; the high-frequency rectifying and filtering circuit comprises a positive output rectifying and filtering circuit and a negative output rectifying and filtering circuit; the coupling power inductor comprises two inductors; the secondary inverter circuit comprises a positive secondary inverter unit and a negative secondary inverter unit; one inductor of the coupling power inductor is connected in series between the positive output rectifying and filtering circuit and the positive secondary inverter unit, and the other inductor is connected in series between the negative output rectifying and filtering circuit and the negative secondary inverter unit; the junction of the positive secondary inversion unit and the negative secondary inversion unit is used as the positive output of the main circuit to be connected with a load; the middle tap of the secondary side of the power transformer is used as the negative output of the main circuit and is connected with a load;
and the pilot arc module is respectively connected with the negative output of the main circuit and the negative secondary inversion unit.
Preferably, the pilot arc module comprises a pilot arc rectifying and filtering circuit BR61, a diode D61, a solid-state relay K61 and a power resistor R64;
any two phases of the three-phase alternating current are connected to a pilot arc rectifying and filtering circuit BR61 through a pilot arc transformer T61; the negative output of the pilot arc rectification filter circuit BR61 is sequentially connected with a diode D61, a power end of a solid-state relay K61 and a power resistor R64 in series and then is respectively connected with the negative secondary inverter units of the main circuit secondary inverter circuits; the control end of the solid-state relay K61 is connected with a digital control system; the positive outputs of the pilot arc rectification filter circuit BR61 are respectively connected with the negative outputs of the main circuits.
Preferably, the three-phase alternating current is respectively connected with the power supply circuit and the three-phase rectifying and filtering circuit of each main circuit through a surge suppression circuit;
the surge suppression circuit comprises an alternating current contactor; the three-phase alternating current is connected to a three-phase rectifying and filtering circuit of each main circuit through an alternating current contactor; any two phases at the front stage of the AC contactor are respectively connected in series to corresponding two phases at the rear stage of the AC contactor through a synchronous switch S1B/S1C and a power resistor R51/R52; the rear ends of the synchronous switch S1B and the synchronous switch S1C are respectively connected to a power supply circuit; any two phases at the front stage of the AC contactor are connected to the A1 port of the AC contactor through a synchronous switch S1A and connected to the A2 port of the AC contactor through a delay closing switch S2; in operation, the synchronous switch S1A, the synchronous switch S1B and the synchronous switch S1C are synchronously closed or synchronously opened.
Preferably, the digital control system includes a DSC minimum system and a fault detection circuit; the fault detection circuit comprises an overheat detection circuit, a three-phase open-phase detection circuit, an overvoltage detection circuit, an undervoltage detection circuit and an overcurrent detection circuit.
Preferably, the three-phase open-phase detection circuit comprises three optocouplers, four comparators, an NPN triode Q32, a diode D31, a resistor R38, a PNP triode Q31 and a capacitor C32; the four comparators are a comparator U1A, a comparator U1B, a comparator U4A and a comparator U4B respectively;
the three-phase alternating current is respectively connected to the primary side input ends of the three optocouplers through current-limiting resistors; the primary side output ends of the three optical couplers are connected, and the primary sides of the three optical couplers are connected with a diode in parallel in an inverted way; the input ends of the three optical coupler secondary sides are connected with signal voltage and are respectively connected to the non-inverting input ends of the comparator U1A, the comparator U1B and the comparator U4B in a one-to-one mode; the output ends of the secondary sides of the three optical couplers are connected to the ground of the signal voltage; the inverting input ends of the comparator U1A, the comparator U1B and the comparator U4B are connected with a reference voltage; the output ends of the comparator U1A, the comparator U1B and the comparator U4B are connected, and the signal voltage and the base electrode of an NPN triode Q32 are connected; the NPN triode Q32, the diode D31, the resistor R38, the PNP triode Q31 and the capacitor C32 form a capacitor charging circuit; when the circuit works, the capacitor C32 is charged when the base electrode of the NPN triode Q32 is at a high level, and the capacitor C32 is discharged when the base electrode of the NPN triode Q32 is at a low level; the non-inverting input terminal of the comparator U4A is connected with the reference voltage, the inverting input terminal of the comparator U4A is connected with the ground of the signal voltage through a capacitor C32, and the output terminal of the comparator U4A is connected with the DSC minimum system.
Compared with the prior art, the utility model has the advantages of as follows and beneficial effect:
1. the utility model can realize three output modes of constant current flow equalizing output, constant voltage flow equalizing output and square wave flow equalizing output under the condition that the main circuit is connected in parallel;
2. the utility model adopts the design of combining the pilot arc module and the coupling power inductor, greatly improving the stability of the electric arc at the zero crossing point, accelerating the speed of polarity switching, improving the utilization rate of energy and increasing the working stability of the submerged arc welding equipment;
3. the utility model discloses be equipped with time delay start, surge suppression circuit and perfect fault detection processing system, can ensure submerged arc welding equipment work more safe and reliable ground.
Drawings
FIG. 1 is a schematic view of the general structure of the multifunctional high-power submerged arc welding equipment of the present invention;
FIG. 2 is an electrical schematic diagram of a pilot arc module of the multifunctional high-power submerged arc welding device of the present invention;
FIG. 3 is an equivalent topological diagram of the energy supply main circuit of the multifunctional high-power submerged arc welding device of the present invention;
FIG. 4 is an electrical schematic diagram of a three-phase open-phase detection circuit of the multifunctional high-power submerged arc welding device of the present invention;
FIG. 5 is a schematic diagram of the surge suppressing circuit structure of the multifunctional high-power submerged arc welding device of the present invention;
FIG. 6 is a schematic diagram of the constant-pressure current-sharing output mode control strategy of the multifunctional high-power submerged arc welding equipment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Examples
The general structure of the multifunctional high-power submerged arc welding equipment is shown in figure 1, and the multifunctional high-power submerged arc welding equipment comprises a power supply main circuit, a digital control system, a cooling device, a submerged arc trolley, a man-machine interaction device and a power supply circuit.
The submerged arc trolley comprises a wire feeding device, a feeding device and a trolley walking device; the trolley traveling device is used for driving the submerged arc welding torch, the wire feeding device and the feeding device to advance along a welding bead; the energy supply main circuit provides energy for the welding arc, the man-machine interaction device is used for setting welding parameters and checking the welding state, and the digital control system is responsible for regulating and controlling the work among all modules.
The three-phase alternating current is respectively and electrically connected with the cooling device, the submerged arc trolley, the man-machine interaction device and the digital control system through the power supply circuit.
The submerged arc trolley and the man-machine interaction device are respectively in signal connection with the digital control system. A CAN network communication system is adopted, and independent communication identifiers are respectively distributed on the submerged arc trolley, the digital control system and the human-computer interaction device; three network nodes are mounted on the same CAN closed-loop bus communication network; the man-machine interaction device modifies the wire feeding speed of the wire feeding device, the walking speed of the trolley walking device, the welding mode and the welding parameters of the digital control system through the CAN communication network; the trolley walking device feeds back and displays the walking speed on the man-machine interaction device through the CAN communication network; and the digital control system feeds back and displays welding parameters and fault information on the man-machine interaction device through the CAN communication network.
The energy supply main circuit comprises at least two main circuits and a pilot arc module; in the embodiment, the number of the main circuits is two; in practice, three, four or even more may be used.
In this embodiment, an equivalent topology schematic diagram of the energy supply main circuit is shown in fig. 3; each main circuit comprises a three-phase rectifying and filtering circuit, a high-frequency inverter circuit, a power transformer, a high-frequency rectifying and filtering circuit, a coupling power inductor and a secondary inverter circuit which are connected in sequence.
The three-phase rectification filter circuit is connected with three-phase alternating current; the high-frequency inverter circuit is full-bridge inverter; the high-frequency inverter circuit can adopt an IGBT module or a SiC power module; an RC absorption circuit is connected in parallel between two stages of the power current channel of each switching device; the secondary side of the power transformer is provided with a middle tap, and two ends of the secondary side of the power transformer are connected with a high-frequency rectifying and filtering circuit; the high-frequency rectifying and filtering circuit comprises a positive output rectifying and filtering circuit and a negative output rectifying and filtering circuit; the high-frequency rectifying and filtering circuit adopts a fast recovery diode; the coupling power inductor comprises two inductors; the secondary inverter circuit comprises a positive secondary inverter unit and a negative secondary inverter unit; one inductor of the coupling power inductor is connected in series between the positive output rectifying and filtering circuit and the positive secondary inverter unit, and the other inductor is connected in series between the negative output rectifying and filtering circuit and the negative secondary inverter unit; the junction of the positive secondary inversion unit and the negative secondary inversion unit is used as the positive output of the main circuit to be connected with a load; the middle tap of the secondary side of the power transformer is used as the negative pole output of the main circuit to be connected with a load. The secondary inverter circuit adopts IGBT as a switching device, and the current capacity is increased by connecting IGBT modules in parallel; the coupling power inductors L1A, L1B, L2A and L2B are used for filtering current ripples, storing energy and assisting in maintaining arcs, and the capacitors C6, C8, C19 and C21 are used for absorbing voltage spikes.
Each main circuit secondary can be divided into a positive unit and a negative unit; taking the main circuit in fig. 3 as an example, when the main circuit outputs a forward current, the upper bridge TR1 of the IGBT module is turned on, the lower bridge TR2 of the IGBT module is turned off, a secondary side current of the power transformer flows from a full-wave rectification circuit composed of diodes D1A, D2A, D3A and D4A to the secondary inverter circuit through an inductor L1A, and returns to a secondary side intermediate tap of the power transformer from a negative output end through a load, a capacitor C6 filters in a positive output stage, and a resistor R6 is a bleeder resistor; when the main circuit outputs reverse current, the lower bridge TR2 of the IGBT module is switched on, the upper bridge TR1 of the IGBT module is switched off, the current flows out from the middle tap of the power transformer, flows through the secondary inverter circuit from the positive output end through a load, returns to the two ends of the secondary side of the power transformer through a full-wave rectification circuit consisting of an inductor L1B and diodes D1B, D2B, D3B and D4B, a capacitor C8 filters in the negative output stage, and a resistor R8 is a bleeder resistor.
In an alternating current square wave output mode, the positive unit and the negative unit work cooperatively. Taking the main circuit in fig. 3 as an example, when a forward current is output, the inductor L1A filters and charges energy, and the current of the inductor L1B is 0; when the current is switched to the reverse current, the current of the inductor L1A is instantly reduced to 0 because the forward channel is closed and the reverse channel is opened, the inductor L1A and the inductor L1B jointly form a coupling power inductor, the inductor L1B is replaced by follow current, the reverse current can be instantly climbed to a target value, and the utilization rate of energy is greatly improved. The reverse current is switched to the forward current for the same reason. At the interchange square wave switching-over process, there is the problem that electric arc extinguishes when crossing the zero to output current, the utility model discloses a solution is, when forward output switches over to reverse output, the forward passageway is closed, if electric arc reignites unsuccessfully, the backward passageway can't be connected, and coupling power inductance falls to 0 because of unable afterflow current this moment, can apply a very big voltage and assist the arcing at positive negative output both ends, has improved the speed and the success rate that electric arc reignited greatly.
As shown in fig. 2, the pilot arc module includes a pilot arc rectifying and filtering circuit BR61, a diode D61, a solid-state relay K61, and a power resistor R64; any two phases of the three-phase alternating current are connected to a pilot arc rectifying and filtering circuit BR61 through a pilot arc transformer T61; the negative output of the pilot arc rectification filter circuit BR61 is sequentially connected with a diode D61, a power end of a solid-state relay K61 and a power resistor R64 in series and then is respectively connected with the negative secondary inverter units of the main circuit secondary inverter circuits; the control end of the solid-state relay K61 is connected with a digital control system; the positive outputs of the pilot arc rectification filter circuit BR61 are respectively connected with the negative outputs of the main circuits.
The digital control system comprises a DSC minimum system, a fault detection circuit, a board-level power supply module, an ADC sampling module, a PWM driving module, a CAN signal processing module and a gun signal control circuit. The fault detection circuit comprises an overheat detection circuit, a three-phase open-phase detection circuit, an overvoltage detection circuit, an undervoltage detection circuit and an overcurrent detection circuit.
In this embodiment, the DSC minimum system adopts an ARM microprocessor based on a Cortex-M4 kernel, and combines an external clock circuit, a JTAG debug and download circuit, an external reset circuit, and the like. The output of the energy supply main circuit is directly regulated and controlled by connecting the plate-level power supply module, the ADC sampling module, the PWM driving module, the fault detection circuit and a plurality of functional modules of the gun signal control circuit. The CAN signal receiving and transmitting processing module is used for carrying out signal isolation transmission with a DSC minimum system through a high-speed optocoupler, and a bus end adopts a TVS diode to protect a CAN receiving and transmitting chip; the gun signal control circuit is divided into a starting circuit and a stopping circuit, is controlled by a inching switch, and transmits a signal to the DSC minimum system through a filter circuit and optical coupling isolation; the PWM driving module is respectively connected with the high-frequency inverter circuit and the secondary inverter circuit of each main circuit and provides a high-frequency inverter driving signal and a secondary inverter driving signal for each main circuit; the secondary inversion signals are output in parallel by adopting the same driving signal, so that the positive and negative output switching synchronization of each main circuit is guaranteed, and the high-frequency inversion driving signals are relatively independent, so that the independent current sharing of each main circuit is guaranteed. The PWM driving module adopts a Darlington tube group chip to amplify and invert a driving signal from a DSC minimum system, and connects a pilot arc control signal into the same Darlington tube group chip to amplify and invert the signal to be transmitted to the pilot arc module.
The board-level power supply module is externally connected with an AC 380V-to-AC 18V transformer, and input alternating current is rectified, filtered and regulated to be required voltage through a voltage management chip. In order to meet the isolation requirements among different modules, a plurality of groups of power supply modules which are not in common with the ground can be designed. The power supply with larger input-output voltage difference can adopt a DC-DC voltage stabilizing chip, so that the power consumption of the control system is reduced; the power supply with smaller pressure difference can adopt a linear voltage stabilization chip, so that the cost of the control system is reduced.
The fault detection circuit sends a high level to the DSC minimum system in a normal state; when a fault occurs, a low level is sent, and an analog filtering mode is adopted. The DSC minimum system enables the EXTI external interrupt mode and immediately enters a fault processing program once a low-level fault signal sent by a fault detection circuit is detected. When an overheating fault occurs, the submerged arc welding equipment normally operates, and the DSC minimum system displays an overheating warning on the human-computer interaction device through the CAN communication network; when any fault of overvoltage, undervoltage, open-phase and overcurrent occurs, the DSC minimum system immediately executes a high-frequency inversion fault soft turn-off program, fault information is displayed on the human-computer interaction device through the CAN communication network, the human-computer interaction device enters a locking state and cannot be operated, the wire feeding device, the feeding device and the trolley walking device stop working, and the submerged arc welding equipment CAN be recovered to be normal again when needing to be closed and restarted.
The overheat detection circuit, the overvoltage detection circuit, the undervoltage detection circuit and the overcurrent detection circuit can all adopt the prior art. The overheating detection circuit is used for isolating and transmitting voltage mutation caused by temperature change to a DSC minimum system through a temperature control switch; the overvoltage detection circuit and the undervoltage detection circuit sample and transmit test voltage to the comparator through the voltage dividing resistor to compare with reference voltage to judge whether overvoltage and undervoltage faults exist; the overcurrent detection circuit judges whether overcurrent exists by detecting whether voltages at two ends of power current channels of each switching device of the energy supply main circuit inversion module reach a threshold value in working.
As shown in fig. 4, the three-phase open-phase detection circuit includes three optocouplers, four comparators, an NPN transistor Q32, a diode D31, a resistor R38, a PNP transistor Q31, and a capacitor C32; the four comparators are a comparator U1A, a comparator U1B, a comparator U4A and a comparator U4B respectively; the three optical couplers are an optical coupler U2, an optical coupler U3 and an optical coupler U5.
The three-phase alternating current is respectively connected to the primary side input ends of the three optocouplers through current-limiting resistors; the primary side output ends of the three optical couplers are connected, and the primary sides of the three optical couplers are connected with a diode in parallel in an inverted way; the input ends of the three optical coupler secondary sides are connected with signal voltage and are respectively connected to the non-inverting input ends of the comparator U1A, the comparator U1B and the comparator U4B in a one-to-one mode; the output ends of the secondary sides of the three optical couplers are connected to the ground of the signal voltage; the inverting input ends of the comparator U1A, the comparator U1B and the comparator U4B are connected with a reference voltage; the output ends of the comparator U1A, the comparator U1B and the comparator U4B are connected, and the signal voltage and the base electrode of an NPN triode Q32 are connected; the NPN triode Q32, the diode D31, the resistor R38, the PNP triode Q31 and the capacitor C32 form a capacitor charging circuit; when the circuit works, the capacitor C32 is charged when the base electrode of the NPN triode Q32 is at a high level, and the capacitor C32 is discharged when the base electrode of the NPN triode Q32 is at a low level; the non-inverting input end of the comparator U4A is connected with a reference voltage, the inverting input end of the comparator U4A is connected with the ground of the signal voltage through a capacitor C32, and the output end of the comparator U4A is connected with a DSC minimum system. And comparing the capacitor voltage with the reference voltage by using a comparator to judge whether the phase is open or not.
When the three-phase alternating current is normal, the three optocouplers U2, U3 and U5 are alternately conducted, the voltages of the non-inverting input ends of the comparators U1A, U1B and U4B are alternately pulled down, the base of the NPN triode Q32 is in a low level for a long time, the PNP triode Q31 cannot be conducted, the voltage of the non-inverting input end of the comparator U4A is always higher than that of the inverting input end, and the comparator U4A outputs a high level; when three-phase alternating current is out of phase, zero point exists in phase voltage, and due to the fact that the optical couplers have conduction threshold values, the three optical couplers cannot be conducted within a certain period of time periodically, so that the base voltage of the NPN triode Q32 rises periodically, the NPN triode Q32 is conducted, the PNP triode Q31 is conducted, the capacitor C32 is charged periodically, the voltage of the reverse-phase input end of the comparator U4A is always higher than that of the positive-phase input end, and the comparator U4A continuously outputs low-level fault signals to the DSC minimum system.
The three-phase alternating current is respectively connected with the power supply circuit and the three-phase rectifying and filtering circuit of each main circuit through the surge suppression circuit. As shown in fig. 5, the surge suppression circuit includes an ac contactor; the three-phase alternating current is connected to a three-phase rectifying and filtering circuit of each main circuit through an alternating current contactor; any two phases at the front stage of the AC contactor are respectively connected in series to corresponding two phases at the rear stage of the AC contactor through a synchronous switch S1B/S1C and a power resistor R51/R52; the rear ends of the synchronous switch S1B and the synchronous switch S1C are respectively connected to a power supply circuit; any two phases at the front stage of the AC contactor are connected to the A1 port of the AC contactor through a synchronous switch S1A and connected to the A2 port of the AC contactor through a delay closing switch S2; in operation, the synchronous switch S1A, the synchronous switch S1B and the synchronous switch S1C are synchronously closed or synchronously opened.
When the synchronous switches S1A, S1B and S1C are closed, the filter capacitor of the three-phase rectification filter circuit in the main circuit starts to be precharged through the power resistors R51 and R52, the power supply starting fault detection processing system of the digital control system is started, and the delay closing switch S2 is closed in a delayed mode; when the time delay closing switch S2 closes the alternating current contactor K1, the filter capacitor of the three-phase rectifying and filtering circuit in the main circuit is charged with higher voltage, and the surge can be restrained from occurring.
The utility model discloses welding method of submerged arc welding equipment is: in the welding process, a digital control system is set to enable each main circuit to output in any one mode of constant current equalizing output, constant voltage equalizing output and square wave equalizing output.
The output of each main circuit in a constant current and current sharing output mode refers to that: the digital control system samples the output current of each main circuit respectively, and executes a current autonomous PID closed-loop regulation strategy to each main circuit to regulate the magnitude of respective high-frequency inversion PWM in a shunt way;
the output of each main circuit in a constant voltage and current sharing output mode refers to that: the digital control system samples the total output voltage,
Respectively sampling output currents of each main circuit, executing a double-closed-loop autonomous regulation strategy, updating a current set value in real time by adopting voltage PID (proportion integration differentiation) closed-loop regulation and control on an outer ring, and adopting current autonomous PID closed-loop regulation and control on an inner ring;
specifically, as shown in fig. 6, a double closed-loop autonomous regulation strategy of an outer loop and an inner loop is adopted, and the purpose of constant voltage and current sharing can be achieved when a plurality of main circuits are connected in parallel; the target voltage is transmitted to a DSC minimum system through communication of a man-machine interaction device, a voltage measuring circuit is arranged to transmit the measured voltage at two ends of the load to the DSC minimum system for ADC sampling and digital filtering, the difference value between the target voltage and the actual voltage is calculated, and the difference value is sent to an outer ring PID to calculate given current to be used as the target current of an inner ring; each main circuit is provided with a current loop and a current sampling circuit, the output current value sampled and processed by each main circuit is compared with a given current, and the obtained difference value is sent to the inner loop PID of each main circuit to calculate the duty ratio of each high-frequency driving signal and output as the adjustment result;
the output of each main circuit in a square wave current-sharing output mode refers to that: output polarity conversion, frequency and duty ratio are regulated and controlled by controlling a secondary inverter circuit, a pilot arc module and a coupling power inductor are used for assisting polarity switching and arc restriking, and output waveforms are cooperatively controlled by combining waveform control and a two-way autonomous PID closed-loop regulation strategy.
When each main circuit outputs in a square wave current-sharing output mode, the pilot arc module and the coupling power inductor are used for assisting polarity switching and arc restriking, and the following steps are included: when the main circuit outputs a forward peak value in the middle period, coupling power inductance energy storage filtering is carried out, and the pilot arc module is closed; when the output time of the main circuit output forward peak reaches a set threshold value, the output of the pilot arc module is started, and the output of the pilot arc module is 0; in the initial stage of the output reverse peak value of the main circuit, if the output arc is extinguished, the coupling power inductor and the arc maintenance module simultaneously apply reverse large voltage between the welding gun and the workpiece to assist arc reignition, and if the output arc is maintained, the coupling power inductor continues current and the arc maintenance module is closed; and when the electric arc is successfully reignited and the output current is greater than or equal to the set current value and is maintained in the set time, closing the output of the arc maintenance module, starting energy storage filtering by the coupling power inductor, and otherwise, timing again to continue arc maintenance.
The utility model discloses submerged arc welding equipment's welding process as follows: the welding mode and the welding parameters are sent to a digital control system by a human-computer interaction device through a CAN communication network, a start button is pressed, a positive output channel is opened by a secondary side of an energy supply main circuit, a primary side is inverted at a high frequency with a large duty ratio to start arc in a no-load mode, the digital control system controls a wire feeding device to assist in arc starting through the CAN communication network, and a feeding device is controlled to start to bury welding flux; after the arc striking is successful, the digital control system sends an arc striking success signal, the wire feeding device starts to normally feed wires, the trolley walking device starts to move, the DSC minimum system carries out sampling calculation and inversion duty ratio closed-loop adjustment at the speed of quadruple high-frequency inversion frequency, and the output state is updated on the human-computer interaction device in real time through the CAN communication network; and in the alternating current square wave output state, the secondary inverter circuit periodically switches the positive polarity and the negative polarity, and the pilot arc module is started. And when a stop button is pressed down, the digital control system sends a stop signal through the CAN communication network, the wire feeding device, the trolley walking device, the feeding device and the arc maintenance module stop working, the energy supply main circuit enters an arc collecting program, and the human-computer interaction device returns to a parameter setting interface.
The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be equivalent replacement modes, and all are included in the scope of the present invention.
Claims (5)
1. A multifunctional high-power submerged arc welding device is characterized in that: the submerged arc welding machine comprises an energy supply main circuit, a digital control system, a cooling device, a submerged arc trolley, a man-machine interaction device and a power supply circuit; the submerged arc trolley and the man-machine interaction device are respectively in signal connection with the digital control system; the three-phase alternating current is respectively and electrically connected with the cooling device, the submerged arc trolley, the human-computer interaction device and the digital control system through the power supply circuit;
the energy supply main circuit comprises at least two main circuits which are connected in parallel and a pilot arc module;
each main circuit comprises a three-phase rectifying and filtering circuit, a high-frequency inverter circuit, a power transformer, a high-frequency rectifying and filtering circuit, a coupling power inductor and a secondary inverter circuit which are connected in sequence; the three-phase rectification filter circuit is connected with three-phase alternating current; the high-frequency inverter circuit is in full-bridge inversion; the secondary side of the power transformer is provided with a middle tap, and two ends of the secondary side of the power transformer are connected with a high-frequency rectifying and filtering circuit; the high-frequency rectifying and filtering circuit comprises a positive output rectifying and filtering circuit and a negative output rectifying and filtering circuit; the coupling power inductor comprises two inductors; the secondary inverter circuit comprises a positive secondary inverter unit and a negative secondary inverter unit; one inductor of the coupling power inductor is connected in series between the positive output rectifying and filtering circuit and the positive secondary inverter unit, and the other inductor is connected in series between the negative output rectifying and filtering circuit and the negative secondary inverter unit; the junction of the positive secondary inversion unit and the negative secondary inversion unit is used as the positive output of the main circuit to be connected with a load; the middle tap of the secondary side of the power transformer is used as the negative output of the main circuit and is connected with a load;
and the pilot arc module is respectively connected with the negative output of the main circuit and the negative secondary inversion unit.
2. The multifunctional high power submerged arc welding apparatus of claim 1, characterized in that: the pilot arc module comprises a pilot arc rectifying and filtering circuit BR61, a diode D61, a solid-state relay K61 and a power resistor R64;
any two phases of the three-phase alternating current are connected to a pilot arc rectifying and filtering circuit BR61 through a pilot arc transformer T61; the negative output of the pilot arc rectification filter circuit BR61 is sequentially connected with a diode D61, a power end of a solid-state relay K61 and a power resistor R64 in series and then is respectively connected with the negative secondary inverter units of the main circuit secondary inverter circuits; the control end of the solid-state relay K61 is connected with a digital control system; the positive outputs of the pilot arc rectification filter circuit BR61 are respectively connected with the negative outputs of the main circuits.
3. The multifunctional high power submerged arc welding apparatus of claim 1, characterized in that: the three-phase alternating current is respectively connected with the power supply circuit and the three-phase rectification filter circuit of each main circuit through the surge suppression circuit;
the surge suppression circuit comprises an alternating current contactor; the three-phase alternating current is connected to a three-phase rectifying and filtering circuit of each main circuit through an alternating current contactor; any two phases at the front stage of the AC contactor are respectively connected in series to corresponding two phases at the rear stage of the AC contactor through a synchronous switch S1B/S1C and a power resistor R51/R52; the rear ends of the synchronous switch S1B and the synchronous switch S1C are respectively connected to a power supply circuit; any two phases at the front stage of the AC contactor are connected to the A1 port of the AC contactor through a synchronous switch S1A and connected to the A2 port of the AC contactor through a delay closing switch S2; in operation, the synchronous switch S1A, the synchronous switch S1B and the synchronous switch S1C are synchronously closed or synchronously opened.
4. The multifunctional high power submerged arc welding apparatus of claim 1, characterized in that: the digital control system comprises a DSC minimum system and a fault detection circuit; the fault detection circuit comprises an overheat detection circuit, a three-phase open-phase detection circuit, an overvoltage detection circuit, an undervoltage detection circuit and an overcurrent detection circuit.
5. The multifunctional high power submerged arc welding apparatus of claim 4, characterized in that: the three-phase open-phase detection circuit comprises three optocouplers, four comparators, an NPN triode Q32, a diode D31, a resistor R38, a PNP triode Q31 and a capacitor C32; the four comparators are a comparator U1A, a comparator U1B, a comparator U4A and a comparator U4B respectively;
the three-phase alternating current is respectively connected to the primary side input ends of the three optocouplers through current-limiting resistors; the primary side output ends of the three optical couplers are connected, and the primary sides of the three optical couplers are respectively connected with diodes D33/D35/D36 in parallel in an inverted way; the input ends of the three optical coupler secondary sides are connected with signal voltage and are respectively connected to the non-inverting input ends of the comparator U1A, the comparator U1B and the comparator U4B in a one-to-one mode; the output ends of the secondary sides of the three optical couplers are connected to the ground of the signal voltage; the inverting input ends of the comparator U1A, the comparator U1B and the comparator U4B are connected with a reference voltage; the output ends of the comparator U1A, the comparator U1B and the comparator U4B are connected, and the signal voltage and the base electrode of an NPN triode Q32 are connected; the NPN triode Q32, the diode D31, the resistor R38, the PNP triode Q31 and the capacitor C32 form a capacitor charging circuit; when the circuit works, the capacitor C32 is charged when the base electrode of the NPN triode Q32 is at a high level, and the capacitor C32 is discharged when the base electrode of the NPN triode Q32 is at a low level; the non-inverting input terminal of the comparator U4A is connected with the reference voltage, the inverting input terminal of the comparator U4A is connected with the ground of the signal voltage through a capacitor C32, and the output terminal of the comparator U4A is connected with the DSC minimum system.
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| CN111992851A (en) * | 2020-08-12 | 2020-11-27 | 华南理工大学 | Multifunctional high-power submerged-arc welding equipment and submerged-arc welding method thereof |
| CN111992851B (en) * | 2020-08-12 | 2024-04-26 | 华南理工大学 | Multifunctional high-power submerged arc welding equipment and submerged arc welding method thereof |
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