Visualized and informatized ac-dc output stud welding system and control method

Abstract

The application provides a stud welding system and a control method for visualizing and informatizing AC / DC output, wherein a control box assembly is arranged in a stud welding system main body; a programmer is detachably connected to the stud welding system main body and connected with the control box assembly; a heat dissipation air duct is arranged in the stud welding system main body; a transformer assembly is arranged in the heat dissipation air duct and connected with the control box assembly; a front bridge power assembly is arranged in a front compartment formed by the heat dissipation air duct and a front door of the stud welding system main body and connected with the control box assembly; a rear bridge power assembly is arranged in a rear compartment formed by the heat dissipation air duct and a rear door of the stud welding system main body and connected with the control box assembly; and a stud welding gun is connected to the stud welding system main body and connected with the control box assembly. The embodiment of the application realizes the design of front and rear independent electrical installation compartments, blocks the front and rear electromagnetic interference, improves the EMC index, and improves the reliability and durability of the equipment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of high-voltage and high-power special welding equipment, and particularly relates to a visual and informationized AC / DC output stud welding system and a control method. BACKGROUND

[0002] The factors affecting the basic function (welding quality) of the stud welding machine include the following core factors: current change rate, high-frequency pulse current, programmable change of current direction, close meshing of the motion trajectory of the linear servo motor and the current trajectory, contact speed and impact pressure of the stud on the plate.

[0003] The secondary factors affecting the welding quality include the following: timely and convenient cognition of multiple welding variables, detailed data analysis and comparison of multiple welding processes, determination of quality change trend, and mass storage of detailed data of welding points for after-recalling and quality feedback.

[0004] As a kind of high-voltage and high-power special equipment, the stud welding machine has a serious impact on the reliability and durability of the equipment due to the production environment and its own EMC disturbance (EMC stands for Electromagnetic Compatibility, which means electromagnetic compatibility). However, the current stud welding machine does not fully consider the production environment and its own EMC disturbance in the design, resulting in low reliability and durability of the equipment. SUMMARY

[0005] The embodiments of the present application provide a visual and informationized AC / DC output stud welding system and a control method, which are aimed at solving the problem that the current stud welding machine does not fully consider the production environment and its own EMC disturbance in the design, resulting in low reliability and durability of the equipment.

[0006] In a first aspect, the embodiments of the present application provide a stud welding system with visualized and informationized AC / DC output, which comprises a stud welding system main body, a programmer, a heat dissipation air duct, a transformer assembly, a front bridge power assembly, a rear bridge power assembly, a control box assembly and a stud welding gun; the control box assembly is arranged in the stud welding system main body; the programmer is detachably connected to the stud welding system main body and connected to the control box assembly; the heat dissipation air duct is arranged in the stud welding system main body; the transformer assembly is arranged in the heat dissipation air duct and connected to the control box assembly; the front bridge power assembly is arranged in a front compartment formed by the heat dissipation air duct and a front door of the stud welding system main body, and the front bridge power assembly is connected to the control box assembly; the rear bridge power assembly is arranged in a rear compartment formed by the heat dissipation air duct and a rear door of the stud welding system main body, and the rear bridge power assembly is connected to the control box assembly; and the stud welding gun is connected to the stud welding system main body and connected to the control box assembly.

[0007] In a second aspect, the embodiments of the present application provide a control method of a stud welding system with visualized and informationized AC / DC output, which is applied to the stud welding system with visualized and informationized AC / DC output as described in the first aspect, and the control method comprises the following steps.

[0008] A voice coil motor servo driver in the control box assembly acquires a welding current-time curve, determines a motion trajectory of a voice coil motor in the stud welding gun based on the welding current-time curve, and sets an interpolation unit with time as an input quantity in an MCU module in the control box assembly;

[0009] The interpolation unit generates a welding current instruction, a position instruction, a speed instruction and an acceleration instruction according to the interpolation unit;

[0010] The interpolation unit sends the welding current instruction, the position instruction, the speed instruction and the acceleration instruction to the stud welding gun to control the stud welding.

[0011] The embodiment of the present application provides a stud welding system and a control method of visualized and informationized AC / DC output, wherein the control box assembly is arranged in the stud welding system main body; the programmer is detachably connected on the stud welding system main body and connected with the control box assembly; the heat dissipation air duct is arranged in the stud welding system main body; the transformer assembly is arranged in the heat dissipation air duct and connected with the control box assembly; the front bridge power assembly is arranged in the front bin formed by the heat dissipation air duct and the front door of the stud welding system main body and connected with the control box assembly; the rear bridge power assembly is arranged in the rear bin formed by the heat dissipation air duct and the rear door of the stud welding system main body and connected with the control box assembly; and the stud welding gun is connected on the stud welding system main body and connected with the control box assembly. The embodiment of the present application realizes the design of front and rear independent electrical installation bins, blocks the front and rear electromagnetic interference, improves the EMC index, and improves the reliability and durability of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0012] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0013] Figure 1 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiment of the present application is shown in the figure.

[0014] Figure 2 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiment of the present application is shown in the figure.

[0015] Figure 3 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiment of the present application is shown in the figure.

[0016] Figure 4 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiment of the present application is shown in the figure.

[0017] Figure 5 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiment of the present application is shown in the figure.

[0018] Figure 6 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiment of the present application is shown in the figure.

[0019] Figure 7A structural schematic diagram of a control box assembly in a visualized and informationized AC / DC output stud welding system provided by the embodiment of the present application is shown in the figure;

[0020] Figure 8 A schematic diagram of an FPGA module in a visualized and informationized AC / DC output stud welding system provided by the embodiment of the present application is shown in the figure;

[0021] Figure 9 A circuit structural diagram of an H full-bridge circuit in a visualized and informationized AC / DC output stud welding system provided by the embodiment of the present application is shown in the figure;

[0022] Figure 10 Another structural schematic diagram of a control box assembly in a visualized and informationized AC / DC output stud welding system provided by the embodiment of the present application is shown in the figure;

[0023] Figure 11 A structural schematic diagram in a visualized and informationized AC / DC output stud welding system provided by the embodiment of the present application is shown in the figure;

[0024] Figure 12 A flowchart of a control method of a visualized and informationized AC / DC output stud welding system provided by the embodiment of the present application is shown in the figure.

[0025] In the figure, various reference signs are as follows:

[0026] 10, stud welding system main body; 100, programmer; 110, programmer body; 120, programmer cable; 200, heat dissipation air duct; 300, transformer assembly; 400, front bridge power assembly; 500, rear bridge power assembly; 600, control box assembly; 610, control box; 620, main circuit board; 630, FPGA module; 631, ADC sampling unit; 632, current PID operation unit; 633, commutation processing unit; 634, phase-shifting pulse unit; 635, commutation pulse unit; 640, MCU module; 650, interface board; 660, front bridge drive board; 670, rear bridge drive board; 680, voice coil motor servo driver; 690, host current controller; 700, Internet of Things data transmission unit; 20, cloud server. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0028] It should be understood that the terms "comprises" and "comprising," when used in this specification and the following claims, indicate the presence of the described features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0029] It should also be understood that the terms used in the specification and the appended claims are intended to describe certain embodiments and do not intentionally limit the application. As used in this specification and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0030] It should also be further understood that the term "and / or" as used in the specification and the appended claims, means any one or more of the associated listed items, as well as all possible combinations of the items.

[0031] Please refer to Figures 1-3 , Figure 1 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiments of the present application, Figure 2 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiments of the present application, which has a perspective heat dissipation air duct, Figure 3 The structural schematic diagram of the stud welding system with visualized and informationized AC / DC output provided by the embodiments of the present application, which has a perspective heat dissipation air duct and a transformer assembly. As shown in Figures 1-3 The stud welding system with visualized and informationized AC / DC output includes a stud welding system body 10, a programmer 100, a heat dissipation air duct 200, a transformer assembly 300, a front bridge power assembly 400, a rear bridge power assembly 500, a control box assembly 600, and a stud welding gun (not shown). The control box assembly 600 is arranged in the stud welding system body 10. The programmer 100 is detachably connected to the stud welding system body 10 and connected to the control box assembly 600. The heat dissipation air duct 200 is arranged in the stud welding system body 10. The transformer assembly 300 is arranged in the heat dissipation air duct 200 and connected to the control box assembly 600. The front bridge power assembly 400 is arranged in a front compartment formed by the heat dissipation air duct 200 and a front door of the stud welding system body 10, and the front bridge power assembly 400 is connected to the control box assembly 600. The rear bridge power assembly 500 is arranged in a rear compartment formed by the heat dissipation air duct 200 and a rear door of the stud welding system body 10, and the rear bridge power assembly 500 is connected to the control box assembly 600. The stud welding gun is connected to the stud welding system body 10 and connected to the control box assembly 600.

[0032] In the embodiment, the programmer 100 is detachably connected to the front door outer wall of the stud welding system body 10. When the user needs to use the programmer 100 as a human-computer interaction interface to set the device parameters, the programmer 100 can be taken off from the front door outer wall of the stud welding system body 10 and handheld to set the device parameters, welding process, view device data, record device events, view data waveform, etc. of the visualized and informatized AC / DC output stud welding system. When the programmer 100 is not needed to be handheld, it is hung on the front door outer wall of the stud welding system body 10.

[0033] The independent heat dissipation air duct 200 is also arranged in the stud welding system body 10. In the specific implementation, please refer to Figure 2 and Figure 3 The bottom, front panel, left panel and rear panel of the heat dissipation air duct 200 are closed, the lower half of the right panel is provided with a ventilation shutter, and the top is completely open. In the above manner, the heat dissipation air duct 200 constitutes a natural convection model as a whole, air can be naturally convected, and good heat dissipation is achieved.

[0034] Moreover, the transformer assembly 300 is arranged in the heat dissipation air duct 200, which is beneficial to the heat dissipation of the transformer assembly 300 and ensures the operation stability of the device. In the specific implementation, the transformer assembly 300 can be subjected to a closed glue filling treatment, so that the front end thereof is in contact with the front panel of the heat dissipation air duct 200, and the rear end thereof is in contact with the rear panel of the heat dissipation air duct 200.

[0035] Please refer to Figures 1-5 , wherein Figure 4 is a structural schematic view of the front bin in the visualized and informatized AC / DC output stud welding system provided by the embodiment of the present application, Figure 5This is a schematic diagram of the rear compartment of the stud welding system with visualized and information-based AC / DC output provided in the embodiments of this application. A front axle power assembly 400 and a rear axle power assembly 500 are also provided within the main body 10 of the stud welding system. The front axle power assembly 400 is located in the front compartment, and the rear axle power assembly 500 is located in the rear compartment. One end of the front axle power assembly 400 is in contact with the front panel of the heat dissipation duct 200 (one end of the front axle power assembly 400 can be a heat dissipation aluminum plate structure, and it is in contact with the front panel of the heat dissipation duct 200). One end of the rear axle power assembly 500 (one end of the rear axle power assembly 500 can be a heat dissipation aluminum plate structure, and it is in contact with the rear panel of the heat dissipation duct 200) is in contact with the rear panel of the heat dissipation duct 200. Both the front and rear panels of the duct can be considered as heat dissipation structures. With the above settings, the heat generated by the front axle power assembly 400 and the rear axle power assembly 500 during operation can be dissipated to the heat dissipation duct 200 to achieve heat dissipation.

[0036] A control box assembly 600 is also provided inside the main body 10 of the stud welding system. Specifically, the front end of the control box assembly 600 is located in the front compartment and the rear end of the control box assembly 600 is located in the rear compartment, which makes it easier for other components installed inside the main body 10 of the stud welding system to connect with the control box assembly 600.

[0037] In one embodiment, such as Figures 1-7 As shown, where Figure 6 This is an exploded structural diagram of the control box assembly in the visualized and information-based AC / DC output stud welding system provided in the embodiments of this application. Figure 7 This is a schematic block diagram of the control box assembly in a visualized and information-based AC / DC output stud welding system provided in this application embodiment. The control box assembly 600 includes a control box 610, a main circuit board 620, an FPGA module 630, an MCU module 640, and an interface board 650. One end of the control box 610 is located in the front compartment, and the other end is located in the rear compartment. The main circuit board 620 is disposed within the control box 610. The FPGA module 630 and the MCU module 640 are both disposed on the main circuit board 620 and are connected. The MCU module 640 is also connected to the programmer 100. The FPGA module 630 is also connected to both the front axle power component 400 and the rear axle power component 500. The interface board 650 is disposed within the control box 610 and is connected to the FPGA module 630. The interface board 650 is used to connect the stud welding torch.

[0038] In the embodiment, the main circuit board 620 is installed in the control box 610, and the control box 610 plays a shielding and protection role, that is, the control box 610 can block the front and rear electromagnetic interference and improve the EMC index. Moreover, the FPGA module 630 and the MCU module 640 are both arranged in the control box 610, which can effectively block the EMC radiation and conduction interference of the main circuit.

[0039] In the embodiment, as shown in Figure 7 The FPGA module 630 is connected with the front bridge power assembly 400 through the front bridge driving board 660, and the FPGA module 630 is connected with the rear bridge power assembly 500 through the rear bridge driving board 670. Through the above connection mode, the control box assembly 600 can serve as the control center of the whole device to control other components.

[0040] In an embodiment, as shown in Figure 8 The FPGA module 630 includes an ADC sampling unit 631, a current PID operation unit 632, a commutation processing unit 633, a phase-shifting pulse unit 634 and a commutation pulse unit 635; the current PID operation unit 632 is connected with the ADC sampling unit 631; the commutation processing unit 633 is connected with the current PID operation unit 632; the phase-shifting pulse unit 634 and the commutation pulse unit 635 are both connected with the commutation processing unit 633.

[0041] In the embodiment, the FPGA module 630 is provided with multiple independent functional units such as the ADC sampling unit 631, the current PID operation unit 632, the commutation processing unit 633, the phase-shifting pulse unit 634 and the commutation pulse unit 635.

[0042] The timer inside the FPGA module 630 can set a 10us (i.e. 10 microseconds) periodic pulse, which makes the timer generate a start pulse every 10us to provide to the ADC sampling unit 631. The specific working process is as follows. For example, when the timer generates a start pulse at a certain time based on the periodicity, the start pulse first starts the ADC sampling unit 631, which drives the AD converter (i.e. analog-to-digital converter) to perform AD data sampling and filtering processing through the SPI serial bus (which is a high-speed full-duplex synchronous serial communication bus), and the process takes 0.1us. When the ADC sampling unit 631 finishes processing the data, it sends a pulse to the current PID operation unit 632 of the next stage and sends the sampling data obtained by AD data sampling to the current PID operation unit 632. Then, the current PID operation unit 632 processes the sampling data based on the preset PID operation algorithm to obtain a calculation result, and the process takes 0.2us. When the calculation is completed, a pulse is sent to the commutation processing unit 633, and the calculation result is sent to the commutation processing unit 633. Then, the commutation processing unit 633 combines the received calculation result and the control data written by the MCU module 640 to obtain the current processing result, and the process takes 0.1us. When the calculation is completed, the phase-shifting pulse unit 634 and the commutation pulse unit 635 are simultaneously outputted with a waveform width and a pulse. Finally, the phase-shifting pulse unit 634 outputs a phase-shifting waveform based on the waveform width, and the commutation pulse unit 635 outputs a commutation logic, and the process takes 0.1us. The total time consumption of the above-mentioned entire processing process, excluding the processing time consumption of the phase-shifting pulse unit 634 and the commutation pulse unit 635, is 0.4us, which is close to zero cycle waiting, and realizes efficient data processing. Moreover, the FPGA module adopts an independent ADC sampling unit to form a pure digital hardware closed-loop control system, which has the ability to control each phase-shifting and pulse separately, and the control period is 10us and the control frequency is 100KHz.

[0043] Through the above settings, the control box assembly 600 has the ability to output high-speed current adjustment rate, and can also adjust the main loop parameters, reduce the main loop inductance, reduce the loop inertia time, and improve the output current change rate. Moreover, without a main loop independent high-frequency pulse circuit, the high-speed current adjustment capability is designed to generate a high-frequency pulse current function by the main controller.

[0044] In an embodiment, as Figure 1 and Figure 7As shown, the programmer 100 comprises a programmer body 110 and a programmer cable 120; the programmer body 110 is detachably arranged in a front panel box on the outer wall of the stud welding system body 10; one end of the programmer cable 120 is connected with the programmer body 110, and the other end of the programmer cable 120 is connected with the interface board 650.

[0045] In the embodiment, the programmer body 110 in the programmer 100 can be handheld and moved, and can also be fixed in the front panel box. Specifically, when the programmer body 110 is fixed in the front panel box, the programmer cable 120 can be wound on the cable hook on one side of the front panel box. When the user needs to use the programmer 100 as a human-computer interaction interface to set the device parameters, the programmer body 110 can be taken out from the front panel box and handheld to set the device parameters, welding process, view device data, record device events, view data waveform, etc. of the visualized and informatized AC / DC output stud welding system.

[0046] In the embodiment, the programmer body 110 is provided with a programmer processor, and the programmer processor is connected with the interface board 650 through the programmer cable 120, so as to realize the communication connection between the programmer processor and the MCU module 640 in the control box assembly 600.

[0047] In an embodiment, as shown in the figure, Figures 1-5 As shown, the front bridge power assembly 400 is an H full-bridge circuit, and the rear bridge power assembly 500 is a half-bridge circuit; wherein the output end of the H full-bridge circuit is connected with the primary of the main transformer in the transformer assembly 300, and the output end of the half-bridge circuit is connected with the secondary of the main transformer in the transformer assembly 300.

[0048] In the embodiment, the front bridge power assembly 400 adopts an H full-bridge circuit, and the rear bridge power assembly 500 adopts a half-bridge circuit. The H full-bridge circuit adopts a KT4 level IGBT module (IGBT stands for Insulated Gate Bipolar Transistor, which means an insulated gate bipolar transistor), and a DC isolation capacitor; the half-bridge circuit adopts a 2400A IGBT module for commutating current. The output end of the H full-bridge circuit (specifically, one end of the H full-bridge circuit provided with an IGBT module is taken as the output end) is connected with the primary of the main transformer of the transformer assembly 300, and the output end of the half-bridge circuit (specifically, one end of the half-bridge circuit provided with a rectifier is taken as the output end) is connected with the secondary of the main transformer of the transformer assembly 300.

[0049] Because the IGBT module is used in the H full-bridge circuit and the half-bridge circuit, both of them have the AC / DC ability. Through the IGBT module, the visual and information AC / DC output stud welding system can freely adjust the output current direction.

[0050] In an embodiment, as shown in Figure 9 The H full-bridge circuit includes the first diode D1, the second diode D2, the third diode D3, the fourth diode D4, the fifth diode D5, the sixth diode D6, the first resistor R1, the first voltage stabilizing diode D7, the first capacitor C1, the first IGBT module Q1, the second IGBT module Q2, the third IGBT module Q3, the fourth IGBT module Q4 and the second capacitor C2. The anode of the first diode D1, the anode of the third diode D3 and the anode of the fifth diode D5 are all connected to the first node a, the cathode of the first diode D1 is connected to the anode of the second diode D2, the cathode of the third diode D3 is connected to the anode of the fourth diode D4, and the cathode of the fifth diode D5 is connected to the anode of the sixth diode D6. The cathode of the second diode D2, the cathode of the fourth diode D4 and the cathode of the sixth diode D6 are all connected to the second node b. One end of the first resistor R1 and the anode of the first voltage stabilizing diode D7 are both connected to the second node b. The other end of the first resistor R1 and the cathode of the first voltage stabilizing diode D7 are both connected to the third node c. The collector of the first IGBT module Q1 and the collector of the third IGBT module Q3 are both connected to the third node c. The emitter of the first IGBT module Q1 is connected to the collector of the second IGBT module Q2. The emitter of the third IGBT module Q3 is connected to the collector of the fourth IGBT module Q4. The emitter of the second IGBT module Q2 and the emitter of the fourth IGBT module Q4 are both connected to the first node a. The emitter of the first IGBT module Q1 is also connected to one end of the second capacitor C2.

[0051] In the embodiment, the H full-bridge circuit with the above circuit structure has the AC / DC ability. Then the half-bridge circuit is used in the bridge power component 500 (the number of the IGBT module used in the half-bridge circuit is half of the number of the IGBT module used in the full-bridge circuit, for example, the number of the IGBT module used in the full-bridge circuit is 4, and the number of the IGBT module used in the half-bridge circuit is 2), and through the IGBT module, the visual and information AC / DC output stud welding system can freely adjust the output current direction. Moreover, the H full-bridge circuit can be regarded as the inverter power using the full-bridge phase-shift soft switching with 50KHz.

[0052] In an embodiment, as shown in Figures 1-10As shown, the control box assembly 600 further comprises a voice coil motor servo driver 680 and a host current controller 690; the voice coil motor servo driver 680 and the host current controller 690 are both arranged on the main circuit board 620, and the voice coil motor servo driver 680 and the host current controller 690 are both connected with the MCU module 640.

[0053] In the embodiment, the voice coil motor servo driver 680 and the host current controller 690 are also arranged on the main circuit board 620, so that the control box assembly 600 integrates the servo driver and the current controller, and has the motor motion control and the current control ability completely synchronized. That is, the same MCU module 640 is used to monitor the voice coil motor servo driver 680 and the host current controller 690, and the full cooperation of the two in the time axis is achieved.

[0054] In an embodiment, as shown in the accompanying drawings, Figure 11 As shown, the visual and informationized AC / DC output stud welding system further comprises an Internet of Things data transmission unit 700 and a cloud server 20; wherein the Internet of Things data transmission unit 700 is arranged on the main circuit board 620, and the Internet of Things data transmission unit 700 is connected with the MCU module 640; the MCU module 640 is in communication connection with the cloud server 20 through the Internet of Things data transmission unit 700.

[0055] In the embodiment, the visual and informationized AC / DC output stud welding system comprises not only the stud welding system body 10 and the functional modules arranged on or in the stud welding system body 10, but also the Internet of Things data transmission unit 700 arranged on the main circuit board 620 (the Internet of Things data transmission unit is also called the Internet of Things DTU unit, and the full name of DTU is Data Transfer Unit). Specifically, the MCU module 640 transmits data to the cloud server 20 through the Internet of Things data transmission unit 700 taking 4G / 5G wireless network as a carrier, and the cloud server 20 performs the application function of data, including but not limited to remote debugging, diagnosis, production data statistics, maintenance warning, automatic distribution of maintenance work order, fault report, etc.

[0056] In the control box assembly 600, an SDRAM module (SDRAM stands for Synchronous Dynamic Random-Access Memory) is further arranged, which is connected with the MCU module 640 and the Internet of Things data transmission unit 700. A 10us recording unit is built in the FPGA module, and after each control cycle of the FPGA module ends, data is buffered in the SRAM module (SRAM stands for Static Random-Access Memory) inside the FPGA module. When the buffer (the storage space of the SRAM module can be regarded as a buffer) is full, an interrupt instruction is sent to the MCU module. After receiving the interrupt instruction, the MCU module reads out the data and stores it in the SDRAM module, and finally the SDRAM module sends the data to the database of the cloud server through Ethernet for saving.

[0057] In summary, the stud welding system with visualized and informatized AC / DC output provided in the application has the following beneficial effects:

[0058] 1) Independent heat dissipation air duct, natural convection, good heat dissipation; the chassis of the stud welding system main body 10 reaches IP54 protection level, isolates external harmful dust, and provides a clean internal environment for the electrical compartment;

[0059] 2) Independent electrical installation compartment design in front and back, blocking front and back electromagnetic interference, improving EMC index;

[0060] 3) High-speed CPU and FPGA digital circuit, installed in a shielded box, blocking EMC radiation and conduction interference of the main circuit;

[0061] 4) Using FPGA and independent ADC to form a pure digital hardware closed-loop control system, achieving the ability to individually control each phase-shifted pulse;

[0062] 5) Connecting the ADC sampling, operation controller, main pulse generator and current commutator in series in the FPGA, realizing zero cycle waiting in control;

[0063] 6) High-speed adjustment rate of output current, adjusting the main circuit parameters, reducing the main circuit inductance, reducing the loop inertia time, and improving the output current change rate;

[0064] 7) High-frequency pulse, that is, without a separate high-frequency pulse circuit in the main circuit, through the high-speed current adjustment capability, a function of generating a high-frequency pulse current by the main controller is designed;

[0065] 8) Through the commutation IGBT in the rear bridge power assembly, the device can freely adjust the output current direction;

[0066] 9) Fusion servo driver and current controller integrated, making the device have motor motion control and current control ability completely synchronized;

[0067] 10) Control system has fast Ethernet and large capacity storage capability, providing 10us interval, 16 channel data recording, providing welding visualization capability; Specifically, the SRAM module in the FPGA module uses 16 channels to record data;

[0068] 11) Handheld programmer, providing on-site programmable capability for the device, the programmer is located on the control front, and can be handheld and moved:

[0069] 12) Connect the Internet of Things module and the cloud platform, with the help of 4G / 5G network, the host data can be transmitted to the cloud platform, and through the cloud platform, remote diagnosis, remote maintenance, automatic maintainability check and other advanced functions can be realized.

[0070] The embodiment of the application also provides a control method of a visual and informationized AC / DC output stud welding system. The control method of the visual and informationized AC / DC output stud welding system is applied to any one of the preceding embodiments of the visual and informationized AC / DC output stud welding system. Specifically, please refer to Figure 12 , Figure 12 is a flowchart of the control method of the visual and informationized AC / DC output stud welding system provided by the embodiment of the application. As Figure 12 shown, the control method of the visual and informationized AC / DC output stud welding system comprises the following steps:

[0071] S110, the voice coil motor servo driver in the control box assembly acquires a welding current-time curve, determines the motion trajectory of the voice coil motor in the stud welding gun based on the welding current-time curve, and sets an interpolation unit taking time as an input quantity in the MCU module in the control box assembly;

[0072] S120, generating a welding current instruction, a position instruction, a speed instruction and an acceleration instruction according to the interpolation unit;

[0073] S130, the interpolation unit sends the welding current instruction, the position instruction, the speed instruction and the acceleration instruction to the stud welding gun to correspondingly control the stud welding.

[0074] In the present embodiment, the current loop-speed loop-position loop control scheme can be adopted in the voice coil motor servo driver in the control box assembly. That is, before each welding starts, the welding current-time curve of the stud welding gun is determined by the pre-made welding process. Then, the motion planner plans the motion trajectory of the voice coil motor in the stud welding gun according to the welding current-time curve and the operating law of the motor, and sets the time as the input of the interpolation unit.

[0075] When the MCU module in the control box assembly performs the welding operation, it outputs the welding current instruction, and also generates the position instruction, the speed instruction and the acceleration instruction required by the voice coil motor servo driver through the interpolation unit.

[0076] The acceleration instruction is used to calculate the current feedforward instruction by combining the mass of the voice coil motor moving part and the thrust / current coefficient of the voice coil motor, and the current feedforward instruction enters the current loop. The speed instruction is used to directly enter the speed loop to form the speed feedforward. Through the above-mentioned multiple feedforward signals, the position error in the most critical falling process can be controlled below 0.02mm.

[0077] In an embodiment, the step S120 further comprises:

[0078] The FPGA module in the control box assembly sends an interrupt instruction to the MCU module in the control box assembly if it detects that the buffer area is full of stored data;

[0079] The MCU module reads all the data in the buffer area and stores them in the SDRAM module connected to the MCU module;

[0080] The SDRAM module sends the stored data to the cloud server for storage through the Internet of Things data transmission unit.

[0081] In the present embodiment, a 10us recording unit is built in the FPGA module, and after each control cycle of the FPGA module ends, the data is buffered in the SRAM module (SRAM stands for Static Random-Access Memory) inside the FPGA module. When the buffer area (the storage space of the SRAM module can be regarded as the buffer area) is full, an interrupt instruction is sent to the MCU module. The MCU module reads out the data after receiving the interrupt instruction, and stores them in the SDRAM module (SDRAM stands for Synchronous Dynamic Random-Access Memory). Finally, the SDRAM module sends the data to the database of the cloud server through Ethernet for storage.

[0082] The above merely provides the specific implementation of the present application, but the protection scope of the present application is not limited to this. Any person skilled in the art can easily think of various equivalent modifications or replacements within the technical range disclosed by the present application, and these modifications or replacements should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A stud welding system with visualized and information-based AC / DC output, characterized in that, The system includes a stud welding system body, a programmer, a heat dissipation duct, a transformer assembly, a front axle power assembly, a rear axle power assembly, a control box assembly, and a stud welding torch. The control box assembly is located within the stud welding system body. The programmer is detachably connected to the stud welding system body and connected to the control box assembly. The heat dissipation duct is located within the stud welding system body. The transformer assembly is located within the heat dissipation duct and connected to the control box assembly. The front axle power assembly is located in the front compartment formed by the heat dissipation duct and the front door of the stud welding system body, and is connected to the control box assembly. The rear axle power assembly is located in the rear compartment formed by the heat dissipation duct and the rear door of the stud welding system body, and is connected to the control box assembly. The stud welding torch is connected to the stud welding system body and connected to the control box assembly. The control box assembly includes a control box, a main circuit board, an FPGA module, an MCU module, and an interface board. One end of the control box is located in the front compartment, and the other end is located in the rear compartment. The main circuit board is disposed within the control box. The FPGA module and the MCU module are both disposed on the main circuit board and are connected. The MCU module is also connected to the programmer. The FPGA module is also connected to both the front axle power component and the rear axle power component. The interface board is disposed within the control box and is connected to the FPGA module. The interface board is used to connect a stud welding torch. The control box assembly also includes a voice coil motor servo driver and a host current controller; both the voice coil motor servo driver and the host current controller are mounted on the main circuit board and are connected to the MCU module. It also includes an IoT data transmission unit and a cloud server; wherein, the IoT data transmission unit is disposed on the main circuit board and is connected to the MCU module; the MCU module communicates with the cloud server through the IoT data transmission unit.

2. The stud welding system with visualized and information-based AC / DC output according to claim 1, characterized in that, The FPGA module includes an ADC sampling unit, a current PID calculation unit, a commutation processing unit, a phase-shifting pulse unit, and a commutation pulse unit; the current PID calculation unit is connected to the ADC sampling unit; the commutation processing unit is connected to the current PID calculation unit; the phase-shifting pulse unit and the commutation pulse unit are both connected to the commutation processing unit.

3. The stud welding system with visualized and information-based AC / DC output according to claim 1, characterized in that, The programmer includes a programmer body and a programmer cable; the programmer body is detachably installed in the front panel box on the outer wall of the stud welding system body; one end of the programmer cable is connected to the programmer body, and the other end of the programmer cable is connected to the interface board.

4. The stud welding system with visualized and information-based AC / DC output according to claim 1, characterized in that, The front axle power component is an H-bridge circuit, and the rear axle power component is a half-bridge circuit; wherein, the output terminal of the H-bridge circuit is connected to the primary winding of the main transformer in the transformer assembly, and the output terminal of the half-bridge circuit is connected to the secondary winding of the main transformer in the transformer assembly.

5. The stud welding system with visualized and information-based AC / DC output according to claim 4, characterized in that, The H-bridge circuit includes: a first diode, a second diode, a third diode, a fourth diode, a fifth diode, a sixth diode, a first resistor, a first Zener diode, a first capacitor, a first IGBT module, a second IGBT module, a third IGBT module, a fourth IGBT module, and a second capacitor; the anodes of the first diode, the third diode, and the fifth diode are all connected to a first node; the cathode of the first diode is connected to the anode of the second diode, the cathode of the third diode is connected to the anode of the fourth diode, and the cathode of the fifth diode is connected to the anode of the sixth diode; the cathodes of the second diode, the fourth diode, and the sixth diode... The negative terminals of all diodes are connected to the second node; one end of the first resistor and the positive terminal of the first Zener diode are both connected to the second node; the other end of the first resistor and the negative terminal of the first Zener diode are both connected to the third node; the collectors of the first IGBT module and the third IGBT module are both connected to the third node; the emitter of the first IGBT module is connected to the collector of the second IGBT module; the emitter of the third IGBT module is connected to the collector of the fourth IGBT module; the emitters of the second IGBT module and the fourth IGBT module are both connected to the first node; the emitter of the first IGBT module is also connected to one end of the second capacitor.

6. A control method for a stud welding system with visualized and information-based AC / DC output, characterized in that, The control method, applied to the stud welding system with visualized and information-based AC / DC output as described in any one of claims 1-5, includes: The voice coil motor servo driver in the control box assembly acquires the welding current-time curve, determines the motion trajectory of the voice coil motor in the stud welding torch based on the welding current-time curve, and sets an interpolation unit with time as the input in the MCU module of the control box assembly. The interpolation unit generates welding current commands, position commands, speed commands, and acceleration commands. The interpolation unit sends the welding current command, position command, speed command, and acceleration command to the stud welding gun to control the stud welding accordingly.

7. The control method for the visualized and information-based AC / DC output stud welding system according to claim 6, characterized in that, Also includes: If the FPGA module in the control box assembly detects that the buffer is full of data, it sends an interrupt command to the MCU module in the control box assembly. The MCU module reads all the data in the buffer and stores it in the SDRAM module connected to the MCU module; The SDRAM module sends the stored data to the cloud server for storage via the Internet of Things data transmission unit.

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