RU2361756C1 - Method of mounting "musat" welding apparatus on vehicle - Google Patents

Abstract

FIELD: automotive appliances.

SUBSTANCE: method of mounting welding apparatus on a vehicle comprises mounting a stationary support on internal combustion engine and fitting auxiliary contactless induction five- or seven-phase like-pole generator (2) which incorporates the main and auxiliary rectifier units thereon. Auxiliary pulley is fitted on the vehicle crankshaft to transmit rotation to aforesaid generator. Portable generator control device (1) is arranged in the vehicle cab to receive instructions from control unit, generate output characteristics, stabilisation of the said characteristics in welding and protection of welding unit against operating conditions that deteriorate its performances. Generator excitation coil is connected, via control unit, with the battery and generator output voltage is sent, via control unit, to welding power connectors. Note that the vehicle is furnished with a cable for electric DC welding, cutting and built-up welding.

EFFECT: expanded performances, lower operating and servicing costs.

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Description

The invention relates to specialized equipment intended for 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 with direct current.

Currently, units mounted on single-axle trailers are used as a source of electricity in the field. These units are not sufficiently effective, have a large mass and low maneuverability.

A known method of mounting an automobile welding unit (RU 2042484, MKI6 V23K 9/10, publ. 08.27.1995) in the form of a prefix to standard electrical equipment.

The method does not provide the stationarity of the installation, which limits the possibilities of application.

A known method of operation of the welding unit (RU, 48849, MKI7 V23K 9/10, publ. 10.11.2005), selected for the prototype, including the transmission of rotational energy to the generator from the crankshaft pulley.

In a known utility model, a method for mounting a welding unit is not described.

The objective of the present invention is to develop a method of mounting a specially designed welding unit under the commercial name "MUSAT" on a vehicle equipped with an internal combustion engine, allowing through modernization to obtain specialized equipment suitable for work in field and extreme conditions.

The present invention allows to expand the possibilities of using the vehicle, namely, it allows to carry out welding work without additional labor costs for the installation of special equipment, to reduce the cost of operation and maintenance. The use of an inductor generator with small dimensions allows you to place the generator under the hood of the vehicle, while providing an increased induction frequency, which allows you to get a softer arc with low spatter, high reliability of the initial ignition of the welding arc, arc elasticity and stability of the welding process.

The technical result is achieved by the fact that the method of mounting the welding unit on a vehicle, which consists in modernization, includes installing a stationary site on the internal combustion engine, fixing an additional non-contact five- or seven-phase eponymous pole generator with one-sided electromagnetic excitation, equipped with the main and additional blocks of rectifiers, installation of a pulley on the crankshaft of a vehicle, taking into account the ratio:

D / d≈8500 / N (min ^-1 ),

where D is the diameter of the crankshaft pulley;

d is the diameter of the generator pulley;

N - nominal revolutions of the engine of the vehicle, ensuring the transmission of rotational energy to the generator from the crankshaft pulley using a drive belt with a tensioning mechanism, the installation of a portable generator control device in the vehicle cabin, which receives commands from the control panel located on the front panel of the device, automatic formation of output characteristics at given modes and parameters, stabilization of characteristics during welding, unit protection from cutting MA, violating the capabilities of the unit, the connection of the generator excitation coil through the control unit with the battery, the output voltage of the generator through the control unit to the power welding connectors, the vehicle is equipped with a cable for manual electric welding, cutting and surfacing with direct current.

The specially developed welding unit “MUSAT” has reduced dimensions, which allows, through the modernization of a vehicle equipped with an internal combustion engine, to obtain specialized equipment designed to work in field and extreme conditions.

Figure 1 presents the General diagram of the unit, figure 2 - control device of the generator (front panel).

The mobile universal welding unit under the commercial name "MUSAT" includes:

- a portable control device for the generator 1, enclosed in a housing containing a single-cycle inverter with an additional demagnetizing winding of the transformer, built on a field-effect transistor, a half-wave output rectifier, an integrated specialized microprocessor, in addition, the control device contains a cooling fan;

- a five- or seven-phase inductor generator 2, electrically connected through contacts 7, 8, 9, 10 and plug connector 3 with a control device 1, equipped with a main and additional rectifier blocks;

- an energy source in the form of a crankshaft of a vehicle, equipped with an additional pulley interconnected with a generator pulley by means of a belt drive with a tension mechanism (not shown);

- battery 4, electrically connected through contacts 5, 6 and plug 3 with the control device 1.

The control panel, located on the front panel of the housing, contains a unit for setting operating modes 11 ("welding"; "14 V"; "28 V"), a unit for setting welding current 12, a unit for setting welding modes 13, respectively, the first mode is from 25 to 140 A ; the second mode is from 140 to 200 A, the third mode is 200-315 A (for a seven-phase engine).

The visual unit for monitoring the operation of the unit, also located on the front panel of the case, includes an ammeter 14, equipped with a shunt to expand the limits of measurement of the welding current, an indicator on the control device 15, indicators of the welding modes 16, indicators of the modes of the output voltage 17.

In addition, a power switch 18, welding sockets 19, an stuffing box for cable entry, output voltage terminals of 14 volts and 28 volts, an automatic switch of the control device are located on the device case 1.

The installation of the welding unit on the vehicle is as follows.

On a vehicle’s internal combustion engine, a fixed installation pad is installed and fixed. An additional inductor generator 2 is fixed at the site. For this, paws are made on the generator body 2, by means of which the generator is attached to the installed site by means of a connection. An additional pulley is installed on the crankshaft of the vehicle, taking into account the ratio providing the rated power take-off from the internal combustion engine:

D / d≈8500 / N (min ^-1 ),

where D is the diameter of the crankshaft pulley;

d is the diameter of the generator pulley;

N - rated engine speed of the vehicle.

To ensure the transfer of rotational energy to the generator when the engine is running, the pulleys of the crankshaft and the generator are interconnected by means of a drive belt. To adjust the belt tension, a tension mechanism is additionally installed, for example, in the form of a tension lever connected to the generator housing. Mounting the generator on an internal combustion engine, using specially selected pulleys of the generator and crankshaft make it possible to ensure rotor speed of up to 8500 min ^-1 , the range of welding operations in the range of 25-315 A.

A portable control device for the generator 1 is installed in the vehicle cabin. The design of the control device 1 provides the reception of commands from the control panel, the automatic generation of output characteristics at specified modes and parameters, stabilization of characteristics during welding, protection of the unit from a mode that violates the capabilities of the unit.

The output terminals 9 and 10 of the generator excitation coil through the plug connector 3 and the control unit 1 are connected to the battery 4. The output voltage terminals 7 and 8 of the generator through the control unit 1 are output to the power welding connectors 19. The vehicle is equipped with a cable for manual electric welding, cutting and surfacing by direct current.

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, to obtain a softer arc with low spatter, high reliability of the initial ignition of the welding arc, arc elasticity and stability of the welding process.

Seven-phase generator 2, which is a non-contact, inductor, pole machine of the same name with one-sided electromagnetic excitation, is arranged as follows. The stator of the generator is made of plates of electrical steel, on the inside there are fourteen teeth on which the coils of the seven-phase winding are fixed. Each coil contains 15 turns made by a double wire PET - 200-1,4. The phases are connected by a heptagon, while two coils are connected in series to the phase. The beginnings of 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 sprocket rays move at the end of the excitation coil. The winding is made of PET - 155 wire with a diameter of 1.25 mm, has 550 turns.

The rectifier unit is a half-wave rectifier of seven-phase current 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 rectifying unit is made on ten diodes, an additional rectifier - on five.

The magnetic flux in the stator windings varies in value due to the displacement of the ferromagnetic mass of the rotor, driven by the energy source. The EMF variable is induced in the turns, while the change in the magnetic field is created by the rotation of the “sprocket” of the rotor magnetized by the same poles of the excitation 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.

Generator 2 has the property of self-limitation given maximum current. Self-limitation of the current occurs due to an increase in the inductance in specially selected stator windings with an increase in the frequency of the alternating current, and also due to a decrease in the magnetic flux penetrating the stator coils, while in the latter, at higher currents, its magnetic flux directed against the magnetic field of the rotor increases.

In a specially made five-phase generator (passport FEGT.2000.000-36PS), the rotor can rotate with a maximum frequency of up to 8500 min ^-1 in sealed bearings installed in the generator covers. The direction of rotation on the drive side is right. Rated voltage - 14 V, rated current - 140 A, rated excitation current - 5 A, mass without pulley - 10 kg. The grease in the bearings does not change during the entire service life, which reduces the costs of maintenance and operation.

Small size and weight of the generator allows you to install it on any vehicle.

Below are the technical specifications of one of the options for permanently installed special equipment on a vehicle that allows manual arc welding with coated electrodes.

Welding mode

Type of welding current - constant

Limits of regulation of welding current, A:

- mode 1 - 25-140 -mode 2- 140-200 Rated welding current, A - 160, not less Rated operational voltage, V - 26.4, not less Rated output power, kVA - 4.2, not less

Power Mode 14 V

Type of current - constant Output voltage, V - fourteen Rated current, A - 160 Rated output power, kVA - 2.5

Power Mode 28 V

Type of current - constant Output voltage, V - 28 Rated current, A - 130 Rated output power, kVA - 4.0

The work of a specialized vehicle during welding is as follows.

When performing welding operations, turn on the engine and bring the generator to the nominal operating mode. The welding mode is set from the control unit block 11, the welding current regulation limits are set from block 13, for example, “25-140 A”, and the welding current parameter, for example 3A, is set from block 12. When the modes and parameters are established, the visual control indicators 14, 15, 16, 17 are automatically triggered. Accepting the specified modes and parameters, the microprocessor automatically generates output characteristics, maintains the stability of the specified mode by controlling the excitation current, and provides automated protection within the specified regulation limits. If necessary, other welding parameters are set using blocks 12, 13. When operating in the "welding" mode with regulation limits of 140-200 A and 200-315 A (for a seven-phase generator), increased heating of the generator windings may occur, when indicator 16 reaches a critical temperature starts to blink and there is an automatic transition to the reduced operating mode. Protection from a mode that violates the capabilities of the unit is carried out by automatically turning off the control device.

The overall dimensions of the prototype of the BUG-01 generator control device are, mm 270 × 290 × 140; weight BUG-01 without welding cables no more than 6 kg.

In general, the invention allows to obtain a specialized vehicle for performing welding work in the field with uninterrupted power generation of high power, provides compactness of installed special equipment, small size, minimizing electrical wiring, which greatly simplifies operation and maintenance, while improving welding quality, automation process, the efficiency of switching to different operating modes, the formation of output welding characteristics with a soft start.

Claims (1)

A method of mounting a welding unit on a vehicle, including providing rotational energy to the generator from the crankshaft pulley, characterized in that the vehicle is modernized by installing a stationary site on the internal combustion engine, attaching an additional five-or seven-phase contactless inductor of the same name to the site generator with one-sided electromagnetic excitation, equipped with primary and secondary units rivelers, installing an additional pulley on the crankshaft of the vehicle, taking into account the ratio:
D / d≈8500 / N (min ^-1 ),
where D is the diameter of the crankshaft pulley;
d is the diameter of the generator pulley;
N - nominal revolutions of the vehicle’s engine, ensuring the transmission of rotational energy to the generator from the crankshaft pulley using a drive belt with a tensioning mechanism, the installation of a portable generator control device in the vehicle cabin, which receives commands from the control panel located on the front panel of the device, automatic formation of output characteristics at given modes and parameters, stabilization of characteristics during welding, unit protection from cutting MA, violating the capabilities of the unit, connecting the generator excitation coil through the control unit to the battery, outputting the generator output voltage through the control unit to power welding connectors, equipping the vehicle with a cable for manual electric welding, cutting and surfacing with direct current.

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