A direct current flash welder and a control method thereof

Abstract

The application provides a direct current flash welding machine and a control method thereof, which comprises a battery pack, a controllable constant-current direct current power supply, a super capacitor, an output confluence assembly, a program control device, a first frequency converter, a hydraulic system motor, a second frequency converter and a cooling system motor. The battery pack stores and outputs electric energy. The capacity of the battery pack is increased or decreased according to a welding task. The controllable constant-current direct current power supply is controlled by the program control device to adjust the output voltage and current value according to a welding process. The super capacitor is connected in parallel with the output of the controllable constant-current direct current power supply. After being connected in parallel, the output confluence assembly is connected. The battery pack is connected with the first frequency converter, the second frequency converter and the controllable constant-current direct current power supply. The controllable constant-current direct current power supply, the output confluence 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, so that the welding current regulation and the control of a servo system of the direct current flash welding are realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of track construction technology of new energy welding, more particularly, the present application relates to a direct current flash welding machine and a control method thereof. BACKGROUND

[0002] At present, track construction welding is very critical; the output current of the power frequency alternating current flash welding machine is a sine wave, and the welding current passes zero twice (20 ms) per cycle, during which the welding area is not heated by the current, but the heat dissipation process does not stop, and the heat loss is serious, so a larger welding power is required; when the alternating current passes through the welding area, the current is uneven due to the skin effect of alternating current; the power frequency welding transformer is large in size and weight, and has large reactive loss, so a reactive compensation device must be adapted; in addition, the tens of kA welding current of the low-voltage output will cause 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 deduplication optimization to at least partially solve the problems in the prior art. SUMMARY

[0003] A series of simplified concepts are introduced in the summary section, which will be further described in detail in the detailed description section; the summary section of the present application does not mean to attempt to limit the key features and necessary technical features of the claimed technical solution, and even less to determine the protection scope of the claimed technical solution.

[0004] To at least partially solve the above problems, the present application provides a direct current flash welding machine, comprising: a battery pack, a controllable constant-current direct current 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; storing and outputting electric energy through the battery pack; increasing or decreasing the capacity of the battery pack according to the welding task; the controllable constant-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 super capacitor is connected in parallel with the output of the controllable constant-current direct current power supply; the parallel connection is connected with the output bus assembly; the battery pack is connected with the first frequency converter, the second frequency converter and the controllable constant-current direct current power supply; the controllable constant-current direct current power supply, 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 build a welding control system, and the welding current adjustment and servo system control of the direct current flash welding are performed.

[0005] Preferably, the battery pack comprises: a power battery, an auxiliary battery or a combined battery pack, the capacity of the battery pack is increased or decreased according to the welding task; the battery pack voltage is connected to the first direct current loop of the first frequency converter and the second direct current loop of the second frequency converter, and soft start and pressure and temperature closed loop speed control of the motor are realized.

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

[0007] Preferably, the super capacitor is connected in parallel with the output of the controllable steady current DC power supply; the output current combining assembly is connected after parallel connection; the battery pack is connected with the first frequency converter, the second frequency converter and the controllable steady current DC power supply; during operation, the current during the flash butt welding process is pulse current rather than constant, especially during the preheating period of the welded part, the pulse current causes the output voltage of the steady current power supply to fluctuate; the super capacitor is set as a good energy storage and filter device, which can effectively improve the stability of the output voltage and reduce the impact of the pulse current on the controllable steady current DC power supply; the output current of the capacitor and the DC power supply is superimposed to provide a peak current of 100kA during the upsetting period.

[0008] Preferably, the program control device adjusts the output voltage and constant current of the controllable steady current DC power supply to adapt to the welding process; the welding control system is established by controlling the controllable steady current DC power supply, the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor through the program control device, so as to control the welding current adjustment and servo system of the DC flash butt welding; the program control device 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; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable steady current DC power supply according to the program control code to output the voltage and constant current suitable for the welding process.

[0009] The application provides a DC flash butt welding machine control method, which comprises the following steps: S100, storing and outputting electric energy by a battery pack; increasing or decreasing the capacity of the battery pack according to a welding task; S200, controlling the controllable steady current DC power supply to adjust the output voltage and current value according to the welding process by a program control device; S300, connecting a super capacitor in parallel with the output of the controllable steady current DC power supply; connecting an output current combining assembly after parallel connection; connecting the battery pack with a first frequency converter, a second frequency converter and the controllable steady current DC power supply; S400, establishing a welding control system by controlling the controllable steady current DC power supply, the first frequency converter, a hydraulic system motor, the second frequency converter and a cooling system motor through the program control device, so as to control the welding current adjustment and servo system of the DC flash butt welding.

[0010] Preferably, S100 comprises: storing and outputting electric energy by the power battery, the auxiliary battery or the combined battery pack; increasing or decreasing the capacity of the battery pack according to the welding task; connecting the first DC circuit of the first frequency converter and the second DC circuit of the second frequency converter through the battery pack voltage, and realizing the soft start of the motor and the closed-loop speed control of pressure and temperature.

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

[0012] Preferably, S300 comprises: the super capacitor is connected in parallel with the output of the controllable constant-current direct-current power supply; the output voltage fluctuates due to the pulse current during the welding process, especially during the preheating of the welded part; the super capacitor is set as a good energy storage and filter device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable constant-current direct-current power supply; the output current of the capacitor and the direct-current power supply is superimposed to provide a peak current of 100kA during the upsetting.

[0013] Preferably, S400 comprises: the program control device adjusts the output of the controllable constant-current direct-current power supply to adapt to the voltage and constant-current of the welding process; the welding control system is built by controlling the controllable constant-current direct-current power supply, the output current assembly, the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor through the program control device, to control the welding current adjustment and the servo system of the direct-current flash welding; the program control device 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; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant-current direct-current power supply according to the program control code to output the voltage and constant-current suitable for the welding process.

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

[0015] The DC flash welding machine and the control method thereof adopt a battery pack, a controllable constant-current DC power supply, a super capacitor, an output confluence assembly, a program control device, a first frequency converter, a hydraulic system motor, a second frequency converter and a cooling system motor. The battery pack stores and outputs electric energy. The capacity of the battery pack is increased or decreased according to the welding task. The controllable constant-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 is connected in parallel with the output of the controllable constant-current DC power supply. The output confluence assembly is connected after the parallel connection. The battery pack is connected with the first frequency converter, the second frequency converter and the controllable constant-current DC power supply. The program control device controls the controllable constant-current DC power supply, the output confluence assembly, the first frequency converter, the hydraulic system motor, the second frequency converter and the cooling system motor to build a welding control system, so as to control the welding current adjustment and the servo system of the DC flash welding. 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. The DC flash welding machine has no current zero-crossing effect and arc breaking, the flash is stable during the steel rail welding process, the current is uniformly distributed on the welding section, the welding joint is not easy to oxidize, the heat-affected flash zone is parallel, the welding seam and the grain are small and uniform, the welding machine cycle is shorter, the welded rail quality is excellent, the welding power is effectively reduced, and the like. On the contrary, the DC current generates a "cluster effect" to the center when passing through the welding area. The DC current can concentrate heat energy, reduce the heat-affected zone around the welding joint, and has higher welding efficiency. The DC flash welding machine can reduce the current by more than 20% than the current of the conventional welding machine, thereby greatly reducing the energy consumption. In addition, the cross section of the confluence feeder cable is also reduced. The DC flash welding machine uses the battery pack as the energy source, converts the DC current into the flash welding power of the welding machine through the DC-DC conversion, has no power frequency isolation transformer, has no reactance loss of the transmission cable, has almost no reactive power in the welding current loop, does not need additional reactive power compensation equipment, and can reduce the cross section size of the feeder wire.

[0016] The DC flash welding machine and the control method thereof, other advantages, objects and features of the DC flash welding machine and the control method thereof will be embodied by the following description, and will be understood by those skilled in the art through the research and practice of the DC flash welding machine and the control method thereof. BRIEF DESCRIPTION OF DRAWINGS

[0017] The accompanying drawings are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application, and do not limit the application. In the drawings:

[0018] Figure 1Figure of one embodiment of the DC flash welder according to the present application.

[0019] Figure 2 Figure of another embodiment of the DC flash welder according to the present application.

[0020] Figure 3 Figure of one embodiment of the DC flash welder and its control method according to the present application. DETAILED DESCRIPTION

[0021] The present application will be further described in detail below with reference to the accompanying drawings and embodiments, so that those skilled in the art can implement the present application according to the description; as shown in the drawings, the present application provides a DC flash welder, comprising: a battery pack 1, a controllable constant-current DC power supply 2, a super capacitor 22, an output bus assembly 21, 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 stores and outputs electric energy; the capacity of the battery pack 1 is increased or decreased according to the welding task; the controllable constant-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 constant-current DC power supply 2; the parallel connection is connected to the output bus assembly 21; the battery pack 1 is connected to the first frequency converter 3, the second frequency converter 4, and the controllable constant-current DC power supply 2; the controllable constant-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 build a welding control system, and the welding current adjustment and the control of the servo system of the DC flash welding are performed.

[0022] The principle and effects of the above technical solution are as follows: the direct current flash welding machine comprises a battery pack 1, a controllable constant-current direct current power supply 2, a super capacitor 22, an output confluence assembly 21, 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 stores and outputs electric energy. The capacity of the battery pack 1 is increased or decreased according to a welding task. The controllable constant-current direct current power supply 2 is controlled by the program control device 23 to adjust the output voltage and current value according to a welding process. The super capacitor 22 is connected in parallel with the output of the controllable constant-current direct current power supply 2. After being connected in parallel, the output confluence assembly 21 is connected. The battery pack 1 is connected with the first frequency converter 3, the second frequency converter 4 and the controllable constant-current direct current power supply 2. The welding control system is constructed by controlling the controllable constant-current direct current power supply 2, the output confluence assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41 through the program control device 23, so as to control the welding current adjustment and the servo system of the direct current flash welding. The arc is broken without current zero effect, and the flash is stable during the steel rail welding process. The current is uniformly distributed on the welding section, and the welding gap is not easy to be oxidized. The heat affected flash zone is parallel, the welding seam and the grain are small and uniform, the welding machine cycle is short, the excellent rail welding quality can be obtained, and the welding power is effectively reduced. On the contrary, the direct current generates a "cluster effect" to the center when passing through the welding area. The heat energy can be concentrated, the heat affected zone around the welding joint is reduced, and the welding efficiency is higher. The direct current flash welding of the present application can reduce more than 20% of the current of the conventional welding, thereby greatly reducing the energy consumption. In addition, the cross section of the confluence feeder cable is also reduced. The battery pack is used as the energy source, and the DC→DC conversion is used as the flash welding power source of the welding machine. The flash welding machine does not have a power frequency isolation transformer, the transmission cable does not have a reactance loss, there is almost no reactive power in the welding current loop, the welding machine does not need to be additionally provided with a reactive power compensation device, and the cross section size of the feeder wire can be reduced. In addition, the welding current does not have zero arc breaking, the flash is stable during the steel rail welding process, the current is uniformly distributed on the welding section, the welding gap is not easy to be oxidized, the heat affected flash zone is parallel, the welding seam and the grain are small and uniform, the excellent rail welding quality can be obtained, and the controllable constant-current direct current power supply 2 comprises a plurality of same modules 2-1, 2-2 and the like.2-parallel composition; PWM synchronous current sharing control of constant current / constant voltage regulation by program control device 23; parallel for solving the technical problem of low voltage and large current output; DC / DC conversion from 700V direct control to 6-9V, after output confluence, parallel with super capacitor, effectively reduces the current impact on DC / DC conversion system in flash welding process, not only flash stability, but also obtain 100000A output current for a short time; after parallel with large capacitor, the stability and redundancy of the power supply are significantly improved; when the direct current passes through the welding area, it produces a cluster effect towards the center, concentrating heat energy and reducing the heat affected zone around the welding joint, with higher welding efficiency; compared with other welding and alternating current flash welding, the current can be reduced by more than 20%, greatly reducing energy consumption; the cross section of the confluence feeder cable is also reduced.

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

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

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

[0027] In one embodiment, the super capacitor 22 is connected in parallel with the output of the controllable constant-current DC power supply 2; the parallel connection is connected to the output bus assembly 21; the battery pack 1 is connected to the first frequency converter 3, the second frequency converter 4 and the controllable constant-current DC power supply 2; during operation, the output voltage of the constant-current power supply fluctuates due to the pulsed current during the flash welding process rather than the constant current, especially during the preheating of the welding parts; the super capacitor 22 is set as a good energy storage and filter device, which effectively improves the stability of the output voltage and reduces the impact of the pulsed current on the controllable constant-current DC power supply 2; the super capacitor 22 and the output current of the DC power supply 2 are superimposed to provide a peak current of 100kA during the upsetting.

[0028] The principle and effect of the above technical solution are as follows: the super capacitor 22 is connected in parallel with the output of the controllable constant-current DC power supply 2; the parallel connection is connected to the output bus assembly 21; the battery pack 1 is connected to the first frequency converter 3, the second frequency converter 4 and the controllable constant-current DC power supply 2; during operation, the output voltage of the constant-current power supply fluctuates due to the pulsed current during the flash welding process rather than the constant current, especially during the preheating of the welding parts; the super capacitor 22 is set as a good energy storage and filter device, which effectively improves the stability of the output voltage and reduces the impact of the pulsed current on the controllable constant-current DC power supply 2; the super capacitor 22 and the output current of the DC power supply 2 are superimposed to provide a peak current of 100kA during the upsetting.

[0029] In one embodiment, the program control device 23 adjusts the output of the controllable constant-current DC power supply 2 to adapt to the voltage and constant current of the welding process; the welding control system is constructed by controlling the controllable constant-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 through the program control device 23, and the welding current adjustment and servo system control of the direct current flash welding are performed; 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; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant-current DC power supply 2 according to the program control code to output the voltage and constant current suitable for the welding process.

[0030] The principle and effect of the above technical solution are: the program control device 23 adjusts the voltage and constant current output by the controllable constant-current direct-current power supply 2 according to the welding process; the welding control system is constructed by the program control device 23 controlling the controllable constant-current direct-current power supply 2 and the output current collection assembly 21, the first frequency converter 3, the hydraulic system motor 31, the second frequency converter 4 and the cooling system motor 41, and the welding current adjustment and servo system control of the direct current flash welding are performed; 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; the welding process data receiving unit receives the preset welding process data through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant-current direct-current power supply 2 according to the program control code, and outputs the voltage and constant current suitable for the welding process.

[0031] The application provides a direct current flash welding machine control method, which comprises the following steps: S100, storing and outputting electric energy by a battery pack 1; increasing or decreasing the capacity of the battery pack 1 according to a welding task; S200, controlling the controllable constant-current direct-current power supply 2 to adjust the output voltage and current value according to the welding process by a program control device 23; S300, connecting the super capacitor 22 in parallel with the output of the controllable constant-current direct-current power supply 2; connecting the output current collection assembly 21 after parallel connection; connecting the battery pack 1 with the first frequency converter 3, the second frequency converter 4 and the controllable constant-current direct-current power supply 2; S400, constructing a welding control system by the program control device 23 controlling the controllable constant-current direct-current 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, and performing the welding current adjustment and servo system control of the direct current flash welding.

[0032] The principle and effect of the above technical solution are as follows: the present application provides a direct current flash welding machine control method, which comprises the following steps: storing and outputting electric energy by a battery pack 1; increasing or decreasing the capacity of the battery pack 1 according to a welding task; controlling the output voltage and current value of a controllable constant-current direct current power supply 2 by a program control device 23 according to a welding process; connecting a super capacitor 22 and the controllable constant-current direct current power supply 2 in parallel; connecting an output bus assembly 21 after parallel connection; connecting the battery pack 1, a first frequency converter 3, a second frequency converter 4 and the controllable constant-current direct current power supply 2; controlling the controllable constant-current direct current power supply 2, the output bus assembly 21, the first frequency converter 3, a hydraulic system motor 31, the second frequency converter 4 and a cooling system motor 41 by the program control device 23 to construct a welding control system, and performing welding current regulation and servo system control of direct current flash welding; the present application has no current zero effect and arc breaking, and the flash is stable during the steel rail welding process; in addition, the current is uniformly distributed on the welding section, the weld is not easy to oxidize, the heat affected zone is parallel, the weld and the grain are small and uniform, the welding machine cycle is short, excellent rail welding quality can be obtained, and the welding power is effectively reduced; on the contrary, the direct current generates a “cluster effect” toward the center when passing through the welding area; it can concentrate heat energy, reduce the heat affected zone around the welding joint and has higher welding efficiency; the direct current flash welding of the present application can reduce the current by more than 20% than the current of the conventional welding, thereby greatly reducing the energy consumption, and the cross section of the bus cable is also reduced; the present application uses a battery pack as the energy source, and uses DC→DC conversion to obtain the flash welding power of the welding machine; the flash welding machine does not have a 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 section size of the feeder wire can be reduced; in addition, since direct current is used for power supply, the welding current has no zero arc breaking, the flash is stable during the steel rail welding process, the current is uniformly distributed on the welding section, the weld is not easy to oxidize, the heat affected zone is parallel, the weld and the grain are small and uniform, and excellent rail welding quality can be obtained; the controllable constant-current direct current power supply 2 is composed of a plurality of same modules 2-1, 2-2,..., 2-n in parallel; the program control device 23 synchronously controls the PWM current sharing of the n modules; parallel connection is used to solve the technical problem of low voltage and large current; DC / DC conversion is reduced from 700V direct control to 6-9V; after output bus connection, the super capacitor is connected in parallel, which can effectively reduce the current impact on the DC / DC conversion system during the flash welding process, the flash is stable, and an output current of 100,000A can be obtained for a short time; after parallel connection of the large capacitor, the stability and redundancy of the flash welding power supply are significantly improved; the direct current generates a cluster effect toward the center when passing through the welding area, concentrates heat energy, reduces the heat affected zone around the welding joint, and has higher welding efficiency; compared with other welding and alternating current flash welding, the current can be reduced by more than 20%, thereby greatly reducing the energy consumption; and the cross section of the bus cable is also reduced.

[0033] In one embodiment, S100, comprising: using power battery, auxiliary battery or combined battery pack, 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; connecting the first DC circuit of the first frequency converter 3 and the second DC circuit of the second frequency converter 4 through the voltage of the battery pack 1, and realizing soft start of the motor and closed-loop speed control of pressure and temperature.

[0034] The principle and effect of the above technical solution are: using power battery, auxiliary battery or combined battery pack, 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; connecting the first DC circuit of the first frequency converter 3 and the second DC circuit of the second frequency converter 4 through the voltage of the battery pack 1, and realizing soft start of the motor and closed-loop speed control of pressure and temperature.

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

[0037] In one embodiment, S300, comprising: the super capacitor 22 is connected in parallel with the output of the controllable constant-current direct-current power supply 2; the output voltage fluctuates due to the pulse current during the welding process rather than the constant during the operation, especially during the preheating of the welded part; the super capacitor 22 is set as a good energy storage and filter device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable constant-current direct-current power supply 2; the output current of the capacitor 22 and the direct-current power supply 2 is superimposed to provide a peak current of 100kA during the upsetting.

[0038] The principle and effect of the above technical solution are: the super capacitor 22 is connected in parallel with the output of the controllable constant-current DC power supply 2; during operation, the welding process is pulse current rather than constant current, especially during preheating of the welding part, which causes fluctuation of the output voltage; the super capacitor 22 is set as a good energy storage and filter device, which effectively improves the stability of the output voltage and reduces the impact of the pulse current on the controllable constant-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 100 kA during upsetting.

[0039] In one embodiment, S400, the program control device 23 adjusts the controllable constant-current DC power supply 2 to output voltage and constant current suitable for the welding process; the controllable constant-current DC power supply 2 and the output current combining 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 build a welding control system, and the welding current adjustment and servo system control of the DC flash welding are performed; 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; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant-current DC power supply 2 according to the program control code to output voltage and constant current suitable for the welding process.

[0040] The principle and effect of the above technical solution are: the program control device 23 adjusts the controllable constant-current DC power supply 2 to output voltage and constant current suitable for the welding process; the controllable constant-current DC power supply 2 and the output current combining 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 build a welding control system, and the welding current adjustment and servo system control of the DC flash welding are performed; 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; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant-current DC power supply 2 according to the program control code to output voltage and constant current suitable for the welding process.

[0041] While embodiments of the application have been disclosed in connection with the above specification and drawings this description is not intended to limit the scope of the application and many modifications, enhancements, alternatives, and variations will become apparent to those skilled in the art from this disclosure. Accordingly, it is intended that the application not be limited to the described embodiments, but that it include all variations falling within the scope of the claims, and their equivalents.

Claims

1. A DC flash welding machine, characterized in that, include: Battery pack (1), controllable constant current DC power supply (2), supercapacitor (22), output combiner assembly (21), program control device (23); first frequency converter (3), hydraulic system motor (31); second frequency converter (4), cooling system motor (41); stores and outputs electrical energy through battery pack (1); increases or decreases the capacity of battery pack (1) according to welding tasks; the controllable constant current DC power supply (2) is controlled by program control device (23) to adjust the output voltage and current value according to the welding process; The output of the supercapacitor (22) and the controllable constant current DC power supply (2) are connected in parallel to each other; after parallel connection, the output busbar assembly (21) is connected; the battery pack (1) is connected to the first frequency converter (3), the second frequency converter (4) and the controllable constant current DC power supply (2); the controllable constant current DC power supply (2) and the output busbar 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 build a welding control system, and to perform welding current adjustment and servo system control for DC flash welding; the controllable constant current DC power supply (2) is composed of multiple identical modules 2-1, 2-2...2-n connected in parallel. The program control device (23) performs synchronous PWM current sharing control on the constant current / constant voltage regulation of n modules; parallel connection is used to solve the technical problem of low voltage and high current; the DC / DC conversion is reduced from 700V direct control to 6~9V; after the output is combined with the supercapacitor, it can effectively reduce the current impact of the flash welding process on the DC / DC conversion system, not only making the flash stable but also obtaining 100,000 amps of output current in a short time; after the large capacitor is connected in parallel, the stability and redundancy of its flash welding power supply are improved; when the current passes through the welding area, it generates a cluster effect towards the center, concentrates the heat energy, reduces the heat-affected zone around the weld joint, and has higher welding efficiency; the heat-affected flash zone is parallel, and the weld and grains are fine and uniform; the welding current is reduced by 20%. The above measures reduce the cross-sectional area of ​​the feeder cable; utilize battery packs as the power source and employ DC-DC conversion for the flash welding power supply of the welding machine; the flash welding machine eliminates the need for a power frequency isolation transformer, and the transmission cable has no reactance loss, resulting in almost no reactive power in the welding current loop. This eliminates the need for additional reactive power compensation equipment and allows for a reduction in the cross-sectional area of ​​the feeder conductor; the welding current does not experience zero-crossing arc interruption, ensuring smooth flashing during rail welding; the current is evenly distributed across the weld cross-section, reducing weld oxidation; and the welding cycle time and welding power are reduced. The program control device (23) adjusts the controllable constant current DC power supply (2) according to the welding process to output the voltage and constant current adapted to the welding process; the program control device (23) controls the controllable constant current DC power supply (2), 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 and servo system control for DC flash welding; 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 / constant voltage conversion and protection unit; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant current DC power supply (2) according to the program control code, and outputs voltage and constant current that meet the welding process requirements.

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

3. A DC flash welding machine according to claim 1, characterized in that, The controllable constant 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 controllable constant current DC power supply (2) has a maximum constant current output of 50kA and a controllable open-circuit voltage of 6~9V; the controllable constant 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.

4. A DC flash welding machine according to claim 1, characterized in that, The output of the supercapacitor (22) and the controllable constant current DC power supply (2) are connected in parallel to each other; 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 constant current DC power supply (2); during operation, the output voltage of the constant current power supply fluctuates because the flash welding process is pulsed current rather than continuous, especially during the flash preheating period of the welded parts; 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 pulse current on the controllable constant current DC power supply (2). The superposition of the output current of the capacitor (22) and the DC power supply (2) provides a peak current of 100kA during upsetting.

5. A control method for a DC flash welding machine, characterized in that, A control method for a DC flash welding machine according to claim 1 includes: S100, storing and outputting electrical energy through a battery pack (1); increasing or decreasing the capacity of the battery pack (1) according to the welding task; S200, the controllable constant 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 output of the supercapacitor (22) and the controllable constant current DC power supply (2) are connected in parallel; after parallel connection, the output busbar assembly (21) is connected; the battery pack (1) is connected to the first frequency converter (3), the second frequency converter (4) and the controllable constant current DC power supply (2); S400, the controllable constant current DC power supply (2), the output busbar 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 control system. The welding current regulation and servo system control for DC flash welding; the controllable constant current DC power supply (2) is composed of multiple identical modules 2-1, 2-2...2-n connected in parallel; the program control device (23) performs synchronous PWM current sharing control on the constant current / constant voltage regulation of the n modules; the parallel connection is used to solve the technical problem of low voltage and high current; the DC / DC conversion is reduced from 700V to 6~9V; after the output is combined with the supercapacitor, it can effectively reduce the current impact on the DC / DC conversion system during the flash welding process, not only making the flash stable but also obtaining an output current of 100,000 amps in a short time; after the large capacitor is connected in parallel, the stability and redundancy of its flash welding power supply are improved; when the current passes through the welding area, it generates a cluster effect towards the center, concentrates the heat energy, reduces the heat-affected zone around the weld joint, and has higher welding efficiency; the heat-affected flash zone is parallel, and the weld and grains are fine and uniform; the welding current is reduced by 20%. The above measures reduce the cross-sectional area of ​​the feeder cable; utilize battery packs as the power source and employ DC-DC conversion for the flash welding power supply of the welding machine; the flash welding machine eliminates the need for a power frequency isolation transformer, and the transmission cable has no reactance loss, resulting in almost no reactive power in the welding current loop. This eliminates the need for additional reactive power compensation equipment and allows for a reduction in the cross-sectional area of ​​the feeder conductor; the welding current does not experience zero-crossing arc interruption, ensuring smooth flashing during rail welding; the current is evenly distributed across the weld cross-section, reducing weld oxidation; and the welding cycle time and welding power are reduced. S400 includes: a program control device (23) that adjusts the controllable constant current DC power supply (2) according to the welding process to output voltage and constant current adapted to the welding process; the program control device (23) controls the controllable constant current DC power supply (2), 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 and servo system control for DC flash welding; 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 / constant voltage conversion and protection unit; the welding process data receiving unit receives the preset welding process data from the front end through wireless data transmission; the process data program conversion unit converts the preset welding process data into program control code; the program control adjustment unit controls and adjusts the controllable constant current DC power supply (2) according to the program control code to output voltage and constant current adapted to the welding process.

6. The DC flash welding machine control method according to claim 5, characterized in that, S100 includes: using a power battery, an auxiliary battery or a combined battery pack to store and output electrical energy through a battery pack (1); increasing or decreasing the capacity of the battery pack (1) according to the welding task; connecting the voltage of the battery pack (1) to the first DC circuit of the first frequency converter (3) and the second DC circuit of the second frequency converter (4), and realizing soft start of the motor and pressure and temperature closed-loop speed regulation control.

7. The DC flash welding machine control method according to claim 5, characterized in that, S200 includes: a controllable constant current DC power supply (2) whose output voltage and current values ​​are adjusted by a program control device (23) according to the welding process; the controllable constant current DC power supply (2) has a maximum constant current output of 50kA and a controllable open-circuit voltage of 6~9V; the controllable constant 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.

8. A DC flash welding machine control method according to claim 5, characterized in that, S300 includes: a supercapacitor (22) and a controllable constant current DC power supply (2) connected in parallel; during operation, the output voltage fluctuates because the welding process is a pulse current rather than a continuous constant current, 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 constant current DC power supply (2); the output current of the capacitor (22) and the DC power supply (2) are superimposed to provide a peak current of 100kA during upsetting.

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