A welding machine start-stop energy-saving device and energy-saving method

Abstract

The present application relates to a kind of welding machine start-stop energy-saving device, comprising: shell, control mainboard, first interface panel and second interface panel;The control mainboard is arranged in the shell;The first interface panel and the second interface panel are connected with the control mainboard;The first interface panel and the second interface panel are embedded in the shell;Control chip and data storage unit are provided on the control mainboard;The control chip is connected with the first interface panel, the second interface panel and the data storage unit respectively;Wherein, the first interface panel can be connected power supply, power supply for the control chip;The second interface panel has a plurality of lead interfaces;The plurality of lead interfaces can be connected with welding machine;The control chip can control the power supply start-stop of welding machine and monitor the working state information of welding machine.The start-stop energy-saving device provided by the present application is not only simple to operate, and energy-saving effect is good.

Description

Technical Field

[0001] This invention belongs to the field of welding machine energy-saving technology, and particularly relates to a welding machine start-stop energy-saving device and energy-saving method. Background Technology

[0002] Energy conservation and emission reduction are major issues facing my country at present regarding environmental protection and improving people's quality of life. Only by adhering to the principles of economical development, clean development, and safe development can we achieve sound and rapid economic development. Meanwhile, greenhouse gas emissions causing global warming have attracted widespread international attention. Further strengthening energy conservation and emission reduction efforts is also a crucial measure to address global climate change.

[0003] Welding machines currently used in industry are high-power devices. They are used in many scenarios and frequently, and they also consume a lot of electricity when in standby mode. Under the national energy conservation and emission reduction policy, it is necessary to meet the requirements of both normal use of welding machines and reducing unit power consumption. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] In view of the existing technical problems, the present invention provides a welding machine start-stop energy-saving device and energy-saving method, which solves the technical problem of high standby power consumption of welding machines in the prior art.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0008] A welding machine start-stop energy-saving device includes: a housing, a control main board, a first interface panel, and a second interface panel;

[0009] The control motherboard is housed within the casing;

[0010] The first interface panel and the second interface panel are connected to the control motherboard;

[0011] Both the first interface panel and the second interface panel are embedded in the housing;

[0012] The control motherboard is equipped with a control chip and a data storage unit;

[0013] The control chip is connected to the first interface panel, the second interface panel, and the data storage unit, respectively.

[0014] The first interface panel can be connected to a power source to power the control chip.

[0015] The second interface panel has multiple lead interfaces;

[0016] The multiple lead interfaces can be connected to a welding machine;

[0017] The control chip can control the power supply to the welding machine and monitor its working status.

[0018] Preferably, the first interface panel is provided with a power lead interface;

[0019] The power lead interface can be connected to a 380V or 220V power supply to power the control chip.

[0020] The control chip is a domestically produced DSP with a main frequency of 120MHz.

[0021] Preferably, the plurality of lead interfaces on the second interface panel include at least: a welding torch lead interface group, a welding machine power supply main contactor coil lead interface group, and a welding machine power supply current transformer lead interface group;

[0022] The welding torch lead interface group can be connected to the welding torch of the welding machine by means of a signal line;

[0023] The main contactor coil lead interface group of the welding machine power supply can be connected to the welding machine power supply via the welding machine power supply line;

[0024] The current transformer lead interface group for the welding machine power supply can be connected to the welding machine via the current transformer lead of the welding machine.

[0025] Preferably, the control motherboard is further provided with a relay;

[0026] The control chip is connected to the relay for control.

[0027] Preferably, the soldering cable lead interface group includes two pins;

[0028] The two pins are respectively connected to the positive and negative terminals of the welding torch of the welding machine;

[0029] The welding machine power supply main contactor coil lead interface group includes three pins;

[0030] The three pins include a normally open relay contact pin, a common relay contact pin, and a normally closed relay contact;

[0031] The current transformer lead interface group for the welding machine power supply includes: transformer A pin and transformer B pin.

[0032] Preferably, it further includes: a display panel assembly;

[0033] The display panel assembly includes: a panel circuit board, a panel display, and panel control buttons;

[0034] The panel circuit board is disposed inside the housing;

[0035] The panel circuit board is connected to the control chip;

[0036] The panel display is embedded in the housing and connected to the panel circuit board;

[0037] The panel control buttons are embedded in the housing and are configured to correspond to the button contacts on the panel circuit board.

[0038] Preferably, the panel display includes six LED digital tubes;

[0039] The panel control buttons include at least: a mode button, an increment button, a decrement button, and an confirm button;

[0040] The panel display can show the working status information of the welding machine.

[0041] This solution also provides a welding machine energy-saving method based on the start-stop energy-saving device described above, including the following steps:

[0042] S1. Power on the start / stop energy-saving device;

[0043] S2. The control chip controls the relay to power the welding machine, and sends a pulse detection current to the welding torch of the welding machine through the welding torch lead interface group;

[0044] S3. The control chip performs timing according to the set first time threshold;

[0045] If the current transformer lead interface group of the welding machine power supply does not detect the current signal of the welding torch during operation within the time period of the first time threshold, the control relay will disconnect the power supply of the welding machine.

[0046] If a mutual inductance detection current signal is detected during the welding torch operation within the time period of the first time threshold, the timing will immediately restart.

[0047] Preferably, step S3 further includes:

[0048] After the power is disconnected, the control chip starts timing according to the set second time threshold;

[0049] If the power disconnection time reaches the second time threshold, the control chip will activate the wake-up relay.

[0050] After the wake-up relay starts working, the control chip starts timing the wake-up time threshold.

[0051] When the time for detecting the mutual inductance current signal reaches the wake-up time threshold, the control chip controls the wake-up relay to power on the welding machine and stops the wake-up relay from working.

[0052] Preferably, the method further includes: after stopping the operation of the wake-up relay, the control chip starts timing according to the set first time threshold.

[0053] (III) Beneficial Effects

[0054] The start-stop energy-saving device in this application uses a domestically produced DSP as the main chip for control, with a main frequency of 120MHz. It consists of three main controls. First, in terms of current judgment, a standard electricity meter is used to collect AC side current and power consumption, which can estimate the welding machine's working time, working current, working frequency, working efficiency, and other effective information. This information can be used as an evaluation standard for the efficiency and status of the workers, and also for monitoring the working status of the welding machine.

[0055] Second: Wake-up control. A scalar truth table is created for different welding machine categories, and the truth table is automatically identified for different welding machines. When the welding machine is in energy-saving silent mode, pulse trickle technology is used to power the welding torch. The pulse current is less than 60mA and the sampling frequency is 20kHz. This technology can quickly and accurately detect the status of the welding torch. When the positive and negative terminals of the welding torch head touch, a judgment can be made within 2ms and reported to the technical module to perform the welding wake-up operation. All of the above technical parameters can be modified online to adapt to various complex and harsh trial environments.

[0056] Third: This application adopts a dual-user interactive interface. First, the system itself can set, store, and query parameters through the built-in button display module. Second, the system has a 485 communication interface, which can communicate with the host computer for information archiving, summarizing, and retrieval. Attached Figure Description

[0057] Figure 1 This is a schematic diagram showing the connection between a welding machine start / stop energy-saving device and a welding machine provided by the present invention;

[0058] Figure 2 A schematic diagram of the structure of the first interface panel and the second interface panel of a welding machine start-stop energy-saving device provided by the present invention;

[0059] Figure 3 This is a schematic flowchart of a welding machine energy-saving method provided by the present invention, which is a welding machine start-stop energy-saving device.

[0060] [Explanation of Labels in the Attached Image]

[0061] 1: Power supply; 2: Power input cable; 3: Welding machine power cord; 4: Start-stop energy-saving device;

[0062] 5: Welding machine; 6: Welding torch lead wire / signal wire. Detailed Implementation

[0063] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0064] Example 1

[0065] like Figure 1 and Figure 2 As shown: This embodiment discloses a welding machine start-stop energy-saving device 4, including: a housing, a control main board, a first interface panel, and a second interface panel; the control main board is disposed within the housing. The first interface panel and the second interface panel are connected to the control main board; both the first interface panel and the second interface panel are embedded in the housing; the control main board is provided with a control chip and a data storage unit; the control chip is connected to the first interface panel, the second interface panel, and the data storage unit respectively.

[0066] The first interface panel can be connected to the power supply 1 to supply power to the control chip; the second interface panel has multiple lead interfaces; the multiple lead interfaces can be connected to the welding machine 5; the control chip can control the power supply start and stop of the welding machine 5 and monitor the working status information of the welding machine 5.

[0067] In this embodiment, the first interface panel is provided with a power lead 2 interface; the power lead interface can be connected to a 380V or 220V working power supply 1 to power the control chip; the control chip is a domestic DSP with a main frequency of 120M.

[0068] In this embodiment, the multiple lead interfaces on the second interface panel include at least: a welding torch lead interface group, a welding machine power supply main contactor coil lead interface group, and a welding machine power supply current transformer lead interface group; the welding torch lead interface group can be connected to the welding torch of the welding machine 5 via the welding torch lead signal line 6; the welding machine power supply main contactor coil lead interface group can be connected to the welding machine 5 for power supply via the welding machine power line 3; and the welding machine power supply current transformer lead interface group can be connected to the welding machine 5 via the current transformer lead of the welding machine.

[0069] In this embodiment, the control motherboard is also equipped with a relay; the control chip is connected to the relay for control. The welding torch lead interface group includes two pins; the two pins are respectively connected to the positive and negative terminals of the welding torch of the welding machine 5; the welding machine power supply main contactor coil lead interface group includes three pins; the three pins include a relay normally open contact pin, a relay common contact pin, and a relay normally closed contact; the welding machine power supply current transformer lead interface group includes: transformer A point pin and transformer B point pin.

[0070] The start-stop energy-saving device 4 provided in this embodiment further includes: a display panel assembly; the display panel assembly includes: a panel circuit board, a panel display, and panel control buttons; the panel circuit board is disposed in the housing; the panel circuit board is connected to the control chip; the panel display is embedded in the housing and connected to the panel circuit board; the panel control buttons are embedded in the housing and are correspondingly set with the button contacts on the panel circuit board.

[0071] In this embodiment, the panel display includes six LED digital tubes; the panel control buttons include at least a mode button, an increment button, a decrement button, and an confirm button; the panel display can show the working status information of the welding machine 5.

[0072] like Figure 3 As shown: This embodiment also provides a welding machine energy-saving method for the welding machine start-stop energy-saving device 4, including the following steps:

[0073] S1, Start / Stop energy-saving device 4 is powered on;

[0074] S2. The control chip controls the relay to power the welding machine 5, and sends a pulse detection current to the welding torch of the welding machine through the welding torch lead interface group;

[0075] S3. The control chip performs timing according to the set first time threshold;

[0076] If the current transformer lead interface group of the welding machine power supply does not detect the current signal of the welding torch during operation within the time period of the first time threshold, the control relay will disconnect the power supply of the welding machine.

[0077] If a mutual inductance detection current signal is detected during the welding torch operation within the time period of the first time threshold, the timing will immediately restart.

[0078] It should be noted that step S3 also includes:

[0079] After the welding machine power is disconnected, the control chip starts timing according to the set second time threshold;

[0080] If the power supply to the welding machine is disconnected for a period of time that reaches the second time threshold, the control chip will activate the wake-up relay.

[0081] After the wake-up relay starts working, the control chip starts timing the wake-up time threshold.

[0082] When the time for detecting the mutual inductance current signal reaches the wake-up time threshold, the control chip controls the wake-up relay to power on welding machine 5 and stops the wake-up relay from working.

[0083] It should be noted that the method further includes: after stopping the operation of the wake-up relay, the control chip starts timing according to the set first time threshold.

[0084] Example 2

[0085] The welding machine start-stop energy-saving device 4 provided in this embodiment has the following dimensions: external dimensions: 110mm*110mm*30mm. Installation dimensions: 100mm*100mm (M4 screw). Power supply voltage: AC380V or 220V.

[0086] 1: Wiring diagram: as shown Figure 2 As shown:

[0087] 1.1 Left side 3-pin power connector: Pin 1 (L1): 380V or 220V,

[0088] 2-pin (NC): Do not connect with the empty pin.

[0089] 3-pin (L2): 380V or 220V.

[0090] 1.2 Right side 11-pin signal interface:

[0091] 1.21 Soldering torch lead: Pin 1 (V+): Positive terminal of the soldering torch (the positive and negative terminals of the soldering torch can be interchanged)

[0092] 2-pin (NC): Do not connect with the empty pin.

[0093] 3-pin (NC): Do not connect the empty pin.

[0094] Pin 4 (V-): Negative terminal of the soldering torch. (The positive and negative terminals of the soldering torch can be interchanged.)

[0095] 5-pin (NC): Do not connect to the empty pin.

[0096] 1.22 Main contactor coil lead interface group lead of the control welding machine power supply:

[0097] Pin 6 (CK): Normally open contact of the relay.

[0098] Pin 7 (COM): Relay common contact.

[0099] Pin 8 (CB): Normally closed contact of the relay.

[0100] 9-foot (NC): Do not connect with an empty foot.

[0101] 1.23 Current transformer leads for welding machine power supply:

[0102] Pin 10 (I1): Point A of the current transformer,

[0103] Pin 11 (I2): Point B of the current transformer.

[0104] 2: Mechanism of Action:

[0105] 2.1: After connecting L1, L2, 380V or 220V working power supply, the controller is powered on.

[0106] 2.2: After power-on, immediately connect the normally open contact of the main contactor coil K1 controlling the welding machine power supply. The contact remains closed, and the K1 signal indicator D5 lights up, thus powering on the welding machine. Open the wake-up relays K2 and K5. The K2 and K5 signal indicator lights D4 and D6 turn off.

[0107] 2.3: At this point, the controller starts timing. If welding occurs during the timing process, the controller restarts the timing. If the welding machine remains without welding current and the timing reaches Pr-2 (parameter meaning: current transformer no current timing (n minutes)), the controller disconnects the normally open contact of the power relay controlling the welding machine. The contact remains open, and the K1 signal indicator D5 goes out, thus de-energizing the welding machine.

[0108] 2.4: After the welding machine is powered off, the controller restarts the timing Pr-3 (parameter meaning: after the current transformer has no current for Pr-2n minutes, the timing (Pr-3*1ms) is restarted for 1 second. This activates the wake-up detection relay), closing the wake-up relays K2 and K5. The signal indicator lights D4 and D6 of K2 and K5 light up.

[0109] 2.5: When wake-up relays K2 and K5, and indicator lights D4 and D6 are lit, it indicates that the welding machine is ready to be woken up at any time. This is confirmed as long as the positive and negative terminals of the welding machine are brought together and the pulse reaches Pr-4 (meaning: the wake-up signal reaches (Pr-4 * 0.1ms)). Start the welding machine. Immediately connect the normally open contact of the power control relay K1, keeping the contact closed. Indicator light D5 on K1 illuminates, powering on the welding machine. Open wake-up relays K2 and K5. Indicator lights D4 and D6 on K2 and K5 then turn off.

[0110] 2.6: After starting the welding machine, repeat step 2.2.

[0111] 3: First power-on adjustment of Pr-0 and Pr-5 parameters:

[0112] 3.1: After connecting L1, L2, 380V or 220V working power supply, the controller is powered on.

[0113] 3.2: Retrieve the monitoring parameter dp-0 (parameter meaning: real-time current transformer AD value: generally around 1800). Observe the value of dp-1 and record it.

[0114] 3.3: Activate the monitoring parameter dp-1 (meaning: maximum value of current transformer AD), and perform drag soldering with the minimum current. Observe the value of dp-1 and record it. Subtract 50 from the recorded value and set it to Pr-0 (meaning: effective current detection value). The value of Pr-0 must be greater than dp-0.

[0115] 3.4: First, disconnect the welding machine power supply. Then, set parameter Pr-4 = 50 (meaning: wake-up signal reaches (50 * 0.1 ms)). Activate monitoring parameter dp-10 (meaning: welding torch short-circuit AD resistance value). Since the equivalent resistance values ​​inside the positive and negative terminals of different welding machines vary, the dp-10 display value will range from 20 to 2000. At this point, short-circuit the welding torch head; the short-circuit time must be less than 2 seconds. Observe the value of dp-10 and record it. Subtract 50 from the recorded value and set it to Pr-5 (meaning: welding torch short-circuit AD resistance value). Finally, set parameter Pr-4 = 50 again.

[0116] 4: Operation and Display

[0117]

[0118] The driver panel consists of a 6-LED digital display and 4 buttons:

[0119] ( Mode key), (Additional bonding), (Decrease bond), It consists of (OK) buttons, used to display various statuses, set parameters, etc.

[0120] When the servo driver control power is turned on, all six LED digital tubes on the driver panel light up. The selected monitoring parameters are displayed after 2 seconds.

[0121] The operation menu is executed in a multi-level manner: the first level is the main menu, the second level is the function menu for each operation mode, and the third level is the data for each parameter.

[0122] 4.1 The first level of the operation menu

[0123] The functions of the display parameters in the first layer are shown in Table 1-1:

[0124] Table 1-1 Functions of the first layer display parameters

[0125]

[0126]

[0127] The first level is the main menu, which has 7 modes. First, press the "Mode key" to enter the first level menu, use the "Increase" and "Decrease" keys to change the mode, and press the "OK" key to enter the second level of the selected mode.

[0128] 4.2 Pr parameter settings

[0129] Note: When setting parameter values, the "Mode key" is used for shifting. The "Increase key" and "Decrease key" are used for addition and subtraction.

[0130] Parameter values ​​are set using the "increase" and "decrease" keys: the setting range is "0-9". If the maximum value of any parameter is less than 9, the maximum setting is "0 - the maximum value of the parameter". If the set value is greater than the maximum value, the maximum value will be displayed; if it is less than the minimum value, the minimum value will be displayed.

[0131] Parameter modification and saving:

[0132] 1. In normal display mode, press the "Mode key" to enter the first-level menu options, use the increase and decrease keys to select the mode to be modified, and then press the "OK key" to enter the second-level menu options.

[0133] 2. Use the increment and decrement keys to select the parameter to modify, and press the "OK" key to enter the parameter modification interface, which displays the current value. The smallest digit will start flashing. (In monitoring parameter mode, all data flashes together, and the data cannot be modified.) Press the "increment" and decrement keys to modify the parameter, and press the "mode" key to move the parameter modification digit.

[0134] 3. After confirming the parameter modifications are complete, press the "OK" button to confirm, or press and hold the "Mode" button to exit parameter setting. Simultaneously pressing the OK button automatically writes the modified parameters to the EEPROM for saving. Control parameters such as PN parameters and electronic gear ratio require a power-on resetting to take effect.

[0135] 4. When setting a negative parameter, shift to the highest bit and press the "Increment" key to switch between 0 and "-". (0: positive, -: negative).

[0136] 5: Parameter Table

[0137]

[0138]

[0139] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of the invention and should not be construed as limiting the scope of protection of the invention in any way. Based on this explanation, those skilled in the art can conceive of other specific embodiments of the invention without creative effort, and these embodiments will all fall within the scope of protection of the present invention.

Claims

1. A welding machine start-stop energy-saving device, characterized in that, include: Housing, control motherboard, first interface panel, and second interface panel; The control motherboard is housed within the casing; The first interface panel and the second interface panel are connected to the control motherboard; Both the first interface panel and the second interface panel are embedded in the housing; The control motherboard is equipped with a control chip and a data storage unit; The control chip is connected to the first interface panel, the second interface panel, and the data storage unit, respectively. The first interface panel can be connected to a power source to power the control chip. The second interface panel has multiple lead interfaces; The multiple lead interfaces can be connected to a welding machine; The control chip can control the power supply start and stop of the welding machine and monitor the working status information of the welding machine; The first interface panel is equipped with a power lead interface; The power lead interface can be connected to a 380V or 220V power supply to power the control chip. The control chip is a domestically produced DSP with a main frequency of 120MHz. The multiple lead interfaces on the second interface panel include at least: a welding torch lead interface group, a welding machine power supply main contactor coil lead interface group, and a welding machine power supply current transformer lead interface group; The welding torch lead interface group can be connected to the welding torch of the welding machine by means of a signal line; The main contactor coil lead interface group of the welding machine power supply can be connected to the welding machine power supply via the welding machine power supply line; The current transformer lead interface group of the welding machine power supply can be connected to the welding machine by means of the current transformer lead of the welding machine. The control motherboard is also equipped with relays; The control chip is connected to the relay for control. The soldering cable lead interface group includes two pins; The two pins are respectively connected to the positive and negative terminals of the welding torch of the welding machine; The welding machine power supply main contactor coil lead interface group includes three pins; The three pins include a normally open relay contact pin, a common relay contact pin, and a normally closed relay contact; The current transformer lead interface group for the welding machine power supply includes: transformer A pin and transformer B pin. It also includes welding machine energy-saving methods with start-stop energy-saving devices; The method includes the following steps: S1. Power on the start / stop energy-saving device; S2. The control chip controls the relay to power the welding machine, and sends a pulse detection current to the welding torch of the welding machine through the welding torch lead interface group; S3. The control chip performs timing according to the set first time threshold; If the current transformer lead interface group of the welding machine power supply does not detect the current signal of the welding torch during operation within the time period of the first time threshold, the control relay will disconnect the power supply of the welding machine. If a mutual inductance detection current signal is detected during the welding torch operation within the time period of the first time threshold, the timing will immediately restart. Step S3 also includes: After the power is disconnected, the control chip starts timing according to the set second time threshold; If the power disconnection time reaches the second time threshold, the control chip will activate the wake-up relay. After the wake-up relay starts working, the control chip starts timing the wake-up time threshold. When the time for detecting the mutual inductance current signal reaches the wake-up time threshold, the control chip controls the wake-up relay to power on the welding machine and stops the wake-up relay from working. The method further includes: after stopping the operation of the wake-up relay, the control chip starts timing according to the set first time threshold.

2. The start-stop energy-saving device according to claim 1, characterized in that, Also includes: display panel components; The display panel assembly includes: a panel circuit board, a panel display, and panel control buttons; The panel circuit board is disposed inside the housing; The panel circuit board is connected to the control chip; The panel display is embedded in the housing and connected to the panel circuit board; The panel control buttons are embedded in the housing and are configured to correspond to the button contacts on the panel circuit board.

3. The start-stop energy-saving device according to claim 2, characterized in that, The panel display includes 6 LED digital tubes; The panel control buttons include at least: a mode button, an increment button, a decrement button, and an confirm button; The panel display can show the working status information of the welding machine.

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