Charging voltage control method and system of capacitance energy storage welding machine

Abstract

The invention discloses a charging voltage control method and system for a capacitive energy storage welding machine, and the method comprises the steps: monitoring the voltage, current and temperature of a capacitor in real time in a charging process, and obtaining data through a sensor, and inputting the data into a controller; the controller dynamically adjusts the charging voltage according to the real-time feedback, and calculates and adjusts the power output by adopting a self-adaptive algorithm; if the temperature of the capacitor reaches the set threshold value, the charging voltage is automatically adjusted or the charging rate is reduced, and the charging voltage is adjusted according to the welding load change; the upper limit of the charging voltage and the charging time are dynamically adjusted according to the working state of the capacitor through an optimization algorithm, so that the capacitor is ensured to operate in a safe interval; the system combines welding parameters, dynamically optimizes charging voltage and current output, and ensures that the charging process is stable and efficient.

Description

TECHNICAL FIELD

[0001] The application relates to the field of welding equipment, in particular to a charging voltage control method and system of a capacitor energy storage welder, and specifically relates to a capacitor energy storage welder charging voltage control technology based on an intelligent control algorithm to optimize charging voltage, improve charging process stability and prolong capacitor service life. BACKGROUND

[0002] The charging voltage control of the capacitor energy storage welder refers to controlling the energy stored in the capacitor by adjusting the charging voltage of the capacitor during the welding process to ensure the stability of the current and power during the welding process. The capacitor energy storage welder usually uses a capacitor to store energy, and releases the energy during welding to perform efficient welding operation. The charging voltage of the capacitor is controlled to reach a predetermined value. This usually relies on a feedback control system to ensure that the charging voltage does not exceed the rated voltage of the capacitor. By adjusting the voltage and current output by the power supply, the voltage of the capacitor during the charging process is kept stable to avoid welding quality problems caused by overcharging or undercharging. By controlling the charging time, the capacitor is charged in a suitable time to achieve the best welding effect.

[0003] However, the charging voltage control of the capacitor energy storage welder, although it can provide efficient welding, also has some defects. In the prior art, the capacitor energy storage welder usually controls the charging of the capacitor by setting a fixed charging voltage. However, with changes in load, aging of the capacitor and other factors, the charging voltage of the capacitor may fluctuate, resulting in unstable welding quality. SUMMARY

[0004] In view of the deficiencies in the prior art, the purpose of the present application is to provide a charging voltage control method and system for a capacitor energy storage welder, which improves the charging voltage control strategy and solves the problems of charging voltage fluctuation, excessive temperature and short capacitor service life in the prior art, thereby improving the welding quality and stability of the equipment.

[0005] The technical solution adopted by the application to solve the technical problems is:

[0006] The charging voltage control method for the capacitor energy storage welder comprises:

[0007] During the charging process, the charging voltage, charging current and temperature of the capacitor are monitored in real time. Sensors are used to obtain voltage, temperature and current data, and the data is input to the controller through a feedback control system;

[0008] According to the real-time feedback data, the controller dynamically adjusts the charging voltage. Through an adaptive control algorithm, the charging voltage is calculated according to the trend of the signal, and the power output voltage is adjusted;

[0009] The temperature of the capacitor is monitored in real time, and when the temperature of the capacitor reaches a set threshold, the charging voltage is automatically adjusted or the charging rate is reduced, and the charging voltage is adjusted according to the change of the welding load;

[0010] During the charging process, the charging process is controlled by an optimization algorithm according to the working state of the capacitor, and the upper limit of the charging voltage and the charging time are dynamically adjusted to ensure that the capacitor operates within the working interval;

[0011] The control system dynamically optimizes the charging voltage and current output in combination with the welding parameters.

[0012] As a preferred, during the charging process, the charging voltage, charging current and temperature of the capacitor are monitored in real time, the voltage, temperature and current data are obtained by sensors, and the data are input to the controller through a feedback control system.

[0013] The relationship between the charging voltage V c (t) and the charging current I c (t) is described by the charging equation of the capacitor, and the relationship between the charging current and the voltage of the capacitor is expressed as:

[0014]

[0015] Wherein, I c (t) is the charging current of the capacitor;

[0016] C is the capacitance of the capacitor;

[0017] V c (t) is the charging voltage of the capacitor;

[0018] It is set that there is a nonlinear relationship between the temperature and the charging voltage and current of the capacitor, and a temperature compensation model is used to describe it, and the change rate of the temperature T(t) is related to the charging current and voltage, which is expressed by the following model:

[0019]

[0020] Wherein, is the temperature change rate;

[0021] I c (t) is the charging current;

[0022] V c (t) is the charging voltage;

[0023] α, β are empirical coefficients between temperature and current, voltage;

[0024] According to real-time voltage, current and temperature data, the controller uses a PID control algorithm or an adaptive control algorithm to dynamically adjust the charging voltage and current. A PID controller is set up, and its output is represented as:

[0025]

[0026] where V c，adjust (t) is the adjusted charging voltage;

[0027] e(t) = V c (t) - V target is the deviation of the charging voltage;

[0028] K p , K i , K d are the proportional, integral and derivative coefficients of the PID controller;

[0029] ∫e(t)dt is the integral term of the deviation;

[0030] is the derivative term of the deviation.

[0031] As a preferred embodiment, according to real-time feedback data, the controller dynamically adjusts the charging voltage by using an adaptive control algorithm to calculate the charging voltage according to the trend of the signal and adjust the output voltage of the power supply. The method is as follows:

[0032] Let the ideal reference model M be the output as follows:

[0033] y ref (t) = V target + V(t)

[0034] where y ref (t) is the output of the reference model;

[0035] V target is the target charging voltage;

[0036] V(t) is the deviation from the target voltage;

[0037] The controller dynamically adjusts according to the real-time monitored voltage V c (t). Let the actual output of the system be y(t), which is represented as:

[0038] y(t) = V c (t) + V c (t)

[0039] where y(t) is the actual charging voltage output of the system;

[0040] V c (t) is the current charging voltage of the capacitor;

[0041] V c (t) is the deviation from the reference model output;

[0042] System error e(t) is defined as the difference between actual output and reference model output:

[0043] e(t) = y(t) - y ref (t)

[0044] Based on the error e(t), the charging voltage output is dynamically adjusted by adaptive control gain K(t), and the output formula of the controller is:

[0045] V adiust (t) = K(t) · e(t)

[0046] Where V adjust (t) is the adjusted charging voltage;

[0047] K(t) is the adaptive gain, which is dynamically adjusted with the change of error;

[0048] e(t) is the control error;

[0049] The adjustment formula of gain K(t) is updated according to the trend of error and the dynamic characteristics of the system, and the gain updating method includes least square algorithm or recursive least square method, and the gain updating formula is:

[0050] K(t+1) = K(t) + μ · e(t) · V(t)

[0051] Where K(t+1) is the gain at next time;

[0052] μ is the step factor, which controls the speed of gain adjustment;

[0053] e(t) is the error signal;

[0054] V(t) is the trend of voltage signal;

[0055] According to the adjusted charging voltage, the controller further adjusts the output voltage of the power supply, and sets the output voltage of the power supply as V out (t), then the output voltage adjustment formula of the power supply is:

[0056] V out (t) = V target + V adjust (t)

[0057] Where V out (t) is the output voltage of the power supply;

[0058] V target is the target charging voltage;

[0059] V adjust (t) is the charging voltage adjusted by adaptive control.

[0060] As a preferred, the temperature of the capacitor is monitored in real time, when the temperature of the capacitor reaches the set threshold, the charging voltage is automatically adjusted or the charging rate is reduced, and the method for adjusting the charging voltage according to the change of the welding load is as follows:

[0061] Let the temperature of the capacitor be T(t), and the target temperature threshold be T th When the temperature of the capacitor reaches or exceeds the threshold, the control system automatically adjusts the charging voltage or reduces the charging rate, and the judgment condition is as follows:

[0062] If T(t)≥T th , then adjust the charging parameters.

[0063] When the temperature exceeds the set threshold T th , the load of the capacitor is reduced by adjusting the charging voltage or reducing the charging rate, and the charging voltage V c (t) is adjusted by the following formula:

[0064] When the temperature exceeds the set threshold, the charging voltage V c (t) is automatically reduced according to the temperature adjustment coefficient a T :

[0065] V c (t) = V target - a T ·(T(t)-T th )

[0066] Wherein, V c (t) is the adjusted charging voltage;

[0067] V target is the target charging voltage;

[0068] T(t) is the current capacitor temperature;

[0069] T th is the set temperature threshold;

[0070] a T is the temperature adjustment coefficient;

[0071] In addition to adjusting the voltage, the speed of temperature rise is controlled by reducing the charging rate, and the adjustment formula of the charging current I c (t) is as follows:

[0072] I c (t) = I targct-β T ·(T(t)-T th )

[0073] wherein I c (t) is the adjusted charging current;

[0074] I target is the target charging current;

[0075] β T is the temperature adjustment coefficient;

[0076] When the load changes, the system dynamically adjusts the charging voltage according to the change of the load, and sets the change amount of the welding load as L(t), and the formula for adjusting the charging voltage is:

[0077] V c (t) = V target + γ L · L(t)

[0078] wherein V c (t) is the adjusted charging voltage;

[0079] V target is the target charging voltage;

[0080] γ L is the load adjustment coefficient;

[0081] L(t) is the change amount of the welding load;

[0082] To ensure the operation of the capacitor, a maximum charging voltage and a maximum charging current are set, and a limiting function is used to deal with the overcharging or overheating under high temperature or high load, and the formula is:

[0083] V c (t) = min(V max , max(V min , V target - α T · (T(t)-T th ) + γ L · L(t))

[0084] wherein V max is the maximum charging voltage;

[0085] V min is the minimum charging voltage.

[0086] As a preferred, during the charging process, an optimization algorithm is used to control the charging process according to the working state of the capacitor, and the method for ensuring the operation of the capacitor within the working range by dynamically adjusting the upper limit of the charging voltage and the charging time is:

[0087] Charging voltage upper limit V max (t) is dynamically adjusted according to the working state of the capacitor, and the working state of the capacitor is affected by its current voltage V(t), temperature T(t), and load change L(t). The upper limit voltage is adjusted by the following optimization formula:

[0088] V max target + a T ·(T(t)-T th )- b L ·L(t)

[0089] Where V max (t) is the dynamically adjusted maximum charging voltage;

[0090] V target is the target charging voltage;

[0091] T(t) is the current temperature of the capacitor;

[0092] T th is the temperature threshold;

[0093] L(t) is the real-time change of the welding load;

[0094] a T and b L are the adjustment coefficients of temperature and load, respectively;

[0095] Charging time t charge (t) is adjusted according to the current working state of the capacitor, and when the temperature of the capacitor is too high, the charging time is extended to reduce the charging rate. The dynamic adjustment formula of the charging time is:

[0096] t charge (t) = t target ·(1+ g T ·(T(t)-T th )).(1+_L.L(t))

[0097] Where t charge (t) is the dynamically adjusted charging time;

[0098] t target is the target charging time;

[0099] T(t) is the current temperature of the capacitor;

[0100] T th is the temperature threshold;

[0101] L(t) is the real-time change of the welding load;

[0102] g T ​and L is the temperature and load impact coefficient on charging time;

[0103] The optimization algorithm is to minimize the energy consumption in the charging process and ensure the capacitor stable operation in the working interval, using the following optimization objective function:

[0104]

[0105] Wherein, λ1 and λ2 are weight coefficients;

[0106] (V(t)-V target ) 2 The difference between the charging voltage and the target voltage;

[0107] I c (t) 2 The square of the charging current;

[0108] T end The end time of the charging process;

[0109] According to the above optimization objective, the dynamic adjustment is realized by the following steps:

[0110] Real-time monitoring of the capacitor temperature, load, voltage data during the charging process;

[0111] Using the optimization algorithm to dynamically adjust the upper limit of the charging voltage V max (t) and the charging time t charge (t);

[0112] According to the optimization results, control the charging process to ensure that the capacitor always operates in the working interval.

[0113] As preferred, the control system combines the welding parameters, dynamically optimizes the charging voltage and current output method:

[0114] The charging voltage V c (t) is dynamically adjusted according to the welding arc voltage, welding current and capacitor temperature, and the adjustment formula is represented as:

[0115]

[0116] Wherein, V target is the target charging voltage;

[0117] V arc (t) is the welding arc voltage;

[0118] I arc (t) is the welding current;

[0119] T(t) is the current temperature of the capacitor;

[0120] Tth is a capacitor temperature threshold value;

[0121] α T is a welding arc voltage, welding current and temperature adjustment coefficient for charging voltage;

[0122] charging current I c (t) is optimized based on the changes of welding current I arc (t), temperature T(t) and welding load L(t), and the charging current adjustment formula is as follows:

[0123]

[0124] wherein I target is a target charging current;

[0125] I arc (t) is a welding current;

[0126] L(t) is a real-time change of welding load;

[0127] T(t) is a current capacitor temperature;

[0128] β L , β T is a welding current, load and temperature adjustment coefficient for charging current;

[0129] Dynamic optimization of charging voltage and current according to welding parameters ensures the stability of the charging process, and the final optimization model combines the changes of welding arc voltage, current, load and temperature, and is as follows:

[0130]

[0131]

[0132] The optimization objective function minimizes the capacitor temperature fluctuation, overcharging and energy consumption in the charging process in the following form:

[0133]

[0134] wherein λ1, λ2, λ3 are weight coefficients for balancing the influence of voltage, current and temperature on the optimization objective;

[0135] V target and I target are target charging voltage and current;

[0136] I target is a target temperature;

[0137] Tend is the end time of the charging process.

[0138] The charging voltage control system of the capacitor energy storage welder comprises:

[0139] The controller module is used for being equipped with a processing unit, processing sensor feedback signals, and adjusting the charging voltage and the charging current according to the feedback information, and an intelligent algorithm is adopted in the controller to adjust the voltage, the time and the current in the charging process in real time;

[0140] The voltage and current sensor module is used for monitoring the charging state of the capacitor in real time, including the voltage, the current and the temperature, and the sensor is connected with the controller to generate feedback data;

[0141] The temperature sensor module is used for deploying the sensor in the capacitor to monitor the temperature of the capacitor;

[0142] The power module is used for providing the charging voltage and the current for the capacitor and adjusting according to the instruction of the controller;

[0143] The redundancy protection module is configured between the power module and the capacitor, and when the system detects an abnormality, the redundancy protection module automatically switches to a safety mode.

[0144] Another technical problem to be solved by the application is to provide an electronic device comprising a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the processor implements the charging voltage control method and system of the capacitor energy storage welder according to any one of the above.

[0145] Another technical problem to be solved by the application is to provide a computer readable storage medium having a computer program stored thereon, wherein the program is executed by a processor to implement the charging voltage control method and system of the capacitor energy storage welder.

[0146] The application has the following beneficial effects:

[0147] By dynamically adjusting the charging voltage, the voltage fluctuation of the traditional capacitor energy storage welder when the load changes is avoided, the stability in the welding process is ensured, and the welding quality is improved; by temperature monitoring and voltage optimization strategy, the capacitor is prevented from running in a high voltage working state for a long time, and the service life of the capacitor is effectively prolonged; by accurate voltage and current adjustment, energy waste is reduced, and the charging efficiency and the welding efficiency are improved; by the combination of the redundancy protection module and the intelligent control system, the stability and reliability of the capacitor energy storage welder in various working environments are improved. BRIEF DESCRIPTION OF DRAWINGS

[0148] Figure 1 It is a charging voltage control system flow diagram of the capacitor energy storage welder of the application. DETAILED DESCRIPTION

[0149] The principles and features of the present application are described below, and the examples are used only to explain the present application and not to limit the scope of the present application. The present application is described in more detail by way of example in the following paragraphs. The advantages and features of the present application will be more apparent from the following description and claims.

[0150] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0151] Embodiments

[0152] The technical scheme adopted by the present application to solve its technical problems is:

[0153] The charging voltage control method of the capacitor energy storage welding machine comprises:

[0154] During the charging process, the charging voltage, charging current and temperature of the capacitor are monitored in real time, the voltage, temperature and current data are obtained by sensors, and the data are input to the controller through the feedback control system;

[0155] According to the real-time feedback data, the controller dynamically adjusts the charging voltage, calculates the charging voltage according to the change trend of the signal through the adaptive control algorithm, and adjusts the output voltage of the power supply;

[0156] The temperature of the capacitor is monitored in real time, and when the temperature of the capacitor reaches a set threshold, the charging voltage is automatically adjusted or the charging rate is reduced, and the charging voltage is adjusted according to the change of the welding load;

[0157] During the charging process, the charging process is controlled by an optimization algorithm according to the working state of the capacitor, the upper limit of the charging voltage and the charging time are dynamically adjusted to ensure that the capacitor operates within the working range;

[0158] The control system dynamically optimizes the charging voltage and current output in combination with the welding parameters.

[0159] By adjusting the charging voltage and current in real time, the system can flexibly adjust the charging process according to actual needs, thereby improving the charging efficiency and reducing energy waste; real-time monitoring and adjustment of temperature and voltage ensure that the capacitor is not overcharged or overheated, thereby greatly prolonging the service life of the capacitor; redundant safety control measures, such as automatically reducing the charging rate when the temperature is too high and automatically adjusting the charging voltage when the welding load changes, effectively avoid overcharging or overheating of the capacitor, and improve the safety of the system; the adaptive control algorithm makes the charging process more intelligent, which can dynamically adjust the charging process according to real-time feedback signals and welding parameters, reduce human intervention, and improve the automation and precision of the system; dynamically adjusting the charging voltage and charging rate can cope with various working condition changes, ensuring the stability of the charging process, and the capacitor energy output during welding is also more reliable; by dynamically adjusting the charging voltage and current in combination with the welding parameters, the system can ensure more accurate power transmission during welding, improving the welding quality.

[0160] During the charging process, the charging voltage, charging current and temperature of the capacitor are monitored in real time, and the voltage, temperature and current data are obtained by sensors, and the data is input to the controller through the feedback control system:

[0161] The charging voltage V c (t) and the charging current I c (t) are related through the charging equation of the capacitor, and for the capacitor, the relationship between the charging current and the voltage is expressed as:

[0162]

[0163] Wherein, I c (t) is the charging current of the capacitor;

[0164] C is the capacitance of the capacitor;

[0165] V c (t) is the charging voltage of the capacitor;

[0166] It is assumed that there is a nonlinear relationship between temperature and the charging voltage and current of the capacitor, which is described by a temperature compensation model, and it is assumed that the rate of change of temperature T(t) is related to the charging current and voltage, which is represented by the following model:

[0167]

[0168] Wherein, is the rate of change of temperature;

[0169] I c (t) is the charging current;

[0170] V c (t) is the charging voltage;

[0171] a, b are empirical coefficients between temperature and current, voltage;

[0172] According to real-time voltage, current and temperature data, the controller uses a PID control algorithm or an adaptive control algorithm to dynamically adjust the charging voltage and current, and sets up a PID controller whose output is represented as:

[0173]

[0174] Where, V c，adjust (t) is the adjusted charging voltage;

[0175] e(t) = V c (t) - V target is the deviation of the charging voltage;

[0176] K p , K i , K d are the proportional, integral and derivative coefficients of the PID controller;

[0177] ∫e(t)dt is the integral term of the deviation;

[0178] is the derivative term of the deviation.

[0179] By monitoring voltage, current and temperature in real time, the control system can continuously adjust the charging voltage and current to maintain the stability of the charging process; dynamically adjusting the charging voltage can ensure that the capacitor is always charged at the appropriate rate, avoiding efficiency loss due to excessively low or high voltage; by precisely controlling voltage and current, and by temperature compensation to protect the capacitor, overheat and overcharge phenomena are avoided, prolonging the service life of the capacitor; the control system dynamically adjusts the charging voltage and current according to real-time feedback data, which can adapt to changes under different load conditions; the combination of temperature monitoring and PID control algorithm ensures that the capacitor is always within a safe temperature range during charging, avoiding potential safety hazards such as overheating or overcharging; the PID control algorithm is a commonly used and mature control method that can achieve precise control through simple parameter adjustment, reducing complexity and improving operational convenience.

[0180] According to real-time feedback data, the controller dynamically adjusts the charging voltage, calculates the charging voltage according to the trend of the signal change through an adaptive control algorithm, and adjusts the output voltage of the power supply in the following method:

[0181] Let the ideal reference model M be the output as follows:

[0182] y ref (t) = V target + V(t)

[0183] where y ref (t) is the reference model output;

[0184] V target is the target charging voltage;

[0185] V(t) is the deviation from the target voltage;

[0186] The controller dynamically adjusts the charging voltage V c (t) based on real-time monitoring, where y(t) is the actual output of the system, which is represented as:

[0187] y(t) = V c (t) + V c (t)

[0188] where y(t) is the actual charging voltage output of the system;

[0189] V c (t) is the current charging voltage of the capacitor;

[0190] V c (t) is the deviation from the reference model output;

[0191] The system error e(t) is defined as the difference between the actual output and the reference model output:

[0192] e(t) = y(t) - y ref (t)

[0193] Based on the error e(t), the charging voltage output is dynamically adjusted through the adaptive control gain K(t), and the output formula of the controller is:

[0194] V adjust (t) = K(t) · e(t)

[0195] where V adjust (t) is the adjusted charging voltage;

[0196] K(t) is the adaptive gain, which is dynamically adjusted with the change of error;

[0197] e(t) is the control error;

[0198] The adjustment formula of the gain K(t) is updated according to the change trend of the error and the dynamic characteristics of the system, and the gain updating method includes the least squares algorithm or the recursive least squares method, and the gain updating formula is:

[0199] K(t+1) = K(t) + μ · e(t) · V(t)

[0200] where K(t+1) is the gain at the next time;

[0201] μ is a step factor, which controls the speed of gain adjustment;

[0202] e(t) is the error signal;

[0203] V(t) is the trend of voltage signal change;

[0204] According to the adjusted charging voltage, the controller further adjusts the output voltage of the power supply, and sets the output voltage of the power supply as V out (t), then the output voltage adjustment formula of the power supply is:

[0205] V out (t) = V target + V adjust (t)

[0206] Wherein, V out (t) is the output voltage of the power supply;

[0207] V target is the target charging voltage;

[0208] V adjust (t) is the charging voltage adjusted by adaptive control.

[0209] Through real-time feedback error signal and gain adjustment, the system can dynamically adjust the charging voltage according to the signal change; the error feedback mechanism monitors the deviation between the charging voltage and the reference model in real time, and adjusts the charging voltage in time to prevent the voltage fluctuation from being too large; the dynamic adjustment of gain can be optimized according to the trend of error signal change and the dynamic characteristics of the system, and the least square algorithm or recursive least square method is used, so that the system can adapt to different load changes and external disturbances; the gain update formula adjusts itself according to the error signal and the trend of voltage change, avoiding the static setting of traditional control method and improving the adaptive ability of the system; by accurately controlling the charging voltage and dynamically adjusting according to real-time data, the system can avoid damage to the capacitor due to unstable or too high charging voltage, ensure that the capacitor will not be damaged due to too high or too low voltage during charging, and avoid overcharging, thereby improving the safety and charging efficiency of the system.

[0210] The temperature of the capacitor is monitored in real time, and when the temperature of the capacitor reaches a set threshold, the charging voltage is automatically adjusted or the charging rate is reduced, and the method for adjusting the charging voltage according to the change of welding load is:

[0211] Let the temperature of the capacitor be T(t), and the target temperature threshold be T th When the temperature of the capacitor reaches or exceeds the threshold, the control system automatically adjusts the charging voltage or reduces the charging rate, and the judgment condition is:

[0212] If T(t)≥Tth then adjust charging parameters.

[0213] When the temperature exceeds the set threshold T th When the load on the capacitor is reduced by adjusting the charging voltage or reducing the charging rate, the charging voltage V is adjusted using the following formula: c (t):

[0214] When the temperature exceeds the set threshold, the charging voltage V c (t) According to the temperature adjustment coefficient α T Automatic lowering:

[0215] V c (t) = V target -α T ·(T(t)-T th )

[0216] Among them, V c (t) is the adjusted charging voltage;

[0217] V target is the target charging voltage;

[0218] T(t) is the current capacitor temperature;

[0219] T th is the set temperature threshold;

[0220] α T is the temperature regulation coefficient;

[0221] In addition to adjusting the voltage, the temperature rise rate is controlled by reducing the charging rate, and the charging current I c The adjustment formula for (t) is:

[0222] I c (t) = I target -β T ·(T(t)-T th )

[0223] Among them, I c (t) is the adjusted charging current;

[0224] I target is the target charging current;

[0225] β T is the temperature regulation coefficient;

[0226] When the load changes, the system dynamically adjusts the charging voltage according to the load change. The change in welding load is represented by L(t). The formula for adjusting the charging voltage is:

[0227] V c (t) = V target +γ L L(t)

[0228] Among them, V c (t) is the adjusted charging voltage;

[0229] V target is the target charging voltage;

[0230] γ L is the load regulation factor;

[0231] L(t) is the change in welding load;

[0232] To ensure the operation of the capacitor, a maximum charging voltage and maximum charging current are set, and a limiting function is used to deal with overcharging or overheating under high temperature or high load. The formula is:

[0233] V c (t)=min(V max ,max(V min ,V target -α T ·(T(t)-T th )+γ L ·L(t)))

[0234] Among them, V max is the maximum charging voltage;

[0235] V min is the minimum charging voltage.

[0236] By real-time monitoring of the capacitor temperature, when the temperature exceeds the set threshold, the system will automatically adjust the charging voltage and current to reduce the capacitor load and prevent it from overheating; by adjusting the relationship between the charging voltage and current and the temperature, the system can flexibly respond to charging needs under different temperature conditions; when the load changes, the system will dynamically adjust the charging voltage according to the change in the welding load to adapt to the load change; by setting the maximum and minimum charging voltage and current, the capacitor is prevented from overcharging or overheating under high temperature or high load conditions; by dynamically adjusting the charging voltage and current, and combining temperature and load changes, the system can intelligently adapt to different working environments. This solution improves the efficiency of the charging process and the adaptability of the capacitor, ensuring that the equipment can operate stably under various loads and environments.

[0237] During the charging process, an optimization algorithm is used to control the charging process according to the working state of the capacitor. By dynamically adjusting the upper limit of the charging voltage and the charging time, the method to ensure that the capacitor operates within the working range is as follows:

[0238] Charging voltage upper limit Vmax (t) As the working state of the capacitor is dynamically adjusted, the working state of the capacitor is affected by its current voltage V(t), temperature T(t), and load change L(t). The upper limit voltage is adjusted using the following optimization formula:

[0239] V max (t) = V target +α T ·(T(t)-T th )-β L L(t)

[0240] Among them, V max (t) is the maximum charging voltage adjusted dynamically;

[0241] V target is the target charging voltage;

[0242] T(t) is the current temperature of the capacitor;

[0243] T th is the temperature threshold;

[0244] L(t) is the real-time change of welding load;

[0245] α T and β L are the regulation coefficients of temperature and load respectively;

[0246] Charging time t charge The adjustment of (t) is optimized based on the current working state of the capacitor. When the temperature of the capacitor is too high, the charging time is extended and the charging rate is reduced. The dynamic adjustment formula of the charging time is:

[0247] t charge (t) = t target (1+γ T .(T(t)-T th ))·(1+_L.L(t))

[0248] Among them, t charge (t) is the charging time after dynamic adjustment;

[0249] t target charging time for the target;

[0250] T(t) is the current temperature of the capacitor;

[0251] T th is the temperature threshold;

[0252] L(t) is the real-time change of welding load;

[0253] γ Tand L is the temperature and load impact coefficient on charging time;

[0254] The optimization algorithm is to minimize the energy consumption in the charging process and ensure the stable operation of the capacitor in the working interval, and the following optimization objective function is adopted:

[0255]

[0256] Where λ1 and λ2 are weight coefficients;

[0257] (V(t)-V target ) 2 The difference between the charging voltage and the target voltage;

[0258] I c (t) 2 The square of the charging current;

[0259] T end The end time of the charging process;

[0260] According to the above optimization objective, the dynamic adjustment is realized through the following steps:

[0261] Real-time monitoring of the temperature, load, and voltage data of the capacitor during the charging process;

[0262] The optimization algorithm is used to dynamically adjust the upper limit of the charging voltage V max (t) and the charging time t charge (t);

[0263] According to the optimization results, the charging process is controlled to ensure that the capacitor always operates within the working interval.

[0264] According to the real-time temperature and load changes of the capacitor, the charging voltage and charging time are dynamically adjusted to ensure that the capacitor is in the best working state during the charging process; the optimization algorithm can calculate the optimal charging voltage, charging current, and charging time in real time, thereby minimizing energy consumption and ensuring the stable operation of the capacitor; the dynamic relationship between temperature, load, and voltage is adjusted through the formula, thereby optimizing the charging process; the optimization algorithm considers the comprehensive influence of charging voltage, charging current, and charging time to minimize energy loss during the charging process; this scheme ensures that the capacitor is always in the safe working interval during the charging process through real-time monitoring and dynamic adjustment, avoiding overcharging, overheating, and load mismatching, etc., improving the safety of the capacitor, avoiding equipment damage due to overcharging or overheating, and thereby improving the reliability of the system.

[0265] The control system combines the welding parameters to dynamically optimize the charging voltage and current output method:

[0266] The charging voltage V c(t) is dynamically adjusted according to the welding arc voltage, welding current and capacitor temperature, and the adjustment formula is expressed as:

[0267]

[0268] V targct is the target charging voltage;

[0269] V arc (t) is the welding arc voltage;

[0270] I arc (t) is the welding current;

[0271] T(t) is the current temperature of the capacitor;

[0272] T th is the capacitor temperature threshold;

[0273] ɑ T is the adjustment coefficient of the welding arc voltage, welding current and temperature to the charging voltage;

[0274] The optimization of the charging current I c (t) is based on the changes of the welding current I arc (t), temperature T(t) and welding load L(t), and the charging current adjustment formula is as follows:

[0275]

[0276] I target is the target charging current;

[0277] I arc (t) is the welding current;

[0278] L(t) is the real-time change of the welding load;

[0279] T(t) is the current temperature of the capacitor;

[0280] β L , β T is the adjustment coefficient of the welding current, load and temperature to the charging current;

[0281] The dynamic optimization of the charging voltage and current according to the welding parameters ensures the stability of the charging process, and the final optimization model combines the changes of the welding arc voltage, current, load and temperature, and is as follows:

[0282]

[0283]

[0284] The optimization objective function minimizes the temperature fluctuations of the capacitor during charging, overcharging, and energy consumption in the following form:

[0285]

[0286] where λ1, λ2, and λ3 are weight coefficients used to balance the influence of voltage, current, and temperature on the optimization objective;

[0287] V target and I target are the target charging voltage and current;

[0288] T target is the target temperature;

[0289] T end is the end time of the charging process.

[0290] By real-time monitoring of the welding arc voltage, current, load, and capacitor temperature, the system dynamically adjusts the charging voltage and current based on these welding parameters to ensure the safety and efficiency of the charging process. Through the optimization objective function, the system considers the influencing factors of charging voltage, current, and temperature, minimizes temperature fluctuations, overcharging, and energy consumption, and optimizes the charging process. The control system responds in real-time to changes in welding current, arc voltage, and load, dynamically adjusts the charging voltage and current, and ensures stability during the charging process. The optimization objective function achieves multi-objective optimization through comprehensive weight adjustment of voltage, current, and temperature, ensuring that the capacitor is always in an optimal working state. The control system not only optimizes the energy efficiency of the charging process, but also ensures that the temperature and voltage of the capacitor during charging are always within a safe range, avoiding damage to the capacitor caused by excessive charging, high voltage, or high temperature, prolonging the life of the capacitor, and improving the overall safety and stability of the system.

[0291] The charging voltage control system of the capacitor energy storage welder includes:

[0292] The controller module is equipped with a processing unit that processes sensor feedback signals and adjusts the charging voltage and current based on feedback information. The controller uses intelligent algorithms to adjust the voltage, time, and current in real-time during the charging process.

[0293] The voltage and current sensor module is used to monitor the charging state of the capacitor in real-time, including voltage, current, and temperature. The sensor is connected to the controller to generate feedback data.

[0294] The temperature sensor module is used to deploy the sensor inside the capacitor to monitor the temperature of the capacitor.

[0295] The power module is used to provide charging voltage and current for the capacitor and adjusts according to the instructions of the controller.

[0296] A redundancy protection module is configured between the power module and the capacitor, which automatically switches to a safe mode when the system detects an abnormality.

[0297] The system receives real-time sensor feedback signals such as voltage, current, and temperature through the controller module, analyzes them using intelligent algorithms, and dynamically adjusts the charging voltage and current based on the current charging state; the voltage and current sensor modules monitor the charging state of the capacitor in real time, ensuring that the voltage and current of the capacitor are always within a reasonable range, and providing accurate data input for the controller; the temperature sensor module is deployed inside the capacitor to monitor the temperature changes of the capacitor in real time; the redundancy protection module is configured between the power module and the capacitor, and its main function is to automatically switch to a safe mode when the system detects an abnormality, preventing the capacitor and other components from being damaged; the intelligent algorithm in the controller adjusts the charging process based on real-time feedback data; by integrating multiple modules, the entire system can monitor and adjust itself at multiple levels, this comprehensive optimization design not only improves the overall performance and efficiency of the system, but also ensures that the device can adapt to changing working environments and loads, thereby reducing the risk of potential failures.

[0298] The embodiment also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor implements the charging voltage control method and system of the capacitor energy storage welding machine when executing the program.

[0299] The embodiment also provides a computer readable storage medium, which stores a computer program, and the program is executed by a processor to implement the charging voltage control method and system of the capacitor energy storage welding machine.

[0300] The intelligent control algorithm adopted by the present application is not described in detail in the claims, but is indirectly expressed by describing its basic principles, and the specific algorithm can be flexibly adjusted according to different welding process requirements;

[0301] During the control of the voltage, the system dynamically adjusts the working range according to the temperature and charging state of the capacitor, and the specific adjustment method and its accuracy will be adjusted according to different actual application scenarios;

[0302] The present application designs a redundancy protection module to enhance the fault tolerance and stability of the device.

[0303] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a non-volatile computer readable storage medium, and when the computer program is executed, the processes of the above-mentioned embodiments of each method can be included. Any reference to memory, storage, database or other medium used in each embodiment provided by the present application can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory can include random access memory (RAM) or external cache memory. As an illustration but not limitation, RAM is available in various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), synchronous link (Synchlink) DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0304] Those skilled in the art can clearly understand that, for the convenience and brevity of description, only the above-mentioned division of each functional unit and module is exemplified, and in actual application, the above-mentioned functions can be completed by different functional units and modules according to needs, that is, the internal structure of the system is divided into different functional units or modules to complete all or part of the above-mentioned functions.

[0305] The above-mentioned embodiments of the present application are not a limitation on the protection scope of the present application, and the embodiments of the present application are not limited thereto. According to the above-mentioned content of the present application, other various forms of modification, replacement or change of the above-mentioned structure of the present application can be made according to ordinary technical knowledge and conventional means in the art without departing from the above-mentioned basic technical idea of the present application, which should fall within the protection scope of the present application.

Claims

1. A method for controlling the charging voltage of a capacitor energy storage welding machine, characterized in that: Includes: During the charging process, the charging voltage, charging current and temperature of the capacitor are monitored in real time. Sensors are used to obtain voltage, temperature and current data, and the data are input into the controller through a feedback control system. Based on real-time feedback data, the controller dynamically adjusts the charging voltage. Through the adaptive control algorithm, it calculates the charging voltage and adjusts the power supply output voltage according to the changing trend of the signal. Monitor the temperature of the capacitor in real time. When the capacitor temperature reaches the set threshold, the charging voltage is automatically adjusted or the charging rate is reduced. The charging voltage is adjusted according to the change of welding load. During the charging process, an optimization algorithm is used to control the charging process according to the working status of the capacitor. The upper limit of the charging voltage and the charging time are dynamically adjusted to ensure that the capacitor operates within the working range. The control system combines welding parameters to dynamically optimize charging voltage and current output.

2. The charging voltage control method of the capacitor energy storage welding machine according to claim 1, characterized in that: During the charging process, the charging voltage, charging current and temperature of the capacitor are monitored in real time. Sensors are used to obtain voltage, temperature and current data, and the method of inputting the data into the controller through the feedback control system is as follows: Charging voltage V c (t) and charging current I c The relationship between the charging current and the voltage is described by the charging equation of the capacitor. For a capacitor, the relationship between the charging current and the voltage is expressed as: Among them, I c (t) is the charging current of the capacitor; C is the capacitance of the capacitor; V c (t) is the charging voltage of the capacitor; A nonlinear relationship exists between temperature and the charging voltage and current of the capacitor. A temperature compensation model is used to describe this relationship. The rate of change of temperature T(t) is related to the charging current and voltage, which can be expressed by the following model: in, is the temperature change rate; I c (t) is the charging current; V c (t) is the charging voltage; α, β are the empirical coefficients between temperature, current and voltage; According to the real-time voltage, current and temperature data, the controller uses the PID control algorithm or the adaptive control algorithm to dynamically adjust the charging voltage and current. The output of the PID controller is expressed as: Among them, V c，adjust (t) is the adjusted charging voltage; e(t)=V c (t)-V targct is the deviation of charging voltage; K p , K i , K d are the proportional, integral and differential coefficients of the PID controller; ∫e(t)dt is the integral term of the deviation; is the differential term of the deviation.

3. The charging voltage control method of the capacitor energy storage welding machine according to claim 2, characterized in that: Based on real-time feedback data, the controller dynamically adjusts the charging voltage. Through the adaptive control algorithm, the charging voltage is calculated according to the changing trend of the signal, and the method of adjusting the power supply output voltage is as follows: Assume that the ideal reference model M is as follows: y ref (t)=V targct +V(t) Among them, y ref (t) is the reference model output; V targct is the target charging voltage; V(t) is the deviation from the target voltage; The controller monitors the voltage V in real time. c (t) is dynamically adjusted. Assuming the actual output of the system is g(t), it can be expressed as: y(t)=V c (t)+V c (t) Where y(t) is the actual charging voltage output of the system; V c (t) is the current charging voltage of the capacitor; V c (t) is the deviation from the reference model output; The systematic error e(t) is defined as the difference between the actual output and the reference model output: e(t)=y(t)-y ref (t) Based on the error e(t), the charging voltage output is dynamically adjusted through the adaptive control gain K(t). The output formula of the controller is: V adjust (t)=K(t)·e(t) Among them, V adjust (t) is the adjusted charging voltage; K(t) is the adaptive gain, which is dynamically adjusted as the error changes; e(t) is the control error; The adjustment formula of the gain K(t) is updated according to the error trend and the dynamic characteristics of the system. The gain update method includes the least mean square algorithm or the recursive least squares method. The gain update formula is: K(t+1)=K(t)+μ·e(t)·V(t) Among them, K(t+1) is the gain at the next moment; μ is the step size factor, which controls the speed of gain adjustment; e(t) is the error signal; V(t) is the changing trend of the voltage signal; According to the adjusted charging voltage, the controller further adjusts the output voltage of the power supply to set the output voltage of the power supply to V out (t), the output voltage adjustment formula of the power supply is: V out (t)=V targct +V adjust (t) Among them, V out (t) is the power supply output voltage; V targct is the target charging voltage; V adjust (t) is the charging voltage adjusted by adaptive control.

4. The charging voltage control method of the capacitor energy storage welding machine according to claim 3, characterized in that: Monitor the temperature of the capacitor in real time. When the capacitor temperature reaches the set threshold, the charging voltage is automatically adjusted or the charging rate is reduced. According to the change of welding load, the method of adjusting the charging voltage is as follows: Assume the temperature of the capacitor is T(t), and the target temperature threshold is T th When the temperature of the capacitor reaches or exceeds the threshold, the control system automatically adjusts the charging voltage or reduces the charging rate. The judgment conditions are: If T(t)≥T th then adjust charging parameters. When the temperature exceeds the set threshold T th When the load on the capacitor is reduced by adjusting the charging voltage or reducing the charging rate, the charging voltage V is adjusted using the following formula: c (t): When the temperature exceeds the set threshold, the charging voltage V c (t) According to the temperature adjustment coefficient α T Automatic lowering: V c (t)=V targct -α T ·(T(t)-T th ) Among them, V c (t) is the adjusted charging voltage; V targct is the target charging voltage; T(t) is the current capacitor temperature; T th is the set temperature threshold; α T is the temperature regulation coefficient; In addition to adjusting the voltage, the temperature rise rate is controlled by reducing the charging rate, and the charging current I c The adjustment formula for (t) is: I c (t)=I targct -β T ·(T(t)-T th ) Among them, I c (t) is the adjusted charging current; I targct is the target charging current; β T is the temperature regulation coefficient; When the load changes, the system dynamically adjusts the charging voltage according to the load change. The change in welding load is represented by L(t). The formula for adjusting the charging voltage is: V c (t)=V targct +γ L ·L(t) Among them, V c (t) is the adjusted charging voltage; V targct is the target charging voltage; γ L is the load regulation factor; L(t) is the change in welding load; To ensure the operation of the capacitor, a maximum charging voltage and maximum charging current are set, and a limiting function is used to deal with overcharging or overheating under high temperature or high load. The formula is: V c (t)=min(V max ,max(V min ,V targct -α T ·(T(t)-T th )+γ L ·L(t))) Among them, V max is the maximum charging voltage; V min is the minimum charging voltage.

5. The charging voltage control method of the capacitor energy storage welding machine according to claim 4, characterized in that: During the charging process, an optimization algorithm is used to control the charging process according to the working state of the capacitor. By dynamically adjusting the upper limit of the charging voltage and the charging time, the method to ensure that the capacitor operates within the working range is as follows: Charging voltage upper limit V max (t) As the working state of the capacitor is dynamically adjusted, the working state of the capacitor is affected by its current voltage V(t), temperature T(t), and load change L(t). The upper limit voltage is adjusted using the following optimization formula: V max (t)=V targct +α T ·(T(t)-T th )-β L ·L(t) Among them, V max (t) is the maximum charging voltage adjusted dynamically; V targct is the target charging voltage; T(t) is the current temperature of the capacitor; T th is the temperature threshold; L(t) is the real-time change of welding load; α T and β L are the regulation coefficients of temperature and load respectively; Charging time t charge The adjustment of (t) is optimized based on the current working state of the capacitor. When the temperature of the capacitor is too high, the charging time is extended and the charging rate is reduced. The dynamic adjustment formula of the charging time is: t charge (t)= targct ·(1+γ T ·(T(t)-T th ))·(1+_L·L(t)) Among them, t charge (t) is the charging time after dynamic adjustment; t targct charging time for the target; T(t) is the current temperature of the capacitor; T th is the temperature threshold; L(t) is the real-time change of welding load; γ T and _L are the influence coefficients of temperature and load on charging time; The optimization algorithm minimizes the energy consumption during the charging process and ensures the stable operation of the capacitor within the working range. The following optimization objective function is used: Among them, λ1 and λ2 are weight coefficients; (V(t)-V targct ) 2 is the difference between the charging voltage and the target voltage; I c (t) 2 is the square of the charging current; T end The end time of the charging process; According to the above optimization goals, dynamic adjustment is achieved through the following steps: Real-time monitoring of capacitor temperature, load, and voltage data during the charging process; Use optimization algorithm to dynamically adjust the charging voltage upper limit V max (t) and charging time t charge (t); Based on the optimization results, the charging process is controlled to ensure that the capacitor always operates within the working range.

6. The charging voltage control method of the capacitor energy storage welding machine according to claim 5, characterized in that: The control system combines welding parameters to dynamically optimize the charging voltage and current output as follows: Charging voltage V c (t) is dynamically adjusted according to the welding arc voltage, welding current and capacitor temperature. The adjustment formula is expressed as: Among them, V targct is the target charging voltage; V arc (t) is the welding arc voltage; I arc (t) is the welding current; T(t) is the current temperature of the capacitor; T th is the capacitor temperature threshold; α T is the adjustment coefficient of welding arc voltage, welding current and temperature on charging voltage; Charging current I c The optimization of (t) is based on the welding current I arc (t), temperature T(t) and welding load L(t), the charging current adjustment formula is as follows: Among them, I targct is the target charging current; I arc (t) is the welding current; L(t) is the real-time change of welding load; T(t) is the current temperature of the capacitor; β L , β T is the adjustment coefficient of welding current, load and temperature on charging current; The charging voltage and current are dynamically optimized according to the welding parameters to ensure the stability of the charging process. The final optimization model combines the changes in welding arc voltage, current, load and temperature to form the following comprehensive optimization formula: The optimization objective function is to minimize the temperature fluctuation, overcharge and energy consumption of the capacitor during the charging process in the following form: Among them, λ1, λ2, and λ3 are weight coefficients used to balance the effects of voltage, current, and temperature on the optimization target; V targct and I targct Target charging voltage and current; T targct is the target temperature; T end The end time of the charging process.

7. The charging voltage control system of the capacitor energy storage welding machine is characterized in that: Includes: The controller module is equipped with a processing unit to process sensor feedback signals and adjust the charging voltage and current based on the feedback information. The controller uses an intelligent algorithm to adjust the voltage, time and current during the charging process in real time; Voltage and current sensor modules are used to monitor the capacitor charging status in real time, including voltage, current, and temperature. The sensors are connected to the controller to generate feedback data. A temperature sensor module is used to deploy a sensor inside the capacitor to monitor the capacitor's temperature; A power module is used to provide charging voltage and current to the capacitor, which is adjusted according to the instructions of the controller; The redundant protection module is configured between the power module and the capacitor. When the system detects an abnormality, the redundant protection module automatically switches to a safe mode.

8. An electronic device, characterized in that: The invention comprises a memory, a processor and a computer program stored in the memory and executable on the processor. When the processor executes the program, the charging voltage control method of the capacitor energy storage welding machine as claimed in any one of claims 1 to 6 is implemented.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the program is executed by a processor, the charging voltage control method of the capacitor energy storage welding machine as described in any one of claims 1 to 6 is implemented.

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