RU202863U1 - MOBILE WELDING UNIT - Google Patents

Abstract

The utility model can be used for manual electric welding, cutting and surfacing with high frequency pulsed current in the absence of stationary power supply. The mobile welding unit includes an alternating current generator in the form of a contactless inductor seven-phase machine of the same name with one-sided electromagnetic excitation. The unit is equipped with an autonomous power source with a capacity of 3.5 kW in the form of an alternator 220/380 V and a transmission unit in the form of a multiplier, made with the possibility of transmitting torque from the rear power take-off shaft of the tractor. The alternator and generator are mounted on a platform fixed to the rear of the tractor frame. The generator excitation coil is connected to the alternator through a 220/28 V step-down transformer and a generator control unit. The generator output voltage is routed directly to the power welding connectors. The welding unit provides the ability to carry out manual electric welding, or cutting, or surfacing of various metals and their alloys with pulsed currents with a frequency of 15-30 kHz with a coated stick electrode.

Description

The utility model refers to a welding unit and mobile special equipment, namely tractors of all models and manufacturers, both wheeled and tracked, which, along with their functional purpose, additionally allow, in the absence of stationary power supply, to carry out manual electric welding, cutting and surfacing of various metals and their alloys by pulsed high-frequency currents.

Known universal welding converter [RU 48849 U1 (ZINAKOVA S.V.) 2005.11.10, the entire document], including a source of energy of rotary motion, mainly a vehicle engine, kinetically connected to a two-winding alternator with an alternating current rectifier into a constant and electrically connected with it, a control unit with terminals for connecting loads and a battery, while the control unit is equipped with a regulator-stabilizer, consisting of functionally electrically interconnected voltage inverter, isolation transformer, rectifier, filter, comparison unit of the voltage stabilizer and short circuit in the voltage circuit 110 / 220 V with a generator overcurrent protection level setter and an output voltage level setter and electrically connected to the generator, control unit and battery.

The disadvantage is the complexity of the design and control, which complicates its practical application.

As a prototype of a mobile welding unit, a mobile universal welding unit transport was adopted [RU 73260 U1 (Usenya V.V., Ovchinnikov A.L., Shangin AM, Ivlev V.A.) motion, kinetically connected to an alternating current generator, a battery and a generator control device with terminals for connecting loads, equipped with an inverter and a rectifier, in which the generator is a contactless, inductor, five- or seven-phase, same-pole machine with one-sided electromagnetic excitation, equipped with a main and additional rectifier units, while the generator is fixed on a platform permanently installed on the vehicle's internal combustion engine, the vehicle's crankshaft is used as an energy source, which is equipped with an additional pulley interconnected with the generator pulley by means of a belt drive with a tensioning mechanism, a device The generator control device is made portable and equipped with a built-in specialized microprocessor, which ensures the receipt of commands from the control panel, automatic generation of output characteristics at specified modes and parameters, stabilization of characteristics during the welding process, protection of the unit from a mode that violates the capabilities of the unit, while the control panel is displayed on the front the panel of the device contains a unit for setting operating modes, a unit for setting a welding current, and a unit for setting welding modes.

The disadvantage is the limited capacity of the unit.

The objective of the claimed utility model is to expand the arsenal of mobile welding units.

The problem is solved by the fact that in a mobile welding unit, including a source of energy of rotational motion, kinetically connected to an alternating current generator, which is a contactless, inductor, seven-phase, like-pole machine with one-sided electromagnetic excitation, equipped with the main and additional rectifier units, portable a generator control device that receives commands, automatically generates output characteristics, stabilizes characteristics during the welding process and protects the unit from a mode that interferes with the capabilities of the unit; the crankshaft of an internal combustion engine connected to the generator through the tractor power take-off shaft is used as an energy source parts of the tractor frame, a platform is permanently installed on which a generator is fixed, designed to perform electric welding of various metals and their alloys in any combination with a stick electrode with any type ohm coverage with high-frequency impulse currents (15-30 kHz), and an alternator (self-excited generator), which is an autonomous power source with a power of 3.5 kW, 220/380 V, the generator excitation coil is connected through a control unit and a step-down transformer 220/28 V with an alternator, the output voltage of the generator is brought directly to the power welding connectors, the mobile tractor welding unit is equipped with a cable for manual electric welding, cutting and surfacing with high-frequency pulsed current (15-30 kHz), the mobile tractor welding unit is equipped with a means of torque transmission from the rear shaft power take-off of the tractor to the transmission unit (multiplier), and from the transmission unit (multiplier) to the generator and alternator. The mobile welding unit includes:

a source of energy of rotational motion, which is used as the crankshaft of the tractor's internal combustion engine;

an alternator (self-excited generator), which is an autonomous power source with a capacity of 3.5 kW, 220/380 V, while the alternator is fixed on a platform permanently installed on the rear of the tractor frame;

an alternating current generator designed to perform electric welding of various metals and their alloys in any combination with a stick electrode with any type of coating with high frequency pulsed currents (15-30 kHz), and is a contactless, inductor, seven-phase, same-pole machine with one-sided electromagnetic excitation, equipped with the main and additional rectifier blocks, while the generator is fixed on a platform permanently installed on the rear of the tractor frame, the generator is connected to the crankshaft of the tractor internal combustion engine through the rear PTO shaft of the tractor, the generator excitation coil is connected through the control unit and the step-down a 220/28 V transformer with an alternator, the generator output voltage is brought directly to the power welding connectors;

a portable generator control device that provides command reception, automatic generation of output characteristics, stabilization of characteristics during welding and protection of the unit from a mode that interferes with the capabilities of the unit, which is connected to the generator and alternator by means of plug connectors.

In addition, the mobile welding unit is equipped with a cable for manual electric welding, cutting and surfacing with a pulsed high frequency current (15-30 kHz), the mobile welding unit is equipped with a means of transmitting torque from the rear PTO shaft of the tractor to the transmission unit (multiplier), and from transfer unit (multiplier) - for generator and alternator.

The use of an inductor generator with six or eight pairs of poles in a specialized vehicle makes it possible to automate the control of the welding process, obtain a softer arc with low spatter, high reliability of the initial ignition of the welding arc, elasticity of the arc and stability of the welding process.

The seven-phase generator, which is a contactless, inductor, like-pole machine with one-sided electromagnetic excitation, is structured as follows. The stator of the generator is made of plates of electrical steel, on the inner side there are fourteen teeth, on which the coils of the seven-phase winding are fixed. Each coil contains 15 turns made with double PET wire - 200-1.4. The phases are connected by a heptagon, with two coils connected in series in the phase. The beginnings of the seven phases are connected to the valves of the rectifier unit. The rotor has eight pairs of poles, is made of a package of plates and is an eight-beam "star".

The excitation coil is an excitation winding on a steel sleeve, fixed in such a way that the beams of the "asterisk" move at the end of the excitation coil. The winding is made with PET-155 wire with a diameter of 1.25 mm, has 550 turns.

The rectifier unit is a seven-phase full-wave rectifier with fourteen diodes. Diodes of direct and reverse polarity are connected in pairs with phase windings. An additional rectifier is made on seven diodes and is designed to power the field winding.

A five-phase generator, unlike a seven-phase one, has a five-phase winding, while the phases are connected by a pentagon. The rotor has six pairs of poles in the form of a six-pointed star. The rectifier unit is made of ten diodes, the additional rectifier is made of five.

The magnetic flux in the stator windings changes in value due to the displacement of the ferromagnetic mass of the rotor, driven by the energy source. A variable electromotive force (EMF) is induced in the turns, while the change in the magnetic field is created by the rotation of the rotor "star", which is magnetized by the same poles of the field coil. The frequency (f) of the EMF induced in the stator windings is proportional to the rotor speed (n) and depends on the number of poles (p), i.e. f = pn / 60.

The generator has the property of self-limiting the maximum current delivered. Self-limitation of the current occurs due to an increase in the inductive resistance in specially selected stator windings with an increase in the frequency of the alternating current, as well as due to a decrease in the magnetic flux penetrating the stator coils, while in the latter, with increased currents, its magnetic flux increases, directed against the magnetic field of the rotor.

In a specially made five-phase generator, the rotor can rotate at a maximum frequency of up to 8000 min-1 in sealed bearings installed in the generator covers. The direction of rotation from the drive side is clockwise. Rated voltage - 14 V, rated current - 140 A, rated excitation current - 5 A, weight without pulley - 3.7 kg. Bearings are not relubricated during their entire service life, which reduces maintenance and operating costs.

The utility model refers to specialized equipment designed to work in field and extreme conditions, which, along with its functional purpose, additionally allows, in the absence of stationary power supply, to carry out manual electric welding, cutting and surfacing of various metals and their alloys by high-frequency pulsed currents (15- 30 kHz), as well as to connect various sources of energy consumption 220/380 V. The use of this technology of high-frequency currents by means of five- or seven-phase contactless generators can significantly (several times) reduce the weight and volume of attached welding equipment.

The torque from the rear PTO shaft of the tractor is transmitted through the cardan shaft to the transmission unit. The transmission unit (multiplier) consists of a shaft and two or more pulleys mounted on this shaft by means of support bearings. Further, the torque from the transmission unit (multiplier) is transmitted by means of belt drives directly to the generator and alternator installed on a platform located at the rear of the tractor frame. At the same time, the operation of additional equipment (generator and alternator) is possible at the minimum permissible engine speed of 1400-1600 rpm, which will significantly save fuel consumption. The generator current control panel is located directly at the welder.

After the transfer of torque from the crankshaft of the internal combustion engine of the tractor through the PTO shaft and the multiplier to the alternator (self-excited alternator 220/380 V), the alternator begins to generate energy. Further, using a 220/12 V or 220/24 V voltage converter, the voltage is transmitted to the input of the power regulator (0-12 V or 0-24 V, 0-30 A), which is built into the portable welding current control unit. Then, from the output terminals of the power regulator, the voltage is transmitted directly to the primary winding of the welding generator. By changing the voltage and current strength of the resistance in the power regulator, the output characteristics of the welding generator are changed.

In general, the utility model makes it possible to expand the arsenal of mobile welding units, obtain a specialized vehicle for performing welding in the field, ensures the compactness of the installed special equipment, small size, minimizes the wiring, which greatly simplifies operation and maintenance, while improving the quality of welding, automation of the process, the formation of output welding characteristics with a soft start, as well as the ability to power any sources of energy consumption of 220/380 V, which can significantly increase the functionality of the tractor and reduce the cost of operation and maintenance.

Claims (1)

A mobile welding unit, including an alternating current generator, made in the form of a contactless inductor seven-phase machine of the same name with one-sided electromagnetic excitation, equipped with a main and additional rectifier units, made with the possibility of kinetic communication with a source of rotational motion energy in the form of a crankshaft of an internal combustion engine of a tractor, characterized in that it is equipped with an autonomous power source with a capacity of 3.5 kW in the form of an alternator 220/380 V and a transmission unit in the form of a multiplier, made with the possibility of transmitting torque from the rear PTO shaft of the tractor to the said generator and alternator, while the alternator and the generator is mounted on a site made with the possibility of fixing it on the rear of the tractor frame, the generator is made with the possibility of performing electric welding with stick electrodes with pulse currents with a frequency of 15-30 kHz, and the generator excitation coil connected to an alternator through a 220/28 V step-down transformer and a generator control unit, configured to automatically generate output characteristics and stabilize them during welding, and the generator output voltage is output directly to the power welding connectors.