CN215601193U - Power supply device and welding machine system - Google Patents
Power supply device and welding machine system Download PDFInfo
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- CN215601193U CN215601193U CN202120568125.XU CN202120568125U CN215601193U CN 215601193 U CN215601193 U CN 215601193U CN 202120568125 U CN202120568125 U CN 202120568125U CN 215601193 U CN215601193 U CN 215601193U
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Abstract
The application provides a power supply device and a welding machine system. The power supply device includes: a direct current bus; the first conversion module is connected to the direct current bus and converts alternating current of an external power supply into direct current transmitted on the direct current bus; the second conversion module is connected to the direct current bus and converts direct current on the direct current bus into direct current or alternating current adaptive to an external load; and the energy storage module is connected to the direct current bus and comprises an energy storage unit and a bidirectional switching unit coupled between the direct current bus and the corresponding energy storage unit, in a first working mode, the bidirectional switching unit is in a conduction state of only allowing current to flow into the energy storage unit from the direct current bus in a single direction, so that an external power supply can charge the energy storage module while supplying power to an external load, and in a second working mode, the bidirectional switching unit is in a conduction state of only allowing current to flow into the direct current bus from the energy storage unit in a single direction, so that the external power supply and the energy storage module can supply power to the external load at the same time.
Description
Technical Field
The utility model relates to a power supply technology, in particular to a power supply device and a welding machine system.
Background
At present, the operation mileage of the operation railways in China exceeds 14 kilometers, wherein the operation mileage of high-speed rails exceeds 3.5 kilometers, and both the operation mileage and the high-speed rails are in the first place of the world. The welding technology (e.g. seamless welding technology) of steel rails is one of the key links for ensuring the safe and comfortable operation of high-speed rails. As an advanced steel rail welding technology, the flash welding technology has the advantages of good welding quality, high operation efficiency and the like. Therefore, the flash welding technology is widely applied to the construction of seamless lines of high-speed railways, urban rail transit and the like.
Welder systems usually require a high-power supply to supply power, for example, flash welders mostly adopt a high-power alternating-current diesel generator set as a power supply device. However, the variety and complexity of the application environment makes the design of power supply devices challenging. For example, two phases of three phases of a diesel generator set are often used as a main power supply of a welder in the existing steel rail welding technology, and three phases of other auxiliary equipment of the welder are often used as auxiliary power supplies, so that the three phases of the diesel generator set are seriously unbalanced, the service life of the equipment is shortened, and the maintenance cost is increased. In addition, when urban rail transit rail welding construction, especially subway tunnel, long and big tunnel construction, diesel generating set has the noise big, the tail gas black smoke discharges much, pollutes seriously and injures operating personnel health scheduling problem. In addition, in a plateau environment, the diesel generator set has the problems of fast power reduction, low power generation efficiency, difficulty in meeting normal operation and the like.
SUMMERY OF THE UTILITY MODEL
In order to solve or at least alleviate one or more of the existing problems, such as those described above, the present application provides the following technical solutions.
According to an aspect of the present application, there is provided a power supply apparatus. The power supply device includes:
a direct current bus;
the first conversion module is connected to the direct current bus and is configured to convert alternating current from an external power supply into direct current transmitted on the direct current bus;
the second conversion module is connected to the direct current bus and is configured to convert the direct current transmitted on the direct current bus into direct current or alternating current adaptive to an external load; and
the energy storage module is connected to the direct current bus and comprises one or more energy storage units and a bidirectional switching unit coupled between the direct current bus and the corresponding energy storage unit,
in a first working mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the direct current bus into the energy storage unit in a unidirectional mode, so that the external power supply also charges the energy storage module while supplying power to the external load, and in a second working mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the energy storage unit into the direct current bus in a unidirectional mode, so that the external power supply and the energy storage module supply power to the external load simultaneously.
Alternatively or additionally to the above, the power supply apparatus according to an embodiment of the application further includes a control unit coupled to the first converting module and the bidirectional switching unit, and configured to generate a control command based on at least one or more of a power supply capability of the external power source, a power demand of the external load, and a power storage level of the energy storage module.
Alternatively or additionally to the above, according to an embodiment of the present application, the control unit generates the control command in the following manner:
generating a control command to place the power supply device in the second operating mode if the power demand of the external load is greater than a predetermined power demand threshold, otherwise generating a control command to place the power supply device in the first operating mode.
Alternatively or additionally to the above, according to an embodiment of the present application, the control unit generates the control command in the following manner:
generating a control command to place the power supply device in the second operating mode if the power supply capability of the external power source is less than or equal to a predetermined power supply capability threshold,
generating a control command to place the power supply in the second mode of operation if the power supply capability of the external power source is greater than the power supply capability threshold and the power demand of the external load is greater than a predetermined power demand threshold,
generating a control command to place the power supply device in the first operating mode if the power supply capability of the external power source is greater than the power supply capability threshold and the power demand of the external load is less than or equal to the power demand threshold.
Alternatively or additionally to the above, according to an embodiment of the present application, the control unit generates the control command in the following manner:
and if the energy storage level of the energy storage module is greater than a predetermined electric quantity threshold value or the external power supply is unavailable, generating a control command for enabling the power supply device to be in a third working mode, wherein in the third working mode, the bidirectional switching unit is in a conduction state of only allowing current to flow into the direct current bus from the energy storage unit in a single direction, and the first conversion module cuts off the connection between the external power supply and the direct current bus or the external power supply stops outputting electric energy, so that only the energy storage module supplies power to the external load.
Alternatively or additionally to the above, according to an embodiment of the present application, the control unit generates the control command in the following manner:
generating a control command to place the power supply device in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold and the power demand of the external load is greater than a predetermined power demand threshold,
generating a control command to place the power supply device in the first operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold and the power demand of the external load is less than or equal to a predetermined power demand threshold.
Alternatively or additionally to the above, according to an embodiment of the present application, the control unit generates the control command in the following manner:
generating a control command to place the power supply in the first operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is less than or equal to a predetermined power demand threshold and the power supply capability of the external power source is greater than the power supply capability threshold,
generating a control command to place the power supply in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is greater than a predetermined power demand threshold and the power supply capability of the external power source is greater than the power supply capability threshold,
generating a control command to place the power supply in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is greater than a predetermined power demand threshold and the power supply capability of the external power source is less than or equal to the power supply capability threshold,
generating a control command to place the power supply device in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is less than or equal to a predetermined power demand threshold, and the power supply capacity of the external power source is less than or equal to the power supply capacity threshold.
Alternatively or additionally to the above, a power supply device according to an embodiment of the application, wherein the external power source comprises at least one of: a power grid power supply and a generator.
Alternatively or additionally to the above solution, according to the power supply device of an embodiment of the present application, the power supply capacity of the external power source is expressed by the set power of the charger.
Alternatively or additionally to the above, in an embodiment of the power supply apparatus, the first conversion module is a charger, and the second conversion module includes at least a DC-AC converter.
Alternatively or additionally to the above, according to an embodiment of the present application, the energy storage unit includes a lithium ion hybrid capacitor.
Alternatively or additionally to the above, according to an embodiment of the present application, the bidirectional switching unit is a power electronic bidirectional switch located at an incoming line end and/or an outgoing line end of the energy storage unit, and the power electronic switch is composed of an IGBT.
Alternatively or additionally to the above solution, according to an embodiment of the application, the external load is a flash welder, and the control unit is configured to generate the control command in real time based on the power supply capability of the external power source, the power demand of the external load and the energy storage level of the energy storage module, so that the power supply device is in the matched operating mode at different stages of the flash welding process.
Further, according to another aspect of the present application, a welder system is provided. The welder system includes:
a flash welding machine; and
the power supply device, wherein the external load supplied by the power supply device comprises the flash welding machine.
Alternatively or additionally to the above, further comprising an auxiliary device, the external load supplied by the power supply device further comprising the auxiliary device, wherein the auxiliary device comprises at least one of: a water chilling unit, a pump station and an air conditioner.
Alternatively or additionally to the above, a welder system according to an embodiment of the application, wherein the welder is an ac flash welder or a dc flash welder for rail welding.
Furthermore, according to yet another aspect of the present application, there is provided a method for controlling a power supply device, wherein the power supply device comprises a dc bus, a first conversion module adapted to convert ac power from an external power source into dc power transmitted over the dc bus, a second conversion module adapted to convert dc power transmitted over the dc bus into dc power or ac power adapted to an external load, and an energy storage module comprising one or more energy storage units and a bidirectional switching unit coupled between the dc bus and a respective energy storage unit, the method comprising the steps of:
acquiring the states of the external power supply, the external load and/or the energy storage unit;
generating a control command to place the power supply device in a first operation mode or a second operation mode based on the acquired state,
in the first working mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the direct current bus into the energy storage unit in a unidirectional mode, so that the external power supply also charges the energy storage module while supplying power to the external load, and in the second working mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the energy storage unit into the direct current bus in a unidirectional mode, so that the external power supply and the energy storage module supply power to the external load simultaneously.
Drawings
The above and other objects and advantages of the present application will become more fully apparent from the following detailed description when taken in conjunction with the accompanying drawings.
Fig. 1 shows a power supply device 100 according to an embodiment of the present application.
Fig. 2 shows a power supply device 200 according to another embodiment of the present application.
Fig. 3 shows a method 300 for controlling a power supply device according to another embodiment of the present application.
Detailed Description
The present application will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the application are shown. This application may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. The embodiments described above are intended to be a complete and complete disclosure of the present disclosure, so as to more fully convey the scope of the present application to those skilled in the art.
It is to be understood that the terms first, second, third and the like in the description and in the claims of the present application are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. Furthermore, unless specifically stated otherwise, the terms "comprising," "including," "having," and the like are intended to mean a non-exclusive inclusion.
Fig. 1 shows a power supply device 100 according to an embodiment of the present application. The power supply device 100 includes a dc bus 110, a first conversion module 120, a second conversion module 130, and an energy storage module 140. The first conversion module 120 is coupled to the dc bus 110 and is configured to convert ac power from the external power source 102 to dc power for transmission over the dc bus 110. The second conversion module 130 is connected to the dc bus 110 and configured to convert the dc power transmitted on the dc bus 110 into dc power or ac power adapted to the external load 103. Also, the energy storage module 140 includes one or more energy storage cells 1421, 1422 … … 142n and a bidirectional switching unit 141 coupled between the dc bus 110 and the respective energy storage cells.
Further, in response to a control command from inside or outside the power supply device, the power supply device is in a first operation mode in which the bidirectional switching unit 141 is in a conduction state that allows only a unidirectional flow of current from the dc bus 110 into the energy storage units 1421, 1422 … … 142n, so that the external power source 102 also charges the energy storage module 140 while supplying power to the external load 103. In addition, in response to a control command from inside or inside the power supply device, the power supply device may be further in a second operation mode, in which the bidirectional switching unit 141 is in a conducting state that only allows current to flow from the energy storage units 1421, 1422 … … 142n to the dc bus 110 in a unidirectional manner, so that the external power source 102 and the energy storage module 140 supply power to the external load 103 at the same time.
In the embodiment illustrated in fig. 1 and described below with reference to fig. 2, the external loads supplied by the power supply device have a multiplicity of applications. Exemplary external loads include a flash welder and an auxiliary device in a welder system, wherein the power supply can supply power to either the flash welder or the auxiliary device or both the flash welder and the auxiliary device. It should be noted that the auxiliary device may also adopt a power supply mode different from that of the welding machine according to actual needs. The flash welding machine can be an alternating current flash welding machine and can also be a direct current flash welding machine. The auxiliary device described herein may comprise at least one of the following: a water chilling unit, a pump station and an air conditioner.
The power supply device 100 may switch between different operating modes in response to different control commands: the external power source 102 can charge the energy storage module 140 while supplying power to the external load 103, thereby saving the charging time; or the external power source 102 and the energy storage module 140 are used for supplying power to the external load 103 at the same time, so as to ensure stable power supply under some working conditions (for example, in a plateau environment or in a case that the power supplied by the grid power (limited by the wire diameter of the cable) is small). The power supply device can generate a control command based on one or more of the external load demand, the energy storage level of the energy storage module and the power supply state of the external power supply, so that the power supply device is in the most appropriate power supply mode in the using process, stable and sufficient electric quantity is provided, the power supply requirement of the external load 103 is better met, and more durable cruising power supply capacity can be provided under the same electric energy supply.
Preferably, the power supply device 100 is used to power a flash welding machine, and in order to keep the power supply device in a matching operating mode at different stages of the flash welding process, control commands can be generated in real time based on the power supply capability of the external power source, the power demand of the external load, and the energy storage level of the energy storage module. Fig. 2 shows a power supply device 200 according to another embodiment of the present application. The power supply device 200 includes a dc bus 210, a first converting module 220, a second converting module 230, and an energy storage module 240, and is formed by one or more energy storage units, which may be selected from energy storage batteries with high energy density and high power characteristics, and preferably have faster charging and discharging speed, for example, a lithium ion hybrid capacitor. Alternatively, the power supply device 200 may be centrally placed in a separate housing. The power supply apparatus claimed in the present application is not limited thereto and may be separately placed in a plurality of different housings or other carriers.
The first conversion module 220 is coupled to the dc bus 210 and configured to convert ac power from the external power source 202 to dc power for transmission on the dc bus 210. The first converting module 220 is a charger (including an AC-DC converter), and may have an overvoltage protection device, an overcurrent protection device, and the like.
The external power source 202 refers to a power source that is a device or unit external to the power supply, which may include, for example, a grid power source and/or a generator (e.g., a diesel generator set). Optionally, a tail gas purification device is configured for the diesel generating set, so that other harmful substances such as black smoke particles in the tail gas of the diesel engine can be effectively removed. This also has a certain effect on noise reduction and silencing. Optionally, the rated power of the diesel generating set is 110KW-150 KW. Preferably, the power of the diesel generator set is 120 KW.
By employing multiple types of energy sources (including the external power source and the energy storage module within the power supply) and multiple power supply mode configurations, the power supply can be adapted to a greater number of applications. For example, when the power grid and the generator are mutually backup power sources, the energy storage module is matched, so that the welding requirements of steel rails such as high altitude, long and large tunnels can be met while the environmental protection requirements such as low noise and low emission are met. Alternatively, the power supply 200 may be configured with a quick disconnect charging input connector to switch between the grid power source and the generator power source. Such switching may be selected based on the actual operating conditions, for example, switching the switch to the grid power source when the site has grid-powered conditions, and switching the switch to the generator when the site does not have grid-powered conditions. The switching can be automatically switched by a control system through actual working conditions, and can also be manually switched by operators. It should be noted that the scope of the present application is not limited in this regard, and the power supply apparatus 200 may also be powered by both a grid power source and a generator when grid-powered conditions exist on the site. For another example, by introducing an energy storage chemical battery as an energy source, dependence on a power grid can be eliminated, so that the power supply device has better maneuverability; meanwhile, the cooperative configuration of multiple energy sources reduces or avoids the use of a high-functional-rate diesel generator, and is beneficial to meeting the challenge of increasingly strict environmental protection requirements.
The second transformation module 230 is connected to the dc bus 210 and configured to convert the dc power transmitted on the dc bus 210 into dc power or ac power adapted to the external load 203. Here, the external load 203 may include a flash welder 2031 for rail welding and an auxiliary device 2032 thereof. Specifically, the auxiliary devices 2032 may include welder pump stations, crane pump stations, chiller units, air conditioners, electrical outlets, and the like. Illustratively, the second conversion module 230 may include a main DC-AC converter 231 and an auxiliary DC-AC converter 232. The main DC-AC converter 231 may convert the DC power on the DC bus 210 into a single phase AC power suitable for the flash welder 2031, and the auxiliary DC-AC converter 232 may convert the DC power on the DC bus 210 into a three phase AC power suitable for the auxiliary device 2032. It should be noted that, when the welder 2031 is a DC welder, a rectifier transformer and the like may be disposed in the main DC-AC converter 231 to convert the DC power on the DC bus 210 into DC power suitable for the DC welder 2031. The conversion module can be designed with the protection functions of output short circuit, battery side overvoltage and undervoltage, output grounding, power module fault, alternating current side short circuit and the like, so as to ensure the reliability and safety of power supply.
The energy storage module 240 includes a plurality of energy storage units 2421, 2422 and 2423. The number of energy storage units claimed in the present application is not limited thereto and may be any suitable number. For example, the energy storage module may include a plurality of energy storage units or energy storage battery packs connected in parallel, and the design capacity of the energy storage module may be set to not less than 480 KWh. In a typical application scenario, even if no other power source is involved in power supply, the energy storage module with the design capacity of 483.84KWh and in a full power state is enough to provide the electric energy required for welding no less than 60 joints, and the operation duration is more than 15 hours. The energy storage unit can comprise a lithium ion hybrid capacitor, so that the advantages of the lithium ion battery and the super capacitor are achieved: high energy density, high power density, long life, etc. These advantages enable the energy storage unit to match the electrical power demand characteristics of short-time large currents in the flash or upset phase of flash welding (when the welding load is relatively large), which facilitates stable supply of electrical energy. Optionally, the energy storage units operate in a parallel connection mode, so that the total electric quantity of the energy storage module 240 can be effectively increased, and the cruising ability of the welding rail construction operation is further improved.
Optionally, the energy storage module 240 is configured with an automatic heating device, so that the energy storage module 240 can work normally even when the ambient temperature is low. Optionally, the energy storage module 240 is equipped with an overhead chiller to operate the energy storage module in a suitable temperature range (e.g., an interval around 25 ℃). For example, when the temperature of the energy storage module is low, the water chilling unit pumps hot water into the lithium ion hybrid capacitor to heat the lithium ion hybrid capacitor, so that the lithium ion hybrid capacitor is ensured to work in a temperature range capable of exerting the highest efficiency; for another example, when the temperature of the energy storage module is high, the water chilling unit pumps cold water into the lithium ion hybrid capacitor to cool the lithium ion hybrid capacitor, so that the lithium ion hybrid capacitor is ensured to work in a temperature range capable of exerting the highest efficiency. And under the condition of continuous work at high temperature, the circulating liquid is used for cooling the energy storage module 240. Optionally, the energy storage module 240 has a comprehensive battery management system, so as to complete functions of internal battery state acquisition, battery energy balance, battery fault analysis, and the like, and ensure the stability of the operation of the energy storage module 240.
The energy storage module 240 also includes a bidirectional switching unit 241 coupled between the dc bus 210 and the respective energy storage unit. The bidirectional switching unit 241 may be a bidirectional power electronic switch composed of devices such as an IGBT and an SCR. Preferably, the bi-directional power electronic switch may be formed using IGBTs. In the first operation mode, the bidirectional switching unit 241 is in a conducting state that only allows current to flow from the dc bus 210 into the energy storage unit in one direction, so that the external power source 202 can charge the energy storage module 240 while supplying power to the external load 203. In addition, in the second operation mode, the bidirectional switching unit 241 is in a conducting state that only allows current to flow from the energy storage unit to the dc bus 210 in a single direction, so that the external power source 202 and the energy storage module 240 supply power to the external load 203 at the same time.
The power supply device (e.g., the power supply device 100, 200) according to an embodiment of the present application further includes a control unit. The control unit is configured to generate control commands for causing the power supply device to enter various operating modes (e.g., first and second operating modes) based on at least factors including the power supply capability of the external power source (e.g., external power source 102, 202), the power requirements of the external load (e.g., external load 103, 203), and the energy storage level of the energy storage unit (e.g., energy storage unit 140, 240). It should be noted that, as a unit for realizing the control command generating function, the control unit may be an internal unit of the power supply apparatus or an external unit of the power supply apparatus (for example, integrated with a control unit of an external load). Alternatively, the power supply capacity of the external power source may be represented by the set power of the charger.
The manner in which the control commands are generated is described further below.
Alternatively, the control unit may generate the respective control command based on a comparison between the power demand of the external load and a predetermined load power threshold. In particular, if the power demand of the external load is less than or equal to the predetermined load power threshold, it is indicative of a lesser load power demand, thus generating a control command for bringing the power supply device into the first operating mode; otherwise, indicating that the load power demand is large, in order to ensure sufficient power supply, a control command for causing the power supply device to enter the second operation mode should be generated. Wherein the power requirement of the external load can be obtained by a sensor (such as including but not limited to a sampling circuit, a filter circuit, etc.) configured on the flash welder. The load power threshold may be determined based on power demand characteristics of the load (e.g., time distribution characteristics, dynamic rate of change, etc.), and the like. For example, in a welder application, a percentage value of the maximum load for welding (e.g., 60% of the maximum load) may be taken as the load power threshold. The load power threshold may be fixed or may be dynamically adjusted, which may be determined, for example, based on the phase of operation of the welder.
Generating control commands based on a comparison between the power demand of the external load and the load power threshold is particularly advantageous for conditions in which the external load is subject to fluctuations, for example, a flash welder may fluctuate significantly in power depending on the different operating phases in which it is used during a complete operating cycle. When the fluctuation of the external load is large load (for example, the large power supply power required by the upsetting stage and a part of the flashing stage in the rail flash welding process is met), the control strategy enables the external power supply and the energy storage module to simultaneously supply power to the external load, so that the stable power supply power is ensured. When the fluctuation of the external load is small load, the control strategy enables the external power supply to supply power to the external load and simultaneously charge the energy storage module, so that the charging time is saved. The above-mentioned mode of dynamically adjusting the load power threshold based on different working phases can make the energy storage unit store as much electric energy as possible while satisfying the power supply.
Optionally, the control unit may also generate the control command based on both the power supply capability of the external power source and the power of the external load. In particular, the control command may be generated based on a comparison of the supply capability of the external power source with a supply power threshold and a comparison between the power demand of the external load and a load power threshold.
Wherein the real-time power supply capability of the external power supply can be provided by the external power supply. The supply power threshold may be determined, for example, based on factors such as the power demand characteristics of the load (e.g., setting the supply power threshold to ensure that the demand for a small welding load can be met). The supply power threshold may be fixed or may be dynamically adjusted, for example, depending on the application environment.
For example, when the external power source is a diesel engine and the construction site altitude is high, the supply power threshold may be set larger to make it less likely to trigger the condition for entering the first operation mode, thereby ensuring that sufficient power is supplied to the load in such an application environment.
Alternatively, the control unit may compare the power supply capability of the external power source with a predetermined power supply threshold, and if the power supply capability of the external power source is less than or equal to the predetermined power supply threshold, it indicates that the condition for edge fill welding is not satisfied, whereupon the control unit generates a control command to cause the power supply apparatus to enter the second mode of operation, otherwise, the power requirement of the external load is compared with the predetermined load power threshold. In the subsequent comparison, if the power demand of the external load is less than or equal to the load power threshold, it is indicated that the risk of insufficient power supply due to the edge-fill welding is small, and therefore the control unit generates a command to cause the power supply apparatus to enter the first operation mode, and if the power demand of the external load is greater than the load power threshold, it is indicated that the risk of insufficient power supply due to the edge-fill welding is large, and therefore the control apparatus generates a control command to cause the power supply apparatus to enter the second operation mode.
Optionally, the energy storage level of the energy storage module may also be taken into account during the generation of the control command. Specifically, the control unit may compare the energy storage level of the energy storage module (in the case of a plurality of energy storage units, the energy storage level may be an average value, a sum, a maximum value, or a minimum value of the energy storage levels of the respective energy storage units) with a predetermined electric quantity threshold value and take the comparison result as a basis for the generation of the control command.
Alternatively, if the external power source is not available (e.g., cannot be connected to an external power grid and the diesel generator cannot operate or is not suitable for use (e.g., gases generated during power generation are not easily discharged or a working environment has a limit on a noise level when a long tunnel performs rail welding, etc.)) or if the energy storage level of the energy storage module is greater than a predetermined threshold amount of electricity (e.g., the remaining amount of electricity is greater than 30% or more of the battery capacity), the control unit may generate a control command for causing the power supply apparatus to enter a third operating mode in which the bidirectional switching unit 141 is in a conduction state in which only current is allowed to flow from the energy storage unit to the dc bus 210 in a unidirectional manner, and the first conversion module cuts off the connection of the external power source to the dc bus.
Alternatively, if the energy storage level of the energy storage module is less than or equal to the predetermined charge threshold, the control unit may generate a control command to cause the power supply device to enter the first or second operating mode based on other conditions, for example in combination with the various ways of generating the first and second operating modes as described above.
For example, when taking into account both the energy storage level of the energy storage module and the power demand of the external load, the control commands may be generated in the following manner:
the control unit generates a control command to place the power supply device in the second operating mode if the energy storage level of the energy storage module is less than or equal to the predetermined charge threshold and the power demand of the external load is greater than the predetermined power demand threshold. On the other hand, if the energy storage level of the energy storage module is less than or equal to the predetermined charge amount threshold and the power demand of the external load is less than or equal to the predetermined power demand threshold, the control unit generates a control command to place the power supply device in the first operating mode.
For another example, when the energy storage level of the energy storage module, the power requirement of the external load and the power supply capability of the external power source are taken into consideration simultaneously, the control command may be generated as follows:
if the energy storage level of the energy storage module is smaller than or equal to a predetermined electric quantity threshold value, the power demand of the external load is smaller than or equal to a predetermined power demand threshold value and the power supply capacity of the external power supply is larger than the power supply capacity threshold value, the control unit generates a control command for enabling the power supply device to be in a first working mode;
if the energy storage level of the energy storage module is less than or equal to a predetermined electric quantity threshold value, the power demand of the external load is greater than a predetermined power demand threshold value and the power supply capacity of the external power supply is greater than a power supply capacity threshold value, the control unit generates a control command for enabling the power supply device to be in a second working mode;
if the energy storage level of the energy storage module is smaller than or equal to a predetermined electric quantity threshold value, the power demand of the external load is larger than a predetermined power demand threshold value and the power supply capacity of the external power supply is smaller than or equal to a power supply capacity threshold value, the control unit generates a control command for enabling the power supply device to be in a second working mode; and
the control unit generates a control command to place the power supply device in the second operating mode if the energy storage level of the energy storage module is less than or equal to the predetermined electric quantity threshold, the power demand of the external load is less than or equal to the predetermined power demand threshold and the power supply capacity of the external power supply is less than or equal to the power supply capacity threshold.
The energy storage level of the energy storage unit can be obtained through a sensor configured for the energy storage unit, an integrated battery management system and other devices. The charge threshold may be determined based on factors such as the rated charge of the energy storage unit, for example, set to 30% of the rated charge. The electric quantity threshold value can be fixed or determined according to real-time working conditions.
It is noted that the above described manner of generating the control commands may be performed in real time. That is, the control unit may generate the corresponding control command in real time according to the current state of the power supply capability, the power demand and the energy storage level. For example, when the power supply device is used for supplying power to the flash welding machine, the power requirements of different stages of the flash welding process are dynamically changed, so that the power supply device can be in a matched working mode at each stage of the flash welding process by the above-mentioned manner of generating the control command in real time.
In a welder system according to an embodiment of the present application, a welder is included along with a power supply (e.g., power supplies 100, 200, etc.) as claimed in the present application. Wherein the welder is coupled with the power supply. Further, the welder system may also include auxiliary devices, such as welder pump stations, crane pump stations, chiller units, air conditioners, outlets, and the like. Further, the welder in the welder system is a flash welder for welding the steel rail.
Fig. 3 shows a method 300 for controlling a power supply device according to another embodiment of the present application. The power supply device (e.g., the power supply device 100, 200) includes a dc bus, a first conversion module, a second conversion module, and an energy storage module. The first conversion module is adapted to convert alternating current from an external power source to direct current transmitted on a direct current bus. The second conversion module is suitable for converting the direct current transmitted on the direct current bus into direct current or alternating current which is suitable for an external load. The energy storage module comprises one or more energy storage units and a bidirectional switching unit coupled between the direct current bus and the corresponding energy storage unit. The method 300 includes the following steps.
In step 301, the states of an external power source, an external load, an energy storage unit, etc. are obtained. This can be achieved by sensors configured for the various components, e.g., current meters, voltage meters, power meters, integrated battery management systems.
In step 302, control commands for placing the power supply device in various operating modes are generated based on the acquired states. For example, in the first operation mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the dc bus into the energy storage unit in a single direction, so that the external power supply also charges the energy storage module while supplying power to the external load. For another example, in the second operating mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the energy storage unit to the dc bus in a single direction, so that the external power source and the energy storage module supply power to the external load at the same time. The method 300 for controlling a power supply may cause the power supply to switch between different operating modes in response to different control commands in different scenarios: the external power supply can charge the energy storage module while supplying power to the external load, so that the charging time is saved; or the external power supply and the energy storage module simultaneously supply power to the external load, so that stable power supply under specific working conditions is ensured.
Specifically, step 302 may be implemented by a comparison between the power demand of the external load and a predetermined load power threshold. Specifically, if the power demand of the external load is greater than the load power threshold, generating a control command to cause the power supply apparatus to enter the second operating mode; otherwise, a first control command is generated. Wherein the power requirement of the external load can be obtained by a sensor (for example, including but not limited to a sampling circuit, a filtering circuit, etc.) disposed at the load side. The load power threshold may be determined based on the rated power, the actual output power, etc. of the external power source. The load power threshold may be fixed or determined prior to the comparison operation based on real-time conditions.
Additionally or alternatively to the above, step 302 may also be implemented by a comparison between the power supply capability of the external power source and a predetermined power supply threshold. In particular, if the power supply capacity of the external power source is less than or equal to a predetermined power supply power threshold, it is indicative that the condition for edge fill welding is not fulfilled, and therefore the control unit generates a control command for bringing the power supply device into the second operating mode, otherwise the power demand of the external load is compared with the predetermined load power threshold. In the subsequent comparison, if the power demand of the external load is less than or equal to the load power threshold, it is indicated that the risk of insufficient power supply due to the edge-fill welding is small, and therefore the control unit generates a command to cause the power supply apparatus to enter the first operation mode, and if the power demand of the external load is greater than the load power threshold, it is indicated that the risk of insufficient power supply due to the edge-fill welding is large, and therefore the control apparatus generates a control command to cause the power supply apparatus to enter the second operation mode. Wherein the power supply capability of the external power supply can be provided by the external power supply. The supply power threshold may be determined, for example, based on factors such as the power demand characteristics of the load (e.g., setting the supply power threshold to ensure that the demand for a small welding load can be met). The supply power threshold may be fixed or determined prior to the comparison operation based on real-time operating conditions.
In addition or alternatively to the above, the generation of the control command in step 302 comprises, in addition to taking into account the power of the external load, a comparison between the energy storage level and a predetermined charge threshold. Specifically, if the energy storage level of the energy storage module is less than or equal to the predetermined charge amount threshold and the power demand of the external load is greater than the predetermined power demand threshold, the control unit generates a control command to place the power supply device in the second operating mode. On the other hand, if the energy storage level of the energy storage module is less than or equal to the predetermined charge amount threshold and the power demand of the external load is less than or equal to the predetermined power demand threshold, the control unit generates a control command to place the power supply device in the first operating mode.
In addition or alternatively to the above, the generation of the control command in step 302 comprises a comparison between the energy storage level and a predetermined charge threshold, in addition to taking into account the power of the external load and the power supply capacity of the external power source. For example, if the energy storage level of the energy storage module is less than or equal to a predetermined electric quantity threshold, the power demand of the external load is less than or equal to a predetermined power demand threshold and the power supply capacity of the external power supply is greater than the power supply capacity threshold, the control unit generates a control command to put the power supply device in the first operating mode; if the energy storage level of the energy storage module is less than or equal to a predetermined electric quantity threshold value, the power demand of the external load is greater than a predetermined power demand threshold value and the power supply capacity of the external power supply is greater than a power supply capacity threshold value, the control unit generates a control command for enabling the power supply device to be in a second working mode; if the energy storage level of the energy storage module is smaller than or equal to a predetermined electric quantity threshold value, the power demand of the external load is larger than a predetermined power demand threshold value and the power supply capacity of the external power supply is smaller than or equal to a power supply capacity threshold value, the control unit generates a control command for enabling the power supply device to be in a second working mode; and if the energy storage level of the energy storage module is less than or equal to the predetermined electric quantity threshold value, the power demand of the external load is less than or equal to the predetermined power demand threshold value and the power supply capacity of the external power supply is less than or equal to the power supply capacity threshold value, the control unit generates a control command for enabling the power supply device to be in the second working mode.
The energy storage level of the energy storage module can be obtained through a sensor configured for the energy storage unit, an integrated battery management system and other devices. The charge threshold may be determined based on factors such as the rated charge of the energy storage unit, for example, set to 30% of the rated charge. The charge threshold may be fixed or determined prior to the comparison operation based on real-time operating conditions.
It is noted that some of the block diagrams shown in the figures of the present application are only intended to schematically represent functional entities and do not necessarily correspond to physically or logically separate entities. These functional entities may be implemented in the form of software, or in one or more hardware modules or integrated circuits, or in different networks and/or processor means and/or microcontroller means.
It should also be understood that in some alternative embodiments, the functions/steps included in the methods may occur out of the order shown in the flowcharts. For example, two functions/steps shown in succession may be executed substantially concurrently or even in the reverse order. Depending on the functions/steps involved.
Although only a few embodiments of the present application have been described in detail above, those skilled in the art will appreciate that the present application may be embodied in many other forms without departing from the spirit or scope thereof. Accordingly, the present examples and embodiments are to be considered as illustrative and not restrictive, and various modifications and substitutions may be made therein without departing from the spirit and scope of the present application as defined in the appended claims.
Claims (16)
1. A power supply device, comprising:
a direct current bus;
the first conversion module is connected to the direct current bus and is configured to convert alternating current from an external power supply into direct current transmitted on the direct current bus;
the second conversion module is connected to the direct current bus and is configured to convert the direct current transmitted on the direct current bus into direct current or alternating current adaptive to an external load; and
the energy storage module is connected to the direct current bus and comprises one or more energy storage units and a bidirectional switching unit coupled between the direct current bus and the corresponding energy storage unit,
in a first working mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the direct current bus into the energy storage unit in a unidirectional mode, so that the external power supply also charges the energy storage module while supplying power to the external load, and in a second working mode, the bidirectional switching unit is in a conducting state that only allows current to flow from the energy storage unit into the direct current bus in a unidirectional mode, so that the external power supply and the energy storage module supply power to the external load simultaneously.
2. The power supply device according to claim 1, further comprising a control unit coupled to the first conversion module and the bidirectional switching unit and configured to generate a control command based on at least one or more of a power supply capability of the external power source, a power demand of the external load, and a power storage level of the energy storage module.
3. The power supply device according to claim 2, wherein the control unit generates the control command in the following manner:
generating a control command to place the power supply device in the second operating mode if the power demand of the external load is greater than a predetermined power demand threshold, otherwise generating a control command to place the power supply device in the first operating mode.
4. The power supply device according to claim 2, wherein the control unit generates the control command in a manner of:
generating a control command to place the power supply device in the second operating mode if the power supply capability of the external power source is less than or equal to a predetermined power supply capability threshold,
generating a control command to place the power supply in the second mode of operation if the power supply capability of the external power source is greater than the power supply capability threshold and the power demand of the external load is greater than a predetermined power demand threshold,
generating a control command to place the power supply device in the first operating mode if the power supply capability of the external power source is greater than the power supply capability threshold and the power demand of the external load is less than or equal to the power demand threshold.
5. The power supply device according to claim 2, wherein the control unit generates the control command in the following manner:
and if the energy storage level of the energy storage module is greater than a predetermined electric quantity threshold value or the external power supply is unavailable, generating a control command for enabling the power supply device to be in a third working mode, wherein in the third working mode, the bidirectional switching unit is in a conduction state of only allowing current to flow into the direct current bus from the energy storage unit in a single direction, and the first conversion module cuts off the connection between the external power supply and the direct current bus or the external power supply stops outputting electric energy, so that only the energy storage module supplies power to the external load.
6. The power supply device according to claim 5, wherein the control unit further generates the control command in the following manner:
generating a control command to place the power supply device in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold and the power demand of the external load is greater than a predetermined power demand threshold,
generating a control command to place the power supply device in the first operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold and the power demand of the external load is less than or equal to a predetermined power demand threshold.
7. The power supply device according to claim 5, wherein the control unit further generates the control command in the following manner:
generating a control command to place the power supply in the first operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is less than or equal to a predetermined power demand threshold and the power supply capability of the external power source is greater than the power supply capability threshold,
generating a control command to place the power supply in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is greater than a predetermined power demand threshold and the power supply capability of the external power source is greater than the power supply capability threshold,
generating a control command to place the power supply in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is greater than a predetermined power demand threshold and the power supply capability of the external power source is less than or equal to the power supply capability threshold,
generating a control command to place the power supply device in the second operating mode if the energy storage level of the energy storage module is less than or equal to a predetermined charge threshold, the power demand of the external load is less than or equal to a predetermined power demand threshold, and the power supply capacity of the external power source is less than or equal to the power supply capacity threshold.
8. The power supply device according to claim 1, wherein the first conversion module is a charger and the second conversion module includes at least a DC-AC converter.
9. The power supply device according to any one of claims 2-7, wherein the external power source comprises at least one of: a power grid power supply and a generator.
10. The power supply device according to claim 8, wherein a power supply capability of the external power supply is expressed in a set power of the first conversion module.
11. The power supply device according to claim 1, wherein the energy storage unit includes a lithium ion hybrid capacitor.
12. The power supply device according to claim 1, wherein the bidirectional switching unit is a bidirectional power electronic switch located at an incoming line end and/or an outgoing line end of the energy storage unit, and the power electronic switch is composed of an IGBT.
13. The power supply device according to any one of claims 2-7, wherein the external load is a flash welder, and the control unit is configured to generate control commands based on the power supply capability of the external power source, the power demand of the external load, and the energy storage level of the energy storage module in real time such that the power supply device is in a matched operating mode at different stages of the flash welding process.
14. A flash welder system, comprising:
a flash welding machine; and
the power supply device according to any one of claims 1-13, wherein the external load powered by the power supply device comprises the flash welder.
15. The flash welder system of claim 14, further comprising an auxiliary device, the external load powered by the power supply further comprising the auxiliary device, wherein the auxiliary device comprises at least one of: a water chilling unit, a pump station and an air conditioner.
16. The flash welder system of claim 14, wherein the flash welder is an ac flash welder or a dc flash welder for rail welding.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202120568125.XU CN215601193U (en) | 2021-03-19 | 2021-03-19 | Power supply device and welding machine system |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202120568125.XU CN215601193U (en) | 2021-03-19 | 2021-03-19 | Power supply device and welding machine system |
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| CN215601193U true CN215601193U (en) | 2022-01-21 |
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Address after: 213011 No.99, Wuyi Road, Changzhou City, Jiangsu Province Patentee after: Changzhou CRRC Ruitai Equipment Technology Co.,Ltd. Country or region after: China Patentee after: CRRC Qishuyan Locomotive and Rolling Stock Technology Research Institute Co.,Ltd. Patentee after: 3TH ENGINEERING CO., LTD. OF CHINA RAILWAY CONSTRUCTION 11TH BUREAU Group Address before: 213011 No.99, Wuyi Road, Changzhou City, Jiangsu Province Patentee before: CHANGZHOU RUITAI ENGINEERING MACHINERY Co.,Ltd. Country or region before: China Patentee before: CRRC QISHUYAN INSTITUTE Co.,Ltd. Patentee before: 3TH ENGINEERING CO., LTD. OF CHINA RAILWAY CONSTRUCTION 11TH BUREAU Group |