WO2012040961A1 - 一种交流钢轨焊机 - Google Patents

一种交流钢轨焊机 Download PDF

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Publication number
WO2012040961A1
WO2012040961A1 PCT/CN2010/078833 CN2010078833W WO2012040961A1 WO 2012040961 A1 WO2012040961 A1 WO 2012040961A1 CN 2010078833 W CN2010078833 W CN 2010078833W WO 2012040961 A1 WO2012040961 A1 WO 2012040961A1
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Prior art keywords
generator
current
engine
phase
transformer
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PCT/CN2010/078833
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English (en)
French (fr)
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郑浩
郑全
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广州三业科技有限公司
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Publication of WO2012040961A1 publication Critical patent/WO2012040961A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/04—Flash butt welding
    • B23K11/043—Flash butt welding characterised by the electric circuits used therewith
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/26—Railway- or like rails

Definitions

  • the invention relates to the field of rail transit engineering, in particular to a rail welding machine, in particular to an AC rail welding machine.
  • a three-phase alternating current excitation synchronous generator with constant voltage and constant frequency operation is driven by a diesel engine running at a constant speed.
  • the high-current bidirectional thyristor is connected to the primary winding of the single-phase transformer of the welding equipment, and the output current of the welding is controlled by the system program to control the conduction angle of the triac according to the process requirements. / Change the flow.
  • the auxiliary hydraulic power is supplied by a hydraulic pump that is driven by a three-phase motor.
  • the phase shift voltage regulation Due to the phase shift voltage regulation using the thyristor, the phase shift chopping causes a large amount of higher harmonics to be generated by the current, and the higher harmonic component limits the output power of the transformer and the generator, and causes loss of heat generated by related components and devices.
  • the phase shift voltage regulation reduces the power factor of the generator, which further leads to an increase in energy consumption.
  • a larger technical defect is: the single-phase transformer is directly stepped down for welding, which has the advantages of simple equipment and strong resistance to large short-circuit current, but since the transformer is single-phase operation, it is a common three-phase power supply.
  • the generator When the welding is in the pre-flash phase (the transformer output is approximately short-circuited, it will require more than three times the input power), the generator is suddenly over 100% load, due to the hysteresis of the excitation regulation current, the generator output voltage will inevitably produce a larger Transient drop deviation (transient deviation greater than -30%) The recovery time is 1 ⁇ 2 seconds), which causes the quality of flash solder to drop.
  • it In order to improve the success rate of welding, it is usually equipped with a generator with a capacity of 3 times that of a single-phase transformer ( For example: 50% duty cycle design, 250KVA welding transformer, multi-configuration 750KVA ⁇ 1000KVA generator) .
  • the power of the generator is greatly selected, and the engine to be dragged must also increase the power distribution. Of course, the energy consumption, volume and cost of the system also increase.
  • the existing mobile rail welding machine has the defects of complex structure, large energy consumption, high cost and large volume.
  • the present invention is directed to the deficiencies of the prior art and provides an AC rail welder with low energy consumption.
  • An AC rail welder comprising a hydraulic pump, a generator, an engine, and a single-phase transformer and a pair of welding electrodes; the generator is driven by an engine, the hydraulic pump is driven by a generator, and the generator is electrically connected to a primary winding of the single-phase transformer, The secondary winding of the single-phase transformer is electrically connected to the welding electrode, and the engine includes a governor, wherein the generator is a single-phase permanent magnet generator, including a front input shaft and a rear output shaft, and a front input shaft and an engine spindle mechanical mechanism. Connected, the rear output shaft is mechanically connected to the hydraulic pump.
  • a current transformer for detecting a current of a primary winding of the single-phase transformer and a current-speed regulator, the current transformer is electrically connected to the current-speed regulator, and the current-speed regulator is electrically connected to the governor.
  • the governor is controlled by a current-speed regulator that controls the governor based on the current sensed by the current transformer to achieve current/speed closed-loop regulation.
  • the current-speed regulator is a PID regulator that is closed-loop regulated by current/speed.
  • the flywheel is further provided.
  • the flywheel is usually disposed on the front input shaft of the generator, or may be disposed on the rear output shaft of the generator, or a flywheel may be disposed at the same time on the front input shaft and the rear output shaft of the generator. Further, the flywheel is a steel energy storage inertia wheel.
  • the engine is a diesel engine or a gas engine.
  • the governor that is configured in the engine is typically an electronically controlled governor or an EFI control governor.
  • the terminal welding process of the invention still adopts the method of directly depressurizing the rail flash welding by the single-phase power frequency transformer, but the power supply generator adopts a high-power single-phase permanent magnet generator, because the output voltage of the permanent magnet generator is The speed is linear, and the speed of the engine can be controlled by the program to achieve precise voltage regulation/control flow, which meets the process requirements of variable current welding in each stage.
  • the permanent magnet generator does not need external excitation current to establish voltage and has excellent transient response characteristics, when the load is increased by 100%, the transient voltage deviation is substantially equal to the steady-state voltage deviation.
  • the steady-state voltage deviation of the motor can be ⁇ -2.5%.
  • the auxiliary hydraulic power is provided by the hydraulic pump directly driven by the rear output shaft of the permanent magnet generator.
  • the invention fundamentally solves the problem of phase loss operation of the three-phase generator, thereby greatly improving the efficiency of the generator. Therefore, in the case of the same welding transformer, the capacity of the generator and the engine can be greatly reduced compared with the prior art, such as pressing 50%
  • the duty ratio design, 250KVA welding transformer, the single-phase permanent magnet generator with 400KVA ⁇ 450KVA of the invention can meet the process requirements, and the prior art is usually a three-phase generator with 750 ⁇ 1000KVA.
  • the invention utilizes a generator including two front and rear axles, and the hydraulic power is directly driven by the engine through the rear output shaft of the generator, eliminating the auxiliary power motor and power distribution, and the structure is simpler and more practical.
  • the present invention has the following advantages:
  • the permanent magnet synchronous generator is used as the welding power source, in addition to the stronger transient load capacity than the conventional electric excitation synchronous generator, and the volume is smaller, lighter and more efficient.
  • Mass-produced permanent magnet generators have lower manufacturing costs than electric-excited generators of the same power.
  • the configured engine power is also greatly reduced compared to the previous design.
  • the engine runs at a relatively low speed, which is beneficial to energy consumption and prolong the life of the engine.
  • the equipment of the invention has significant energy saving benefits.
  • the hydraulic pump is directly driven by the rear output shaft of the generator, eliminating the need for associated drive motors and power distribution facilities.
  • the engine output of the AC rail welder is equipped with a flywheel, which improves the transient characteristics of the engine during the pre-flash phase and further improves the welding quality.
  • FIG. 1 is a schematic view showing the structure of an AC rail welder of the present invention.
  • Figure 2 is a schematic view of the structure of a conventional AC rail welder.
  • the AC rail welder of the present invention comprises a hydraulic pump 1, a single-phase permanent magnet generator 2, a flywheel 3, an engine 4, a governor 5, a current-speed regulator 6, a current transformer 7, and a single-phase transformer 8. , welding electrode 9.
  • the AC rail welder is mechanically connected to the flywheel 3 by a spindle of the engine 4, the flywheel 3 is mechanically connected to the front input shaft of the single-phase permanent magnet generator 2, and the rear output shaft of the single-phase permanent magnet generator 2 is mechanically connected to the hydraulic pump 1,
  • the power output of the single-phase permanent magnet generator 2 is electrically connected to the primary winding of the single-phase transformer 8, and the secondary winding of the single-phase transformer 8 is electrically connected to the welding electrode 9, and the welding electrode 9 is electrically connected to the rail 10 during the welding process.
  • the sensing end of the current transformer 7 is mounted on the power output loop of the single-phase permanent magnet generator 2 for detecting the current of the primary winding of the single-phase transformer 8 (the output current of the single-phase permanent magnet generator 2), and the current transformer 7
  • the output of the current-speed regulator 6 is connected to the input of the current-speed regulator 6, and the control output of the current-speed regulator 6 is electrically connected to the governor 5.
  • the working principle of the invention is: coaxially driving the energy storage flywheel 3, the single-phase permanent magnet generator 2 and the hydraulic pump 1 by the diesel engine 4, and the single-phase permanent magnet generator 2 output power terminal electrically connecting the single-phase transformer 8 primary winding, single The phase transformer 8 is subjected to flash welding of the rail 10 through the welding electrode 9 after being stepped down by the secondary winding.
  • the hydraulic power supply system of the hydraulic pump 1 is used by the hydraulic station of the hydraulic power supply system.
  • the current-speed regulator 6 is programmed by the welding current required for the rail welding process.
  • the current-speed regulator 6 feeds back to the governor 5 according to the output current of the single-phase permanent magnet generator 2 sensed by the current transformer 7, and adjusts the operating speed of the engine 4 through the closed loop of the governor 5 to satisfy ( Variable speed ⁇ pressure regulation ⁇ ) process requirements for current regulation.
  • FIG. 2 is a schematic structural view of a conventional AC rail welder.
  • the constant voltage, constant frequency, and electric excitation three-phase synchronous generator 11 is driven by a constant speed running engine 12, the three-phase motor 13 is driven by a three-phase synchronous generator 11, and the hydraulic pump 15 is driven by a three-phase motor.
  • Thyristor 14 and current transformer 17 are disposed in the loop of the primary winding of single-phase transformer 19, current transformer 17 is used to sense current, thyristor 14 is used for phase shift voltage regulation, and current sensing and control system 16 acquires current transformer 17 The conduction angle of the thyristor 14 is controlled after the current signal.
  • the system structure of the invention is quite simple, and the electronic voltage regulator which greatly affects the reliability of the generator is eliminated, and the system reliability is improved.
  • the invention realizes the voltage regulation by directly adopting the speed regulation, cancels the high-power thyristor, saves the system energy-saving and reliability improvement, and because the current waveform is not distorted, the power factor of the generator and the transformer is greatly improved, and the harmonics are caused. The loss is also minimized, the supporting capacity is also reduced, and the welding quality is also guaranteed.
  • the hydraulic pump is driven directly by the generator's rear output shaft, eliminating the associated drive motor and power distribution facilities, and the cost of the complete plant is further reduced.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding Control (AREA)
  • Generation Of Surge Voltage And Current (AREA)
  • Control Of Eletrric Generators (AREA)

Description

一种交流钢轨焊机
技术领域
本发明涉及轨道交通工程领域，特别涉及钢轨焊机，尤其是一种交流钢轨焊机。
背景技术
轨道交通（高铁、普铁、地铁、轻轨、重轨）的高速发展导致了轨道机械质高、量大的需求，其中轨道敷设已全面采用无缝焊接工艺，以致全球大量需求高质量的轨道焊接设备。基于成本、效率与可靠性，目前世界上多采用交流闪光焊接工艺，采用单相变压器降压至 6~7V 后直接碰焊，碰焊电流峰值超过 10 万安培，最大功率超过 500KVA 。由于焊接过程的预闪、顶锻阶段，电源近似被短路而产生很大的冲击电流，另外因焊接工艺的需要必须对输入电压进行调压 / 变流处理，通常是采用双向晶闸管进行移相调压，从而导致电源的功率因素偏低，并产生较大的谐波电流，因而须配置高性能的电源供给系统。当焊接在固定的施工场合，若由市电网供电，问题相对容易解决。但轨道施工通常是移动作业，因而，移动式柴油发电机为常规配置。那么对该移动式柴油发电机的容量、抗冲击能力、电压调节器的励磁能力与调节性能、可靠性均提出较高的要求。
现有技术中，在轨道施工中应用最多的是钢轨焊机的结构示意图如图 2 所示，采用恒速运行的柴油发动机拖动恒压、恒频运行的三相交流电励磁同步发电机。通过大电流的双向晶闸管与焊接设备的单相变压器的初级绕组连接，焊接的输出电流由系统程序根据工艺要求控制双向晶闸管的导通角实现调压 / 变流。辅助液压动力由三相电动机拖动的液压泵提供。由于采用晶闸管进行移相调压，移相斩波导致电流产生大量的高次谐波，高次谐波分量限制了变压器及发电机的输出功率，并导致相关部件、器件发热产生损耗。另外移相调压使发电机的功率因数下降，进一步导致能耗增加。另外，一个更大的技术缺陷是：由单相变压器直接降压方式进行焊接，具有设备简单、抗大短路电流冲击能力强的优点，但由于该变压器是单相运行，对普通的三相电源，特别是常用的柴油机驱动的三相同步发电机，缺一相应用，电机的最高利用率只有0.577，而单相不对称运行导致发电机产生大量的负序电流和零序电流，这些负序电流和零序电流会大大增加发电机的功率损耗及震动，降低了发电机的效率与使用寿命。通常的同步发电机均须采用自动电压调节器进行励磁 / 输出电压调节。当焊接在预闪阶段（变压器输出近似被短路，将需求三倍以上的输入功率），发电机被突加超过100%负载，由于励磁调节电流的滞后，发电机输出电压必然会产生较大的瞬态下跌偏差（瞬态偏差大于-30% ，恢复时间1~2 秒），导致闪光焊接质量下降。为了提高焊接的成功率，通常是选配为单相变压器3倍容量的发电机 ( 例如：50%暂载率设计，250KVA的焊接变压器，多配置750KVA~1000KVA的发电机 ) 。发电机的功率选大了，拖动的发动机也须同时加大配给功率，当然系统的能耗、体积及造价也同时增大了。
现有的移动式钢轨焊机具有结构复杂、能耗大、造价高、体积大等缺陷。
发明内容
本发明针对现有技术的不足，提供一种能耗低的交流钢轨焊机。
一种交流钢轨焊机，包括液压泵、发电机、发动机以及单相变压器以及一对焊接电极；发电机由发动机驱动，液压泵由发电机驱动，发电机与单相变压器的初级绕组电气连接，单相变压器的次级绕组与焊接电极电气连接，发动机包括调速器，其特征在于：发电机为单相永磁发电机，包括前输入轴和后输出轴，前输入轴与发动机的主轴机械连接，后输出轴与液压泵机械连接。
进一步的，还包括用于检测单相变压器的初级绕组的电流的电流互感器以及电流-速度调节器，电流互感器与电流-速度调节器电气连接，电流-速度调节器与调速器电气连接。调速器受电流-速度调节器控制，电流-速度调节器根据电流互感器检测的电流来控制调速器，实现电流/速度闭环调节。
进一步的，所述的电流-速度调节器为以电流/速度闭环调节的PID调节器。
进一步的，还包括飞轮，飞轮通常设于发电机的前输入轴，也可以设于发电机的后输出轴，也可以在发电机的前输入轴和后输出轴同时各设置一个飞轮。进一步的，所述的飞轮为钢制蓄能惯性轮。
进一步的，所述的发动机为柴油机或燃气机。
配置于发动机中的调速器通常为电子控制调速器或电喷控制调速器。
本发明的终端焊接工艺仍然采用由单相工频变压器直接降压进行钢轨闪光焊接的方式，但供电的发电机采用了大功率的单相永磁发电机，因永磁发电机的输出电压与转速成线性关系，由程序控制发动机的转速可达到精确调压/控流，满足各个阶段变电流焊接的工艺要求。又由于永磁发电机不需要外给定励磁电流来建立电压而具有优秀的瞬态响应特性，突加100%的负载时，其瞬态电压偏差基本等于稳态电压偏差。通过优化永磁体的设计可使电机的稳态电压偏差达到≤-2.5%。辅助液压动力由永磁发电机的后输出轴直接拖动液压泵提供。本发明从根本上解决了三相发电机缺相运行的问题，从而大大提高了发电机的效率。所以在同等焊接变压器的情况下，发电机、发动机的容量比现有技术可大大降低，如按 50% 暂载率设计，250KVA的焊接变压器，本发明配置400KVA~450KVA的单相永磁发电机就能满足工艺要求，而现有技术通常是配置750~1000KVA的三相发电机。
本发明利用包括前后两轴的发电机，液压动力由发动机通过发电机的后输出轴直接拖动，省去了辅助动力的电动机及配电，结构更为简单且更为实用。
与现有技术相比，本发明具有如下优点：
1、采用永磁同步发电机作焊接电源，除了比通常的电励磁同步发电机具有更强的瞬态带载能力外，而且体积更小、更轻、效率更高。
2、批量生产的永磁发电机比同功率的电励磁发电机制造成本更低。
3、取消了极大影响发电机可靠性的电子式电压调节器，系统可靠性进一步得以提高。
4、由于直接采用调速实现调压，电流波形没有畸变，而使发电机、变压器的功率因素大大提高，因谐波而导致的损耗也降到最低，焊接质量也更有保证。
5、所配置的发动机功率也相比过往的设计大为下降，另外在小电流工作阶段，发动机以相对较低转速运行，对能耗及延长发动机的寿命均有利。本发明的装备有明显节能效益。
6、液压泵由发电机的后输出轴直接驱动，省却相关的驱动电动机和配电设施。
7、交流钢轨焊机的发动机输出配备飞轮，改善了发动机在预闪阶段的瞬态特性，进一步提高焊接质量。
8、系统结构相当简单，易于推广，而且成套设备的成本也大为下降。
附图说明
图 1 是本发明的交流钢轨焊机的结构示意图。
图 2 是现有交流钢轨焊机的结构示意图。
具体实施方式
以下结合附图对本发明作详细描述。
如图 1 所示，本发明的交流钢轨焊机包括液压泵1、单相永磁发电机2、飞轮3、发动机4、调速器5、电流-速度调节器6、电流互感器7、单相变压器8、焊接电极9。所述的交流钢轨焊机由发动机4的主轴机械连接飞轮3，飞轮3机械连接单相永磁发电机2的前输入轴，单相永磁发电机2的后输出轴机械连接液压泵1，单相永磁发电机2的电源输出端电气连接单相变压器8的初级绕组，单相变压器8的次级绕组电气连接焊接电极9，焊接过程中，焊接电极9电气连接钢轨10。电流互感器7的感应端安装于单相永磁发电机2的电源输出回路，用于检测单相变压器8的初级绕组的电流（单相永磁发电机2的输出电流），电流互感器7的输出端连接电流-速度调节器6的输入端，电流-速度调节器6的控制输出端电气连接调速器5。
本发明的工作原理为：由柴油机4同轴驱动储能飞轮3、单相永磁发电机2及液压泵1，单相永磁发电机2输出电源端电气连接单相变压器8初级绕组，单相变压器8经次级绕组降压后通过焊接电极9对钢轨10进行闪光焊接。液压泵1所产生的液压动力供给系统的液压站使用。电流-速度调节器6根据钢轨焊接工艺所需要的焊接电流由程序进行设定。焊接工作时，电流-速度调节器6根据电流互感器7所感应单相永磁发电机2的输出电流，反馈给调速器5，通过调速器5闭环调整发动机4的运行转速，满足（变速→调压→）调节电流的工艺要求。
图2是现有交流钢轨焊机的结构示意图。恒压、恒频、电励磁三相同步发电机11由恒速运行发动机12驱动，三相电动机13由三相同步发电机11驱动，液压泵15由三相电动机 13 驱动，恒速运行发动机12内置恒速调速器18；单相变压器19是焊接变压器，初级绕组接三相同步发电机11的其中2相输出，次级线圈接焊接电极20，焊机作业时，焊接电极20与钢轨21相连。晶闸管14和电流互感器17设置于单相变压器19的初级绕组的回路中，电流互感器17用于检测电流，晶闸管14用于相移调压，电流检测与控制系统16获取电流互感器17的电流信号后控制晶闸管14的导通角。
从图1、图2对比可以看出，本发明系统结构相当简单，取消了极大影响发电机可靠性的电子式电压调节器，系统可靠性得以提高。本发明由于直接采用调速实现调压，取消了大功率的晶闸管，除系统节能与可靠性提高，更因为电流波形没有畸变，而使发电机、变压器的功率因素大大提高，因谐波而导致的损耗也降到最低，配套容量也因此下降，焊接质量也更有保证。液压泵由发电机的后输出轴直接驱动，省却相关的驱动电动机和配电设施，而且成套设备的成本也进一步下降。

Claims (7)

  1. 一种交流钢轨焊机，包括液压泵（1）、发电机（2）、发动机（4）以及单相变压器（8）以及一对焊接电极（9）；发电机（2）由发动机（4）驱动，液压泵（1）由发电机（2）驱动，发电机（2）与单相变压器（8）的初级绕组电气连接，单相变压器（8）的次级绕组与焊接电极（9）电气连接，发动机（4）包括调速器（5），其特征在于：发电机（2）为单相永磁发电机，包括前输入轴和后输出轴，前输入轴与发动机（4）的主轴机械连接，后输出轴与液压泵（1）机械连接。
  2. 根据权利要求1所述的交流钢轨焊机，其特征在于：还包括用于检测单相变压器（ 8 ）的初级绕组的电流的电流互感器（ 7 ）以及电流-速度调节器（6），电流互感器（7）与电流-速度调节器（6）电气连接，电流-速度调节器（6）与调速器（5）电气连接。
  3. 根据权利要求2所述的交流钢轨焊机，其特征在于所述的电流 - 速度调节器（ 6 ）为以电流 / 速度闭环调节的 PID 调节器。
  4. 根据权利要求1至3任一项所述的交流钢轨焊机，其特征在于：还包括飞轮（3），飞轮（3）设于发电机（2）的前输入轴和/或后输出轴。
  5. 根据权利要求4所述的交流钢轨焊机，其特征在于所述的飞轮（3）为钢制蓄能惯性轮。
  6. 根据权利要求1至3任一项所述的交流钢轨焊机，其特征在于所述的发动机（4）为柴油机或燃气机。
  7. 根据权利要求 1 至 3 任一项所述的交流钢轨焊机，其特征在于所述的调速器（ 5 ）为电子控制调速器或电喷控制调速器。
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