Electromagnetic welding head control system, control method and device

Abstract

The present application discloses an electromagnetic welding head control system, control method and device, the system includes: an inverter module, which is used to output high-frequency alternating current to power the electromagnetic welding head; an acquisition module, which includes a frequency acquisition unit, and the frequency acquisition unit is used to acquire the working frequency of the electromagnetic welding head; a control module, which is used to generate a first control signal according to the working frequency, and the first control signal includes a control signal for controlling the frequency; a frequency control module, which is used to generate a second control signal according to the first control signal, and the second control signal is a PWM signal; a drive module, which is used to drive the inverter module according to the second control signal. The working frequency of the electromagnetic welding head is acquired in real time by the frequency acquisition unit. When the working frequency drifts, the working frequency of the electromagnetic welding head can be corrected in time by using the coordinated use of the control module, the frequency control module and the drive module to ensure the welding efficiency of the electromagnetic welding head. The present application can be widely used in the field of electromagnetic welding technology.

Description

Technical Field

[0001] The present application relates to the technical field of electromagnetic welding, and in particular to an electromagnetic welding head control system, control method and device. Background Art

[0002] The electromagnetic welding head realizes the welding function by high-frequency electromagnetic induction heating and tin melting welding. The realization process is as follows: the high-frequency alternating current output by the inverter passes through the resonant matching unit of the electromagnetic welding head and enters the inductor coil in the welding head cavity seat. The inductor coil generates an alternating magnetic field under the action of the high-frequency alternating current. A plurality of closely arranged magnetic conductors are embedded in the inductor coil. The alternating magnetic field is concentrated at the four corner ends of the magnetic conductors, which plays a role in gathering the magnetic field, so that a plurality of closely arranged magnetic field concentration points are formed at the end of the lower cavity of the welding head. The alternating magnetic field generates large current and heat in photovoltaic component materials such as the lead wires and bus bars of the solar cell or the bus terminals. Due to the skin effect of the high-frequency alternating current, the tin-plated layer on the surface of the material is heated and melted, and the contact pressure between the materials is generated through the action of the buffer lifting mechanism. When the surface tin melts and bonds, the welding function can be realized.

[0003] Based on the working principle of the above-mentioned electromagnetic welding head, in order to change the welding efficiency, it is usually necessary to adjust the current and frequency of the high-frequency alternating current output by the inverter, so as to improve the welding efficiency of the electromagnetic welding head. However, in the prior art, technicians usually use a multimeter to measure relevant parameters at the test point of the electromagnetic welding head. Repeated measurements consume a lot of labor costs. Manual testing is prone to cause circuit short circuits, thereby burning hardware and even endangering the safety of personnel. In the later stage, when adjusting the frequency and other parameters of the inverter using the test data collected at the test point, it depends more on the engineering experience of the technicians. Summary of the invention

[0004] In order to solve one of the technical problems existing in the prior art to at least a certain extent, the purpose of the present invention is to provide an electromagnetic welding head control system, control method and device.

[0005] According to a first aspect of an embodiment of the present application, there is provided an electromagnetic welding head control system, which is applied to an electromagnetic welding head, comprising:

[0006] An inverter module, used for outputting high-frequency alternating current to power the electromagnetic welding head;

[0007] An acquisition module, wherein the acquisition module comprises a frequency acquisition unit, and the frequency acquisition unit is used to acquire the working frequency of the electromagnetic welding head;

[0008] A control module, configured to generate a first control signal according to the operating frequency, wherein the first control signal comprises a control signal for controlling the frequency;

[0009] A frequency control module, used for generating a second control signal according to the first control signal, wherein the second control signal is a PWM signal;

[0010] A driving module, configured to drive the inverter module according to the second control signal;

[0011] The output end of the acquisition module is connected to the input end of the control module, the output end of the control module is connected to the input end of the frequency control module, the output end of the frequency control module is connected to the input end of the driving module, the output end of the driving module is connected to the input end of the inverter module, and the output end of the inverter module is connected to the electromagnetic welding head.

[0012] Furthermore, the frequency control module includes a digital potentiometer of model MCP41010 and a phase shift resonance controller of model UC3875DW.

[0013] Furthermore, the acquisition module further includes a current acquisition unit, and the current acquisition unit is used to acquire the working current of the electromagnetic welding head;

[0014] The output end of the current acquisition unit is connected to the input end of the control module.

[0015] Furthermore, the acquisition module further includes a voltage acquisition unit, and the voltage acquisition unit is used to acquire the input voltage of the inverter module;

[0016] The output end of the voltage acquisition unit is connected to the input end of the control module.

[0017] Furthermore, the electromagnetic welding head control system further comprises a phase detection module, and the phase detection module is used to fine-tune the second control signal;

[0018] The input end of the phase detection module is connected to the current sampling unit block, the input end of the phase detection module is also connected to the output end of the phase shift resonance controller, and the output end of the phase detection module is connected to the input end of the phase shift resonance controller.

[0019] Furthermore, the electromagnetic welding head control system further includes a communication module, and the communication module is used for the control module to communicate with a host computer;

[0020] The input end of the communication module is connected to the control module, and the other end of the communication module is used to connect to the host computer.

[0021] Furthermore, the inverter module is a full-bridge inverter circuit.

[0022] According to a second aspect of an embodiment of the present application, a control method is provided, which is applied to the electromagnetic welding head control system, comprising the following steps:

[0023] Collecting the working frequency of the electromagnetic welding head;

[0024] Generate a first control signal according to the operating frequency, wherein the first control signal includes a control signal for controlling the frequency;

[0025] Generate a second control signal according to the first control signal, wherein the second control signal is a PWM signal;

[0026] The inverter module is driven according to the second control signal.

[0027] Furthermore, the control method further comprises the following steps:

[0028] Collecting the working current of the electromagnetic welding head;

[0029] According to the relationship between the operating current and the preset operating current range, the output condition of the first control signal is determined.

[0030] According to a third aspect of an embodiment of the present application, a device is provided, including:

[0031] Electromagnetic welding head;

[0032] The electromagnetic welding head is driven by the electromagnetic welding head control system mentioned above.

[0033] The beneficial effects of the present invention are as follows: the present invention collects the working frequency of the electromagnetic welding head in real time through the frequency acquisition unit. When the control module determines that the working frequency has frequency drift, the control module, the frequency control module and the drive module can be used in coordination to timely correct the working frequency of the electromagnetic welding head to ensure the welding efficiency of the electromagnetic welding head, and the present invention has the characteristics of a high degree of automation. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following introduction is made to the drawings of the embodiments of the present application or the related technical solutions in the prior art. It should be understood that the drawings introduced below are only for the convenience of clearly describing some embodiments of the technical solutions of the present application. For technical personnel in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0035] Figure 1 It is a module block diagram of an electromagnetic welding head control system in an embodiment of the present application;

[0036] Figure 2 is a circuit schematic diagram of a control module in an embodiment of the present application;

[0037] Figure 3 is a circuit schematic diagram of a frequency control module in an embodiment of the present application;

[0038] Figure 4 is a circuit schematic diagram of the inverter module in the embodiment of the present application;

[0039] Figure 5 is a circuit schematic diagram of a driving module in an embodiment of the present application;

[0040] Figure 6 is a circuit schematic diagram of the phase detection module in the embodiment of the present application;

[0041] Figure 7 is a circuit schematic diagram of the communication module in the embodiment of the present application;

[0042] Figure 8 It is a flow chart of control method steps provided in an embodiment of the present application. DETAILED DESCRIPTION

[0043] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present application.

[0044] The terms "first", "second", "third" and "fourth" etc. in the specification and claims of the present application and the drawings are used to distinguish different objects, rather than to describe a specific order. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but optionally includes steps or units that are not listed, or optionally includes other steps or units inherent to these processes, methods, products or devices.

[0045] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0046] The following is a description of the shortcomings of an electromagnetic welding head control system at this stage with reference to the accompanying drawings. Figure 1 The present application provides an electromagnetic welding head control system, which is applied to an electromagnetic welding head, including:

[0047] The inverter module is used to output high-frequency alternating current to power the electromagnetic welding head;

[0048] The acquisition module includes a frequency acquisition unit, and the frequency acquisition unit is used to acquire the working frequency of the electromagnetic welding head;

[0049] A control module, configured to generate a first control signal according to an operating frequency, wherein the first control signal includes a control signal for controlling a frequency;

[0050] A frequency control module, used for generating a second control signal according to the first control signal, wherein the second control signal is a PWM signal;

[0051] A driving module, used for driving the inverter module according to the second control signal;

[0052] The output end of the acquisition module is connected to the input end of the control module, the output end of the control module is connected to the input end of the frequency control module, the output end of the frequency control module is connected to the input end of the drive module, the output end of the drive module is connected to the input end of the inverter module, and the output end of the inverter module is connected to the electromagnetic welding head.

[0053] Specifically, the acquisition module is mainly used to collect the operation data of the electromagnetic welding head. In this embodiment, the acquisition module includes a frequency acquisition unit, which uses the frequency acquisition unit to collect the working frequency of the electromagnetic welding head. In a specific embodiment, the frequency meter / pulse counter built into the MCU can be used as an implementation method of the frequency acquisition unit.

[0054] The control module has the functions of control and data processing. In a specific embodiment, Figure 2 The control module includes a single-chip microcomputer U15 of model HC32F005. The control module compares the working frequency of the electromagnetic welding head obtained by the frequency acquisition unit with the preset frequency. When it is determined that the working frequency of the electromagnetic welding head deviates from the preset frequency, the control module generates a first control signal, and the first control signal includes a frequency control function. The frequency control module outputs a second control signal according to the first control signal including frequency control output by the control module. The second control signal is a PWM signal including a specific frequency. The driving module drives the inverter module using the PWM signal, so that the inverter module generates a high-frequency alternating current for controlling the electromagnetic welding head.

[0055] It can be seen from the above content that the present application collects the working frequency of the electromagnetic welding head in real time. When it is determined that the working frequency drifts, the working frequency of the electromagnetic welding head can be corrected in time to ensure the welding efficiency of the electromagnetic welding head. Compared with manual testing and adjustment of parameters, it has the characteristics of a high degree of automation.

[0056] As an optional embodiment, see Figure 3 The frequency control module includes a digital potentiometer U24 of model MCP41010 and a phase shift resonant controller U6 of model UC3875DW.

[0057] Specifically, the frequency control module is used to generate a PWM signal of a specific frequency. In a specific embodiment, the frequency control module includes a digital potentiometer U24 of model MCP41010 and a phase shift resonant controller U6 of model UC3875DW. Among them, the digital potentiometer U24 of model MCP41010 integrates a 10kΩ potentiometer and an 8-bit E2PROM data register. Therefore, the sliding end of the potentiometer has a total of 256 discrete adjustment nodes, and an 8-bit word can be written to the data register through the corresponding instruction, thereby changing the position of the sliding brush, so that the digital potentiometer U24 outputs different resistance values.

[0058] The resistance value output by the digital potentiometer U24 is output to the FREQSET pin of the phase-shift resonant controller U6. The resistance value determines the output frequency of the phase-shift resonant controller U6, which is model UC3875DW. Therefore, the frequency of the PWM signal output by the phase-shift resonant controller U6 can be adjusted by changing the resistance value of the adjusting resistor.

[0059] In a specific embodiment, referring to Figure 4 The inverter module is a full-bridge inverter circuit, including four field effect transistors, wherein the first field effect transistor Q1 and the fourth field effect transistor Q4 form a half-bridge circuit, and the second field effect transistor Q2 and the fifth field effect transistor Q5 form a half-bridge circuit. Figure 5 The drive module may include two IR2110 drivers. One IR2110 driver drives a half-bridge circuit through two sets of complementary PWM signals. Therefore, four sets of PWM signals are used to drive the four power switch tubes of the inverter module to achieve the purpose of converting the DC power input to the inverter module into high-frequency AC power.

[0060] Further as an optional implementation, the acquisition module also includes a current acquisition unit, and the current acquisition unit is used to collect the working current of the electromagnetic welding head;

[0061] The output end of the current acquisition unit is connected to the input end of the control module.

[0062] Specifically, the current acquisition unit is used to acquire the working current of the electromagnetic welding head. In a specific embodiment, a current transformer can be used as a specific implementation of the current acquisition unit, so as to obtain the magnitude of the working current of the electromagnetic welding head in real time.

[0063] The control module determines whether the working current of the electromagnetic welding head exceeds the preset working current range based on the obtained working current. If the working current exceeds the preset working current range, the control module stops outputting the first control signal; otherwise, the control module continues to output the first control signal, so that the inverter module continues to provide high-frequency alternating current to the electromagnetic welding head, ensuring that the working current of the electromagnetic welding head is always within the limited working current range.

[0064] Further as an optional implementation, the acquisition module further includes a voltage acquisition unit, and the voltage acquisition unit is used to acquire the input voltage of the inverter module;

[0065] The output end of the voltage acquisition unit is connected to the input end of the control module.

[0066] Specifically, the present application further provides a voltage acquisition unit, which is used to acquire the DC voltage input to the inverter module. In a specific embodiment, the voltage to be acquired is divided by a resistor and then the input DC voltage is acquired using the ADC built into the MCU.

[0067] As an optional implementation, the electromagnetic welding head control system further includes a phase detection module, and the phase detection module is used to fine-tune the second control signal;

[0068] The input end of the phase detection module is connected to the current sampling unit block, and the input end of the phase detection module is also connected to the output end of the phase shift resonance controller U6. The output end of the phase detection module is connected to the input end of the phase shift resonance controller U6.

[0069] Specifically, the phase detection module is used to fine-tune the waveform of the PWM signal. Figure 6 The phase detection module uses a logic chip U9 with model number 74LVC1G86 to compare the waveform of the working current of the electromagnetic welding head (the current acquisition unit obtains the working current) with the waveform of the PWM signal output by the phase-shift resonant controller U6 (the phase-shift resonant controller U6 outputs a total of four PWM signals, and one of the PWM signals can be input to the input end of the phase detection module). The comparison result is amplified by operation and then output to the phase-shift resonant controller U6. When the comparison result is phase-detection coupling, the phase-shift resonant controller U6 does not need to change the frequency of the four PWM signals it outputs. When the comparison result is phase-detection decoupling, the phase-shift resonant controller U6 adaptively reduces the frequency of the four PWM signals it outputs, and fine-tunes the frequency of the second control signal output by the frequency control module through the phase detection module, so that the inverter module realizes the frequency tracking function to ensure that the electromagnetic welding head is in the best working state.

[0070] As a further optional implementation, the electromagnetic welding head control system further includes a communication module, and the communication module is used for the control module to communicate with the host computer;

[0071] The input end of the communication module is connected to the control module, and the other end of the communication module is used to connect to the host computer.

[0072] Specifically, the electromagnetic welding head control system of the present application is also equipped with a communication module, which realizes the communication between the control module and the host computer, wherein the host computer can be a PLC or a computer, etc., and the data such as the working frequency, working current and DC voltage of the input inverter module of the electromagnetic welding head collected by the acquisition module can be transmitted to the host computer, and the technicians can view various parameters in real time on the host computer side, and the technicians can also adjust the preset working frequency and modify the preset working current range on the host computer side. In a specific embodiment, refer to Figure 7 The communication module includes a communication unit, which includes a communication chip U18 of model SP485. In addition, the communication module also includes an isolation unit, which includes two optocouplers of model 6N137 and one optocoupler of model TLP521. The isolation unit is used to electrically isolate the front and rear circuits to suppress crosstalk. Of course, the communication between the control module and the host computer can also be achieved through communication methods including but not limited to Ethernet, Bluetooth or WiFi, and no excessive restrictions are placed on the communication module here.

[0073] On the other hand, referring to Figure 8 The present invention also provides a control method, which is applied to the above-mentioned electromagnetic welding head control system, comprising the following steps S1-S3:

[0074] S1, collecting the working frequency of the electromagnetic welding head;

[0075] S2. Generate a first control signal according to the operating frequency, the first control signal including a control signal of the control frequency;

[0076] S3, generating a second control signal according to the first control signal, where the second control signal is a PWM signal;

[0077] S4. Drive the inverter module according to the second control signal.

[0078] Specifically, this embodiment provides a control method applied to the above-mentioned system embodiment, by obtaining the working frequency of the electromagnetic welding head and taking the working frequency as the judgment object. When it is determined that the working frequency has frequency point drift, a first control signal including frequency control is generated. The first control signal is used to control the frequency control module to generate a PWM model with a specific frequency. Finally, the PWM signal is used to drive the inverter module to generate high-frequency alternating current for the operation of the electromagnetic welding head.

[0079] As an optional implementation, the control method further includes the following steps:

[0080] S5, collecting the working current of the electromagnetic welding head;

[0081] S6. Determine the output condition of the first control signal according to the relationship between the operating current and the preset operating current range.

[0082] Specifically, the working current of the electromagnetic welding head is collected. When it is determined that the working current exceeds the preset working current range, it indicates that the current working current is large, so the output of the first control signal is stopped, and the inverter module also stops working accordingly. When it is determined that the working current is within the preset working current range, the first control signal continues to be output, and the inverter module continues to provide high-frequency alternating current to the electromagnetic welding head to ensure that the electromagnetic welding head continues to work in a stable state.

[0083] Finally, the embodiment of the present application further provides a device, including:

[0084] Electromagnetic welding head;

[0085] The electromagnetic welding head is driven by the electromagnetic welding head control system mentioned above.

[0086] Similarly, the contents of the above-mentioned electromagnetic welding head control system embodiment are applicable to the embodiment of the present device. The functions specifically implemented by the embodiment of the present device are the same as those of the above-mentioned electromagnetic welding head control system embodiment, and the beneficial effects achieved are also the same as those achieved by the above-mentioned electromagnetic welding head control system embodiment.

[0087] It is understood that all or some steps and systems in the disclosed method above can be implemented as software, firmware, hardware and appropriate combinations thereof. Some physical components or all physical components can be implemented as software executed by a processor, such as a central processing unit, a digital signal processor or a microprocessor, or implemented as hardware, or implemented as an integrated circuit, such as an application-specific integrated circuit. Such software can be distributed on a computer-readable medium, and the computer-readable medium can include a computer storage medium (or a non-transitory medium) and a communication medium (or a temporary medium). As known to those of ordinary skill in the art, the term computer storage medium includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information (such as computer-readable instructions, data structures, program modules or other data). Computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cassette, magnetic tape, disk storage or other magnetic storage device, or any other medium that can be used to store desired information and can be accessed by a computer. Furthermore, it is well known to those skilled in the art that communication media typically embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism, and may include any information delivery media.

[0088] The embodiments of the present application are described in detail above in conjunction with the accompanying drawings, but the present application is not limited to the above embodiments, and various changes can be made within the knowledge scope of ordinary technicians in the technical field without departing from the purpose of the present application.

Claims

1. An electromagnetic welding head control system, applied to an electromagnetic welding head, characterized in that: include: An inverter module, used for outputting high-frequency alternating current to power the electromagnetic welding head; An acquisition module, wherein the acquisition module comprises a frequency acquisition unit and a current acquisition unit, wherein the frequency acquisition unit is used to acquire the working frequency of the electromagnetic welding head, and the current acquisition unit is used to acquire the working current of the electromagnetic welding head; A control module, configured to generate a first control signal according to the operating frequency, wherein the first control signal comprises a control signal for controlling the frequency; A frequency control module, used for generating a second control signal according to the first control signal, wherein the second control signal is a PWM signal, and the frequency control module comprises a digital potentiometer of model MCP41010 and a phase shift resonant controller of model UC3875DW; A phase detection module, the phase detection module is used to fine-tune the second control signal according to the working current; A driving module, configured to drive the inverter module according to the second control signal; The output end of the acquisition module is connected to the input end of the control module, the output end of the control module is connected to the input end of the frequency control module, the output end of the current acquisition unit is connected to the input end of the control module, the output end of the frequency control module is connected to the input end of the drive module, the input end of the phase detection module is connected to the current acquisition unit block, the input end of the phase detection module is also connected to the output end of the phase shift resonance controller, the output end of the phase detection module is connected to the input end of the phase shift resonance controller, the output end of the drive module is connected to the input end of the inverter module, and the output end of the inverter module is connected to the electromagnetic welding head.

2. The electromagnetic welding head control system according to claim 1, characterized in that: The acquisition module further includes a voltage acquisition unit, and the voltage acquisition unit is used to acquire the input voltage of the inverter module; The output end of the voltage acquisition unit is connected to the input end of the control module.

3. The electromagnetic welding head control system according to claim 1, characterized in that: The electromagnetic welding head control system further includes a communication module, which is used for the control module to communicate with the host computer; The input end of the communication module is connected to the control module, and the other end of the communication module is used to connect to the host computer.

4. The electromagnetic welding head control system according to claim 1, characterized in that: The inverter module is a full-bridge inverter circuit.

5. A control method, characterized in that: An electromagnetic welding head control system as claimed in claim 1, comprising the following steps: Collecting the working frequency of the electromagnetic welding head; Generate a first control signal according to the operating frequency, wherein the first control signal includes a control signal for controlling the frequency; Generate a second control signal according to the first control signal, wherein the second control signal is a PWM signal; driving an inverter module according to the second control signal; The control method further comprises the following steps: Collecting the working current of the electromagnetic welding head; According to the relationship between the operating current and the preset operating current range, the output condition of the first control signal is determined.

6. A welding device, characterized in that: include: Electromagnetic welding head; The electromagnetic welding head is driven by an electromagnetic welding head control system according to any one of claims 1 to 4.

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