A self-powered welding machine system utilizing a shielding gas to store energy and a method of using the same

Abstract

This invention relates to an autonomous welding machine system utilizing shielding gas energy storage and its usage method. The system includes a pressure vessel storing high-pressure liquid shielding gas. The pressure vessel's output is connected to the inlet of a heat exchanger. An outlet of the heat exchanger, connected to the inlet, leads to the welding torch's outlet. A pump is connected to the outlet of the heat exchanger, with its output connected to the workpiece and the welding torch, and then to the inlet of the heat exchanger, forming a circulating flow of the working fluid. An expander is connected in series between the outlet of the heat exchanger and the welding torch. The expander's power output is connected to a generator, and the generator's output is electrically connected to the welding machine. Thus, relying on the shielding gas energy storage in the pressure vessel, the system achieves the necessary cooling, gas protection, and welding power supply during welding, greatly simplifying welding support requirements, optimizing welding operations, and realizing autonomous welding processes. It is particularly suitable for on-site welding operations in the field.

Description

Technical Field

[0001] This invention relates to the field of welding machine technology, and in particular to an automatic welding machine system that utilizes protective gas for energy storage and its usage method. Background Technology

[0002] In the welding of metals such as titanium alloys, a continuous supply of welding shielding gas is required to prevent oxidation of the metal at the high welding temperatures and ensure weld quality. The shielding gas is typically stored in a Dewar flask in liquid form. When needed, it is introduced from the Dewar flask into a vaporizer, heated, and then depressurized via a pressure reducing valve to obtain the welding gas for protection. Because the liquid shielding gas possesses a large amount of cold energy, during the vaporization process, liquid shielding gases, such as liquid argon, absorb a significant amount of heat from the air. This results in a substantial waste of energy as a result of inefficient utilization of cold energy.

[0003] On the other hand, during the welding process, welding machines typically use a high-voltage electric arc to generate high temperatures for fusion of the workpiece. The highest temperature at the weld location can reach over 1000℃, resulting in a large amount of unutilized heat energy. Especially in multi-layer welding, timely cooling of the welded workpiece is crucial to prevent excessively high interpass temperatures, which could lead to coarse weld microstructure and affect the weld's mechanical properties. Furthermore, the welding torch tip also requires cooling; current welding techniques primarily employ cooling water circulation for this purpose.

[0004] Throughout the welding process, additional energy, water, and gas sources are required for welding machine startup, welding torch cooling, and shielding gas supply, involving multiple aspects such as water, gas, and electricity. The existing welding operation has complex requirements for ensuring its operation. Summary of the Invention

[0005] In response to the shortcomings of the existing production technologies, the applicant provides a self-powered welding machine system with a reasonable structure that utilizes protective gas energy storage and its usage method. By relying on the protective gas energy storage in the pressure vessel, it realizes the cooling, gas protection and welding power supply necessary in the welding process, greatly simplifies the welding support requirements, saves energy and optimizes the welding operation, and realizes the self-powered welding process, which is especially suitable for on-site welding operations in the field.

[0006] The technical solution adopted in this invention is as follows:

[0007] An autonomous welding machine system utilizing protective gas for energy storage includes a pressure vessel storing high-pressure liquid protective gas. The pressure vessel's output is connected to the inlet of a heat exchanger. An outlet of the heat exchanger, connected to the inlet, is then connected to the welding torch's outlet. A pump is connected to the outlet of the heat exchanger, with its output connected to the workpiece and the welding torch, and then to the inlet of the heat exchanger, forming a circulating flow of the organic working fluid. An expander is connected in series between the outlet of the heat exchanger and the welding torch. The expander's power output is connected to a generator, and the generator's output is electrically connected to the welding machine.

[0008] As a further improvement to the above technical solution:

[0009] The expander's power output end is connected to the pump via a coupling, driving the pump to operate.

[0010] The generator output is connected to a storage battery for energy storage; the storage battery is electrically connected to the welding machine and / or pump for power supply.

[0011] A second heat exchanger is connected in series between the outlet of the first heat exchanger and the first expander. The protective gas exchanges heat with the air in the second heat exchanger to room temperature.

[0012] An expander is connected in series between the welding torch and the inlet of the heat exchanger, and the expander is connected to the generator.

[0013] The welding position of the workpiece is provided with a flow channel for the organic working medium to flow through. When the organic working medium flows through the flow channel in the workpiece, it directly absorbs the heat energy generated by welding and exchanges heat. Alternatively, a heat exchange protective cover is provided at the welding position of the workpiece. The heat exchange protective cover has a flow channel for the organic working medium to flow through. When the organic working medium flows through the heat exchange protective cover, it undergoes radiative heat exchange to absorb the heat energy generated by welding.

[0014] The heat exchange protective cover is a convex shell structure that covers the welding position of the workpiece. One end of the heat exchange protective cover has a liquid inlet and the other end has a liquid outlet. The liquid inlet and the liquid outlet are connected by a flow channel set on the wall of the heat exchange protective cover. The flow channel covers the entire shell of the heat exchange protective cover.

[0015] The structure of the heat exchange protective cover is as follows: it includes a top plate, and the three edges of the top plate are bent and extended in the same direction to form a circumferential enclosure; the liquid inlet and liquid outlet are respectively set on two opposite enclosures, and the flow channel located between the liquid inlet and liquid outlet is continuously bent and extended on the top plate and each enclosure.

[0016] A method of using the self-powered welding machine system that utilizes protective gas energy storage includes the following steps:

[0017] Open the valve of the pressure vessel and control the flow rate of the high-pressure liquid protective gas to direct it to heat exchanger one;

[0018] The organic working fluid and the high-pressure liquid protective gas exchange heat at one point in the heat exchanger;

[0019] The high-pressure liquid protective gas flows out of heat exchanger 1 after gaining heat and flows to expander 1. The high-pressure liquid protective gas consumes its internal energy to do work in expander 1, which drives generator to generate electricity. The output power of generator supplies power to welding machine, which drives welding torch to work and perform welding. After passing through expander 1, the pressure of high-pressure liquid protective gas is reduced and it is converted into gas, which is then delivered to welding torch for welding gas protection.

[0020] The organic working fluid is cooled in heat exchanger one. Under the action of the pump, the cooled organic working fluid flows sequentially through the workpiece to be welded and the welding torch to absorb heat during welding. The organic working fluid that has absorbed heat then flows back to heat exchanger one to form a cycle.

[0021] As a further improvement to the above technical solution:

[0022] The pump is powered by an external battery, or it is driven by the power output of the expander.

[0023] The beneficial effects of this invention are as follows:

[0024] This invention features a compact and rational structure, and is convenient to operate and use. Through the circulation of an organic working medium, the organic working medium absorbs the heat energy generated during welding and exchanges heat with the high-pressure liquid protective gas at the outlet of the pressure vessel, achieving mutual supplementation of the cooling energy of the protective gas and the welding heat energy. Furthermore, through an expander, the internal energy of the high-pressure liquid protective gas itself is utilized and converted into electrical energy supplied to the welding machine via a generator. Thus, relying solely on the energy stored in the protective gas in the pressure vessel, the necessary cooling, gas protection, and welding power supply during the welding process are implemented, achieving energy self-sufficiency in the welding process. This greatly simplifies the welding support requirements, optimizes welding operations through energy conservation, and realizes the automation of the welding process, making it particularly suitable for on-site welding operations in the field.

[0025] In this invention, the organic Rankine cycle based on organic working fluid fully utilizes the cold energy and pressure energy of the protective gas itself, as well as the heat energy generated during welding, and provides the electrical energy required for welding through the conversion of the expander.

[0026] In this invention, the welding process can be carried out simply by replenishing a sufficient amount of high-pressure liquid protective gas, such as liquid argon, into the pressure vessel at one time, which greatly simplifies the energy requirements for welding operations and is especially suitable for outdoor welding operations. Attached Figure Description

[0027] Figure 1 This is a system structure diagram of the present invention.

[0028] Figure 2 This is a schematic diagram of the structure of the heat exchange protective cover of the present invention.

[0029] The components include: 1. Pressure vessel; 2. Heat exchanger one; 3. Heat exchanger two; 4. Expander one; 41. Generator; 42. Storage battery; 5. Welding torch; 51. Welding machine; 6. Component to be welded; 7. Heat exchanger protective cover; 8. Expander two; 9. Pump;

[0030] 71. Top plate; 72. Enclosure; 73. Liquid inlet; 74. Handle; 75. Liquid outlet. Detailed Implementation

[0031] The specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0032] like Figure 1 As shown, this embodiment of an automatic welding machine system utilizing protective gas energy storage includes a pressure vessel 1, which stores high-pressure liquid protective gas. The output end of the pressure vessel 1 is connected to the inlet 1 of a heat exchanger 2. The outlet 1 of the heat exchanger 2, which is connected to the inlet 1, is then connected to the gas outlet of the welding torch 5. A pump 9 is connected to the outlet 2 of the heat exchanger 2. The output end of the pump 9 is connected to the workpiece 6 to be welded and the welding torch 5, and then connected to the inlet 2 of the heat exchanger 2, forming a flow circulation of organic working fluid. An expander 4 is also connected in series between the outlet 1 of the heat exchanger 2 and the welding torch 5. The power output end of the expander 4 is connected to a generator 41, and the output end of the generator 41 is electrically connected to the welding machine 51.

[0033] Through the circulation of the organic working medium, the organic working medium absorbs the heat energy generated during welding and exchanges heat with the high-pressure liquid protective gas at the outlet of pressure vessel 1, realizing the mutual supplementation of the cooling energy of the protective gas and the welding heat energy; and through the expander 4, the internal energy of the high-pressure liquid protective gas itself is further utilized and converted into electrical energy supplied by the welding machine 51 after passing through the generator 41; thus, relying solely on the energy stored in the protective gas in pressure vessel 1, the necessary cooling, gas protection and welding power supply during the welding process are implemented, realizing energy self-sufficiency in the welding process.

[0034] Furthermore, the power output end of the expander 4 is connected to the pump 9 via a coupling, driving the pump 9 to work; of course, the pump 9 can also be electrically driven, such as by the generator 41 or an external battery.

[0035] Furthermore, the output terminal of the generator 41 is connected to the storage battery 42, which stores electricity; the storage battery 42 is electrically connected to the welding machine 51 and / or the pump 9, and is powered by the storage battery 42.

[0036] Furthermore, a second heat exchanger 3 is connected in series between the outlet of the first heat exchanger 2 and the first expander 4. The protective gas is heated to room temperature in the second heat exchanger 3, thereby reliably ensuring that the protective gas reaches the operating temperature.

[0037] In this embodiment, heat exchanger 2 3 can be an air bath heat exchanger, in which heat is exchanged between protective gas and air.

[0038] Furthermore, an expander 8 is connected in series between the welding torch 5 and the inlet of the heat exchanger 2. The expander 8 is connected to the generator 41, thereby effectively utilizing the internal energy of the organic working fluid during the circulation process.

[0039] Furthermore, a flow channel for the organic working fluid is provided at the welding position of the welded part 6. When the organic working fluid flows through the flow channel in the welded part 6, it directly absorbs the heat energy generated by welding and exchanges heat, thereby achieving cooling of the welded part 6 during welding.

[0040] In another embodiment, the workpiece 6 and the welding process can also be cooled indirectly. For example, a heat exchange shield 7 is provided at the welding position of the workpiece 6. The heat exchange shield 7 has a flow channel for the organic working fluid to flow through. When the organic working fluid flows through the heat exchange shield 7, it undergoes radiative heat exchange to absorb the heat energy generated by welding.

[0041] The outlet of the flow channel is connected to the inlet of the cooling channel in the welding torch 5, and the outlet of the cooling channel in the welding torch 5 is connected to the inlet of the heat exchanger 2.

[0042] After the organic working medium cools the workpiece 6, it flows further in the welding torch 5 to perform convective heat transfer on the welding torch 5; thus, while recovering and utilizing the welding residual heat, it achieves enhanced cooling of the welding torch 5, especially the weld seam, which is beneficial to improving welding quality and efficiency.

[0043] Furthermore, the heat exchange shield 7 has an outwardly convex shell structure, which covers the welding position of the workpiece 6. One end of the heat exchange shield 7 has a liquid inlet 73, and the other end has a liquid outlet 75. The liquid inlet 73 and the liquid outlet 75 are connected by a flow channel provided on the wall of the heat exchange shield 7. The flow channel covers the entire shell of the heat exchange shield 7. Thus, during the welding process, the heat exchange shield 7 absorbs heat through radiation and exchanges heat with the organic medium flowing in the flow channel, thereby achieving radiative heat exchange during welding for indirect cooling.

[0044] exist Figure 2 In the embodiment shown, the structure of the heat exchange shield 7 is as follows: it includes a top plate 71, and the three edges of the top plate 71 are bent and extended in the same direction to form a circumferential enclosure 72; the liquid inlet 73 and the liquid outlet 75 are respectively disposed on two opposite enclosures 72, and the flow channel located between the liquid inlet 73 and the liquid outlet 75 is continuously bent and extended on the top plate 71 and each enclosure 72.

[0045] A handle 74 can also be installed on the top plate 71 to facilitate the movement and application of force on the heat exchange protective cover 7.

[0046] Of course, the heat exchange protective cover 7 can also be installed and fixed to the welded part 6 according to the actual situation.

[0047] Specifically, such as Figure 2 As shown, the organic medium enters the flow channel from the inlet 73, first flows up and down within the enclosure 72 where the inlet 73 is located, then flows to the top plate 71 and flows horizontally before flowing to the top of the enclosure 72 in the middle, where it also flows horizontally before flowing to the last enclosure 72, and finally flows out from the outlet 75 after flowing horizontally.

[0048] Of course, the flow channel can also be set in other forms, or even a complex flow channel in the form of convergence-diversion-convergence can be set between the liquid inlet 73 and the liquid outlet 75. The purpose of the flow channel is to absorb the heat energy generated by welding. The flow channel can be arranged and set in an adaptive manner according to the actual situation, such as direction and shape.

[0049] In this embodiment, pressure vessel 1 is a Dewar jar, which stores high-pressure, low-temperature liquid argon and has the largest gas storage density.

[0050] In this embodiment, valves can be installed in series between pressure vessel 1 and heat exchanger 2, and valves can also be installed in series between expander 4 and welding torch 5 to open or close the flow of protective gas or control the flow rate.

[0051] In this embodiment, based on the organic Rankine cycle, the cold energy and pressure energy of the shielding gas itself, as well as the heat energy generated during welding, are fully utilized to provide the electrical energy required for welding through the conversion of the expander.

[0052] The method of using the self-powered welding machine system utilizing protective gas energy storage in this embodiment includes the following steps:

[0053] Open the valve of pressure vessel 1 and control the flow rate of high-pressure liquid protective gas to make it flow to heat exchanger 2;

[0054] The organic working fluid and the high-pressure liquid protective gas exchange heat at heat exchanger 2; the organic working fluid will be cooled, and the high-pressure liquid protective gas will be heated;

[0055] The high-pressure liquid protective gas flows out of heat exchanger 2 and into expander 4. Inside expander 4, the high-pressure liquid protective gas consumes its internal energy to do work and outputs energy, which drives generator 41 to generate electricity. The output power of generator 41 supplies power to welding machine 51, which drives welding torch 5 to work and perform welding. After passing through expander 4, the pressure of the high-pressure liquid protective gas decreases and it is converted into gas. It is then transported to welding torch 5 and sprayed out from the front end of welding torch 5 for welding gas protection. Combined with heat exchange shield 7, it protects the weld surface of the workpiece 6 from oxidation.

[0056] After the high-pressure liquid protective gas exits heat exchanger 2, it can continue to flow to heat exchanger 3 connected in series to ensure that the high-pressure liquid protective gas is heated to room temperature.

[0057] Expander 4 drives generator 41 to charge battery 42. When welding operation begins, battery 42 continuously outputs power to welding machine 51 to ensure welding operation.

[0058] The organic working fluid is cooled in heat exchanger 2. Under the action of pump 9, the cooled organic working fluid flows sequentially through the workpiece 6 and the welding torch 5 to absorb heat during welding, thereby cooling the weld surface on the workpiece 6 and the welding torch 5. The organic working fluid that has absorbed heat then flows back to heat exchanger 2 to form a cycle.

[0059] After the organic working fluid flows out of the welding torch 5, it can flow to the expander 2 8 connected in series. The organic working fluid consumes its internal energy to do work on the outside and outputs energy. The expander 2 8 synchronously drives the generator 41 to generate electricity.

[0060] In this embodiment, pump 9 can be powered by an external battery, or pump 9 can be driven by the power output of expander 4.

[0061] In this invention, the welding process can be carried out simply by replenishing a sufficient amount of high-pressure liquid protective gas, such as liquid argon, into the pressure vessel 1 at one time, which greatly simplifies the energy requirements for welding operations and is especially suitable for outdoor welding operations.

[0062] Furthermore, taking argon as one of the protective gases and an organic working fluid with the grade R1240 as an example, the energy conversion during use is explained.

[0063] Liquid argon is stored in a Dewar flask at 2 MPa and -180.6°C. The liquid phase valve of the Dewar flask is opened, and the liquid argon enters heat exchanger 2 at a flow rate of 150 kg / h. In heat exchanger 2, the liquid argon exchanges heat with the R1240 working fluid, cooling the R1240 from -23.92°C to -48.30°C. After heat exchange with R1240, the liquid argon further enters an air-bath heat exchanger, where it is heated to room temperature (20°C). Then, it enters expander 4 to perform work, outputting 3.225 kW of power. The liquid argon is converted to a gaseous state, and the pressure decreases. The exhaust gas from the expander 4 outlet flows to the welding torch 5, serving as the welding shielding gas, and is ejected from the torch 5 nozzle onto the surface of the workpiece 6.

[0064] Meanwhile, expander 4 drives pump 9 via coupling, circulating the R1240 working fluid. At the outlet of pump 9, the R1240 working fluid is pressurized from 100 kPa to 750 kPa. After welding begins, the R1240 working fluid at -48.30℃ and 750 kPa enters the heat exchange shield 7, where it cools the weld surface through radiative heat exchange, raising the temperature of the R1240 working fluid to -6.85℃. The heated R1240 working fluid then enters the welding torch 5, cooling the torch 5 which is hot due to the welding current. The R1240 working fluid will then further heat up from -6.85℃ to 36.46℃, reaching a superheated state. The superheated R1240 working fluid enters expander 8 to perform work, with an output power of 1.635 kW. The R1240 working fluid changes from a gaseous state to a gas-liquid coexistence state, and the pressure decreases. The exhaust gas from the outlet of expander 8 returns to heat exchanger 2, where it is condensed from liquid argon into a liquid state.

[0065] This invention relies solely on the protective gas stored in the pressure vessel 1 to implement the necessary cooling, gas protection, and welding power supply during the welding process, thereby achieving energy self-sufficiency in the welding process. This greatly simplifies the requirements for welding support conditions, saves energy, optimizes welding operations, and realizes the automation of the welding process, making it particularly suitable for on-site welding operations in the field.

[0066] The above description is an explanation of the present invention and not a limitation thereof. The scope of the present invention is defined by the claims. Within the scope of protection of the present invention, any form of modification may be made.

Claims

1. A self-powered welding machine system utilizing protective gas energy storage, comprising a pressure vessel (1), characterized in that: The pressure vessel (1) stores high-pressure liquid protective gas. The output end of the pressure vessel (1) is connected to the inlet of the heat exchanger (2). The outlet of the heat exchanger (2) connected to the inlet is connected to the outlet of the welding torch (5). The outlet of the heat exchanger (2) is connected to the pump (9). The output end of the pump (9) is connected to the workpiece (6) to be welded and the welding torch (5) in sequence, and then connected to the inlet of the heat exchanger (2) to form a flow circulation of organic working fluid. An expander (4) is connected in series between the outlet of the heat exchanger (2) and the welding torch (5). The power output end of the expander (4) is connected to the generator (41). The output end of the generator (41) is electrically connected to the welding machine (51). The power output end of the expander (4) is connected to the pump (9) via a coupling to drive the pump (9) to work. (41) The output end is connected to the storage battery (42) for power storage; the storage battery (42) is electrically connected to the welding machine (51) and / or the pump (9) for power supply; a second heat exchanger (3) is connected in series between the outlet of the first heat exchanger (2) and the first expander (4), and the protective gas exchanges heat with the air in the second heat exchanger (3) to room temperature; an second expander (8) is connected in series between the welding torch (5) and the inlet of the first heat exchanger (2), and the second expander (8) can drive the generator (41) to generate electricity; a heat exchange protective cover (7) is provided at the welding position of the workpiece (6), and a flow channel for the organic working medium is opened in the heat exchange protective cover (7). When the organic working medium flows through the heat exchange protective cover (7), it conducts radiation heat exchange to absorb the heat energy generated by welding.

2. The self-powered welding machine system utilizing protective gas energy storage as described in claim 1, characterized in that: The heat exchange shield (7) is a convex shell structure that covers the welding position of the welded part (6); one end of the heat exchange shield (7) is provided with a liquid inlet (73) and the other end of the heat exchange shield (7) is provided with a liquid outlet (75). The liquid inlet (73) and the liquid outlet (75) are connected by a flow channel provided on the wall of the heat exchange shield (7); the flow channel covers the entire shell of the heat exchange shield (7).

3. The self-powered welding machine system utilizing protective gas energy storage as described in claim 2, characterized in that: The structure of the heat exchange protective cover (7) is as follows: it includes a top plate (71), and the three edges of the top plate (71) are bent and extended in the same direction to form a circumferential enclosure (72); the liquid inlet (73) and the liquid outlet (75) are respectively set on two opposite enclosures (72), and the flow channel between the liquid inlet (73) and the liquid outlet (75) is continuously bent and extended on the top plate (71) and each enclosure (72).

4. A method of using a self-powered welding machine system utilizing shielding gas energy storage, wherein the method relates to the self-powered welding machine system utilizing shielding gas energy storage as described in claim 1, characterized in that: Includes the following steps: Open the valve of the pressure vessel (1) and control the flow rate of the high-pressure liquid protective gas to make it flow to the heat exchanger (2). The organic working fluid and the high-pressure liquid protective gas exchange heat at heat exchanger 1 (2); After absorbing heat, the high-pressure liquid protective gas flows out of heat exchanger 1 (2) and into expander 1 (4). The high-pressure liquid protective gas consumes its internal energy to do work in expander 1 (4), and expander 1 (4) drives generator (41) to generate electricity. The output power of generator (41) supplies power to welding machine (51), and welding machine (51) drives welding torch (5) to work and perform welding. After passing through expander 1 (4), the pressure of high-pressure liquid protective gas decreases and it is converted into gas, and continues to be delivered to welding torch (5) for welding gas protection. The organic working medium is cooled in heat exchanger 1 (2). Under the action of pump (9), the cooled organic working medium flows through the workpiece (6) and welding torch (5) in sequence to absorb the heat generated by welding. The organic working medium after absorbing heat flows back to heat exchanger 1 (2) to form a cycle.

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