Welding machine control system, welding machine and method based on anti-electric shock protection and energy saving

Abstract

The invention belongs to the technical field of welding machine control, and proposes a welding machine control system based on anti-electric shock protection and energy saving, a welding machine and a method. The control system comprises a control panel, a signal line, a mutual inductor and a magnetic latching relay connected to the control panel; the signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current at the output end of a power supply; the control panel is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the magnetic latching relay to be continuously attracted and released according to the current detected by the mutual inductor; the magnetic latching relay is used to connect or disconnect the power supply to the welding machine; the invention controls the magnetic latching relay to be continuously attracted and released according to the current detected by the mutual inductor, the magnetic latching relay is connected to the primary power supply of the welding machine, and automatically identifies whether the welding machine is in a working state by real-time acquisition of the output side signal of the welding machine. If the welding machine is not working, the electronic relay is automatically disconnected to cut off the power supply, and the relay is automatically closed to work when the welding machine is working.

Description

Technical Field

[0001] The present invention belongs to the technical field of welding machine control, and in particular relates to a welding machine control system, a welding machine and a method based on anti-electric shock protection and energy saving. Background Art

[0002] Arc welders are commonly used in the manufacturing industry as low-voltage electrical equipment. To ensure proper arc ignition during welding, they require a relatively high arc ignition voltage of approximately 80 volts when not in use. Because this voltage is higher than the safe voltage, human contact can easily lead to electric shock. Therefore, arc welders should be connected to a no-load voltage-reducing protector to prevent injuries and fatalities. Furthermore, since arc welders operate at either 380 or 220 volts, they experience a certain amount of power loss when not in use.

[0003] The inventors have found that existing arc welding machines do not consider the problem of damage to workers caused by arc striking voltage when the arc welding machine is idling, nor do they solve the problem of certain power loss when not welding. Summary of the Invention

[0004] In order to solve the above problems, the present invention proposes a welding machine control system, a welding machine and a method based on anti-electric shock protection and energy saving. In the present invention, a control board is provided in the control system. The signal line in the control board starts the attraction of the magnetic latching relay by detecting the secondary load resistance of the electric welding machine, thereby achieving the purpose of not working when the welding is unloaded and working when loaded; at the same time, the magnetic latching relay is controlled to continuously attract and release according to the current detected by the built-in mutual inductor, thereby achieving the purpose of powering on when the welding is in the working state and powering off when the welding is not in the working state; the magnetic latching relay is connected to the primary power supply of the electric welding machine to realize automatic power control.

[0005] In order to achieve the above objectives, in a first aspect, the present invention provides a welding machine control system based on anti-electric shock protection and energy saving, which adopts the following technical solutions:

[0006] A welding machine control system based on electric shock prevention and energy saving, comprising a control panel, and signal lines, mutual inductors and magnetic latching relays connected to the control panel;

[0007] The signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current at the output end of the power supply;

[0008] The control board is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the continuous attraction and release of the magnetic latching relay according to the current detected by the mutual inductor;

[0009] The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

[0010] Furthermore, the mutual inductor is a current mutual inductor, which is arranged on the wire between the magnetic latching relay and the power output terminal.

[0011] Furthermore, the current sensed by the current transformer is converted into a voltage under the action of a resistor connected thereto, and the voltage is transmitted to the control board after A / D conversion.

[0012] Furthermore, when the detection resistance is less than or equal to the preset resistance, the magnetic latching relay is energized; after a set time delay, if the detection current is lower than the preset current value within the delay range, the magnetic latching relay is released after the delay;

[0013] After a set time delay, if the detected current within the delay range is higher than the preset current value, the magnetic latching relay will continue to be energized until the detected current is lower than the preset current value, and then the delay will be re-set for the set time and the cycle will be executed. Otherwise, the magnetic latching relay will continue to be energized; after the magnetic latching relay is released, the resistance detection will be re-executed and the cycle will be executed.

[0014] Furthermore, during welding, the welding handle and the ground are short-circuited, and the magnetic latching relay is controlled to be attracted; at the same time, timing is performed, and within a preset time, if the detected welding machine working current is less than a preset current value, the magnetic latching relay is controlled to be disconnected.

[0015] Furthermore, the control panel is connected to a running indicator light and a stop indicator light.

[0016] In order to achieve the above-mentioned purpose, in a second aspect, the present invention further provides a welding machine based on anti-electric shock protection and energy saving, which adopts the following technical solutions:

[0017] A welding machine based on anti-electric shock protection and energy saving comprises at least a control system, wherein the control system comprises a control panel, and signal lines, mutual inductors and magnetic latching relays connected to the control panel;

[0018] The signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current;

[0019] The control board is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the continuous attraction and release of the magnetic latching relay according to the current detected by the mutual inductor;

[0020] The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

[0021] Furthermore, the mutual inductor is a current mutual inductor, which is arranged on the wire between the magnetic latching relay and the power output terminal; when the detection resistance is less than or equal to the preset resistance, the magnetic latching relay is attracted; after a set time delay, if the detection current within the delay range is lower than the preset current value, the magnetic latching relay is released after the delay;

[0022] After a set time delay, if the detected current within the delay range is higher than the preset current value, the magnetic latching relay will continue to be energized until the detected current is lower than the preset current value, and then the delay will be re-set for the set time and the cycle will be executed. Otherwise, the magnetic latching relay will continue to be energized; after the magnetic latching relay is released, the resistance detection will be re-executed and the cycle will be executed.

[0023] Furthermore, during welding, the welding handle and the ground are short-circuited, and the magnetic latching relay is controlled to be attracted; at the same time, timing is performed, and within a preset time, if the detected welding machine working current is less than a preset current value, the magnetic latching relay is controlled to be disconnected.

[0024] In order to achieve the above objectives, in a third aspect, the present invention further provides a welding machine control method based on anti-electric shock protection and energy saving, which adopts the following technical solutions:

[0025] The welding machine control method based on anti-electric shock protection and energy saving adopts the welding machine control system based on anti-electric shock protection and energy saving as described in the first aspect, comprising:

[0026] Detect the secondary load resistance of the welding machine and the current at the power output end;

[0027] The magnetic latching relay is activated based on the detected secondary load resistance of the welding machine, and the magnetic latching relay is controlled to continuously be activated and released based on the detected current;

[0028] The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] 1. The present invention provides a control panel in the control system. The signal line in the control panel starts the magnetic latching relay by detecting the secondary load resistance of the electric welder. The magnetic latching relay is continuously closed and released according to the current detected by the built-in mutual inductor. The magnetic latching relay is connected to the primary power supply of the electric welder. By real-time acquisition of the output side signal of the welding machine, it is automatically identified whether the welding machine is in working state. If it is not working, it automatically issues a command to cut off the electronic relay and cut off the power supply. When working, the relay is automatically closed to work. The purpose of not working when the welding machine is unloaded and working when loaded is achieved.

[0031] 2. When the present invention is unloaded, the power supply is cut off, and the safety and energy-saving effects are very obvious;

[0032] 3. The start signal detection circuit of the present invention is simple in design, has high detection sensitivity and good anti-interference performance; and is input into the microprocessor in the form of a digital signal, which is convenient for logical judgment and processing; since the stability and anti-interference performance of digital signals are higher than those of analog signals, this ensures that the welding machine will not be falsely triggered due to unexpected interference;

[0033] 4. The present invention uses a small-sized annular electromagnetic sensor and its signal conditioning circuit to collect working signals, which has high collection sensitivity and can filter out interference signals, ensuring reliability and safety. In addition, the electromagnetic sensor is simple to wind and easy to process.

[0034] 5. The activation time of the present invention is short, which can be less than 0.5s;

[0035] 6. The present invention combines the characteristics of welding work with the powerful logic processing function of the microprocessor, making the operation simple and the function powerful, realizing the intelligentization, electronization and miniaturization of the device, and solving the disadvantage that the welding quality is affected by the previous connection of the protector;

[0036] 7. The present invention adopts magnetic latching relay, which greatly improves reliability and service life;

[0037] 8. The present invention is small in size, light in weight and easy to install. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The drawings constituting a part of the specification of this embodiment are used to provide a further understanding of this embodiment. The schematic embodiments and descriptions of this embodiment are used to explain this embodiment and do not constitute an improper limitation on this embodiment.

[0039] Figure 1 This is a schematic structural diagram of Example 1 of the present invention;

[0040] Figure 2 This is a working principle diagram of the first part of Example 1 of the present invention;

[0041] Figure 3 This is a diagram of the working principle of the second part of Example 1 of the present invention. DETAILED DESCRIPTION

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0043] It should be noted that the following detailed descriptions are exemplary and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present application belongs.

[0044] Glossary:

[0045] The welding machine has secondary loads. The welding machine is divided into primary and secondary sides. The primary side is the power input, which is equipped with a leakage protector and has electric shock protection. The secondary side is the output of the welding machine to the weldment and is isolated from the primary side. The primary side protection does not work on the secondary side and requires separate protection. Once the secondary side is electrocuted, there is no protection and you will be electrocuted.

[0046] Instrument transformers, also known as instrument transformers, are a general term for current transformers and voltage transformers. They convert high voltages into low voltages and high currents into low currents for use in measurement or protection systems. Their primary function is to proportionally convert high voltages or high currents into standard low voltages (100V) or standard low currents (5A or 1A, both rated values), enabling the standardization and miniaturization of measuring instruments, protection devices, and automatic control equipment. Instrument transformers can also be used to isolate high-voltage systems to ensure personal and equipment safety.

[0047] Signal line, the signal line is divided into positive and negative wires, which are connected to the positive and negative terminals of the welding secondary output respectively. The signal line carries a 12V voltage. If the positive and negative terminals on the secondary side of the welding machine are in contact, it is in working state by default. The resistance value collected by the signal line is lower than 200 ohms, R=U / I. If the resistance value collected by the signal line is higher than 200 ohms, it is defaulted that the secondary side of the welding machine is suspended and not working.

[0048] A magnetic latching relay maintains its contacts in an open or closed state by the magnetic force of a permanent magnet. To open or close the relay contacts, the coil is energized with a positive or negative DC pulse voltage, instantly switching between open and closed states. While the contacts are in the latched state, the coil does not need to be energized; the magnetic force of the permanent magnet alone maintains the relay's position.

[0049] Example 1:

[0050] like Figure 1 As shown, this embodiment provides a welding machine control system based on electric shock prevention and energy saving, including a control board, and signal lines, mutual inductors and magnetic latching relays connected to the control board; the working power supply of the control board can be set to single-phase AC380V;

[0051] The signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current at the output end of the power supply. In this embodiment, the focus is on emphasizing that the acquired signal is the secondary load resistance of the welding machine, and the specific detection method of the load resistance is a conventional setting and will not be detailed here.

[0052] The control board is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the continuous attraction and release of the magnetic latching relay according to the current detected by the mutual inductor;

[0053] The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

[0054] In this embodiment, when the detection resistance is less than or equal to the preset resistance, the magnetic latching relay is energized; after a set time delay, if the detection current within the delay range is lower than the preset current value, the magnetic latching relay is released after the delay; after a set time delay, if the detection current within the delay range is higher than the preset current value, the magnetic latching relay is continuously energized until the moment the detection current is lower than the preset current value, the delay is re-enforced by the set time and the cycle is executed; otherwise, the magnetic latching relay is continuously energized; after the magnetic latching relay is released, the resistance detection is re-executed and the cycle is executed. The specific steps of the protection action may be:

[0055] S1, signal line detection resistance ≤ 200Ω, the specific measurement shall be subject to the actual sample, the magnetic latching relay is closed;

[0056] S2, after a set time delay, the detection current is lower than the preset current value of 5A within the delay range, and the magnetic latching relay is released after the delay;

[0057] S3, delaying for a set time, and if the detected current within the delay range is higher than the preset current value of 5A, the magnetic latching relay continues to be energized until the detected current is lower than the preset current value of 5A, and then delaying for a set time again, and looping through step S2, otherwise the magnetic latching relay continues to be energized;

[0058] S4: After the magnetic latching relay is released, execute step S1 and execute it in a loop.

[0059] In this embodiment, Figure 2 and Figure 3 As shown, H1 is connected to 220V AC power, which is converted into 5Vdc and 12Vdc through the switch circuit. 5Vdc powers the microcontroller and 12Vdc powers the relay.

[0060] In this embodiment, the mutual inductor is a current mutual inductor, which is provided on the wire between the magnetic latching relay and the power output terminal; the current sensed by the current mutual inductor is converted into a voltage under the action of the resistor connected thereto, and the voltage is transmitted to the control board after A / D conversion; specifically, Figure 2 and Figure 3 As shown, the ACIin interface is connected to the current transformer. The current sensed by the current transformer is converted into a voltage through the resistor R7. This voltage is collected by the microcontroller after A / D conversion, and the microcontroller can thus determine the working current of the welding machine.

[0061] SWin is connected to a switch, which is used to switch between protection mode and normal mode. The switch is disconnected for protection mode and connected for normal mode.

[0062] During welding, the welding handle is short-circuited with the ground, and the magnetic latching relay is controlled to be attracted; at the same time, timing is performed, and within a preset time, if the detected welding machine working current is less than a preset current value, the magnetic latching relay is controlled to be disconnected; specifically, Figure 2 and Figure 3 As shown, J1 is connected to the trigger line and, in actual use, is connected to the welding torch and ground. During welding, the welding torch and ground are effectively short-circuited, sending a trigger signal to the microcontroller via optocoupler ED1. The microcontroller then sends a pull-in signal to Q1, which in turn controls the latching relay to close. Simultaneously, the microcontroller counts the time. If the welder's operating current is less than the set current value within 6 seconds, the microcontroller sends a shutdown signal to Q2, which in turn controls the latching relay to open. K2 is connected to the latching relay.

[0063] It should be noted that Figure 2 The three lines on the right are Figure 3 The three wires on the left correspond to the connections.

[0064] The control panel is connected to a running indicator light and a stop indicator light; the LED interface is connected to a working indicator light, when the electric welder is working, the red light is on, when the electric welder is not working, the green light is on.

[0065] Example 2:

[0066] This embodiment provides a welding machine based on anti-electric shock protection and energy saving, which includes at least a control system, wherein the control system includes a control board, and signal lines, mutual inductors, and magnetic latching relays connected to the control board; the control system in this embodiment adopts all the functions of the welding machine control system based on anti-electric shock protection and energy saving in Example 1;

[0067] The signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current;

[0068] The control board is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the continuous attraction and release of the magnetic latching relay according to the current detected by the mutual inductor;

[0069] The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

[0070] In this embodiment, the mutual inductor is a current mutual inductor, which is arranged on the wire between the magnetic latching relay and the power output terminal; when the detection resistance is less than or equal to the preset resistance, the magnetic latching relay is attracted; after a set time delay, if the detection current within the delay range is lower than the preset current value, the magnetic latching relay is released after the delay;

[0071] After a set time delay, if the detected current within the delay range is higher than the preset current value, the magnetic latching relay will continue to be energized until the detected current is lower than the preset current value, and then the delay will be re-set for the set time and the cycle will be executed. Otherwise, the magnetic latching relay will continue to be energized; after the magnetic latching relay is released, the resistance detection will be re-executed and the cycle will be executed.

[0072] In this embodiment, during welding, the welding handle and the ground are short-circuited, and the magnetic latching relay is controlled to be attracted; at the same time, timing is performed. Within a preset time, if the detected welding machine working current is less than a preset current value, the magnetic latching relay is controlled to be disconnected.

[0073] Example 3:

[0074] This embodiment provides a welding machine control method based on anti-electric shock protection and energy saving, which adopts the welding machine control system based on anti-electric shock protection and energy saving as described in Example 1, including:

[0075] Detect the secondary load resistance of the welding machine and the current at the power output end;

[0076] The magnetic latching relay is activated based on the detected secondary load resistance of the welding machine, and the magnetic latching relay is controlled to continuously be activated and released based on the detected current;

[0077] The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

[0078] The above description is merely a preferred embodiment of this embodiment and is not intended to limit this embodiment. Those skilled in the art will readily appreciate that this embodiment may be modified and varied in various ways. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this embodiment shall be within the scope of protection of this embodiment.

Claims

1. The welding machine control system based on anti-electric shock and energy saving is characterized by: It includes a control panel, and signal lines, mutual inductors and magnetic latching relays connected to the control panel; The signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current at the output end of the power supply; the control board is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the continuous attraction and release of the magnetic latching relay according to the current detected by the mutual inductor; The magnetic latching relay is used to connect or disconnect the power supply to the welding machine; When the detection resistance is less than or equal to the preset resistance, the magnetic latching relay is energized; after a set time delay, if the detection current is lower than the preset current value within the delay range, the magnetic latching relay is released after the delay; After a set time delay, if the detected current within the delay range is higher than the preset current value, the magnetic latching relay will continue to be energized until the detected current is lower than the preset current value, and then the delay will be reset to the set time and the cycle will continue; otherwise, the magnetic latching relay will continue to be energized; after the magnetic latching relay is released, the resistance detection will be re-executed and the cycle will continue; During welding, the welding handle is short-circuited with the ground, and the magnetic latching relay is controlled to be attracted; at the same time, timing is performed, and within a preset time, if the detected welding machine working current is less than a preset current value, the magnetic latching relay is controlled to be disconnected.

2. The welding machine control system based on electric shock prevention and energy saving as claimed in claim 1, characterized in that: The mutual inductor is a current mutual inductor, which is arranged on the wire between the magnetic latching relay and the power output terminal.

3. The welding machine control system based on electric shock prevention and energy saving as claimed in claim 2, characterized in that: The current sensed by the current transformer is converted into a voltage under the action of the resistor connected thereto, and the voltage is transmitted to the control board after A / D conversion.

4. The welding machine control system based on electric shock prevention and energy saving as claimed in claim 1, characterized in that: The control panel is connected to a running indicator light and a stop indicator light.

5. The welding machine based on anti-electric shock protection and energy saving is characterized by: At least includes a control system, the control system includes a control board, and signal lines, mutual inductors and magnetic latching relays connected to the control board; The signal line is used to detect the secondary load resistance of the welding machine, and the mutual inductor is used to detect the current at the output end of the power supply; the control board is used to start the attraction of the magnetic latching relay according to the secondary load resistance of the welding machine detected by the signal line, and to control the continuous attraction and release of the magnetic latching relay according to the current detected by the mutual inductor; The magnetic latching relay is used to connect or disconnect the power supply to the welding machine; When the detection resistance is less than or equal to the preset resistance, the magnetic latching relay is energized; after a set time delay, if the detection current is lower than the preset current value within the delay range, the magnetic latching relay is released after the delay; After a set time delay, if the detected current within the delay range is higher than the preset current value, the magnetic latching relay will continue to be energized until the detected current is lower than the preset current value, and then the delay will be reset to the set time and the cycle will continue; otherwise, the magnetic latching relay will continue to be energized; after the magnetic latching relay is released, the resistance detection will be re-executed and the cycle will continue; During welding, the welding handle is short-circuited with the ground, and the magnetic latching relay is controlled to be attracted; at the same time, timing is performed, and within a preset time, if the detected welding machine working current is less than a preset current value, the magnetic latching relay is controlled to be disconnected.

6. The welding machine based on electric shock protection and energy saving as claimed in claim 5, characterized in that: The mutual inductor is a current mutual inductor, which is arranged on the wire between the magnetic latching relay and the power output terminal.

7. A welding machine control method based on anti-electric shock protection and energy saving, characterized in that: The welding machine control system based on electric shock prevention and energy saving as described in any one of claims 1 to 4 is adopted, comprising: Detect the secondary load resistance of the welding machine and the current at the power output end; The magnetic latching relay is activated based on the detected secondary load resistance of the welding machine, and the magnetic latching relay is controlled to continuously be activated and released based on the detected current; The magnetic latching relay is used to connect or disconnect the power supply to the welding machine.

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