An inverter welding power source, a welding machine, and a welding method

Abstract

An inverter welding power source selects a resistance welding mode through a mode and parameter setting module, collects an output signal of a rectification output module through a signal collection module, controls an output current of the rectification output module according to the resistance welding mode and the state of an electrode and a workpiece through a control module, applies pressure to the workpiece through the resistance welding electrode, and welds the workpiece through the output current and the pressure. The inverter welding power source of the present application can complete resistance welding only by adding a resistance welding electrode on the basis of a traditional arc welding power source. The inverter welding power source, electric welding machine and welding method of the present application are convenient to operate, low in cost, widely applicable and high in practical value.

Description

Technical Field

[0001] This invention belongs to the field of electric welding machines, specifically relating to an inverter welding power source, an electric welding machine, and a welding method. Background Technology

[0002] Inverter arc welding machines are a new type of arc welding machine. They typically input AC mains voltage into a rectifier and filter to output DC voltage. Then, through the alternating switching action of high-power switching electronic components, the DC voltage is inverted into a medium-frequency AC voltage. After being reduced to a suitable welding voltage by a transformer, the DC welding current is rectified again and filtered by a reactor to output a relatively stable DC welding current. The high-temperature arc generated between the positive and negative poles melts the filler material and the material being welded, achieving the purpose of bonding them together.

[0003] Traditional arc welding machines generally refer to welding machines capable of shielded metal arc welding, argon arc welding, and gas metal arc welding. When arc welding is used to weld plates thinner than 1mm, the following problems exist:

[0004] 1. Under normal conditions, shielded metal arc welding (SMAW) is difficult to weld materials smaller than 1 mm, unless specific backing and auxiliary systems are added;

[0005] 2. Argon arc welding can weld thin plates, but it requires argon gas as a shielding gas and also requires high skill from the welder.

[0006] 3. Conventional gas metal arc welding (GMAW) is difficult to weld thin plates less than 1 mm thick unless pulses and backing are added for support.

[0007] It is evident that existing arc welding machines require additional auxiliary functions or have high operational requirements when welding thin plates, making them inconvenient to use. Therefore, there is an urgent need for a welding power source, welding machine, and welding method that can be used for thin plates and is easy to operate. Summary of the Invention

[0008] To overcome the shortcomings of existing technologies, one objective of this invention is to provide an inverter-type welding power supply; another objective is to provide an electric welding machine; and a further objective is to provide a welding method. To achieve the above objectives, the technical solutions adopted by this invention are as follows:

[0009] One aspect of the present invention provides an inverter welding power supply, including a mode and parameter setting module and a control module. The mode and parameter setting module selects a resistance welding mode, the workpiece is connected to the output terminal of the inverter welding power supply, and the control module controls the output current of the inverter welding power supply according to the resistance welding mode and the state of the resistance welding electrode and the workpiece. The output current is used to apply pressure to the workpiece for welding.

[0010] Preferably, the inverter welding power supply further includes a signal acquisition module. The input terminal of the signal acquisition module is connected to the output terminal of the inverter welding power supply, and the output terminal of the signal acquisition module is connected to the control module. The signal acquisition module acquires the output signal of the inverter welding power supply. The control module determines the state of the resistance welding electrode and the workpiece based on the output signal. Based on the resistance welding mode and the state of the resistance welding electrode and the workpiece, the control module controls the output current of the inverter welding power supply and applies pressure to the workpiece through the output current to weld the workpiece.

[0011] Preferably, the inverter welding power supply further includes an output feedback module, the input terminal of which is connected to the output terminal of the inverter welding power supply, and the output terminal of which is connected to the input terminal of the signal acquisition module.

[0012] Preferably, the inverter-type welding power supply further includes a rectifier filter module, an inverter module, and a rectifier output module. The input terminal of the rectifier filter module is connected to the mains power, and its output terminal is connected to the input terminal of the inverter module. The input terminal of the rectifier output module is connected to the output terminal of the inverter module. The input terminal of the signal acquisition module is connected to the output terminal of the rectifier output module, and its output terminal is connected to the control module. The output terminal of the control module is connected to the inverter module. The workpiece is connected to the output terminal of the rectifier output module. The automatic identification resistance welding mode is selected through the mode and parameter setting module. The output signal of the rectifier output module is acquired through the signal acquisition module. The control module determines the state of the resistance welding electrode and the workpiece based on the output signal. Based on the resistance welding mode and the state of the resistance welding electrode and the workpiece, the control module controls the output current of the rectifier output module and applies pressure to the workpiece through the output current to weld the workpiece.

[0013] Another aspect of the present invention provides an electric welding machine, comprising an inverter welding power source and a resistance welding electrode as described above, wherein a workpiece to be welded is connected to the output terminal of the inverter welding power source, pressure is applied to the workpiece through the resistance welding electrode, and the workpiece is welded by the output current of the inverter welding power source and the pressure.

[0014] Another aspect of the present invention provides a welding method comprising the following steps:

[0015] Select automatic resistance welding mode identification;

[0016] Set welding parameters;

[0017] Enter initialization mode;

[0018] Acquire the output signal of the inverter welding power supply;

[0019] When the output signal indicates a short circuit between the resistance welding electrode and the workpiece, the output current of the inverter welding power supply is controlled.

[0020] Preferably, when the resistance welding electrode applies pressure to the workpiece, the output current passes through the workpiece, welding the workpiece together.

[0021] Preferably, when it is determined by the output signal that the resistance welding electrode and the workpiece are not short-circuited, the output signal of the inverter welding power supply is returned.

[0022] Preferably, after controlling the output current of the inverter welding power supply, the welding is terminated when the resistance welding electrode separates from the workpiece, as determined by the output signal.

[0023] Preferably, after controlling the output current of the inverter welding power supply, if it is determined by the output signal that the resistance welding electrode and the workpiece have not separated, the process returns to collecting the output signal of the inverter welding power supply.

[0024] The inverter welding power supply of this invention selects the resistance welding mode through a mode and parameter setting module, acquires the output signal of the rectifier output module through a signal acquisition module, and controls the output current of the rectifier output module according to the resistance welding mode and the state of the electrode and workpiece. Pressure is applied to the workpiece through the resistance welding electrode, and the workpiece is welded through the output current and the pressure. Based on traditional arc welding power supplies, the inverter welding power supply of this invention only requires the addition of resistance welding electrodes to complete resistance welding. The inverter welding power supply, welding machine, and welding method of this invention are easy to operate, low in cost, and widely applicable, possessing high practical value. Attached Figure Description

[0025] After reading the detailed embodiments of the present invention with reference to the accompanying drawings, the reader will gain a clearer understanding of various aspects of the present invention.

[0026] Figure 1 This is a system structure diagram of an inverter welding power supply according to an embodiment of the present invention;

[0027] Figure 2 A flowchart of a welding method according to another embodiment of the present invention;

[0028] Explanation of reference numerals in the attached figures:

[0029] 1: Mode and parameter setting module; 2: Control module; 3: Signal acquisition module; 4: Output feedback module; 5: Rectification and filtering module; 6: Inverter module; 7: Rectified output module. Detailed Implementation

[0030] To make the technical content disclosed in this application more detailed and complete, reference can be made to the accompanying drawings and the following specific embodiments of the invention. However, those skilled in the art should understand that the embodiments provided below are not intended to limit the scope of the invention. Furthermore, the drawings are for illustrative purposes only and are not drawn to their original dimensions.

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

[0032] Example 1:

[0033] This embodiment provides an inverter-type welding power supply. Please refer to [link / reference]. Figure 1 The inverter welding power supply includes a mode and parameter setting module 1, a control module 2, a signal acquisition module 3, a rectification and filtering module 4, an inverter module 5, a rectified output module 6, and an output feedback module 7.

[0034] The input terminal of the rectifier-filter module 5 is connected to the mains power, and its output terminal is connected to the input terminal of the inverter module 6. The input terminal of the rectifier-output module 7 is connected to the output terminal of the inverter module 6. The input terminal of the output feedback module 4 is connected to the output terminal of the rectifier-output module 7, and its output terminal is connected to the input terminal of the signal acquisition module 3. The output terminal of the signal acquisition module 3 is connected to the control module 2; the output terminal of the control module 2 is connected to the inverter module 6.

[0035] In this embodiment, the workpiece to be welded is connected to the output terminal of the rectifier output module 7. Specifically, the two workpieces to be welded are respectively connected to the output terminal of the rectifier output module 7.

[0036] In this embodiment, the mode and parameter setting module 1 is a human-machine interface that transmits the mode and parameters selected by the operator to the control module 2. The inverter welding power supply internally implements the corresponding functions and parameter outputs through specific software. Specifically, the mode and parameter setting module 1 can select either an arc welding mode or a resistance welding mode. The arc welding mode may include shielded metal arc welding mode, argon arc welding mode, and gas metal arc welding mode. The resistance welding mode may include a gun switch-triggered resistance welding mode and an automatically identified resistance welding mode. Specifically, according to the material of the workpiece to be welded, the welding parameters can be set through the mode and parameter setting module 1. The parameter values ​​are determined based on the material and thickness of the workpiece to be welded, combined with experience.

[0037] In this embodiment, the automatic resistance welding mode is selected by the mode and parameter setting module 1, and the output signal of the rectifier output module 7 is acquired by the signal acquisition module 3. Specifically, the output signal is the output voltage and output current of the inverter welding power supply. The control module 2 determines the state of the resistance welding electrode and the workpiece based on the output signal, and controls the output current of the rectifier output module 7 according to the selected resistance welding mode and the state of the resistance welding electrode and the workpiece. The workpiece is welded by applying pressure to the workpiece through the output current. Specifically, the states of the resistance welding electrode and the workpiece include short circuit, no short circuit, separation, and no separation. Specifically, when the electrode and workpiece are short-circuited, the output voltage is detected to change from 14V to 0V for the first time. When the electrode and workpiece are not short-circuited, the output voltage is 14V. When the electrode and workpiece are separated, the output voltage changes from 0V to 14V. When the electrode and workpiece are not separated, the output voltage remains at 0V. The control module 2 can determine the state of the electrode and workpiece through the output voltage, and judge the welder's operation based on the state of the electrode and workpiece, thus improving the intelligence of the inverter welding power supply. Specifically, on the one hand, the control module 2 can precisely control the output current of the inverter welding power supply, adjusting the resistance welding energy by the magnitude and duration of the output current, making the resistance welding more precise. On the other hand, the control module 2 can predict the start and end of the welding, which is more intelligent and convenient compared to the traditional gun switch triggering method.

[0038] In this embodiment, the control module 2 controls the output current of the rectifier output module 7 through the inverter module 6; a certain pressure is applied to the two workpieces through the resistance welding electrode, and the output current of the inverter welding power supply passes through the workpieces to weld the two workpieces together.

[0039] The working process of the inverter welding power source will be described in detail below to further illustrate the technical solution of this embodiment.

[0040] Please see Figure 1 The inverter welding power supply is supplied by mains power. The mains power is converted into DC power by the rectifier and filter module 5. The DC power is reduced in output voltage and isolated by the inverter module 6. Then, the current and voltage are output by the rectifier output module 7. The welder applies a certain pressure to the workpiece through the resistance welding electrode. The workpiece to be welded flows through the output current controlled by the control module 2, which causes the workpiece to be welded together.

[0041] After selecting the automatic resistance welding mode, during the welding process, the output feedback signal module 4 transmits the output signal of the rectifier output module 7 to the signal acquisition module 3. Specifically, the output signal is a current signal and a voltage signal. The signal acquisition module 3 samples the output signal, divides it into a signal that the control module 2 can recognize, and transmits the signal to the control module 2. The control module 2 controls the inverter process through the inverter module 6 according to the received signal, thereby controlling the output current of the rectifier output module 7.

[0042] Example 2:

[0043] This embodiment provides a welding machine, including an inverter welding power source and a resistance welding electrode as described above. The workpiece to be welded is connected to the output terminal of the inverter welding power source. Pressure is applied to the workpiece through the resistance welding electrode, and the workpiece is welded by the output current of the inverter welding power source and the pressure.

[0044] In this embodiment, the system structure and function of the inverter welding power source are as described in Embodiment 1, and will not be repeated here.

[0045] In this embodiment, the welding machine is an inverter-type multi-functional welding machine, which adds resistance welding functionality to the traditional arc welding machine. Compared with the traditional arc welding machine, it has a wider range of applications. Through the resistance welding function, it can easily weld thin plates, stainless steel plates, etc., and only requires the addition of resistance welding electrodes, without the need for other hardware equipment. This enables welding from ultra-thin plates to medium-thick plates, further expanding the scope of application and reducing the cost of purchasing the machine for customers. In other embodiments of the present invention, the welding machine may also include only the resistance welding function, while also realizing automatic resistance welding identification.

[0046] Example 3:

[0047] This embodiment provides a welding method applicable to the inverter welding power supply described in Embodiment 1 or the welding machine described in Embodiment 2. Please refer to [link / reference]. Figure 2 The welding method includes the following steps:

[0048] S1: Select the automatic resistance welding mode. In this embodiment, other welding modes such as arc welding mode can also be selected.

[0049] S2: Set welding parameters, which are set through a human-machine interface according to the material, thickness, etc. of the workpiece to be welded;

[0050] S3: Enter initialization mode; specifically, the control module 2 performs preparatory work before starting automatic identification of resistance welding, mainly including turning off the inverter of the inverter welding power supply, turning on the dummy open-circuit voltage 14V, identifying the welding parameters and giving the corresponding output;

[0051] S4: Acquire the output signal of the inverter welding power supply, including output current signal, voltage signal, etc., and determine the state of the resistance welding electrode and the workpiece by the output voltage. The state includes short circuit between electrode and workpiece, no short circuit between electrode and workpiece, separation between electrode and workpiece, and no separation between electrode and workpiece. Specifically, when the electrode and workpiece are short-circuited, the output voltage is detected to change from 14V to 0V for the first time. When the electrode and workpiece are not short-circuited, the output voltage is 14V. When the electrode and workpiece are separated, the output voltage changes from 0V to 14V. When the electrode and workpiece are not separated, the output voltage remains at 0V.

[0052] S41: When the output signal indicates a short circuit between the resistance welding electrode and the workpiece, welding is initiated. The electrode applies pressure to the workpiece, and the output current of the inverter welding power supply is controlled. Specifically, the magnitude and duration of the output current are controlled. The output current passes through the workpiece, welding the workpieces together. When the output signal indicates that the resistance welding electrode and the workpiece are not short-circuited, welding has not yet started, and the process returns to S3: The output signal of the inverter welding power supply is collected. By continuously collecting and monitoring the output signal, the start of welding is monitored in real time. Compared with manual triggering, this eliminates the need to manually press the switch, requires no switch wires, and offers faster response, higher efficiency, and simpler operation.

[0053] S5: After controlling the output current of the inverter welding power supply, when the resistance welding electrode is separated from the workpiece by the output voltage, the welding is judged to be over, and the process proceeds to S6: Welding is over, the inverter welding power supply stops outputting current, and the process returns to S3: The output voltage of the inverter welding power supply is collected and continuously collected and monitored until the resistance welding electrode is judged to be separated from the workpiece, and the welding is over.

[0054] In this embodiment, the welding method may also be selected as arc welding mode, gun switch triggering mode, etc.

[0055] The following detailed description of the welding method applied to the inverter welding power supply described in Embodiment 1 or the welding machine described in Embodiment 2 will further illustrate the technical solution of this embodiment.

[0056] Please see Figure 1 , Figure 2When the inverter welding power supply is set to automatic resistance welding mode, after setting the welding parameters according to the material and thickness of the workpiece, it enters the initialization mode of automatic resistance welding. At this time, the signal acquisition module 3 periodically acquires the output signal of the inverter welding power supply and transmits the acquired results to the control module 2. The control module 2 analyzes and processes the acquired output signal and judges the state of the electrode and the workpiece through the output signal. Specifically, it first detects whether the electrode and the workpiece are short-circuited. If no short circuit is detected, it returns to signal acquisition. Once a short circuit is detected, the control module 2 controls the inverter welding power supply to output an output current for a certain period of time through a command. During this time, after the output current flows through the two workpieces to be welded, a certain amount of heat will be generated due to the contact resistance after the current flows. At the same time, the welder will apply a certain pressure to the workpiece through the electrode. At this time, a weld point will be formed at the workpiece pressed by the electrode, thereby welding the two workpieces together.

[0057] During the welding process, the signal acquisition module 3 continuously acquires the output signal of the inverter welding power supply. If the electrode separates from the workpiece based on the output signal, the welding is considered complete and the welding process ends. If the separation of the electrode from the workpiece is not detected, signal acquisition continues. At this point, the control module 2 determines that the welding process is not yet complete and continues signal acquisition until the separation of the electrode from the workpiece is detected, at which point the welding process ends.

[0058] The inverter welding power supply of this invention selects the resistance welding mode through a mode and parameter setting module, acquires the output signal of the rectifier output module through a signal acquisition module, and controls the output current of the rectifier output module according to the resistance welding mode and the state of the electrode and workpiece. Pressure is applied to the workpiece through the resistance welding electrode, and the workpiece is welded through the output current and the pressure. Based on traditional arc welding power supplies, the inverter welding power supply of this invention only requires the addition of resistance welding electrodes to complete resistance welding. The inverter welding power supply, welding machine, and welding method of this invention are easy to operate, low in cost, and widely applicable, possessing high practical value.

[0059] Obviously, the above embodiments of this invention are merely examples for clearly illustrating the invention, and are not intended to limit the implementation of the invention. Those skilled in the art can make other variations or modifications based on the above description. The embodiments exemplified in this invention cannot exhaustively describe all implementation methods. All obvious variations or modifications derived from the technical solutions of this invention are still within the protection scope of this invention. All documents mentioned in this invention are incorporated herein by reference as if a single document were independently incorporated by reference.

Claims

1. An inverter-type welding power supply, characterized in that, It includes a mode and parameter setting module and a control module. The mode and parameter setting module selects the resistance welding mode, the workpiece is connected to the output terminal of the inverter welding power supply, and the control module controls the output current of the inverter welding power supply according to the resistance welding mode, the state of the resistance welding electrode and the workpiece, and applies pressure to the workpiece through the output current to weld the workpiece. The inverter welding power supply also includes a signal acquisition module. The input terminal of the signal acquisition module is connected to the output terminal of the inverter welding power supply, and the output terminal of the signal acquisition module is connected to the control module. The signal acquisition module acquires the output signal of the inverter welding power supply. The control module determines the state of the resistance welding electrode and the workpiece based on the output signal. Based on the resistance welding mode and the state of the resistance welding electrode and the workpiece, the control module controls the output current of the inverter welding power supply and applies pressure to the workpiece through the output current to weld the workpiece. The inverter welding power supply also includes an output feedback module, the input terminal of which is connected to the output terminal of the inverter welding power supply, and the output terminal of which is connected to the input terminal of the signal acquisition module. The inverter-type welding power supply further includes a rectifier and filter module, an inverter module, and a rectifier and output module. The input terminal of the rectifier and filter module is connected to the mains power, and its output terminal is connected to the input terminal of the inverter module. The input terminal of the rectifier and output module is connected to the output terminal of the inverter module. The input terminal of the signal acquisition module is connected to the output terminal of the rectifier and output module, and its output terminal is connected to the control module. The output terminal of the control module is connected to the inverter module. The workpiece is connected to the output terminal of the rectifier and output module. The automatic resistance welding mode is selected by the mode and parameter setting module, the output signal of the rectifier output module is acquired by the signal acquisition module, the control module determines the state of the resistance welding electrode and the workpiece according to the output signal, and controls the output current of the rectifier output module according to the resistance welding mode and the state of the resistance welding electrode and the workpiece, and applies pressure to the workpiece through the output current to weld the workpiece.

2. An electric welding machine, characterized in that, The system includes an inverter welding power source and a resistance welding electrode as described in claim 1. The workpiece to be welded is connected to the output terminal of the inverter welding power source. Pressure is applied to the workpiece through the resistance welding electrode, and the workpiece is welded by the output current of the inverter welding power source and the pressure.

3. A welding method applied to the inverter welding power source of claim 1, characterized in that, Includes the following steps: Select automatic resistance welding mode identification; Set welding parameters; Enter initialization mode; Acquire the output signal of the inverter welding power supply; When the output signal indicates a short circuit between the resistance welding electrode and the workpiece, the output current of the inverter welding power supply is controlled.

4. The welding method according to claim 3, characterized in that, When the resistance welding electrode applies pressure to the workpiece, the output current passes through the workpiece, welding the workpiece together.

5. The welding method according to claim 3, characterized in that, If the output signal determines that the resistance welding electrode and the workpiece are not short-circuited, the signal is returned to the output signal of the inverter welding power supply.

6. The welding method according to claim 3, characterized in that, After controlling the output current of the inverter welding power supply, the welding ends when the resistance welding electrode separates from the workpiece, based on the output signal.

7. The welding method according to claim 3, characterized in that, After controlling the output current of the inverter welding power supply, if it is determined by the output signal that the resistance welding electrode and the workpiece have not separated, the system returns to the source of the inverter welding power supply output signal.

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