CN107052514A - A kind of mini inversion manual arc welder - Google Patents
A kind of mini inversion manual arc welder Download PDFInfo
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- CN107052514A CN107052514A CN201710410395.6A CN201710410395A CN107052514A CN 107052514 A CN107052514 A CN 107052514A CN 201710410395 A CN201710410395 A CN 201710410395A CN 107052514 A CN107052514 A CN 107052514A
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Classifications
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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
-
- 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
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
- B23K9/1043—Power supply characterised by the electric circuit
- B23K9/1056—Power supply characterised by the electric circuit by using digital means
-
- 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
- B23K9/32—Accessories
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Generation Of Surge Voltage And Current (AREA)
- Arc Welding Control (AREA)
Abstract
The present invention relates to a kind of mini inversion manual arc welder, internal control board is designed as three parts, one is power amplifier board, its circuit being laid out is mainly the single-end ortho-exciting inverter circuit being made up of rectifier bridge, electrochemical capacitor, IGBT and diode, main transformer, current detecting transformer, output rectification etc., and radiator and part component；Two be power panel, mainly including upper electricity buffering, Switching Power Supply and IGBT drive circuit；Three be control panel; mainly include the control of PWM output characteristics, floating voltage limitation, excessively stream and overtemperature protection, long-time output short circuit protection circuit; it is designed as the purpose of three pieces of circuit boards; it is not only the size and weight for considering welding machine; the cost factor of transport and after-sales service is further contemplated simultaneously; it is easy to maintenance with reasonable in design, the characteristics of reliable and stable.
Description
Technical field
The present invention relates to a kind of mini inversion manual arc welder, belong to inverter type welder technical field.
Technical background
The sales volume of hand arc welding machine is very big, and application is wider.However, such welding machine, different circuit, circuit board
Designed with complete machine structure, control principle is different with mode, the layout and connected mode of circuit board and complete machine, or the complexity connected
Degree is different, and process and manufacture craft of its production etc. also can be entirely different.These can all influence the performance, reliable of product
Property, production efficiency and cost of transportation etc., finally influence the competitiveness of product in market.
At present, on domestic and international market, the rated current of IGBT pipe contravariant hand arc welding machines is generally in 80 ~ 200A（It is negative
Carry water holdup 100 ~ 20%）Level.For such welding machine product, under the conditions of how realizing small size, low weight, high current
It is the target that designer pursues always with the output of high capacity water holdup.Small size, low weight can reduce cost（Including production system
The cost made and transported）, under identical rated current and cyclic duration factor, the competitiveness of product in market can be lifted.Here it is
Pursue the power of mini design.
In addition, the design of welder circuit also decides the welding performance of product, if design is bad, it there is also as next
A little problems：1）Board design is unreasonable, causes maintenance cost high.2）Product size and weight are excessive, increase manufacturing cost；3）
Anti-dust performance is bad, causes the reduction of welding machine functional reliability.After inverter type welder is used for a long time, some of working site contain electric conductivity
Metallic dust can be adsorbed onto between the device pins such as IGBT pipes, in control board, cause creep age distance to reduce, device and control
Circuit malfunction；4）Anti- net voltage fluctuation ability.For example, when the input supply voltage of power supply grid is relatively low, during such as below 180VAC,
Even with thinner welding rod, welding machine can not also carry out normal weld；This just makes the application of welding machine receive necessarily
Limitation；5）Control circuit functional reliability not high, easily cause failure, improve the repair rate of welding machine.Therefore, how low
On the premise of cost, above mentioned problem is resolved, structure is developed and performance is good, reliability is high welding machine, the present invention is solved
Problem and purpose.
The content of the invention
It is an object of the invention to provide a kind of mini inversion manual arc welder, internal control board is designed as three
Part, one is power amplifier board, and the circuit that it is laid out is mainly by rectifier bridge, electrochemical capacitor, IGBT and diode, main transformer, electricity
The single-end ortho-exciting inverter circuit of the compositions such as stream detection transformer, output rectification, and radiator and part component；Two be power supply
Plate, mainly including upper electricity buffering, Switching Power Supply and IGBT drive circuit；Three be control panel, mainly includes PWM output characteristics controls
System, floating voltage limitation, excessively stream and overtemperature protection, long-time output short circuit protection circuit, are designed as the purpose of three pieces of circuit boards,
The size and weight for considering welding machine are not only, while the cost factor of transport and after-sales service is further contemplated, with reasonable in design, dimension
Repair conveniently, the characteristics of reliable and stable.
Following technical scheme is used to achieve the above object：
A kind of mini inversion manual arc welder, including exterior section and internal core section, internal core section include three
Electronic component, output filter reactor, thermal protector on block circuit board and its plate；Three pieces of control boards are power respectively
Plate, control panel and power panel；Single-end ortho-exciting inverter main circuit is set on described power amplifier board, and single-end ortho-exciting inverter main circuit includes
Single-phase input rectifier bridge, electrochemical capacitor filtering, two IGBT pipes and fast recovery diode and inversion main transformer, current transformer
And output commutation diode, the also heat sink part including radiator I, radiator II and the fast extensive diode of output；Two
After IGBT pin is all inserted in using tube leg sheathing, then it is welded on power amplifier board；Two fast recovery diodes, rectifier bridge, inversions
Main transformer, current transformer, output commutation diode are also welded on power amplifier board；
It is provided with power panel including switching power circuit, upper electric buffer control circuit and IGBT drive control circuit, upper electricity is slow
Punching control circuit, switching power circuit and IGBT drive controls circuit are fixedly mounted on the radiating of power amplifier board by three long struts
On device I and radiator II；
Include relay, switching mode power supply transformer and driving transformer on described control panel；Electric cushioning control on power panel
The installation direction of circuit, switching power circuit and IGBT drive control plates is and the relay on control panel, Switching Power Supply transformation
Device and driving transformer both face towards the radiator I and radiator II of power amplifier board；
Also two pieces of circuit boards are connected by some connecting wires with plug between power amplifier board and the circuit board of power supply plate part
Together, one end of output filter reactor is connected to the positive pole output snap joint of welding machine, other end and fast extensive radiator
Connection；The surface of thermal protector held against heat sink is installed, and its control line is connected with corresponding circuit part, by thermal protector,
The temperature of detectable radiator, together with overheating protection circuit, completes overtemperature protection control function；Pass through above-mentioned assembling, connection
Mode, makes them constitute an integral movement part.
Described exterior section includes casing part, front-facing portion and rear board part；
Casing part includes enclosing cover, bottom plate, brace；
Positive pole output snap joint, negative pole output snap joint, control panel, control panel are provided with the front panel of front-facing portion
On power supply indicator and Thermal protection indicator lamp, electric current regulation potentiometer knob, in the circuit board of control panel, be disposed with PWM
Pulse width modulating chip, four-operational amplifier, power supply indicator, Thermal protection indicator lamp, an electric current adjust potentiometer and resistance
With electric capacity, voltage-stabiliser tube and diode, the control of PWM output characteristics, floating voltage limitation, excessively stream and overtemperature protection, long-time are realized
Output short circuit protection circuit.
In described above-mentioned three pieces of circuit boards, the size of power amplifier board is maximum for 125 × 106mm, the size of power panel
It is 105 × 40mm, the size of control panel is minimum, is 65 × 30mm, three pieces of circuit boards is all dual platen；Above-mentioned three pieces of circuits
Plate, can also be respectively that they design a shield box, circuit board is put into shield box, and pour into a mould PGL；Three pieces of control panels
Linked together by some plugs, then additional upper casing, fan, collectively constitute the welding machine of the present invention.
Rear panel portion point includes power supply line and its drawn not take off and cooling fan, and cooling fan makes cold wind behind welding machine
The air admission hole of plate enters, and some heater members and parts inside welding machine is had good cooling effect.
The present invention, by configuring Wind Volume, high speed（4000~5500rpm/min）Direct cooling fan, using good
" air channel " improves the cooling effectiveness of heating power key components and parts, improves high current（Such as 120 ~ 150A）Load during output
Water holdup（During 120A, up to 40%）, solve weld interval it is short the problem of.Meanwhile, effectively reduce IGBT or fast and recover two poles
The fault rate of the parts such as pipe, contravariant transformer；Anti- net voltage fluctuation ability is designed to deal with by using new type control circuit
The problem of difference and reliability.Under new control circuit function, when power network input supply voltage is relatively low, during such as 130VAC, use
Thin welding rod, welding machine can also carry out normal weld；If supply voltage rise is no more than 270VAC, all without influence welding machine weldering
Connect performance.This provides for improved the anti-net voltage fluctuation ability of welding machine, the application of welding machine is expanded, arc stability is improved.
Various kinds of protective circuit, improves the reliability of welding machine.
Welding machine of the present invention can form different output rated current by parts specifications parameter a small amount of on adjustment circuit plate
With the product of cyclic duration factor.For example, changing the current class of IGBT device；Change inversion main transformer and output filter reactance
Specification and parameter of device etc., you can easily form the series of products of different size.Such as 80A/23.2V（40% cyclic duration factor, under
Together）、140A/25.6V（27%）、150A/26V（20%）Deng series of products.Rated current is smaller, then rated duty cycle is got over
It is high.Certainly, these change, it is therefore an objective to the cost of manufacture of product and the specifications parameter of corresponding machine and performance indications is matched.
So, the welding machine of every kind of specifications and models could realize the cost control of optimization.The market that this just improves institute's development is competing
Strive power.Circuit theory, circuit board and the complete machine structure of welding machine of the present invention are designed with the unique distinction of oneself.This is also that application is originally special
Where the basic goal of profit protection.
Brief description of the drawings
Fig. 1 is the decomposition texture schematic diagram of manual arc welder of the present invention；
Fig. 2 is the structural representation of manual arc welder core section of the present invention；
Fig. 3 is the wiring diagram between three pieces of circuit boards of manual arc welder of the present invention；
Fig. 4 is manual arc welder power amplifier board circuit theory diagrams of the present invention；
Fig. 5 is manual arc welder power panel circuit theory diagrams of the present invention；
Fig. 6 is the components' placement figure of manual arc welder power panel of the present invention；
Fig. 7 is the circuit theory of welding machine control panel of the present invention；
Fig. 8 is the components' placement figure of welding machine control panel of the present invention；
The title of name part is as follows in accompanying drawing：1st, cooling fan；2nd, rectifier bridge；3rd, relay；4th, switching mode power supply transformer；5th, drive
Dynamic transformer；6th, power panel；7th, fast recovery diode；8th, radiator II；9th, power amplifier board；10th, current detecting transformer；11st, it is inverse
Become main transformer；12nd, fast recovery diode radiator is exported；13rd, plastic support pin；14th, fast recovery diode is exported；15th, it is defeated
Go out filter reactor；16th, electrochemical capacitor；17th, IGBT and its tube leg sheathing；18th, radiator I；19th, power line and its drawing do not take off；
20th, chassis backplane；21st, control panel；22nd, electric current regulation potentiometer and knob；23rd, Thermal protection indicator lamp；24th, power supply indicator；
25th, negative pole output snap joint；26th, positive pole output snap joint；27th, cover of electric equipment casing；28th, brace.
Embodiment
As shown in figures 1-8, chief component of the present invention includes：
1）Front-facing portion.Mainly there is positive pole to export snap joint 26, negative pole output snap joint 25, control panel 21.Control panel
21 are arranged on the front panel of chassis backplane 20.Power supply indicator 24 and Thermal protection indicator lamp 23, electric current on control panel 21 are adjusted
Nodal potential device knob 22 etc., control panel 21 is characterised by：On control panel, be disposed with UC3842 PWM pulse width modulating chips,
One four-operational amplifier, power supply indicator, Thermal protection indicator lamp, electric current regulation potentiometer, and it is some resistance and electric capacity, steady
Pressure pipe and diode etc..Distinguished according to control circuit function, the control of UC3842 PWM output characteristics, floating voltage limit can be divided into
System, excessively stream and overtemperature protection, long-time output short circuit protection circuit.
2）Rear board part.Mainly there is power supply line and its draw and do not take off 19, cooling fan 1 etc..Cold wind is from welding machine rear portion
Air admission hole enter, some heater members or parts inside welding machine can be made to have good cooling effect.
3）Casing part includes enclosing cover 27, bottom plate 20 and brace 28.
4）Internal core section, mainly includes three pieces of circuit boards and its electronic component and parts on plate, three pieces
Circuit board is power amplifier board, control panel and power panel respectively, also has output filter reactor 15, thermal protector and some circuits certainly
Between connecting wire.
The part of power amplifier board 9 is characterised by：Its circuit is mainly single-end ortho-exciting inverter main circuit, including single-phase input rectification
Bridge 2, electrochemical capacitor filtering 16, two IGBT pipes 17 and fast recovery diodes 7 and inversion main transformer 11, current transformer 10 etc.
The single-end ortho-exciting inverter circuit of composition, and the output grade circuit devcie of commutation diode 14 part.In addition to radiator I certainly,
18th, the part of radiator 12 of radiator II 8 and the fast extensive diode of output, two IGBT 17 pin all uses tube leg sheathing set
After entering, then it is welded on power amplifier board 9.Two fast recovery diodes 7, rectifier bridge 2, inversion main transformer 11, current transformer 10,
Output commutation diode 14 is also welded on power amplifier board 9.Wherein, two IGBT 17, two fast recovery diodes 7, rectifier bridges 2
Also smeared after heat-conducting silicone grease with the radiating surface of output commutation diode 14 these devices and the He of accompanying drawing 1 is fixed on using their screw
In accompanying drawing 2 on their corresponding radiators.Plastic support pin 13, which is then adopted, to be screwed on radiator 12, also, is being installed
When movement, also with key screw, it is fixed with chassis backplane 20, plays a part of supporting movement, insulation.In order to ensure two
IGBT 17, fast recovery diode 7, rectifier bridge 2, inversion main transformer 11 and output commutation diode 14, and three radiators
There is preferable radiating condition, also using one piece of thin plastic plate（Special instruction：In accompanying drawing 1 and accompanying drawing 2, this is not given expression to
Individual plastic plate）The upper surface for being close to three radiators is fixed using three long struts screws cited below.So, in the modeling
Also good " air channel " is formed between flitch and power amplifier board 9.In the presence of cooling fan 1, the presence in this " air channel ",
The heater members such as above-mentioned IGBT can be made preferably to be cooled down, to ensureing that the high capacity water holdup work of welding machine is to serve preferably
Effect.If the output current of welding machine is small, cyclic duration factor can be higher, or even can continuously be welded.This is just
Preferably solve weld interval it is short the problem of.Meanwhile, effectively reduce the device such as IGBT or fast recovery diode, contravariant transformer
Or the fault rate of parts.In addition, in the solder side of power amplifier board 9, being also welded has a small amount of electronic component.
Power panel 6 includes upper electricity buffering, Switching Power Supply and drive control part circuit part and is characterised by：According to its control
Function distinguishing processed, circuit can be divided into switching power circuit, upper electric buffer control circuit, IGBT drive control circuits etc..Including this
Many circuit devcies such as relay 3, switching mode power supply transformer 4 and driving transformer 5 on circuit board.Power panel 6 passes through three
Individual long struts special instruction：In accompanying drawing 1 and accompanying drawing 2, the radiating that these three pillars are fixedly mounted on power amplifier board 9 is not given expression to
On device I 18 and radiator II 8.The installation direction of power panel 6 is：Relay 3, switching mode power supply transformer 4 on the control panel
The radiator I 18 and radiator II 8 of power amplifier board 9 are both faced towards with driving transformer 5, on power panel 6, except component side is welded
Have outside above-mentioned device or parts, being also welded on the solder side of the plate has substantial amounts of electronic component.
Between power amplifier board 9 and power panel 6 also by some connecting wires with plug the circuits of two pieces of circuit boards according to
Circuit theory diagrams relation links together.One end of output filter reactor 15 is connected to the positive pole output snap joint of welding machine
26, other end is connected with fast extensive radiator 12；The surface of thermal protector held against heat sink is installed, its control line and corresponding electricity
Road part is connected.By thermal protector, the temperature of radiator can detect.Together with overheating protection circuit, overtemperature protection control is completed
Function processed.
By above-mentioned assembling, connected mode, them are made to constitute an integral movement part.Above core section, then it is additional
The parts such as upper casing, fan, front panel, collectively constitute the welding machine of the present invention.
In above-mentioned three pieces of circuit boards, the size of power amplifier board 9 is maximum, is 125 × 106mm.Rapid wear on the circuit board
Part is IGBT；The size of power panel 6 is 105 × 40mm.The consumable accessory that the circuit board is is the device of IGBT driving circuit section
Part；The size of control panel 21 is minimum, is 65 × 30mm.Three pieces of circuit boards are all dual platens.It is well known that inverter type welder work
When work, influenceed by various factors, the situation of IGBT bombings or damage occurs in a small amount of welding machine.In that case,
Being usually associated with the device of IGBT driving circuit section can also damage.During maintenance, IGBT replacement operation is very simple, and
Its driving circuit section, uses a large amount of surface-mounted devices.Which component is broken, for the personnel for understanding technology, relatively simple
It is more single.But, for the people being ignorant of, the circuit of drive part is repaired, often the limitation of the means such as examined, it is difficult to
Realize.Therefore, whole power panel 6 of changing is probably relatively good selection.Just think：If power amplifier board 9 is designed as with power panel 6
One piece of large circuit board, if 1）IGBT bombings are very serious, burnt out circuit board, cause the circuit board fabrication producer basic without Faville
Repair, can only thoroughly change whole circuit board, the cost of that factory repair is comparable to high；2）IGBT bombings or damage be not very
Seriously, user or dealer or maintenance personal can change IGBT, but they do not repair the parts such as IGBT drive circuit, still
So need to change whole circuit board.The cost that manufacturing firm can equally repaired is comparable to height.This is not reprocessed also including product
The costs such as packaging, transport.As can be seen here, it is three pieces board design, there are many benefits for the maintenance of product from now on.
This is also the reason for board design of the present invention is three pieces.
For above-mentioned three pieces of control panels, it can also be respectively that they design a shield box, circuit board is put into shield box, and is poured
Note PGL.The dust-proof of welding machine, waterproof, mould proof, anticorrosion, protection against the tide, vibrationproof performance issue can be solved through the above way.
These technical measures, can avoid inverter type welder be used for a long time after working site some adsorbing powder dusts containing conductive metal to IGBT
Between the device pins such as pipe；Water and moisture etc. enter in control board.Creep age distance will not be caused to reduce.Device and control electricity
Road is not easy failure.This can just improve welding machine functional reliability to a certain extent.
Control connecting line between welding machine of the present invention, circuit board is few, not only production process and simple production process, Er Qie electricity
It is small that road plate also takes up space, makes package size small, lightweight.Welding machine maximum appearance and size is 220 × 120 × 135mm, and weight is only
There is 2.3kg.This reduces production and cost of transportation, product competitiveness in the market is improved.
From the point of view of the control function of circuit, mainly the generation of completion power supply, pwm pulse width adjusting, IGBT are managed
Drive control and inversion, the inverter circuit output parameter of manual soldering method（Electric current, voltage）The work such as control, protection control.Most
Eventually in the presence of control circuit, realize that every control of manual electric arc welding is required.
See accompanying drawing 6, the component side and solder side of the components' placement design of power panel in the plate, that is to say, that it is two-sided all
There is component.On its solder side, some surface-mounted devices, such as Q6 are designed with（AO4606）, optocoupler U5, resistance R1~R2 and R59
~R66, electric capacity C1~C3 and C20~C21, voltage-stabiliser tube Z2~Z3 and ZD2 and TVS1, diode D6~D9 and D28, triode Q3
~Q4 etc..These surface-mounted devices utilize SMT technique welding processings.On its component side, it is mainly some large-sized components
And parts, such as MC driving transformers；JDQ relays and RT1 PTC temperature-sensitive devices；Switching mode power supply transformer B3；Switching Power Supply
Control chip U10；Electrochemical capacitor EC3~EC5, C17, C19 and C32；Thermal device connection socket RT, fan interface socket
Eight connection sockets such as FAN, socket KZ.By these sockets, with other circuit boards and parts（Such as fan, overheat protector）
Carry out circuit connection.Shown in the design principle figure as accompanying drawing 5 of circuit board.
See accompanying drawing 8, the component of control panel also component side and solder side of the layout designs in the plate.In its solder side, have
Electric current regulation potentiometer RP1, overheat D1 and power supply D2 indicator lamps.Remaining electronic component, except electrochemical capacitor C8, socket
CN1（It is connected with the socket KZ of power panel）Outside trimmer potentiometer VR2, all using surface-mounted device, and it is welded on using SMT techniques
On its component side.Shown in the design principle figure as accompanying drawing 7 of circuit board.
It is visible according to above-mentioned specification, because big metering device employs advanced SMT techniques processing, therefore, circuit board
Production efficiency it is high, disposable qualification rate almost may be up to 100%.This can reduce the cost of production.Improve the market of product
Competitiveness.
The operation principle of welding machine each part mentioned above circuit of the present invention is summarized as follows：As shown in accompanying drawing 4 and accompanying drawing 5, welding machine leads to
After electricity, the power network alternating current come from power network J2 and J3 is changed into Rectified alternating current after first passing through the rectification of BG1 rectifier bridges 2.By J1 terminals
Exported between over the ground.By the contact JDQB of the relay JDQA 3 on power panel 6 in accompanying drawing 5 conducting, then through RT1 temperature-sensitives electricity
Resistance, afterwards, to EC1 ~ EC2 electrochemical capacitors（680µF/400V）16 are charged.Voltage on EC1 ~ EC2 electrochemical capacitors gradually rises
Height, eventually becomes relatively stable+310V direct currents.EC1 ~ EC2 electrochemical capacitors play a part of filtering.+ 310V direct currents one
Aspect supply is examined by IGBT1, IGBT2 pipe 17, D1 ~ D2 fast recovery diodes, T2 inversions main transformer, the primary bus currents of T3
Survey the single-end ortho-exciting inverter main circuit of the compositions such as transformer, D3~D5 output fast recovery rectifier diodes.Its function is mainly：
High voltage direct current is converted to intermediate frequency（Tens KHz）Alternating current.T2 contravariant transformers realize the change of voltage step-down and High-current output
Change.D3 ~ D5 fast recovery diodes are then that the medium frequency alternating current that contravariant transformer is exported is transformed to direct current, by OUT+ over the ground
Between output supply welding circuit.On the other hand, by the connection of plug ,+310V the power supplys from J1 terminals over the ground are also supplied
By B3 switching mode power supply transformers 4（There are four windings, be N1, N2, N3, N4 respectively.N1（B3A）It is armature winding, it is other
（B3B、B3C）It is secondary windings）, TVS1 and Z2 ~ Z3 voltage-stabiliser tubes, D16 ~ D17 and D21 ~ D23 diodes, the control of U10 Switching Power Supplies
Chip（TOP264VG）, and the resistance around them（R1, R2 etc.）, electric capacity（EC3 ~ EC4, C3, C34, C19 ~ C21 etc.）Deng device
The switching power circuit of part composition, generation+12V ,+15V, -12V supply voltages, supply is other to control the live line works such as circuits.
Due to the armature winding N1 of B3 switching mode power supply transformers 4, and the composition such as TVS1 voltage-stabiliser tubes, D16 diodes around them
Circuit, is connected to+310V, belongs to high tension loop.To ensure the safety for controlling circuit, U5 EL817 photoelectric couplings are employed
Device is isolated.The kernel control chip of Switching Power Supply is U10, i.e. TOP264VG chips.On this partial circuit of Switching Power Supply
Operation principle, it is necessary to go to understand Switching Power Supply and TOP264VG Switching Power Supply control chips if further understanding in detail
Related work principle and knowledge.It is only to have made a brief description here between the relation of length.In a word, electricity is switched
Source control circuit part, can be in B3 2 voltage follower circuit parts, acquisition+12V ,+15V, -12V supply voltages respectively.For
Used to other different devices and circuit.For example ,+12V supply fans FAN；+ 15V supplies drive control circuit and control panel
Circuit etc..It is of the invention without using general control transformer and correlation from the circuit and principle of switching power supply parts
Voltage conversion circuit produces above-mentioned 3 supply voltages.+ 310V of its circuit power taking in major loop.Switch transformer
Volume and size, general control transformer is significantly less weight than, this just reduces the cost of welding machine of the present invention, improves the skill of welding machine
Art added value.
Switching power circuit of the present invention, there is following advantage：In the case of voltage ripple of power network, even in 130VAC
~ 270VAC scopes range of the fluctuation of voltage, switching power circuit remains able to produce stable+12V ,+15V, -12V supply voltages.This is just
The normal work of the other control circuits of welding machine can be ensured.Experiment shows：Under the control circuit function of the present invention, when power network is defeated
Enter supply voltage relatively low, during such as 130VAC, even with thin welding rod, welding machine can also carry out normal weld；If power supply
Voltage rise is no more than 270VAC, all without influence welder performance.This provides for improved the anti-net voltage fluctuation ability of welding machine, expand
The big application of welding machine.The problem of this just preferably solves " anti-net voltage fluctuation ability ".
In accompanying drawing 5, JDQA pull up times lag behind power switch and close the moment.That is JDQA relays are
Deferred action.After the charging voltage on EC1 ~ EC2 electrochemical capacitors is stable, the relay is just acted, its contact JDQB closures
The branch road of RT1 thermistors, when making welding machine of the present invention normal inversion work, high current is flowed through from the contact of relay.This
The circuit of sample, referred to as upper electric buffer circuit.Upper electric buffer circuit is mainly by relay JDQA, triode Q2, and these devices
Some resistance of part periphery（Such as R50, R70）, voltage-stabiliser tube（Such as ZD2）, diode（Such as D28）Constituted with electrochemical capacitor C32 etc..
Mainly prevent power switch connect moment, due to there is no voltage on EC1 ~ EC2 electrochemical capacitors, equivalent to short circuit, can be formed compared with
Big surge current, burns out power switch.And the effect of upper electric buffer circuit, RT1 temperature-sensitives electricity is exactly sealed in by moment of closing a floodgate
The method of resistance carrys out limit inrush currents.Also, the resistance of RT1 thermistors, is to rise with its temperature and increase.Therefore,
Upper electric buffer circuit can play preferable protective effect.
In accompanying drawing 5, MC driving transformers（It is divided into primary MCA, secondary MCB and MCC）And its D6~D9 diodes of periphery,
Resistance R59 ~ R66, voltage-stabiliser tube ZD4 ~ ZD5, triode Q3 and Q6, MCA left side chip Q6（AO4606）And its peripheral components etc.
Constitute IGBT1 and IGBT2 drive circuit.2 IGBT, the driving of 2 tunnels, the drive circuit form of each part is consistent.Should
Partial circuit, the control signal of input is connected respectively the IC1 chips into accompanying drawing 7 by controller plug KZ 6,5,4 ends
（UC3842）1,2,3 ends of output.Due to the IC1 chips in accompanying drawing 7（UC3842）The signal of output, driving power is small, therefore needs
To be amplified by IGBT drive control circuit, then control 2 is gone by the drive circuit of MC driving transformers and its periphery
Individual IGBT working condition.In accompanying drawing 5, the control signal of drive circuit input is by the IC1 pulse width modulations in accompanying drawing 7
（PWM）Chip（UC3842）The control signal of output.These signals are a prescription wave pulse signals.Square-wave pulse signal has one
Fixed frequency.It is to ensure one of important parameter of IGBT switchs.The time is by IC1 chips（UC3842）Chip
Peripheral components parameter setting and determine.As to how determining, it is necessary to check IC1 chips（UC3842）Data used in connection with or
Explanation.Between the relation of length, explanation is not repeated herein.It should be noted that：Pwm pulse bandwidth modulation signals are to determine weldering
The signal of machine inverter main circuit output voltage and size of current.
Accompanying drawing 7 is the control panel circuit theory diagrams of welding machine of the present invention.In accompanying drawing 7, IC1 chips（UC3842）It is pwm pulse
Width control system chip；U2 is four-operational amplifier chip.In accompanying drawing 7, " 4 " on the left side are connected to 3 of KZ plugs in accompanying drawing 5, i.e.,
IF terminals, are actually connected to the primary current transformer T3 output ends of inversion main transformer in inverter main circuit.Pass through
The transformer, can detect the primary current of inversion main transformer, obtain the Current Feedback Control letter required for welding machine output control
Number Ufi." 5 " in accompanying drawing 7 are connected to 2 of KZ plugs in accompanying drawing 5, the i.e. terminal of RT thermistors, are actually connected to
Overtemperature protection controls circuit part.RT overheat protectors are arranged on power amplifier board on IGBT aluminium radiator.
KZ plug KZ-1 in accompanying drawing 5, is additionally coupled to the output end OUT of welding machine（+）, it is anti-with the output voltage for welding machine of sampling
Feedback signal, is actually connected to " 6 " in accompanying drawing 7.D1（Yellow）For overtemperature protection indicator lamp, D2 is power supply indicator,
On welding machine front panel.After welding machine controls circuit generation+15V, D2 power supply indicators are lighted, and indicate welding machine band electrician
Make.+ 5V supply voltages come from IC1（UC3842）8 pin, be the internal reference power supply by the chip（Vre）The voltage of output.Can
The related circuit of supply is used.RP1 is the electric current regulation potentiometer of welding machine.VR2 is the correction regulation current potential of welding machine output current
Device.U2A operational amplifiers and its peripheral components composition control circuit.From accompanying drawing 7, RP1 electric currents regulation potentiometer is provided
Ug given value of current signal is input to input one end of opamp control circuit by R15；Current transformer T3 is detected
Signal, after the rectifying conversions such as D9, obtains the negative-feedback Ufi signals of output current control.Current Negative Three-Point Capacitance Ufi signals are then
Another input of opamp control circuit is input to by R10, D12 etc., is compared with Ug given value of current signals.It
Afterwards, by controlling unit, the Uk control signals of U2A operational amplifiers output decide IC1（UC3842）The PWM arteries and veins of chip output
Rush the time width of signal.When Ug given value of current signal and Current Negative Three-Point Capacitance Ufi signals change, pwm pulse will be made
The time width of signal changes, and eventually through inverter main circuit, realizes the change of welding machine output voltage and electric current, to meet
The performance control needs of manual arc welding.
In accompanying drawing 7, " 5 " to " " between be connection overheat protector RT.Thermal protector RT is close to IGBT radiators peace
Dress.In welding machine output procedure, when superheating phenomenon occurs for IGBT radiators, or the thermal protector RT generations inside welding machine
During big state change, the output state of U2C operational amplifiers changes, and on the one hand makes D1 overtemperature protection indicator lamps（Yellow）
Light, on the other hand turn on triode Q3, limit given value of current signal.Control circuit can close the pulse output of PWM chip,
Welding machine is set to stop output current.Meanwhile, welding machine stops welding output.In the presence of cooling fan, when the temperature of IGBT radiators
Spend after declining to a certain extent, or when the superheating phenomenon inside welding machine is eliminated, thermal protector recovers, control circuit could continue
Export pwm control signal.While overheating indicator lamp（Yellow）Extinguish.Which achieves welding machine overtemperature protection.
In accompanying drawing 7, " 6 " to " " between be sampling welding machine output voltage feedback signal.During welding machine use, such as
When there is between welding rod and welded piece short circuit for a long time or output short-circuit phenomenon in fruit, " 6 " to " " between voltage be very
Low.U2B operational amplifiers are a voltage comparators.Its in-phase input end is connection+5V by R23.Now, due to
" 6 " to " " between voltage be less than+5V, therefore, the output U2B-7 of U2B operational amplifiers is high level, therefore, triode
Q3 is turned on, and limits given value of current signal.Control circuit can close the pulse output of PWM chip, welding machine is stopped output current.Weldering
In termination process（Generally there was only several milliseconds）Normal instantaneous short-circuit will not cause above-mentioned control process, and main cause is electricity
Solve electric capacity C8 presence.Prolonged improper short circuit is only occurred, output current can be just limited." if 6 " to " " between
Voltage be very high, then can puncture voltage-stabiliser tube Z1, make Z1 voltage stabilizings.Then, there is high voltage on R3 resistance, triode Q5 can be led
It is logical.Can be IC1（UC3842）" 1 " pin level drag down.So, IC1（UC3845）The pwm pulse signal of chip output is closed.
So, the output voltage of welding machine is also just controlled.It is exactly floating voltage limitation and the work of long-time short-circuit protection circuit above
Principle.
In accompanying drawing 7, " 4 " to " " between be sampling welding machine output voltage feedback signal.If the feedback electricity detected
There is over-current phenomenon avoidance in stream signal, and U2A operational amplifiers can be made to export low level, by diode D10 clamping action, same meeting
IC1（UC3842）" 1 " pin level drag down.So, IC1（UC3845）The pwm pulse signal of chip output is closed.So,
Also it is achieved that the overcurrent protection of welding machine.
The brief control process of welding machine manual electric arc welding output characteristics of the present invention is summarized as follows：
The switch of welding machine rear board, which closes, to be connected after the power supply extremely short time（During this, welder circuit carries out upper electricity buffering
Control, there is certain delays time to control）, above-mentioned each control panel live line work inside welding machine.Power supply instruction LED on front panel
It is bright, indicate that welding machine is powered.IGBT pwm pulses Width Control circuit inside welding machine produces the larger pulse letter of a dutycycle
Number, make IGBT drive circuit works, IGBT is in alternating conductive state, finally make the output of single-end ortho-exciting inverter main circuit empty
Carry voltage.When operator regulates the potentiometer of welding current on front panel, and when being welded, control circuit passes through T3 electric currents
Transformer, can detect output current signal.By signal transacting, and in this, as current feedback control Ufi signals, with weldering
Given value of current Ug signals are connect to be compared.Difference signal after comparing, carries out operational amplifier UA2 circuits and controls to adjust, then defeated
Enter to welding machine and export pwm control circuit, its output control welding machine exported exports the pulse width or dutycycle of PWM chip, certainly
Determine welding machine output current and the size of voltage, realize the accurate control of output current parameter.And meet the output characteristics of welding machine
The requirement of manual arc welding.Further say, when welding current Setting signal is constant, the electricity detected with welder circuit
Stream increase, also, reaches after given setting value, and the difference of welding current Setting signal and current feedback control signal can be with
Electric current increases and reduced, after being controlled by operational amplifier UA2 circuits, welding machine is exported the pulse width or duty of PWM chip
Than reducing, the output voltage reduction of welding machine.This process, that is, the control of so-called Current cut-off negative feedback.I.e. only when electricity
Stream reaches the feedback control just worked after the setting value Ug of welding current potentiometer.Hereafter, with the small increase of electric current, electricity
Pressure drop is low can be a lot.When voltage drops to below certain numerical value, with the reduction of voltage, control circuit can export welding machine
Pulse width or the dutycycle increase of PWM chip, make welding current increase according to the parameter of setting, ultimately form and dragged outside constant current band
Dropping characteristic.When welding current gives Ug signal intensities, Current cut-off negative feedback setting value is different, but others were controlled
Journey is similar.So, between the minimum and maximum that potentiometer is set, so that it may obtain without several negative characteristic curves.So
Control, be also meet manual arc welding basic demand.On the feedback and PWM and output characteristics control process of electric current,
Reference can be made to other related control principle explanations make further understanding.
The above-mentioned control circuit of welding machine of the present invention, is tested by actual performance, functional.Even not received welding
Layman's operation welding machine of training carries out manual arc welding, its operation technique is poor, arc length neglects long suddenly short feelings
Under condition, as long as arc length, which is elongated, is no more than 5mm range above, welding arc is still stablized.Be not easy to occur arc extinction or
Current interruption phenomenon.This provides for improved arc stability.The problem of solving " the bad easy current interruption of arcing performance ".
Above is the brief control process explanation of each circuit board section of welding machine of the present invention.Because the present invention has been presented for
The detailed construction design and the components' placement design drawing of circuit theory diagrams and each circuit board of 1 ~ accompanying drawing of accompanying drawing 8, therefore, for having
Machine structure and circuit reading ability（Or possess relevant knowledge）People for, can understand completely.Circuit diagram is exactly one
Plant noiseless language.But, for there is no circuit reading ability（Or do not possess interlock circuit knowledge）People for, even if explain
It is many again, they are also elusive.In view of the relation of length, can only illustrate main part herein, so that reader can
More fully understand the operation principle and process of correlation.
Visible by described above, the present invention has oneself unique mentality of designing and method.Not only realize the hand of welding machine
The controls such as work soldering method output, moreover, designed control circuit, include their circuit board and connection pass each other
System, and the complete machine structure of welding machine are designed, and are all welding machine product of the present invention is had control performance is good, machine structure is compact etc.
It is also to meet product efficiently and inexpensive production, high reliability, manufacturing process technology are advanced where the basic reason of technical advantage
The important leverage of property.The content of present patent application protection is that the structure design for protecting this welding machine.
Above content is to combine specific machine structure and circuit board and control function detailed description made for the present invention,
It cannot be assumed that the specific implementation of the present invention is only limited to these explanations.The others skilled in the art of technical field of the present invention are come
Say, without departing from the inventive concept of the premise, some other deductions can also be made and converted, these should all be considered as category
The category protected in the present invention.
Claims (3)
1. a kind of mini inversion manual arc welder, including exterior section and internal core section, internal core section include
Three pieces of circuit boards and its electronic component, output filter reactor, thermal protector on plate；Three pieces of control boards are work(respectively
Rate plate, control panel and power panel；Single-end ortho-exciting inverter main circuit, single-end ortho-exciting inverter main circuit bag are set on described power amplifier board
Include single-phase input rectifier bridge, electrochemical capacitor filtering, two IGBT pipes and fast recovery diode and inversion main transformer, Current Mutual Inductance
Device and output commutation diode, the also heat sink part including radiator I, radiator II and the fast extensive diode of output；Two
After IGBT pin is all inserted in using tube leg sheathing, then it is welded on power amplifier board；Two fast recovery diodes, rectifier bridge, inversions
Main transformer, current transformer, output commutation diode are also welded on power amplifier board；
It is provided with power panel including switching power circuit, upper electric buffer control circuit and IGBT drive control circuit, upper electricity is slow
Punching control circuit, switching power circuit and IGBT drive controls circuit are fixedly mounted on the radiating of power amplifier board by three long struts
On device I and radiator II；
Include relay, switching mode power supply transformer and driving transformer on described control panel；Electric cushioning control on power panel
The installation direction of circuit, switching power circuit and IGBT drive control plates is and the relay on control panel, Switching Power Supply transformation
Device and driving transformer both face towards the radiator I and radiator II of power amplifier board；
Also two pieces of circuit boards are connected by some connecting wires with plug between power amplifier board and the circuit board of power supply plate part
Together, one end of output filter reactor is connected to the positive pole output snap joint of welding machine, other end and fast extensive radiator
Connection；The surface of thermal protector held against heat sink is installed, and its control line is connected with corresponding circuit part, by thermal protector,
The temperature of detectable radiator, together with overheating protection circuit, completes overtemperature protection control function；Pass through above-mentioned assembling, connection
Mode, makes them constitute an integral movement part.
2. a kind of mini inversion manual arc welder as claimed in claim 1, it is characterised in that：Described exterior section includes outer
Shell parts, front-facing portion and rear board part；
Casing part includes enclosing cover, bottom plate, brace；
Positive pole output snap joint, negative pole output snap joint, control panel, control panel are provided with the front panel of front-facing portion
On power supply indicator and Thermal protection indicator lamp, electric current regulation potentiometer knob, in the circuit board of control panel, be disposed with PWM
Pulse width modulating chip, four-operational amplifier, power supply indicator, Thermal protection indicator lamp, an electric current adjust potentiometer and resistance
With electric capacity, voltage-stabiliser tube and diode, the control of PWM output characteristics, floating voltage limitation, excessively stream and overtemperature protection, long-time are realized
Output short circuit protection circuit.
3. a kind of mini inversion manual arc welder as claimed in claim 2, it is characterised in that：Described above-mentioned three pieces of circuit boards
In, the size of power amplifier board is maximum for 125 × 106mm, and the size of power panel is 105 × 40mm, and the size of control panel is most
Small, it is 65 × 30mm, three pieces of circuit boards are all dual platens；Above-mentioned three pieces of circuit boards, can also be respectively that they design a shield
Box, circuit board is put into shield box, and pour into a mould PGL；Three pieces of control panels are linked together by some plugs, then outer
Plus casing, fan, the welding machine of the present invention is collectively constituted.
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| CN201710410395.6A CN107052514A (en) | 2017-06-03 | 2017-06-03 | A kind of mini inversion manual arc welder |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112139644A (en) * | 2020-11-25 | 2020-12-29 | 西安贝伦环保科技有限公司 | Portable pipeline electric welding machine |
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