WO2022021810A1 - 直流快频次脉冲焊机 - Google Patents

直流快频次脉冲焊机 Download PDF

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Publication number
WO2022021810A1
WO2022021810A1 PCT/CN2021/071093 CN2021071093W WO2022021810A1 WO 2022021810 A1 WO2022021810 A1 WO 2022021810A1 CN 2021071093 W CN2021071093 W CN 2021071093W WO 2022021810 A1 WO2022021810 A1 WO 2022021810A1
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module
terminal
output end
output
flt
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PCT/CN2021/071093
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周志霖
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周志霖
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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
    • B23K9/00—Arc welding or cutting
    • B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
    • B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
    • 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
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means

Definitions

  • the present application relates to a DC fast frequency pulse welding machine.
  • DC fast frequency pulse welding machine is a new generation of low heat input welding equipment.
  • the welding machine uses the latest technology.
  • Advanced welding arc control technology and InterPulse technology to assist welders to reduce heat input to control welding quality to complete these complex welding jobs.
  • the general-purpose argon arc welding machine uses the frequency conversion technology of the 1960s. Although repackaged and renamed, it's essentially the same technology. Science and technology have made great progress in various fields, and metallurgical technology is no exception. The invention of new materials requires new welding techniques.
  • the DC fast frequency pulse welding machine is designed for the welding requirements of new special difficult-to-weld metals.
  • the technical problem to be solved by this application is to provide a DC fast frequency pulse welding machine.
  • the application can easily produce small welds and thus reduce the heat affected zone, the same as the traditional welding process, high adaptability, titanium welding does not require an argon chamber, can use the standard parts of traditional welding, high mobility, can be automated in parts with complex shapes .
  • a DC fast-frequency pulse welding machine includes a unit test module and adopts EP244KE2 chip; the unit test module includes a DPM module for data output; an encoder realizes that welding material parameters are converted into digital parameters; an output end of the unit test module is connected with a program lock;
  • the output end of the unit test module is connected with the main control system, and the main control system is connected with the surge protector, memory, VFP module, remote module, the wake-up unit of the actuator and the cooling fault reporting module;
  • the main control system is connected with the oil pump relay and the flow sensor or switch; the flow sensor or switch controls the start and stop of the oil pump, and is controlled by the remote drive module;
  • the main control system is connected with the welding unit module of the welding machine, so as to realize the control of the welding machine.
  • the DC fast frequency pulse welder is controlled by an ultra-fast power source that controls the arc characteristics and can be programmed to create a precise electromagnetic field that minimizes the heat-affected zone and the width of the arc.
  • These systems provide higher weld quality and control technology far beyond inverters for deeper penetration and narrower welds.
  • the gentle arc produced by the welder makes welding less reliant on the heat sink, while distortion is kept to a minimum.
  • the present application enhances the arc strength or, in the case of low current input, can also have sufficient penetrating power.
  • Critical welds that are very sensitive to heat input can be improved while still achieving full penetration.
  • significant advantages due to the reduction of the weld pool can also be found in the final microstructure when wire bonding is performed. With these excellent properties, the present application is particularly advantageous when welding single crystal and oriented crystal products.
  • the present application has the advantages of reasonable design, low cost, strong durability, safety and reliability, simple operation, time and labor saving, capital saving, compact structure and convenient use.
  • FIG. 2 is an overall wiring diagram of the present application.
  • 3-16 are partial schematic diagrams of various parts of the present application.
  • this application includes a unit test module, using EP244KE2 chip; the unit test module includes a DPM module for data output; an encoder, which converts welding material parameters into digital parameters; the output end of the unit test module is connected with a program lock;
  • the output end of the unit test module is connected with the main control system, and the main control system is connected with the surge protector, memory, VFP module, remote module, the wake-up unit of the actuator and the cooling fault reporting module;
  • the main control system is connected with the oil pump relay and the flow sensor or switch; the flow sensor or switch controls the start and stop of the oil pump, and is controlled by the remote drive module;
  • the main control system is connected with the welding unit module of the welding machine, so as to realize the control of the welding machine.
  • Figure 2 is a layout diagram, including specific characters and the presence or absence of the whole of Figure 2 does not affect the protection scope, and the specific structure is shown in the split partial diagram of Figure 3-15.
  • This application includes a power filter
  • the forward circuit is divided into two circuits, one is connected to the control relay FM2 to control the disconnection of the normally closed switch F6, and the other is connected to the control relay FM1 through the safety resistor R1;
  • the control relay FM2 is connected with the cooler supply module SX6. When the temperature is higher than the set temperature, the control relay FM2 controls the cooler supply module SX6 to start up and the cooler supply module SX6;
  • the control relay FM1 is connected to several current transformers TX1-TX3 and the power supply of the controller; the output terminals of terminals 26 and 27 of the first group 22 of the secondary coil of the current transformer are connected in parallel with the ANT of the integrated circuits EP269A and EP277 and the bridge rectifier filter BR3 ;
  • the terminal 26 of the second group 28 of the secondary coil of the current transformer is output to the parallel capacitors C1-C6 and the resistor R2 through the bridge rectifier filter BR1, and the positive terminal 29 passes through the diode D1 and the parallel surge protector FLT.
  • -C, FLT-L1 and inductor L1 are connected to the work indicator light work and integrated circuit EP217C and integrated circuit EP270;
  • the negative terminal 22 is respectively connected to the stock module and the connector SX5;
  • the positive output terminal 25 and the negative output terminal 24 of the third group 230 of the secondary coil of the current transformer are respectively connected to the connector SX and the integrated circuit EP277;
  • the output end 23, the output end 22 and the output end 21 of the fourth group 15 of the secondary coil of the current transformer are respectively connected to the connector SX5;
  • the output end 16 and the output end 17 of the fifth group 70 of the secondary coil of the current transformer are respectively connected to the bridge rectifier filter BR2.
  • the output ends of the bridge rectifier filter BR2 are connected in parallel with a resistor R3 and a capacitor C7 to filter out interference signals , its output end 20 is connected to the positive terminal 29 of the parallel surge protector FLT-C, FLT-L1 and the inductor L1 through the resistors R4 and R5, and the HV switch; its output end 19 is connected to the input end of the surge protector FLT-L2;
  • the output end 15 and the output end 14 of the sixth group 25 of the secondary coil of the current transformer are respectively connected to the connector SX;
  • the input end 10 of the seventh group 12 of the secondary coil of the current transformer is connected to the controller power supply SX1;
  • the stop/emergency button group SB1 includes a series-connected touch normally closed switch, a normally open switch and an indicator light; a control relay is connected in parallel between the terminal 2 and the terminal 4 of the normally open switch through the line 12 and the line 13;
  • the control relay is connected to line 13 through terminal 43;
  • the terminal 33 of the integrated circuit EP270 is grounded, the terminals 31 and 32 are respectively connected to the output terminals of the surge protector FLT-C and FLT-L1, and the output terminal 30 corresponding to the terminal 31 is connected to the A terminal of the surge protector FLT-L2;
  • the surge protector FLT-L2 After the A terminal of the surge protector FLT-L2 is connected in parallel with the sampling resistor SHUNT and the working motor, it is connected with the STOCK module through the parallel resistors R6-R8;
  • the B end of the surge protector FLT-L2 is connected to the warning light TORCH and the integrated circuit EP217C respectively; the integrated circuit EP217C is connected to the HD and HB ends of the connector SX;
  • the integrated circuit EP277 is connected to the cooling fan motor
  • the integrated circuit EP277 is connected to the STOCK module
  • the connector SX5 is connected to the integrated circuit EP269A;
  • the integrated circuit EP269A is respectively connected to the connector SX2, temperature control warning light and high-speed analog-to-digital converter, filter module and high-voltage power module.
  • the application assigns the circuit on demand, the HEATER heater control circuit, and the ARC EST arc monitoring circuit to realize monitoring. This application realizes high-tech welding of welding machine, temperature monitoring, controlled by program and feedback to minimize heat-affected zone and arc width to create precise electromagnetic field. Arc control and good heat dissipation are achieved.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Arc Welding Control (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

一种直流快频次脉冲焊机，其包括单元测试模块，采用EP244KE2芯片；在单元测试模块中包括DPM模块，进行数据输出；编码器，实现焊接物料参数变为数字参数；在单元测试模块输出端连接有程序锁；单元测试模块输出端连接有主控系统，主控系统连接有电涌保护器、内存、VFP模块、remote模块、执行机构的唤醒单元及冷却故障报模块；主控系统连接有油泵继电器与流量传感器或开关；流量传感器或开关控制油泵的启停，并通过远程驱动模块控制；主控系统连接有焊接机的焊接机组模块，从而实现焊接机的控制。该直流快频次脉冲焊剂设计合理、结构紧凑且使用方便。

Description

直流快频次脉冲焊机 技术领域
本申请涉及直流快频次脉冲焊机。
背景技术
直流快频次脉冲焊机是新一代低热量输入焊接设备,在当今需要完成很多难焊金属的焊接需求下，随着著名的直流快频次脉冲(InterPulse)技术焊接电源的推出，焊机使用了最新的焊弧控制技术和InterPulse技术，来协助焊工减少热量输入以控制焊接品质，来完成这些复杂的焊接工作。目前通用氩弧焊机使用的是六十年代的变频技术。虽然经过重新包裝和重新命名，但本质上是相同的技术。科技在各领域取得了很大进展，冶金技术也不例外。新材料的发明，需要新的焊接技术。而直流快频次脉冲焊机就是针对新的特殊难焊金属的焊接要求而设计的。
诸多在航空航天和相关行业里我们日常要焊的材料，诸如：CMSX-10,In738,713,625,C263,PK33,MAR-M 247，René 80,René 142和钛合金等，可以在没有氩气室和氩气拖罩的情况下完成焊接。同时能极大的减小开裂和变形。
申请内容
本申请所要解决的技术问题总的来说是提供一种直流快频次脉冲焊机。本申请能够轻易产生细小焊缝因而减少热量影响区，与传统焊接过程相同，高适应性，钛焊接无需氩气室，能采用传统焊接的标准配件，高机动性，能自动化在形状复杂的零件。
为解决上述问题，本申请所采取的技术方案是：
一种直流快频次脉冲焊机包括单元测试模块，采用EP244KE2芯 片；在单元测试模块中包括DPM模块，进行数据输出；编码器，实现焊接物料参数变为数字参数；在单元测试模块输出端连接有程序锁；
单元测试模块输出端连接有主控系统，主控系统连接有电涌保护器、内存、VFP模块、remote模块、执行机构的唤醒单元及冷却故障报模块；主控系统连接有油泵继电器与流量传感器或开关；流量传感器或开关控制油泵的启停，并通过远程驱动模块控制；主控系统连接有焊接机的焊接机组模块，从而实现焊接机的控制。
直流快频次脉冲焊机由超快速电源控制电弧特性，可以由程序控制，以尽量减少热影响区和电弧的宽度创建精确的电磁场。这些系统提供了更高的焊接质量和远远超越逆变的控制技术，以实现更深的熔深和更窄的焊缝。焊机产生的柔和的电弧，使焊接更少的依赖散热器，同时变形也保持在最低限度。
本申请增强了电弧力度或者在低电流输入的情况下，也可以有足够的穿透力。可以改进那些对热量输入非常敏感的关键焊接，同时仍然达到完全熔透。此外，当在进行填丝焊的时候，在最终的显微结构上，也可以发现由于熔池的减小而产生的显著优势。这些卓越的特性，本申请在焊接单晶和定向晶产品时特别有优势。
本申请设计合理、成本低廉、结实耐用、安全可靠、操作简单、省时省力、节约资金、结构紧凑且使用方便。
附图说明
图1是本申请的结构示意图。
图2是本申请的整体接线图。
图3-图16是本申请的各部分局部原理图。
具体实施方式
如图1-16，本申请包括单元测试模块，采用EP244KE2芯片；在单元测试模块中包括DPM模块，进行数据输出；编码器，实现焊接物料参数变为数字参数；在单元测试模块输出端连接有程序锁；
单元测试模块输出端连接有主控系统，主控系统连接有电涌保护器、内存、VFP模块、remote模块、执行机构的唤醒单元及冷却故障报模块；主控系统连接有油泵继电器与流量传感器或开关；流量传感器或开关控制油泵的启停，并通过远程驱动模块控制；主控系统连接有焊接机的焊接机组模块，从而实现焊接机的控制。
图2是布置图，包括具体字符及图2整体其有无并不影响保护范围，具体结构见图3-15的拆分局部图。本申请包括电源滤波器；
三相电接电源滤波器后，正向电路分两路，一路接控制继电器FM2，以控制常闭开关F6的断开，另一路通过安全电阻R1接入控制继电器FM1；
控制继电器FM2连接有冷却器供给模块SX6，当高于设定温度，控制继电器FM2控制有冷却器供给模块SX6启动以冷却器供给模块SX6；
控制继电器FM1接入若干电流互感器TX1-TX3及控制器电源；电流互感器次级线圈第一组22的端子26、27输出端并接集成电路EP269A、EP277的ANT及桥式整流滤波器BR3；
电流互感器次级线圈第二组28的端子26，经过桥式整流滤波器BR1输出给并接的电容C1-C6、电阻R2后输出，其中正端子29通过 二极管D1及并联电涌保护器FLT-C、FLT-L1及电感L1接工作指示灯work及集成电路EP217C、集成电路EP270；负端子22分别接stock模块及接线器SX5；
电流互感器次级线圈第三组230正输出端25与负输出端24分别接接线器SX及集成电路EP277；
电流互感器次级线圈第四组15输出端23、输出端22及输出端21分别接接线器SX5；
电流互感器次级线圈第五组70输出端16、输出端17分别接桥式整流滤波器BR2，桥式整流滤波器BR2输出端之间具有并联的电阻R3及电容C7，以滤除干扰信号，其输出端20通过电阻R4、R5，HV开关接并联电涌保护器FLT-C、FLT-L1及电感L1的正端子29；其输出端19接电涌保护器FLT-L2的输入端；
电流互感器次级线圈第六组25输出端15、输出端14分别接接线器SX；
电流互感器次级线圈第七组12输入端10接控制器电源SX1；
控制器电源SX1输出端11通过停起/紧急按钮组SB1
停起/紧急按钮组SB1包括串联的点触的常闭开关、常开开关及指示灯；常开开关的端子2与端子4之间通过线路12及线路13并联有控制继电器；
控制继电器通过端子43接线路13；
在电流互感器次级线圈第七组12输出端9与端子43之间具有并联有控制继电器的线圈及用于监控电缆的时域反射器；
集成电路EP270端子33接地，端子31、32分别接电涌保护器FLT-C、FLT-L1的输出端，端子31对应的输出端子30接电涌保护器 FLT-L2的A端；
电涌保护器FLT-L2的A端并接采样电阻SHUNT及工作电机后，通过并联电阻R6-R8接STOCK模块；
电涌保护器FLT-L2的B端分别接警示灯TORCH及集成电路EP217C；集成电路EP217C接接线器SX的HD及HB端；
集成电路EP277接冷却风扇电机；
集成电路EP277接STOCK模块；
接线器SX5接集成电路EP269A；
集成电路EP269A分别接接线器SX2、温控警示灯及高速模数转换器、滤波模块及高压电模块。本申请按需指配电路、HEATER加热器控制电路、ARC EST电弧监控电路实现监控。本申请实现了焊接机的高新能焊接，温度监控，由程序控制及反馈，以尽量减少热影响区和电弧的宽度创建精确的电磁场。实现了电弧控制、散热良好。

Claims (2)

  1. 一种直流快频次脉冲焊机，其特征在于：包括单元测试模块，采用EP244KE2芯片；在单元测试模块中包括DPM模块，进行数据输出；编码器，实现焊接物料参数变为数字参数；在单元测试模块输出端连接有程序锁；
    单元测试模块输出端连接有主控系统，主控系统连接有电涌保护器、内存、VFP模块、remote模块、执行机构的唤醒单元及冷却故障报模块；主控系统连接有油泵继电器与流量传感器或开关；流量传感器或开关控制油泵的启停，并通过远程驱动模块控制；主控系统连接有焊接机的焊接机组模块，从而实现焊接机的控制。
  2. 根据权利要求1所述的直流快频次脉冲焊机，其特征在于：主控系统包括电源滤波器；
    三相电接电源滤波器后，正向电路分两路，一路接控制继电器FM2，以控制常闭开关F6的断开，另一路通过安全电阻R1接入控制继电器FM1；
    控制继电器FM2连接有冷却器供给模块SX6，当高于设定温度，控制继电器FM2控制有冷却器供给模块SX6启动以冷却器供给模块SX6；
    控制继电器FM1接入若干电流互感器TX1-TX3及控制器电源；电流互感器次级线圈第一组22的端子26、27输出端并接集成电路EP269A、EP277的ANT及桥式整流滤波器BR3；
    电流互感器次级线圈第二组28的端子26，经过桥式整流滤波器BR1输出给并接的电容C1-C6、电阻R2后输出，其中正端子29通过二极管D1及并联电涌保护器FLT-C、FLT-L1及电感L1接工作指示灯work及集成电路EP217C、集成电路EP270；负端子22分别接stock模块及接线器SX5；
    电流互感器次级线圈第三组230正输出端25与负输出端24分别接接线器SX及集成电路EP277；
    电流互感器次级线圈第四组15输出端23、输出端22及输出端21分别接接线器SX5；
    电流互感器次级线圈第五组70输出端16、输出端17分别接桥式整流滤波器BR2，桥式整流滤波器BR2输出端之间具有并联的电阻R3及电容C7，以滤除干扰信号，其输出端20通过电阻R4、R5，HV开关接并联电涌保护器FLT-C、FLT-L1及电感L1的正端子29；其输出端19接电涌保护器FLT-L2的输入端；
    电流互感器次级线圈第六组25输出端15、输出端14分别接接线器SX；
    电流互感器次级线圈第七组12输入端10接控制器电源SX1；
    控制器电源SX1输出端11通过停起/紧急按钮组SB1
    停起/紧急按钮组SB1包括串联的点触的常闭开关、常开开关及指示灯；常开开关的端子2与端子4之间通过线路12及线路13并联有控制继电器；
    控制继电器通过端子43接线路13；
    在电流互感器次级线圈第七组12输出端9与端子43之间具有并联有控制继电器的线圈及用于监控电缆的时域反射器；
    集成电路EP270端子33接地，端子31、32分别接电涌保护器FLT-C、FLT-L1的输出端，端子31对应的输出端子30接电涌保护器FLT-L2的A端；
    电涌保护器FLT-L2的A端并接采样电阻SHUNT及工作电机后，通过并联电阻R6-R8接STOCK模块；
    电涌保护器FLT-L2的B端分别接警示灯TORCH及集成电路 EP217C；集成电路EP217C接接线器SX的HD及HB端；
    集成电路EP277接冷却风扇电机；
    集成电路EP277接STOCK模块；
    接线器SX5接集成电路EP269A；
    集成电路EP269A分别接接线器SX2、温控警示灯及高速模数转换器、滤波模块及高压电模块。
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