Direct current flash welding machine and control method thereof

Abstract

The invention provides a direct-current flash welding machine and a control method thereof. The direct-current flash welding machine comprises a storage battery pack, a controllable steady-current direct-current power supply, a super capacitor, an output confluence assembly and a program control device. A first frequency converter and a hydraulic system motor; a second frequency converter cooling the system motor; electric energy is stored and output through the storage battery pack; increasing and decreasing the capacity of the storage battery pack according to the welding task; the controllable steady-current direct-current power supply is controlled by the program control device to adjust the output voltage and current value according to the welding process; the supercapacitor and the output of the controllable steady-current direct-current power supply are connected in parallel and converged; the output confluence assembly is connected after parallel connection; the storage battery pack is connected with the first frequency converter, the second frequency converter and the controllable steady-current direct-current power supply; a program control device is used for controlling a controllable steady-current direct-current power supply and an output confluence assembly, a first frequency converter, a hydraulic system motor, a second frequency converter and a cooling system motor to construct a welding control system, and welding current adjustment of direct-current flash welding and control of a servo system are carried out.

Description

Technical Field

[0001] The present invention relates to the technical field of track construction of new energy welding, and more specifically, to a direct current flash welding machine and a control method thereof. Background Art

[0002] At present, welding is very critical in rail construction; usually flash welding uses an industrial frequency AC flash welder with an output current of a sine wave, and its welding current crosses zero twice per cycle (20ms). During this period, the welding area is not heated by the current, but the heat dissipation process does not stop, the heat loss is serious, and a larger welding power must be adapted; when the AC current passes through the welding area, due to the skin effect of the AC current, the current is uneven; the industrial frequency welding transformer is large in size and weight, and has a large reactive loss and must be adapted to a reactive compensation device. In addition, the low-voltage output welding current of tens of kA will cause a large reactive loss due to the inductance of the feeder cable, and other problems remain to be solved; therefore, it is necessary to propose a subgraph matching system and method based on a hybrid expansion strategy and de-duplication optimization to at least partially solve the problems existing in the prior art. Summary of the invention

[0003] A series of simplified concepts are introduced in the content of the invention, which will be further described in detail in the specific implementation method section; the content of the invention of the present invention does not mean to attempt to limit the key features and essential technical features of the technical solution claimed for protection, nor does it mean to attempt to determine the scope of protection of the technical solution claimed for protection.

[0004] In order to at least partially solve the above problems, the present invention provides a DC flash welding machine, comprising: a battery pack, a controllable steady-current DC power supply, a super capacitor, an output bus assembly, a program control device; a first frequency converter, a hydraulic system motor; a second frequency converter, a cooling system motor; the battery pack is used to store and output electric energy; the capacity of the battery pack is increased or decreased according to the welding task; the controllable steady-current DC power supply is controlled by the program control device to adjust the output voltage and current value according to the welding process; the output of the super capacitor and the controllable steady-current DC power supply are connected in parallel and bused; the output bus assembly is connected after parallel connection; the battery pack is connected to the first frequency converter, the second frequency converter and the controllable steady-current DC power supply; the controllable steady-current DC power supply and the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor are controlled by the program control device to construct a welding control system, and the welding current of the DC flash welding is adjusted and the servo system is controlled.

[0005] Preferably, the battery pack includes: a power battery, an auxiliary battery or a combined battery pack, and the capacity of the battery pack is increased or decreased according to the welding task; the battery pack voltage is connected to the first DC circuit of the first inverter and the second DC circuit of the second inverter, and realizes soft starting of the motor and closed-loop speed control of pressure and temperature.

[0006] Preferably, the controllable regulated-current DC power supply adjusts the output voltage and current value according to the welding process by a program control device; the maximum regulated-current output of the controllable regulated-current DC power supply is 50kA, and the controllable no-load voltage is 6-9V; the controllable regulated-current DC power supply is a DC / DC high-frequency switching power supply with a design capacity of 200kW; the volume, weight, and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

[0007] Preferably, the output of the supercapacitor and the controllable regulated DC power supply are connected in parallel and converged; after being connected in parallel, an output convergence assembly is connected; the battery pack is connected to the first inverter, the second inverter and the controllable regulated DC power supply; during operation, since the current in the flash welding process is a pulse current rather than a continuous constant, especially during the preheating period of the weldment, the pulse current causes the output voltage of the regulated DC power supply to fluctuate; the supercapacitor is configured as a good energy storage and filtering device, which can effectively improve the stability of the output voltage and reduce the impact of the pulse current on the controllable regulated DC power supply, and the output current of the capacitor and the DC power supply is superimposed to provide a peak current of 100kA during upset forging.

[0008] Preferably, the program control device adjusts the controllable steady-current DC power supply to output a voltage and constant current that adapt to the welding process according to the welding process; the program control device controls the controllable steady-current DC power supply and the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor to construct a welding control system to adjust the welding current of DC flash welding and control the servo system; the program control device includes: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, a constant current / constant voltage conversion and protection unit; a welding process data receiving unit receives the preset welding process data at the front end through wireless data transmission; a process data program conversion unit converts the preset welding process data into a program control code; a program control adjustment unit controls and adjusts the controllable steady-current DC power supply according to the program control code to output a voltage and constant current that adapt to the welding process.

[0009] The present invention provides a control method for a DC flash welding machine, comprising: S100, storing and outputting electric energy through a battery pack; increasing or decreasing the capacity of the battery pack according to a welding task; S200, a controllable steady-current DC power supply is controlled by a program control device to adjust the output voltage and current value according to a welding process; S300, a supercapacitor and the output of the controllable steady-current DC power supply are connected in parallel and converged; after being connected in parallel, an output convergence component is connected; the battery pack is connected to a first frequency converter, a second frequency converter and a controllable steady-current DC power supply; S400, a welding control system is constructed by controlling the controllable steady-current DC power supply and the first frequency converter, a hydraulic system motor, a second frequency converter and a cooling system motor through a program control device, and welding current regulation of DC flash welding and control of a servo system are performed.

[0010] Preferably, S100 includes: utilizing power batteries, auxiliary batteries or combined battery packs to store and output electric energy through battery packs; increasing or decreasing the capacity of the battery pack according to the welding task; connecting the first DC circuit of the first inverter and the second DC circuit of the second inverter through the battery pack voltage, and realizing soft starting of the motor and closed-loop speed control of pressure and temperature.

[0011] Preferably, S200 includes: a controllable regulated current DC power supply, whose output voltage and current value are adjusted by a program control device according to the welding process; the maximum regulated current output of the controllable regulated current DC power supply is 50kA, and the controllable no-load voltage is 6-9V; the controllable regulated current DC power supply is a DC / DC high-frequency switching power supply with a design capacity of 200kW; the volume, weight and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

[0012] Preferably, S300 includes: the output of the supercapacitor and the controllable steady-current DC power supply are connected in parallel; during operation, the output voltage fluctuates because the welding process is a pulsed current rather than a continuous constant, especially during the preheating period of the weldment; the supercapacitor is configured as a good energy storage and filtering device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable steady-current DC power supply, and the output current of the capacitor and the DC power supply are superimposed to provide a peak current of 100kA during top forging.

[0013] Preferably, S400 includes: a program control device adjusts the controllable steady-current DC power supply to output a voltage and a constant current adapted to the welding process according to the welding process; a welding control system is constructed by controlling the controllable steady-current DC power supply and the output bus assembly, the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor through the program control device to adjust the welding current of DC flash welding and control the servo system; the program control device includes: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, a constant current / constant voltage conversion and protection unit; a welding process data receiving unit receives the preset welding process data at the front end through wireless data transmission; a process data program conversion unit converts the preset welding process data into a program control code; a program control adjustment unit controls and adjusts the controllable steady-current DC power supply according to the program control code to output a voltage and a constant current adapted to the welding process.

[0014] Compared with the prior art, the present invention has at least the following beneficial effects:

[0015] The present invention discloses a DC flash welding machine and a control method thereof, which adopts a battery pack, a controllable steady-current DC power supply, a super capacitor, an output bus assembly, a program control device; a first frequency converter, a hydraulic system motor; a second frequency converter, a cooling system motor; the battery pack is used to store and output electric energy; the capacity of the battery pack is increased or decreased according to the welding task; the controllable steady-current DC power supply is controlled by the program control device to adjust the output voltage and current value according to the welding process; the super capacitor and the output of the controllable steady-current DC power supply are connected in parallel and bused; the output bus assembly is connected after parallel connection; the battery pack is connected to the first frequency converter, the second frequency converter and the controllable steady-current DC power supply; the controllable steady-current DC power supply and the output bus assembly, the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor are controlled by the program control device to construct a welding control system, and the welding current of the DC flash welding is adjusted and the servo system is controlled; the volume, weight and energy consumption of the DC flash welding machine of the present application are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved; the present invention does not break the arc due to the current zero-crossing effect, and the flash is stable during the rail welding process; in addition, the electric current on the welding section is The current is evenly distributed, and the weld is not easy to oxidize; and the heat-affected flash zone is parallel, the weld and the grains are small and uniform, the welding machine cycle is shorter, and excellent welding rail quality can be obtained and the welding power can be effectively reduced; on the contrary, when the direct current passes through the welding area, it produces a "cluster effect" toward the center; it can concentrate heat energy, reduce the heat-affected zone around the welding joint and have higher welding efficiency; the direct current flash welding of the present invention can reduce the current by more than 20% compared with the usual welding and greatly reduce the energy consumption. In addition, the cross-section of the feeder cable is also reduced accordingly; the present invention uses a battery pack as energy The flash welding power source is DC→DC converted to a flash welding power source for the welding machine. The flash welding machine does not have an industrial frequency isolation transformer, and the transmission cable has no reactance loss. There is almost no reactive power in the welding current loop, and the welding machine does not need additional reactive power compensation equipment, and the cross-sectional size of the feeder wire can be reduced. In addition, due to the use of DC power supply, the welding current does not cross zero and the arc is broken, and the rail welding process flashes smoothly. The DC welding section also has a uniform current distribution, and the weld is not easy to oxidize. It also ensures that the heat-affected flash zone is parallel, and the weld and grains are small and uniform, so that excellent weld rail quality can be obtained.

[0016] The DC flash welding machine and control method thereof described in the present invention, and other advantages, objectives and features of the present invention will be partially reflected through the following description, and will also be partially understood by technicians in this field through research and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0018] Figure 1This is a diagram of an embodiment of a DC flash welding machine described in the present invention.

[0019] Figure 2 This is another embodiment of a DC flash welding machine described in the present invention.

[0020] Figure 3 This is a diagram of an application example of a DC flash welding machine and a control method thereof according to the present invention. DETAILED DESCRIPTION

[0021] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments, so that those skilled in the art can implement it according to the instructions; as shown in the figure, the present invention provides a DC flash welding machine, including: a battery pack 1, a controllable steady-current DC power supply 2, a super capacitor 22, an output bus assembly 21, and a program control device 23; a first frequency converter 3, a hydraulic system motor 31; a second frequency converter 4, and a cooling system motor 41; the battery pack 1 is used to store and output electric energy; the capacity of the battery pack 1 is increased or decreased according to the welding task; the controllable steady-current DC power supply 2 is controlled by the program control device 23 to adjust the output voltage and current value according to the welding process; the super capacitor 22 is connected in parallel with the output of the controllable steady-current DC power supply 2; after being connected in parallel, the output bus assembly 21 is connected; the battery pack 1 is connected to the first frequency converter 3, the second frequency converter 4 and the controllable steady-current DC power supply 2; the controllable steady-current DC power supply 2 and the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 are controlled by the program control device 23 to construct a welding control system, and the welding current adjustment and servo system control of the DC flash welding are performed.

[0022] The principle and effect of the above technical solution are as follows: the present invention provides a DC flash welding machine, comprising: a battery pack 1, a controllable regulated DC power supply 2, a super capacitor 22, an output bus assembly 21, and a program control device 23; a first frequency converter 3, a hydraulic system motor 31; a second frequency converter 4, and a cooling system motor 41; the battery pack 1 is used to store and output electric energy; the capacity of the battery pack 1 is increased or decreased according to the welding task; the controllable regulated DC power supply 2 is controlled by the program control device 23 to adjust the output voltage and current value according to the welding process; the super capacitor 22 and the controllable regulated DC power supply 2 output parallel convergence; after parallel connection, the output convergence component 21 is connected; the battery pack 1 is connected to the first inverter 3, the second inverter 4 and the controllable steady-current DC power supply 2; the program control device 23 controls the controllable steady-current DC power supply 2 and the output convergence component 21, the first inverter 3, the hydraulic system motor 31, the second inverter 4 and the cooling system motor 41 to construct a welding control system, and perform welding current regulation of DC flash welding and control of the servo system; the present invention does not break the arc due to the current zero-crossing effect, and the rail welding process flashes smoothly; in addition, the current is evenly distributed on the welding section, and the weld is not easy to oxidation; and ensure that the heat affected flash zone is parallel, the weld and grains are small and uniform, the welding machine cycle is shorter, and excellent welding rail quality can be obtained and the welding power can be effectively reduced; on the contrary, when the direct current passes through the welding area, it produces a "cluster effect" toward the center; it can concentrate heat energy, reduce the heat affected zone around the welding joint and have higher welding efficiency; the direct current flash welding of the present invention can reduce the current by more than 20% compared with the conventional welding, thereby greatly reducing energy consumption, and the cross section of the feeder cable is also reduced accordingly; the present invention uses a battery pack as energy, and uses DC→DC conversion for flash welding of the welding machine Power supply; the flash welding machine has no power frequency isolation transformer, the transmission cable has no reactance loss, there is almost no reactive power in the welding current loop, the welding machine does not need additional reactive power compensation equipment, and the cross-sectional size of the feeder wire can be reduced; in addition, due to the use of direct current power supply, the welding current does not cross zero and the arc is broken, and the rail welding process flashes smoothly, the direct current welding section current is evenly distributed, and the weld is not easy to oxidize; and it ensures that the heat-affected flash zone is parallel, the weld and the grain are small and uniform, and excellent rail welding quality can be obtained; the controllable steady-current direct current power supply 2 is composed of multiple identical modules 2-1, 2-2......2-n parallel composition; PWM synchronous current sharing control of constant current / constant voltage regulation is performed through program control device 23; parallel connection is used to solve the technical problem of low-voltage and high-current output; DC / DC conversion is directly controlled from 700V to 6-9V, and after output convergence, it is connected in parallel with super capacitors to effectively reduce the current impact of flash welding on the DC / DC conversion system, not only the flash is stable, but also an output current of 100,000A is obtained in a short time; after large capacitors are connected in parallel, the stability and redundancy of the power supply are significantly improved; when the DC current passes through the welding area, a cluster effect is generated toward the center, heat energy is concentrated, and the heat-affected zone around the welding joint is reduced, which has higher welding efficiency; the current can be reduced by more than 20% compared with other welding and AC flash welding, which greatly reduces energy consumption; the cross-section of the convergence feeder cable is also reduced accordingly. .

[0023] In one embodiment, the battery pack 1 includes: a power battery, an auxiliary battery or a combined battery pack, and the capacity of the battery pack 1 is increased or decreased according to the welding task; the voltage of the battery pack 1 is connected to the first DC circuit of the first inverter 3 and the second DC circuit of the second inverter 4, and the soft start of the motor and the closed-loop speed control of pressure and temperature are realized.

[0024] The principle and effect of the above technical solution are as follows: the battery pack 1 includes: a power battery, an auxiliary battery or a combined battery pack, and the capacity of the battery pack 1 is increased or decreased according to the welding task; the voltage of the battery pack 1 is connected to the first DC circuit of the first inverter 3 and the second DC circuit of the second inverter 4, and the soft start of the motor and the closed-loop speed control of pressure and temperature are realized.

[0025] In one embodiment, the controllable regulated current DC power supply 2 adjusts the output voltage and current value according to the welding process by the program control device 23; the maximum regulated current output of the controllable regulated current DC power supply 2 is 50kA, and the controllable no-load voltage is 6~9V; the controllable regulated current DC power supply 2 is a DC / DC high-frequency switching power supply with a designed capacity of 200kW; the volume, weight and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

[0026] The principle and effect of the above technical solution are: the controllable steady-current DC power supply 2 adjusts the output voltage and current value according to the welding process by the program control device 23; the maximum steady-current output of the controllable steady-current DC power supply 2 is 50kA, and the controllable no-load voltage is 6~9V; the controllable steady-current DC power supply 2 is a DC / DC high-frequency switching power supply with a designed capacity of 200kW; the volume, weight and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

[0027] In one embodiment, the supercapacitor 22 is connected in parallel with the output of the controllable regulated DC power supply 2; after being connected in parallel, the output merging component 21 is connected; the battery pack 1 is connected to the first inverter 3, the second inverter 4 and the controllable regulated DC power supply 2; during operation, the output voltage of the regulated DC power supply fluctuates because the flash welding process is a pulse current rather than a continuous constant, especially during the preheating period of the weldment; the supercapacitor 22 is set as a good energy storage and filtering device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable regulated DC power supply 2, and the output current of the capacitor 22 and the DC power supply 2 is superimposed to provide a peak current of 100kA during the upset forging period.

[0028] The principle and effect of the above technical solution are as follows: the supercapacitor 22 is connected in parallel with the output of the controllable regulated DC power supply 2; after being connected in parallel, the output merging component 21 is connected; the battery pack 1 is connected to the first inverter 3, the second inverter 4 and the controllable regulated DC power supply 2; during operation, the output voltage of the regulated DC power supply fluctuates because the flash welding process is a pulse current rather than a continuous constant, especially during the preheating period of the weldment; the supercapacitor 22 is set as a good energy storage and filtering device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable regulated DC power supply 2. The output current of the capacitor 22 and the DC power supply 2 is superimposed to provide a peak current of 100kA during the upset forging period.

[0029] In one embodiment, the program control device 23 adjusts the controllable steady-current DC power supply 2 according to the welding process to output a voltage and a constant current that adapts to the welding process; the program control device 23 controls the controllable steady-current DC power supply 2 and the output bus assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 to construct a welding control system to adjust the welding current of DC flash welding and control the servo system; the program control device 23 includes: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, a constant current / constant voltage conversion and protection unit; a welding process data receiving unit receives the preset welding process data at the front end through wireless data transmission; a process data program conversion unit converts the preset welding process data into a program control code; a program control adjustment unit controls and adjusts the controllable steady-current DC power supply 2 according to the program control code to output a voltage and a constant current that adapts to the welding process.

[0030] The principle and effect of the above technical solution are as follows: the program control device 23 adjusts the controllable steady-current DC power supply 2 according to the welding process to output the voltage and constant current that are suitable for the welding process; the program control device 23 controls the controllable steady-current DC power supply 2 and the output bus assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 to construct a welding control system to adjust the welding current of DC flash welding and control the servo system; the program control device 23 includes: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, a constant current / constant voltage conversion and protection unit; a welding process data receiving unit receives the preset welding process data at the front end through wireless data transmission; a process data program conversion unit converts the preset welding process data into a program control code; a program control adjustment unit controls and adjusts the controllable steady-current DC power supply 2 according to the program control code to output the voltage and constant current that are suitable for the welding process.

[0031] The present invention provides a control method for a DC flash welding machine, comprising: S100, storing and outputting electric energy through a battery pack 1; increasing or decreasing the capacity of the battery pack 1 according to a welding task; S200, a controllable steady-current DC power supply 2 is controlled by a program control device 23 to adjust the output voltage and current value according to a welding process; S300, a supercapacitor 22 is connected in parallel with the output of the controllable steady-current DC power supply 2; after being connected in parallel, an output bus assembly 21 is connected; the battery pack 1 is connected to a first frequency converter 3, a second frequency converter 4 and the controllable steady-current DC power supply 2; S400, a welding control system is constructed by controlling the controllable steady-current DC power supply 2 and the first frequency converter 3, a hydraulic system motor 31, a second frequency converter 4 and a cooling system motor 41 through the program control device 23, and welding current regulation of DC flash welding and control of a servo system are performed.

[0032] The principle and effect of the above technical solution are as follows: the present invention provides a DC flash welding machine control method, including: storing and outputting electric energy through a battery pack 1; increasing or decreasing the capacity of the battery pack 1 according to the welding task; the controllable steady-current DC power supply 2 is controlled by a program control device 23 to adjust the output voltage and current value according to the welding process; the supercapacitor 22 is connected in parallel with the output of the controllable steady-current DC power supply 2; after parallel connection, the output bus assembly 21 is connected; the battery pack 1 is connected to a first frequency converter 3, a second frequency converter 4 and a controllable steady-current DC power supply 2; the controllable steady-current DC power supply 2 and the output bus assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 are controlled by the program control device 23 to construct a welding The control system is connected to adjust the welding current of DC flash welding and control the servo system; the invention does not break the arc due to the current zero-crossing effect, and the flash is stable during the rail welding process; in addition, the current is evenly distributed on the welding section, and the weld is not easy to oxidize; and the heat-affected flash zone is guaranteed to be parallel, the weld and the grains are small and uniform, the welding machine cycle is shorter, and excellent rail welding quality can be obtained and the welding power can be effectively reduced; on the contrary, when the DC passes through the welding area, it produces a "cluster effect" toward the center; it can concentrate heat energy, reduce the heat-affected zone around the welding joint, and have a higher welding efficiency; the DC flash welding of the invention can reduce the current by more than 20% compared with the usual welding, thereby greatly reducing energy consumption, and the cross-section of the feeder cable is also reduced accordingly; the invention adopts a storage battery The flash welding power supply of the welding machine is made of a group as energy, and DC→DC conversion is used as the flash welding power supply of the welding machine; the flash welding machine has no power frequency isolation transformer, the transmission cable has no reactance loss, and there is almost no reactive power in the welding current loop. The welding machine does not need additional reactive power compensation equipment, and the cross-sectional size of the feeder wire can be reduced; in addition, due to the use of direct current power supply, the welding current does not cross zero and the arc is broken, and the flash of the rail welding process is stable. The current on the direct current welding section is evenly distributed, and the weld is not easy to oxidize; and the heat-affected flash zone is parallel, the weld and the grain are small and uniform, and excellent weld rail quality can be obtained; the controllable steady-current direct current power supply 2 is composed of a plurality of identical modules 2-1, 2-2...2-n connected in parallel; the program control device 23 controls the constant current / Constant voltage regulation is used for synchronous PWM current sharing control; parallel connection is used to solve low-voltage and high-current technical problems; DC / DC conversion is directly controlled from 700V to 6-9V; after the output is merged, it is connected in parallel with super capacitors to effectively reduce the current impact of the flash welding process on the DC / DC conversion system, not only the flash is stable, but also an output current of 100,000A can be obtained in a short time; after the large capacitors are connected in parallel, the stability and redundancy of the flash welding power supply are significantly improved; when the DC current passes through the welding area, it produces a cluster effect toward the center, concentrates heat energy, reduces the heat-affected zone around the welding joint, and has higher welding efficiency; the current can be reduced by more than 20% compared with other welding and AC flash welding, which greatly reduces energy consumption; the cross-section of the merge feeder cable is also reduced accordingly.

[0033] In one embodiment, S100 includes: using a power battery, an auxiliary battery or a combined battery pack to store and output electric energy through the battery pack 1; increasing or decreasing the capacity of the battery pack 1 according to the welding task; connecting the first DC circuit of the first inverter 3 and the second DC circuit of the second inverter 4 through the voltage of the battery pack 1, and realizing soft starting and pressure and temperature closed-loop speed control of the motor.

[0034] The principle and effect of the above technical solution are: using power batteries, auxiliary batteries or combined battery packs to store and output electric energy through the battery pack 1; increasing or decreasing the capacity of the battery pack 1 according to the welding task; connecting the first DC circuit of the first inverter 3 and the second DC circuit of the second inverter 4 through the voltage of the battery pack 1, and realizing soft starting of the motor and closed-loop speed control of pressure and temperature.

[0035] In one embodiment, S200 includes: a controllable regulated current DC power supply 2 adjusts the output voltage and current value according to the welding process by a program control device 23; the maximum regulated current output of the controllable regulated current DC power supply 2 is 50kA, and the controllable no-load voltage is 6-9V; the controllable regulated current DC power supply 2 is a DC / DC high-frequency switching power supply with a design capacity of 200kW; the volume, weight, and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

[0036] The principle and effect of the above technical solution are: the controllable steady-current DC power supply 2 adjusts the output voltage and current value according to the welding process by the program control device 23; the maximum steady-current output of the controllable steady-current DC power supply 2 is 50kA, and the controllable no-load voltage is 6~9V; the controllable steady-current DC power supply 2 is a DC / DC high-frequency switching power supply with a designed capacity of 200kW; the volume, weight and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

[0037] In one embodiment, S300 includes: a supercapacitor 22 and the output of a controllable regulated DC power supply 2 are connected in parallel; during operation, the output voltage fluctuates because the welding process is a pulsed current rather than a continuous constant, especially during the preheating period of the weldment; the supercapacitor 22 is set as a good energy storage and filtering device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable regulated DC power supply 2. The output current of the capacitor 22 and the DC power supply 2 is superimposed to provide a peak current of 100kA during top forging.

[0038] The principle and effect of the above technical solution are as follows: the supercapacitor 22 is connected in parallel with the output of the controllable steady-current DC power supply 2; during operation, the output voltage fluctuates because the welding process is a pulse current rather than a continuous constant, especially during the preheating period of the weldment; the supercapacitor 22 is set as a good energy storage and filtering device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable steady-current DC power supply 2. The output current of the capacitor 22 and the DC power supply 2 is superimposed to provide a peak current of 100kA during upsetting.

[0039] In one embodiment, S400 includes: a program control device 23 adjusts the controllable steady-current DC power supply 2 according to the welding process to output a voltage and a constant current that adapts to the welding process; the program control device 23 controls the controllable steady-current DC power supply 2 and the output bus assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 to construct a welding control system to adjust the welding current of DC flash welding and control the servo system; the program control device 23 includes: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit and a constant current and constant voltage cycle protection unit; a welding process data receiving unit receives the preset welding process data at the front end through wireless data transmission; a process data program conversion unit converts the preset welding process data into a program control code; a program control adjustment unit controls and adjusts the controllable steady-current DC power supply 2 according to the program control code to output a voltage and a constant current that adapts to the welding process.

[0040] The principle and effect of the above technical solution are as follows: the program control device 23 adjusts the controllable steady-current DC power supply 2 according to the welding process to output the voltage and constant current that are suitable for the welding process; the program control device 23 controls the controllable steady-current DC power supply 2 and the output bus assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 to construct a welding control system to adjust the welding current of DC flash welding and control the servo system; the program control device 23 includes: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, a constant current and constant voltage conversion and protection unit; a welding process data receiving unit receives the preset welding process data at the front end through wireless data transmission; a process data program conversion unit converts the preset welding process data into a program control code; a program control adjustment unit controls and adjusts the controllable steady-current DC power supply 2 according to the program control code to output the voltage and constant current that are suitable for the welding process.

[0041] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A DC flash welding machine, characterized in that: include: A battery pack (1), a controllable regulated DC power supply (2), a super capacitor (22), an output bus assembly (21), and a program control device (23); a first frequency converter (3), a hydraulic system motor (31); a second frequency converter (4), and a cooling system motor (41); storing and outputting electric energy through the battery pack (1); increasing or decreasing the capacity of the battery pack (1) according to the welding task; the controllable regulated DC power supply (2) is controlled by the program control device (23) to adjust the output voltage and current value according to the welding process; the super capacitor (22) and the controllable The outputs of the steady-current DC power supply (2) are connected in parallel and merged; after being connected in parallel, they are connected to an output merge component (21); the battery pack (1) is connected to a first frequency converter (3), a second frequency converter (4) and a controllable steady-current DC power supply (2); and a program control device (23) is used to control the controllable steady-current DC power supply (2), the output merge component (21), the first frequency converter (3), the hydraulic system motor (31), the second frequency converter (4) and the cooling system motor (41) to construct a welding control system, and perform welding current regulation of DC flash welding and control of a servo system.

2. A DC flash welding machine according to claim 1, characterized in that: The battery pack (1) comprises: a power battery, an auxiliary battery or a combined battery pack, and the capacity of the battery pack (1) is increased or decreased according to the welding task; the battery pack (1) is connected to a first DC circuit of a first frequency converter (3) and a second DC circuit of a second frequency converter (4), and realizes soft starting of the motor and closed-loop speed regulation control of pressure and temperature.

3. A DC flash welding machine according to claim 1, characterized in that: The controllable regulated-current DC power supply (2) has an output voltage and a current value adjusted by a program control device (23) according to the welding process; the maximum regulated-current output of the controllable regulated-current DC power supply (2) is 50 kA, and the controllable no-load voltage is 6 to 9 V; the controllable regulated-current DC power supply (2) is a DC / DC high-frequency switching power supply with a designed capacity of 200 kW; the volume, weight, and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

4. A DC flash welding machine according to claim 1, characterized in that: The supercapacitor (22) and the output of the controllable steady-current DC power supply (2) are connected in parallel and converged; after being connected in parallel, they are connected to an output convergence assembly (21); the storage battery pack (1) is connected to a first frequency converter (3), a second frequency converter (4) and the controllable steady-current DC power supply (2); during operation, since the flash welding process is a pulse current rather than a continuous current, especially during the flash preheating period of the welded part, the output voltage of the steady-current power supply fluctuates; the supercapacitor (22) is set as a good energy storage and filtering device, effectively improving the stability of the output voltage and reducing the impact of the pulse current on the controllable steady-current DC power supply (2); the output current of the capacitor (22) and the DC power supply (2) is superimposed to provide a peak current of 100kA during the upset forging period.

5. A DC flash welding machine according to claim 1, characterized in that: The program control device (23) adjusts the controllable steady-current DC power supply (2) to output a voltage and a constant current adapted to the welding process according to the welding process; the program control device (23) controls the controllable steady-current DC power supply (2) and the first frequency converter (3), the hydraulic system motor (31), the second frequency converter (4) and the cooling system motor (41) to construct a welding control system, and performs welding current adjustment of DC flash welding and control of the servo system; The program control device (23) comprises: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, and a constant current / constant voltage conversion and protection unit; the welding process data receiving unit receives the front-end preset welding process data through wireless data transmission; the process data program conversion unit converts the preset welding process data into a program control code; and the program control adjustment unit controls and adjusts the controllable constant current DC power supply (2) according to the program control code to output a voltage and a constant current that meet the welding process requirements.

6. A DC flash welding machine control method, characterized in that: include: S100, storing and outputting electric energy through a battery pack (1); The capacity of the battery pack (1) is increased or decreased according to the welding task; S200, the controllable steady-current DC power supply (2) is controlled by a program control device (23) to adjust the output voltage and current value according to the welding process; S300, the supercapacitor (22) and the output of the controllable steady-current DC power supply (2) are connected in parallel and converged; after parallel connection, the output convergence component (21) is connected; the battery pack (1) is connected to a first frequency converter (3), a second frequency converter (4) and the controllable steady-current DC power supply (2); S400, the controllable steady-current DC power supply (2) and the output convergence component (21), the first frequency converter (3), the hydraulic system motor (31), the second frequency converter (4) and the cooling system motor (41) are controlled by the program control device (23) to construct a welding control system, and the welding current of DC flash welding is adjusted and the servo system is controlled.

7. A DC flash welding machine control method according to claim 6, characterized in that: S100 comprises: utilizing a power battery, an auxiliary storage battery or a combined battery pack to store and output electric energy through a storage battery pack (1); increasing or decreasing the capacity of the storage battery pack (1) according to a welding task; connecting a first DC circuit of a first frequency converter (3) and a second DC circuit of a second frequency converter (4) through the voltage of the storage battery pack (1), and realizing soft starting of the motor and closed-loop speed regulation control of pressure and temperature.

8. A DC flash welding machine control method according to claim 6, characterized in that: S200, comprising: a controllable regulated current DC power supply (2) whose output voltage and current value are adjusted by a program control device (23) according to a welding process; the maximum regulated current output of the controllable regulated current DC power supply (2) is 50kA, and the controllable no-load voltage is 6-9V; the controllable regulated current DC power supply (2) is a DC / DC high-frequency switching power supply with a designed capacity of 200kW; the volume, weight and energy consumption of the DC flash welding machine are significantly reduced, the welding cycle is effectively shortened, and the welding quality is significantly improved.

9. A DC flash welding machine control method according to claim 6, characterized in that: S300, comprising: a super capacitor (22) and an output of a controllable steady-current DC power supply (2) are connected in parallel and converged; during operation, since the welding process is a pulsed current rather than a continuous and constant current, especially during the preheating period of the welded parts, the output voltage fluctuates; the super capacitor (22) is set as a good energy storage and filtering device, effectively improving the stability of the output voltage and reducing the impact of the pulse current on the controllable steady-current DC power supply (2); the output current of the capacitor (22) and the DC power supply (2) is superimposed to provide a peak current of 100kA during the upset forging period.

10. A DC flash welding machine control method according to claim 6, characterized in that: S400, comprising: a program control device (23) adjusting a controllable steady-current DC power supply (2) to output a voltage and a constant current suitable for the welding process according to the welding process; a welding control system is constructed by controlling the controllable steady-current DC power supply (2) and a first frequency converter (3), a hydraulic system motor (31), a second frequency converter (4) and a cooling system motor (41) through the program control device (23), and performing welding current regulation of DC flash welding and servo system control; the program control device (23) comprises: a welding process data receiving unit, a process data program conversion unit, a program control adjustment unit, a constant current / constant voltage conversion and protection unit; a welding process data receiving unit, receiving front-end preset welding process data through wireless data transmission; a process data program conversion unit, converting the preset welding process data into a program control code; and a program control adjustment unit, controlling and adjusting the controllable steady-current DC power supply (2) according to the program control code, and outputting a voltage and a constant current suitable for the welding process.

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