A hybrid energy storage welding inverter power source

Abstract

The present invention relates to the technical field of welding equipment, and in particular to a hybrid energy storage welding inverter power supply. Its technical solutions include: a power controller and a control panel are installed on the upper end of the power supply box, and the bottom can be flexibly moved by means of a sliding seat with rollers and a telescopic rod pull rod. The power controller is built with multiple modules. The bidirectional inverter coordinates the energy between the power grid and the energy storage module, and the adaptive switching circuit module monitors the signal to switch the power supply. The high-frequency and DC pulse modules cooperate to output current. The heat dissipation module in the power supply box uses a semiconductor refrigeration sheet and other components for efficient heat dissipation. The heat dissipation module in the power supply box realizes efficient heat dissipation through a semiconductor refrigeration sheet, a heat spreader, a coolant circulation, and a fan. Through the full-bridge topology and pulse width modulation of the bidirectional inverter, the adaptive switching circuit, the soft switching of the high-frequency inverter module, and the precise control technology of the DC pulse, as well as the intelligent heat dissipation system, the present invention comprehensively improves the performance of the equipment, ensures stable welding, and meets different welding requirements.

Description

Technical Field

[0001] The present invention relates to the technical field of welding equipment, and particularly to a hybrid energy storage welding inverter power supply. Background Art

[0002] A welding machine power supply is a device that provides electrical energy for a welding equipment and is a crucial component in the welding process. Its function is to convert the electrical energy input from the power grid into an electrical energy form suitable for the welding process requirements, and provide the necessary energy for the generation and stable combustion of the welding arc.

[0003] After retrieval, a patent with the patent publication number CN222403873U discloses a three-phase arc welding power supply. Although this device can protect the power supply main body by setting a protective box, a heat dissipation component, and a dust-proof component during use, and through various heat dissipation methods, such as the cold water generated by the cold water tank flowing through the water-cooling pipe for cooling and the fan driving cold air to further cool the power supply main body, the power supply main body can operate more stably, and the occurrence of faults in the operation of the power supply main body caused by too high temperature in the protective box can be avoided. However, this device lacks an intelligent switching function for the power supply mode during use, and it is difficult to flexibly adjust the power supply method according to the power grid power supply situation and load demand. In the face of power grid fluctuations or complex load changes, the continuous stability of the welding process may not be guaranteed. At the same time, there are deficiencies in energy storage and utilization. It does not combine energy storage technology, cannot reasonably utilize electrical energy when the power grid electricity price fluctuates, and cannot continue to provide power support for welding operations in the event of sudden situations such as power grid power outages. Summary of the Invention

[0004] In view of the deficiencies of the prior art, the present invention provides a hybrid energy storage welding inverter power supply, which solves the problems raised in the background art.

[0005] The solution of the present invention to the above technical problems is as follows:

[0006] A hybrid energy storage welding inverter power supply includes a power supply box, a power supply controller is installed at the upper end of the power supply box, and a control panel is provided on the power supply controller;

[0007] The power supply box is installed on a sliding seat, rollers are installed on both sides of the sliding seat, and the sliding seat moves through the rollers; and a telescopic rod is installed on the sliding seat, a pull rod is installed at the top of the telescopic rod, an input power supply socket is provided on one side of the power supply box, and the input power supply socket is sleeved and installed at one end of the pull rod close to the sliding seat;

[0008] The power controller is built-in with a bidirectional inverter, an adaptive switching circuit module, a high-frequency inverter module, and a DC pulse welding module. One end of the bidirectional inverter is connected to the power grid through an input power supply socket, and the other end is respectively connected to a supercapacitor module and a lithium phosphate battery module, which is used to coordinate the bidirectional flow of energy in each part. The high-frequency inverter module and the DC pulse welding module are connected in series through electrical lines and are jointly connected to a welding output interface. The two work together to provide a composite welding output, and the high-frequency inverter module and the DC pulse welding module are adjacently arranged on the circuit board to reduce signal interference.

[0009] The adaptive switching circuit module includes a voltage sensor, a current sensor, and a single-chip microcomputer. The voltage sensor and the current sensor are installed on the connection line between the bidirectional inverter and the power grid and the energy storage output line to collect electrical signals in real time. The single-chip microcomputer is connected to the voltage and current sensors and the bidirectional inverter through data lines, receives the sensor signals, and controls the bidirectional inverter to switch working modes. A bidirectional smart meter is connected in series through an electrical line between the power grid and the bidirectional inverter, which is used to collect power grid electricity prices and electricity consumption data and is connected to the single-chip microcomputer through a data line to achieve data interaction.

[0010] A heat dissipation module is installed inside the power supply box. The heat dissipation module is provided with a protective shell. A supercapacitor module and a lithium phosphate battery module are respectively installed on both sides of the heat dissipation module inside the power supply box. A heat sink is inlaid at the bottom end of the power supply box where the heat dissipation module is located. The heat sink is provided with first heat exchange fins on one side surface outside the power supply box. Support feet are installed on one side of the bottom end of the power supply box away from the sliding seat.

[0011] A handle is installed on the power controller, and lock catches are provided on both sides of the power controller and the power supply box. The power controller and the power supply box are tightly fixed through the lock catches.

[0012] On the basis of the above technical solutions, the present invention can be further improved as follows.

[0013] Furthermore, the telescopic rod can adjust its length and can adjust the height of the pull rod according to the usage requirements.

[0014] The beneficial effects of adopting the above further solution are:

[0015] The telescopic rod can adjust the height of the pull rod according to the usage requirements, enabling the operator to find the most comfortable operating position in different working scenarios. For example, in some sites with limited space or when facing operators of different heights, the flexibly adjustable pull rod height improves the usability and versatility of the equipment. Moreover, this height adjustability is associated with the mobility of the equipment (rollers and sliding seats), and the height can be adjusted to a suitable level at any time during the movement, facilitating operation in different terrains or usage scenarios, greatly enhancing the adaptability of the equipment, which is an advantage not possessed by many fixed-height devices.

[0016] Furthermore, the bidirectional inverter adopts a full-bridge topology structure, featuring high energy conversion efficiency and stable output performance. The full-bridge topology structure of this bidirectional inverter consists of four power switch tubes, which are connected into bridge arms in a pairwise opposite form. The power switch tubes are selected from insulated gate bipolar transistors (IGBTs) or metal oxide semiconductor field effect transistors (MOSFETs). During the forward energy conversion process, that is, the inverter process from the DC side to the AC side, by controlling the alternating conduction and turn-off of two switch tubes on the diagonal, the DC electrical energy is converted into AC electrical energy for output. For example, when the switch tubes on one pair of diagonals are conducting, the current flows from the positive pole of the DC power supply through the conducting switch tubes into the AC load, and then returns to the negative pole of the DC power supply through the other pair of conducting switch tubes, forming a complete loop to output the positive half-cycle of the AC voltage. In the other half-cycle, by controlling the conduction of the switch tubes on the other pair of diagonals, the negative half-cycle of the AC voltage is output. During the reverse energy conversion, that is, the rectification process from the AC side to the DC side, similarly based on the phase of the AC input voltage, the conduction sequence of the four switch tubes is reasonably controlled to convert the AC electrical energy into DC electrical energy and store it in the energy storage device. This full-bridge topology structure reduces energy loss and improves energy conversion efficiency compared with other topology structures because it can fully utilize the voltage of the DC power supply in each switching cycle. At the same time, by adopting advanced pulse width modulation technology, the conduction time and frequency of the switch tubes are precisely controlled, effectively reducing the harmonic content of the output voltage and current, making the output AC electrical energy purer, ensuring stable output performance, and meeting the strict requirements for electrical energy conversion and output of the hybrid energy storage welding inverter power supply under different working conditions.

[0017] The beneficial effects of adopting the above further solution are:

[0018] The bidirectional inverter adopts a full-bridge topology structure and consists of four power switch tubes. It can make full use of the DC power supply voltage in each switching cycle, which greatly improves the energy conversion efficiency and reduces energy loss compared with other topology structures. At the same time, combined with advanced pulse width modulation technology, it accurately controls the conduction time and frequency of the switch tubes, effectively reducing the harmonic content of the output voltage and current and outputting pure AC electric energy. This stable and efficient electric energy conversion ensures that the hybrid energy storage welding inverter power supply can stably output electric energy under complex welding conditions, whether facing high-power demands or low-power fine operations, and meets the strict requirements for the power quality and stability during the welding process. The full-bridge topology structure and pulse width modulation technology complement each other to jointly achieve efficient and stable electric energy conversion, ensuring the reliable operation of the equipment under various working conditions, which is an effect that ordinary inverters are difficult to achieve simultaneously.

[0019] Furthermore, the single-chip microcomputer of the adaptive switching circuit module adopts a high-performance and low-power microcontroller, which can quickly and accurately process the electrical signals collected by the sensors and control the bidirectional inverter. Specifically, when the sensors collect electrical signals such as voltage and current on the input side, these analog signals will be transmitted to the analog-to-digital conversion module built in the single-chip microcomputer for digital processing. The single-chip microcomputer analyzes the digitalized signals according to the preset control algorithm, judges information such as the current power supply state, load demand, and state of charge of the energy storage device. When detecting power supply fluctuations from the grid or changes in load demand, the single-chip microcomputer adjusts the switching frequency and duty cycle of the bidirectional inverter by controlling the drive circuit of the bidirectional inverter, thereby realizing the charge and discharge control of the energy storage device and the smooth switching between grid power supply and energy storage power supply, ensuring the stable and reliable operation of the welding inverter power supply.

[0020] The beneficial effects of adopting the above further scheme are as follows:

[0021] The adaptive switching circuit module adopts a high-performance and low-power single-chip microcomputer, which can quickly and accurately process the electrical signals collected by the sensors. When there are power supply fluctuations from the grid or changes in load demand, the single-chip microcomputer can analyze the signals according to the preset algorithm and adjust the switching frequency and duty cycle by controlling the drive circuit of the bidirectional inverter to realize the charge and discharge control of the energy storage device and the smooth switching between grid power supply and energy storage power supply. This single-chip microcomputer closely cooperates with the voltage and current sensors to monitor the power supply state in real time. Its processing speed and control accuracy ensure that the welding inverter power supply can operate stably and reliably under different power supply conditions, avoiding welding interruptions or quality degradation caused by power supply problems, guaranteeing the continuity and stability of the welding work, and providing a reliable power supply guarantee for the welding operation.

[0022] Furthermore, the high-frequency inverter module adopts soft-switching technology to reduce switching losses and improve the inverter efficiency. Specifically, the high-frequency inverter module forms a resonant circuit by adding a resonant inductor and a resonant capacitor to the main circuit. During the on and off processes of the switching device, by utilizing the resonance phenomenon generated by the resonant circuit, the voltage across the switching device or the current flowing through the switching device approaches zero instantaneously during the switching operation. For example, in the zero-voltage switching mode, before the switching device is turned on, the voltage across the switching device is reduced to zero through the resonant circuit. At this time, when the switching device is turned on, the conduction loss caused by the existence of voltage can be avoided. In the zero-current switching mode, before the switching device is turned off, the current flowing through the switching device is reduced to zero by using resonance, thereby eliminating the current tailing phenomenon during turn-off and reducing the turn-off loss. At the same time, the soft-switching technology enables the switching frequency to be increased. Under the same power output, the volume and weight of the filtering components are reduced, the harmonic content in the circuit is decreased, the power quality is improved, and the inverter efficiency is significantly enhanced under the combined action, ensuring the efficient and stable operation of the hybrid energy storage welding inverter power supply.

[0023] The beneficial effects of adopting the above further solution are as follows:

[0024] The high-frequency inverter module forms a resonant circuit by adding a resonant inductor and a resonant capacitor, and realizes soft switching by utilizing the resonance phenomenon, making the voltage or current approach zero instantaneously during the on and off of the switching device, reducing the switching loss and improving the inverter efficiency. At the same time, the soft-switching technology increases the switching frequency, enabling the reduction of the volume and weight of the filtering components under the same power output, decreasing the harmonic content in the circuit, and improving the power quality. This technology not only enhances the inverter efficiency and ensures the efficient and stable operation of the hybrid energy storage welding inverter power supply, but also reduces the volume of the equipment, lightens the weight, facilitates the handling and installation of the equipment, optimizes the physical characteristics of the equipment while improving the performance, and realizes the combination of multiple advantages.

[0025] Furthermore, the DC pulse welding module can accurately control the frequency, width and amplitude of the pulse to meet the requirements of different welding processes; the DC pulse welding module has a built-in high-performance digital signal processor as the control core; in terms of controlling the pulse frequency, the DSP generates a precise clock signal through an internal timer based on the preset welding process parameters to determine the pulse repetition period, thereby achieving precise adjustment of the pulse frequency, and can be flexibly switched within a wider frequency range, such as 10Hz-1000Hz, to meet the requirements of high-frequency pulses for thin plate welding and low-frequency pulses for thick plate welding; when controlling the pulse width, the DSP uses pulse width modulation technology to change the PW according to the requirements of droplet transition, weld formation, etc. in the welding process. The duty cycle of the M signal can accurately control the on-time of the pulse, and the pulse width can be finely adjusted within the microsecond range, such as 10μs-1000μs, to ensure accurate control of energy input during welding. For the control of pulse amplitude, the DC pulse welding module is equipped with a high-performance power amplifier and a closed-loop feedback circuit. The DSP outputs the corresponding control signal to the power amplifier according to the requirements of different welding materials and welding positions for current amplitude, adjusts its amplification factor, and thus changes the pulse output amplitude. At the same time, the output current signal is collected in real time through the sampling resistor and fed back to the DSP for comparative analysis. If there is a deviation between the actual amplitude and the set value, the DSP immediately adjusts the control signal to ensure that the pulse amplitude is always stable within the set range, effectively improving the welding quality and adaptability.

[0026] The beneficial effects of adopting the above further scheme are:

[0027] The DC pulse welding module has a built-in high-performance digital signal processor (DSP), which can accurately control the frequency, width and amplitude of the pulse. When controlling the frequency, the DSP generates a precise clock signal to adjust the frequency according to the preset welding process parameters, and can be flexibly switched in the range of 10Hz-1000Hz to meet the welding requirements of different plate thicknesses. When controlling the pulse width, the pulse width modulation technology is used to adjust the conduction time according to the welding process requirements, and fine control is performed in the range of 10μs-1000μs. When controlling the amplitude, the power amplifier and closed-loop feedback circuit are used to adjust the amplitude according to different welding materials and position requirements and feedback adjustment in real time. These precise control functions cooperate with each other, making the energy input in the welding process precisely controllable, greatly improving the welding quality and adaptability, being able to cope with various complex welding tasks, and achieving a high degree of adaptability to different welding processes, which is a precise control effect that is difficult to achieve with traditional welding modules.

[0028] Furthermore, the lithium phosphate battery module is provided with a housing. Inside the housing, battery cells are installed through a sealed casing. There is a cavity between the sealed casing and the housing, and the cavity between the sealed casing and the housing is communicated with a water tank through a connecting pipe. A wiring electrode is provided at the top of the housing; the sealed casing is made of insulating and heat-insulating materials to prevent electrical interference and heat transfer between the battery cells and the housing.

[0029] The beneficial effects of adopting the above further scheme are as follows:

[0030] The sealed casing of the lithium phosphate battery module is made of insulating and heat-insulating materials, preventing electrical interference and heat transfer between the battery cells and the housing. The prevention of electrical interference ensures the stable operation of the battery cells and avoids the influence of external electrical factors on the battery performance; the heat-insulating effect effectively blocks the heat generated during battery operation from being transferred outward, reducing the thermal influence on other surrounding components and improving the stability and service life of the battery module itself. At the same time, the cavity between the sealed casing and the housing is communicated with the water tank through a connecting pipe, laying the foundation for subsequent heat dissipation circulation. This design not only ensures the stability inside the battery module but also connects with the overall heat dissipation system, achieving functional coordination and complementarity.

[0031] Furthermore, a semiconductor refrigeration sheet is installed on the upper surface of the heat dissipation plate inside the protective casing. The hot end of the semiconductor refrigeration sheet is in contact with the heat dissipation plate, and the cold end of the semiconductor refrigeration sheet is in contact with the water tank. A heat exchange pipe is erected above the water tank, and second heat exchange fins are arranged on the outer side of the heat exchange pipe. A fan is erected behind the heat exchange pipe. The fan drives low-temperature air flow to cool the supercapacitor module. One end of the heat exchange pipe is communicated with the water tank through a connecting pipe, and the other end of the heat exchange pipe is communicated with the cavity between the housing and the battery cells through a connecting pipe.

[0032] The beneficial effects of adopting the above further scheme are as follows:

[0033] The hot end of the semiconductor refrigeration sheet is in contact with the heat dissipation plate, and the cold end is in contact with the water tank. The heat exchange pipe, the second heat exchange fins and the fan above the water tank together constitute a heat dissipation system. The fan drives low-temperature air flow to cool the supercapacitor module. One end of the heat exchange pipe is communicated with the water tank, and the other end is communicated with the cavity of the lithium phosphate battery module, forming a complete heat dissipation cycle. This structural design makes full use of the refrigeration effect of the semiconductor refrigeration sheet. The heat is evenly transferred through the heat dissipation plate, and then the circulating coolant in the water tank and the heat exchange pipe and the forced convection of the fan are used to achieve efficient heat dissipation of key components such as the supercapacitor module and the lithium phosphate battery module, ensuring that these components work at an appropriate temperature, improving the stability and reliability of the entire power supply system, and guaranteeing the long-term stable operation of the equipment.

[0034] Furthermore, a circulation pump is built into the water tank, and a cooling medium is filled in the water tank. The cooling medium circulates through the circulation pump in the cavities between the water tank, the heat exchange tubes, and the sealed housing and the outer housing; the cooling medium is a coolant, which has good heat dissipation performance and chemical stability.

[0035] The beneficial effects of adopting the above further solution are as follows:

[0036] A circulation pump is built into the water tank, and a coolant with good heat dissipation performance and chemical stability is filled. The coolant circulates through the circulation pump in the water tank, the heat exchange tubes, and the cavity of the battery module, continuously taking away heat. The good heat dissipation performance ensures efficient heat dissipation, and the chemical stability ensures that the coolant will not deteriorate or corrode the equipment during long-term circulation, extending the service life of the equipment. This circulating heat dissipation method cooperates with components such as the semiconductor refrigeration chip, the vapor chamber, the heat exchange tubes, and the fan to form an efficient and stable heat dissipation system, providing reliable heat dissipation protection for the hybrid energy storage welding inverter power supply, enabling the equipment to maintain a normal operating temperature under long-term and high-load working conditions.

[0037] Furthermore, the refrigeration power of the semiconductor refrigeration chip can be adaptively adjusted according to the temperature inside the power supply box; specifically, a plurality of high-precision temperature sensors are evenly distributed inside the power supply box to collect temperature data at different positions inside the box in real time; these temperature sensors transmit the collected analog temperature signals to the signal conditioning circuit connected thereto for preprocessing such as filtering and amplifying the signals, and then send them to the microcontroller; a temperature-power adjustment algorithm formulated according to the normal operating temperature range of the electronic components inside the power supply box is pre-stored in the microcontroller; when receiving the processed temperature signal, the microcontroller performs arithmetic analysis based on this algorithm to judge the current temperature condition inside the power supply box; if the temperature is higher than the set threshold upper limit, the microcontroller outputs a control signal to the drive circuit of the semiconductor refrigeration chip, and by adjusting the pulse width modulation signal of the drive circuit, increases the working current of the semiconductor refrigeration chip, thereby increasing its refrigeration power; conversely, if the temperature is lower than the set threshold lower limit, the microcontroller reduces the working current of the semiconductor refrigeration chip through the drive circuit to reduce the refrigeration power, so as to ensure that the inside of the power supply box always maintains an appropriate operating temperature range and ensure the stable operation of the hybrid energy storage welding inverter power supply.

[0038] The beneficial effects of adopting the above further solution are as follows:

[0039] A plurality of high-precision temperature sensors are evenly distributed inside the power supply box to collect temperature data in real time. After being preprocessed by the signal conditioning circuit, the data is sent to the microcontroller. The microcontroller adjusts the cooling power of the semiconductor refrigeration sheet according to the preset temperature-power adjustment algorithm based on the temperature condition. When the temperature is higher than the upper threshold, the cooling power is increased; when it is lower than the lower threshold, the cooling power is decreased. This adaptive adjustment mechanism ensures that the temperature inside the power supply box is always maintained within a suitable operating temperature range, avoiding over-cooling or under-cooling situations, ensuring the stable operation of the equipment and saving energy at the same time. The layout of multiple temperature sensors ensures comprehensive monitoring of the temperature inside the power supply box, forming an intelligent and efficient temperature control system together with the control and adjustment of the microcontroller and the semiconductor refrigeration sheet. Compared with the traditional heat dissipation method with a fixed cooling power, it can better adapt to different working environments and load changes, providing a more reliable guarantee for the stable operation of the equipment.

[0040] The present invention provides a hybrid energy storage welding inverter power supply. It has the following beneficial effects:

[0041] The power supply box is installed on a sliding seat with rollers and can be easily moved, facilitating flexible use in different working sites. The telescopic rod on the sliding seat can adjust its length, and the height of the pull rod can be adjusted according to the operator's height, operating habits or the requirements of different working scenarios, improving the convenience and comfort of operation. The power supply controller and the power supply box are locked and fixed by a buckle, which is convenient for installation and disassembly, facilitating the assembly, maintenance and transportation of the equipment. Moreover, there is a handle on the power supply controller, which is convenient for carrying and moving the power supply controller.

[0042] The bidirectional inverter adopts a full-bridge topology structure, reducing energy loss and improving conversion efficiency. It can also reduce the harmonic content through pulse width modulation technology and output purer AC electrical energy to ensure stable output under different working conditions. The bidirectional inverter can coordinate the bidirectional energy flow among the power grid, the supercapacitor module and the lithium iron phosphate battery module to achieve "peak shaving and valley filling", charging at low electricity prices and discharging at peak times, saving costs and reducing the pressure on the power grid. The high-frequency inverter module adopts soft-switching technology, realizes zero-voltage or zero-current switching through the resonant circuit, reduces the switching loss, improves the inverter efficiency, reduces the volume and weight of the filtering components at the same time, reduces the harmonic content, and improves the power quality. The DC pulse welding module can accurately control the frequency, width and amplitude of the pulse, and can be flexibly adjusted within a wide frequency range and a microsecond-level pulse width range to adapt to different welding process requirements and improve the welding quality and adaptability.

[0043] The adaptive switching circuit module can monitor the electrical signal in real time, and automatically control the charging and discharging of the bidirectional inverter and the smooth switching between the power grid and the energy storage power supply according to the power grid power supply fluctuation, the load demand and the state of charge of the energy storage device, so as to ensure the stable operation of the welding inverter power supply. The refrigeration power of the thermoelectric cooler in the heat dissipation module can be adaptively adjusted according to the temperature in the power supply box. Through the cooperation of the temperature sensor, the signal conditioning circuit and the microcontroller, the temperature in the power supply box is always maintained within the appropriate working temperature range to ensure the stable operation of the equipment. The sealing case of the lithium iron phosphate battery module adopts insulating and heat-insulating materials to prevent electrical interference and heat transfer. The cooling medium in the water tank circulates, and together with the fan and the heat exchange fins, it can effectively cool down the supercapacitor module, the lithium iron phosphate battery module, etc., and ensure the performance and service life of each component. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The drawings described herein are used to provide a further understanding of the present invention, and constitute a part of this application. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention.

[0045] In the drawings:

[0046] Figure 1 is the front view external appearance schematic diagram of the present invention;

[0047] Figure 2 is the rear view external appearance schematic diagram of the present invention;

[0048] Figure 3 is the external appearance schematic diagram of the power supply box of the present invention;

[0049] Figure 4 is the external appearance schematic diagram of the heat dissipation module of the present invention;

[0050] Figure 5 is the internal structure schematic diagram of the heat dissipation module of the present invention;

[0051] Figure 6 is the bottom view structure schematic diagram of the heat sink of the present invention;

[0052] Figure 7 is the external appearance schematic diagram of the lithium iron phosphate battery module of the present invention.

[0053] In the drawings, the list of components represented by each reference numeral is as follows:

[0054] 1. Tie rod; 10. Supercapacitor module; 11. Heat dissipation module; 1101. Protective shell; 1102. Heat exchange tube; 1103. Second heat exchange fin; 1104. Semiconductor refrigeration sheet; 1105. Heat pipe; 1106. Water tank; 1107. Fan; 1108. Connecting pipe; 12. Lithium phosphate battery module; 1201. Wiring electrode; 1202. Shell; 2. Telescopic rod; 3. Handle; 4. Power controller; 401. Control panel; 5. Power supply box; 501. First heat exchange fin; 502. Support foot; 6. Roller; 7. Lock; 8. Sliding seat; 9. Input power supply socket. Detailed implementation mode

[0055] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.

[0056] Please refer to Figures 1 to 7 As shown, the embodiment provided by the present invention:

[0057] Embodiment 1

[0058] A hybrid energy storage welding inverter power source includes a power supply box 5. A power controller 4 is installed at the upper end of the power supply box 5. A control panel 401 is provided on the power controller 4. The power supply box 5 is installed on a sliding seat 8. Rollers 6 are installed on both sides of the sliding seat 8. The sliding seat 8 moves through the rollers 6; and a telescopic rod 2 is installed on the sliding seat 8. The telescopic rod 2 can adjust its length and can adjust the height of the tie rod 1 according to the usage requirements. The telescopic rod 2 can adjust the height of the tie rod 1 according to the usage requirements, so that the operator can find the most comfortable operating position in different working scenarios. For example, in some venues with limited space or in the face of operators of different heights, the height of the adjustable tie rod 1 improves the usability and versatility of the equipment. Moreover, this height adjustability is associated with the mobility of the equipment (rollers 6 and sliding seat 8), and the height can be adjusted at any time during the movement, which is convenient for operation in different terrains or usage scenarios, greatly enhancing the adaptability of the equipment, which is an advantage that many fixed-height equipment do not have. The top of the telescopic rod 2 is installed with a tie rod 1. An input power supply socket 9 is provided on one side of the power supply box 5. And the input power supply socket 9 is sleeved and installed at one end of the tie rod 1 close to the sliding seat 8;

[0059] The power controller 4 is built-in with a bidirectional inverter, an adaptive switching circuit module, a high-frequency inverter module, and a DC pulse welding module. The bidirectional inverter adopts a full-bridge topology structure, which has high energy conversion efficiency and stable output performance. The full-bridge topology structure of this bidirectional inverter consists of four power switching tubes, which are connected into bridge arms in a pairwise opposite form. The power switching tubes are selected as insulated gate bipolar transistors (IGBTs) or metal-oxide-semiconductor field-effect transistors (MOSFETs). During the forward energy conversion process, that is, the inversion process from the DC side to the AC side, by controlling the alternate conduction and turn-off of two switching tubes on the diagonal, the DC electrical energy is converted into AC electrical energy for output. For example, when the switching tubes on one pair of diagonals are conducting, the current flows from the positive pole of the DC power supply through the conducting switching tubes into the AC load, and then returns to the negative pole of the DC power supply through the other pair of conducting switching tubes, forming a complete loop to output the positive half-cycle of the AC voltage. In the other half-cycle, by controlling the conduction of the switching tubes on the other pair of diagonals, the negative half-cycle of the AC voltage is output. During the reverse energy conversion, that is, the rectification process from the AC side to the DC side, similarly according to the phase of the AC input voltage, the conduction sequence of the four switching tubes is reasonably controlled to convert the AC electrical energy into DC electrical energy and store it in the energy storage device. This full-bridge topology structure can make full use of the voltage of the DC power supply in each switching cycle. Compared with other topology structures, it reduces energy loss and improves energy conversion efficiency. At the same time, by adopting advanced pulse width modulation technology, the conduction time and frequency of the switching tubes are precisely controlled, effectively reducing the harmonic content of the output voltage and current, making the output AC electrical energy purer, ensuring stable output performance, and meeting the strict requirements of the hybrid energy storage welding inverter power supply for power conversion and output under different working conditions. The bidirectional inverter adopts a full-bridge topology structure and consists of four power switching tubes, which can make full use of the DC power supply voltage in each switching cycle, resulting in a significant increase in energy conversion efficiency and a reduction in energy loss compared with other topology structures. At the same time, combined with advanced pulse width modulation technology, the conduction time and frequency of the switching tubes are precisely controlled, effectively reducing the harmonic content of the output voltage and current, and outputting pure AC electrical energy. This stable and efficient power conversion ensures that the hybrid energy storage welding inverter power supply can stably output electrical energy under complex welding working conditions, whether facing high-power demands or small-power fine operations, meeting the strict requirements of the welding process for power quality and stability.The full-bridge topology and pulse-width modulation technology complement each other to achieve efficient and stable power conversion, ensuring the reliable operation of the device under various working conditions, which is difficult to achieve simultaneously by ordinary inverters. One end of the bidirectional inverter is connected to the power grid through the input power supply socket 9, and the other end is respectively connected to the supercapacitor module 10 and the lithium phosphate battery module 12, which is used to coordinate the bidirectional flow of energy in each part. The high-frequency inverter module adopts soft-switching technology to reduce switching losses and improve the inverter efficiency. Specifically, the high-frequency inverter module adds a resonant inductor and a resonant capacitor in the main circuit to form a resonant circuit. During the on and off processes of the switching tube, the resonant phenomenon generated by the resonant circuit is utilized to make the voltage across the switching tube or the current flowing through the switching tube approach zero at the moment of the switching action. For example, in the zero-voltage switching mode, before the switching tube conducts, the voltage across the switching tube is reduced to zero through the resonant circuit. At this time, when the switching tube is turned on, the conduction loss caused by the existence of voltage can be avoided. In the zero-current switching mode, before the switching tube turns off, the current flowing through the switching tube is reduced to zero by using resonance, thereby eliminating the current tailing phenomenon during turn-off and reducing the turn-off loss. At the same time, the soft-switching technology enables the switching frequency to be increased. Under the same power output, the volume and weight of the filtering components are reduced, the harmonic content in the circuit is decreased, the power quality is improved, and the inverter efficiency is significantly enhanced under the combined action, ensuring the efficient and stable operation of the hybrid energy storage welding inverter power supply. The high-frequency inverter module adds a resonant inductor and a resonant capacitor to form a resonant circuit, and uses the resonant phenomenon to achieve soft switching, making the voltage or current approach zero at the moment of the on and off of the switching tube, reducing the switching loss and improving the inverter efficiency. At the same time, the soft-switching technology increases the switching frequency, enabling the reduction of the volume and weight of the filtering components under the same power output, and also decreasing the harmonic content in the circuit and improving the power quality.This technology not only improves the inversion efficiency, ensures the efficient and stable operation of the hybrid energy storage welding inverter power supply, but also reduces the equipment volume, lightens the weight, facilitates the handling and installation of the equipment, optimizes the physical characteristics of the equipment while improving the performance, and realizes the combination of multiple advantages. The high-frequency inversion module and the DC pulse welding module are connected in series through electrical circuits and jointly connected to the welding output interface. The two work together to provide a composite welding output. Moreover, the high-frequency inversion module and the DC pulse welding module are adjacently arranged on the circuit board to reduce signal interference. The DC pulse welding module can precisely control the frequency, width, and amplitude of the pulse to meet the requirements of different welding processes. The DC pulse welding module has a high-performance digital signal processor built-in as the control core. In terms of controlling the pulse frequency, the DSP generates accurate clock signals through the internal timer according to the preset welding process parameters, thereby determining the repetition period of the pulse, and then realizing the precise adjustment of the pulse frequency. It can be flexibly switched within a relatively wide frequency range, such as 10Hz - 1000Hz, to meet the requirements of high-frequency pulses for thin plate welding and low-frequency pulses for thick plate welding. When controlling the pulse width, the DSP uses pulse width modulation technology. According to the requirements for droplet transfer, weld formation, etc. in the welding process, by changing the duty cycle of the PWM signal, it precisely controls the conduction time of the pulse. The pulse width can be finely adjusted within the microsecond level range, such as 10μs - 1000μs, to ensure the precise control of energy input during the welding process. For the control of the pulse amplitude, the DC pulse welding module is equipped with a high-performance power amplifier and a closed-loop feedback circuit. The DSP outputs corresponding control signals to the power amplifier according to the requirements of the current amplitude for different welding materials and welding positions, adjusts its amplification factor, thereby changing the pulse output amplitude. At the same time, the output current signal is real-time collected through the sampling resistor and fed back to the DSP for comparison and analysis. If there is a deviation between the actual amplitude and the set value, the DSP immediately adjusts the control signal to ensure that the pulse amplitude is always stable within the set range, effectively improving the welding quality and adaptability. The DC pulse welding module has a high-performance digital signal processor (DSP) built-in, which can precisely control the frequency, width, and amplitude of the pulse. When controlling the frequency, the DSP generates accurate clock signals according to the preset welding process parameters to adjust the frequency, and can be flexibly switched within the range of 10Hz - 1000Hz to meet the welding requirements of different plate thicknesses. When controlling the pulse width, the conduction time is adjusted according to the welding process requirements using pulse width modulation technology, and is precisely controlled within the range of 10μs - 1000μs. When controlling the amplitude, through the power amplifier and the closed-loop feedback circuit, the amplitude is adjusted according to the requirements of different welding materials and positions and is real-time feedback adjusted. The cooperation of these precise control functions enables the precise control of energy input during the welding process, greatly improving the welding quality and adaptability, being able to handle various complex welding tasks, and realizing a high degree of adaptation to different welding processes. This is the precise control effect that traditional welding modules are difficult to achieve.

[0060] Embodiment 2

[0061] To ensure the stable and reliable operation of the welding inverter power supply, exemplarily, as Figures 1 to 7 shown, the present invention further includes:

[0062] The adaptive switching circuit module includes a voltage sensor, a current sensor and a single-chip microcomputer. The single-chip microcomputer of the adaptive switching circuit module adopts a high-performance and low-power microcontroller, which can quickly and accurately process the electrical signals collected by the sensors and control the bidirectional inverter. Specifically, when the sensors collect electrical signals such as voltage and current on the input side, these analog signals will be transmitted to the analog-to-digital conversion module built in the single-chip microcomputer for digital processing. The single-chip microcomputer analyzes the digitized signals according to the preset control algorithm, judges information such as the current power supply state, load demand and state of charge of the energy storage device. When it detects fluctuations in the grid power supply or changes in the load demand, the single-chip microcomputer adjusts the switching frequency and duty cycle of the bidirectional inverter by controlling the drive circuit of the bidirectional inverter, thereby realizing the charge and discharge control of the energy storage device and the smooth switching between grid power supply and energy storage power supply, ensuring the stable and reliable operation of the welding inverter power supply. The adaptive switching circuit module adopts a high-performance and low-power single-chip microcomputer, which can quickly and accurately process the electrical signals collected by the sensors. When there are fluctuations in the grid power supply or changes in the load demand, the single-chip microcomputer can analyze the signals according to the preset algorithm and adjust the switching frequency and duty cycle by controlling the drive circuit of the bidirectional inverter to realize the charge and discharge control of the energy storage device and the smooth switching between the grid and the energy storage power supply. This single-chip microcomputer closely cooperates with the voltage and current sensors to monitor the power supply state in real time. Its processing speed and control accuracy ensure that the welding inverter power supply can operate stably and reliably under different power supply conditions, avoiding welding interruption or quality decline caused by power supply problems, guaranteeing the continuity and stability of the welding work, and providing a reliable power supply guarantee for the welding operation. The voltage sensor and the current sensor are installed on the connection line between the bidirectional inverter and the grid and the energy storage output line to collect electrical signals in real time; the single-chip microcomputer is connected to the voltage and current sensors and the bidirectional inverter through data lines, receives the sensor signals and controls the bidirectional inverter to switch the working mode; a bidirectional smart meter is connected in series between the grid and the bidirectional inverter through an electrical line, which is used to collect grid electricity prices and electricity consumption data and is connected to the single-chip microcomputer through a data line to realize data interaction.

[0063] Embodiment 3

[0064] To cool the inside of the power supply box 5, exemplarily, as Figures 1 to 7As shown in the figure, the present invention further includes: a heat dissipation module 11 is installed inside the power supply box 5, the heat dissipation module 11 is provided with a protective shell 1101, a supercapacitor module 10 and a lithium iron phosphate battery module 12 are respectively installed on both sides of the heat dissipation module 11 inside the power supply box 5, the lithium iron phosphate battery module 12 is provided with a housing 1202, battery cells are installed in the housing 1202 through a sealed shell, and there is a cavity between the sealed shell and the housing 1202, and the cavity between the sealed shell and the housing 1202 is communicated with a water tank 1106 through a connecting pipe 1108, and a wiring electrode 1201 is provided at the top of the housing 1202; the sealed shell is made of insulating and heat-insulating materials to prevent electrical interference and heat transfer between the battery cells and the housing 1202. The sealed shell of the lithium iron phosphate battery module 12 is made of insulating and heat-insulating materials, which prevents electrical interference and heat transfer between the battery cells and the housing 1202. The prevention of electrical interference ensures the stable operation of the battery cells and avoids affecting the battery performance due to external electrical factors; the heat-insulating effect effectively blocks the heat generated during battery operation from being transferred outwards, reduces the heat impact on other surrounding components, and improves the stability and service life of the battery module itself.Meanwhile, the cavity between the sealed housing and the outer housing 1202 is communicated with the water tank 1106 through the connecting pipe 1108, laying a foundation for the subsequent heat dissipation cycle. This design not only ensures the stability inside the battery module but also connects with the overall heat dissipation system, achieving functional coordination and complementarity. The power supply box 5 is located at the bottom end of the heat dissipation module 11 and is inlaid with a heat pipe 1105. On one side surface of the heat pipe 1105 located outside the power supply box 5, there are first heat exchange fins 501. Inside the protective housing 1101, a semiconductor refrigeration sheet 1104 is installed on the upper surface of the heat pipe 1105. The refrigeration power of the semiconductor refrigeration sheet 1104 can be adaptively adjusted according to the temperature inside the power supply box 5. Specifically, a plurality of high-precision temperature sensors are evenly distributed inside the power supply box 5 to collect temperature data at different positions inside the box in real time. These temperature sensors transmit the collected analog temperature signals to the connected signal conditioning circuit for preprocessing such as filtering and amplifying the signals, and then send them to the microcontroller. A temperature-power adjustment algorithm formulated according to the normal operating temperature range of the electronic components inside the power supply box 5 is pre-stored in the microcontroller. When receiving the processed temperature signal, the microcontroller performs arithmetic analysis based on this algorithm to judge the current temperature condition inside the power supply box 5. If the temperature is higher than the set upper threshold, the microcontroller outputs a control signal to the drive circuit of the semiconductor refrigeration sheet 1104, and by adjusting the pulse width modulation signal of the drive circuit, increases the working current of the semiconductor refrigeration sheet 1104, thereby increasing its refrigeration power. On the contrary, if the temperature is lower than the set lower threshold, the microcontroller reduces the working current of the semiconductor refrigeration sheet 1104 through the drive circuit to reduce the refrigeration power, so as to ensure that the inside of the power supply box 5 always maintains an appropriate operating temperature range, ensuring the stable operation of the hybrid energy storage welding inverter power supply. A plurality of high-precision temperature sensors are evenly distributed inside the power supply box 5 to collect temperature data in real time. After being preprocessed by the signal conditioning circuit, the data is sent to the microcontroller. The microcontroller adjusts the refrigeration power of the semiconductor refrigeration sheet 1104 according to the preset temperature-power adjustment algorithm according to the temperature situation. When the temperature is higher than the threshold upper limit, the refrigeration power is increased, and when it is lower than the threshold lower limit, the refrigeration power is reduced. This adaptive adjustment mechanism ensures that the inside of the power supply box 5 always maintains an appropriate operating temperature range, avoiding over-cooling or under-cooling situations, ensuring the stable operation of the equipment and saving energy at the same time.The layout of multiple temperature sensors ensures comprehensive monitoring of the temperature inside the power supply box 5, forming an intelligent and efficient temperature control system in conjunction with the control and regulation of the microcontroller and the semiconductor refrigeration chip 1104. Compared with the traditional heat dissipation method with a fixed refrigeration power, it can better adapt to different working environments and load changes, providing a more reliable guarantee for the stable operation of the equipment. The hot end of the semiconductor refrigeration chip 1104 is in contact with the heat sink plate 1105, and the cold end of the semiconductor refrigeration chip 1104 is in contact with the water tank 1106. An exchange heat tube 1102 is installed above the water tank 1106, and second exchange heat fins 1103 are arranged on the outer side of the exchange heat tube 1102. A fan 1107 is installed behind the exchange heat tube 1102. The fan 1107 drives the low-temperature air flow to cool the supercapacitor module 10. One end of the exchange heat tube 1102 is connected to the water tank 1106 through a connecting pipe 1108, and the other end of the exchange heat tube 1102 is connected to the cavity between the outer shell 1202 and the battery cells through a connecting pipe 1108. The hot end of the semiconductor refrigeration chip 1104 is in contact with the heat sink plate 1105, and the cold end is in contact with the water tank 1106. The exchange heat tube 1102, the second exchange heat fins 1103 and the fan 1107 above the water tank 1106 together constitute a heat dissipation system. The fan 1107 drives the low-temperature air flow to cool the supercapacitor module 10. One end of the exchange heat tube 1102 is connected to the water tank 1106, and the other end is connected to the cavity of the lithium phosphate battery module 12, forming a complete heat dissipation cycle. This structural design makes full use of the refrigeration effect of the semiconductor refrigeration chip 1104, evenly transfers the heat through the heat sink plate 1105, and then realizes the efficient heat dissipation of key components such as the supercapacitor module 10 and the lithium phosphate battery module 12 through the coolant circulation in the water tank 1106 and the exchange heat tube 1102 and the forced convection of the fan 1107, ensuring that these components work at an appropriate temperature, improving the stability and reliability of the entire power supply system, and guaranteeing the long-term stable operation of the equipment. The water tank 1106 is internally provided with a circulation pump, and a cooling medium is filled in the water tank 1106. The cooling medium circulates through the circulation pump in the cavities between the water tank 1106, the exchange heat tube 1102 and the sealing shell and the outer shell 1202; the cooling medium is a coolant, which has good heat dissipation performance and chemical stability. The water tank 1106 is internally provided with a circulation pump and filled with a coolant with good heat dissipation performance and chemical stability. The coolant circulates through the circulation pump in the water tank 1106, the exchange heat tube 1102 and the battery module cavity, continuously taking away heat. The good heat dissipation performance ensures an efficient heat dissipation effect, and the chemical stability ensures that the coolant will not deteriorate or corrode the equipment during the long-term circulation process, extending the service life of the equipment.This circulating heat dissipation method cooperates with components such as semiconductor refrigeration plate 1104, heat spreader 1105, heat exchange tube 1102 and fan 1107 to form an efficient and stable heat dissipation system, which provides reliable heat dissipation guarantee for the hybrid energy storage welding inverter power supply, allowing the equipment to maintain normal operating temperature even under long-term, high-load working conditions. A support foot 502 is installed on the side of the bottom end of the power supply box 5 away from the sliding seat 8.

[0065] Embodiment 4

[0066] In order to facilitate the assembly of the power supply controller 4 and the power supply box 5, for example, Figures 1 to 7 As shown, the present invention further includes: a handle 3 is installed on the power controller 4, and lock buckles 7 are provided on both sides of the power controller 4 and the power supply box 5, and the power controller 4 and the power supply box 5 are locked and fixed by the lock buckles 7.

[0067] Working principle:

[0068] Initial preparation stage:

[0069] Place the device at a suitable location and adjust the height of the pull rod 1 through the telescopic rod 2 to suit different operators and working environments. Use the rollers 6 and the sliding seat 8 to move the device to the desired working location, and then connect the input power supply seat 9 to the power grid to power the device. This stage mainly involves the physical placement of the device and preparation for the grid connection, without complex electrical principles.

[0070] Energy input and storage stage:

[0071] The AC power of the power grid enters the bidirectional inverter through the input power supply socket 9, and the bidirectional inverter converts the AC power into DC power. A part of the DC power is used to charge the supercapacitor module 10 and the lithium phosphate battery module 12 to store electrical energy; the other part of the DC power enters the subsequent welding module. The bidirectional smart meter collects the power price and power consumption data of the power grid in real time, and interacts with the microcontroller of the adaptive switching circuit module to provide data support for the subsequent power supply strategy adjustment.

[0072] The bidirectional inverter adopts a full-bridge topology structure and consists of four power switching tubes (insulated gate bipolar transistor IGBT or metal oxide semiconductor field effect transistor MOSFET are selected), which are connected pairwise to form a bridge arm. During the forward energy conversion (the inversion process from the DC side to the AC side), the two switching tubes on the diagonal are controlled to alternately conduct and turn off, converting DC electrical energy into AC electrical energy for output. For example, when the switching tubes on one pair of diagonals conduct, the current flows from the positive pole of the DC power supply through the conducting switching tubes into the AC load, and then returns to the negative pole of the DC power supply through the other pair of conducting switching tubes, forming a complete loop and outputting the positive half-cycle of the AC voltage; in the other half cycle, the switching tubes on the other pair of diagonals are controlled to conduct, realizing the output of the negative half-cycle of the AC voltage. During the reverse energy conversion (the rectification process from the AC side to the DC side), according to the phase of the AC input voltage, the conduction sequence of the four switching tubes is reasonably controlled to convert AC electrical energy into DC electrical energy and store it in the energy storage device. At the same time, advanced pulse width modulation technology is adopted to precisely control the conduction time and frequency of the switching tubes, effectively reducing the harmonic content of the output voltage and current, and improving the energy conversion efficiency and output performance stability.

[0073] Welding output stage:

[0074] When welding operations are required, the DC pulse welding module and the high-frequency inverter module work together according to the welding process requirements. The high-performance digital signal processor (DSP) built into the DC pulse welding module precisely controls the frequency, width, and amplitude of the pulse according to the preset welding process parameters, and outputs a pulse signal that meets the requirements. The high-frequency inverter module adopts soft-switching technology to reduce the switching loss through the resonant circuit, invert the DC pulse signal into high-frequency alternating current, and after being connected in series through the electrical circuit, they are jointly connected to the welding output interface to output a composite welding current for welding operations.

[0075] The high-frequency inverter module adopts soft-switching technology and adds a resonant inductor and a resonant capacitor in the main circuit to form a resonant circuit. During the on and off processes of the switching tube, by utilizing the resonance phenomenon generated by the resonant circuit, the voltage across the switching tube or the current flowing through the switching tube approaches zero instantaneously during the switching operation. In the zero-voltage switching mode, before the switching tube conducts, the voltage across the switching tube is reduced to zero through the resonant circuit to avoid conduction loss; in the zero-current switching mode, before the switching tube turns off, the current flowing through the switching tube is reduced to zero by resonance to eliminate the current tailing phenomenon during turn-off and reduce the turn-off loss. The soft-switching technology increases the switching frequency. Under the same power output, it reduces the volume and weight of the filtering components, decreases the harmonic content in the circuit, improves the power quality, and enhances the inverter efficiency. The DC pulse welding module has a high-performance digital signal processor (DSP) as the control core. In terms of controlling the pulse frequency, the DSP generates precise clock signals through the internal timer according to the preset welding process parameters to determine the repetition period of the pulses, achieving precise adjustment of the pulse frequency and enabling flexible switching within a relatively wide frequency range of 10Hz - 1000Hz. When controlling the pulse width, the DSP uses pulse-width modulation technology. According to the requirements for droplet transfer, weld formation, etc. in the welding process, by changing the duty cycle of the PWM signal, it precisely controls the conduction time of the pulse, and the pulse width can be finely adjusted within the microsecond range of 10μs - 1000μs. For the control of the pulse amplitude, a high-performance power amplifier and a closed-loop feedback circuit are equipped. The DSP outputs corresponding control signals to the power amplifier according to the requirements of different welding materials and welding positions for the current amplitude, adjusts its amplification factor to change the pulse output amplitude; at the same time, the output current signal is collected in real time through a sampling resistor and fed back to the DSP for comparison and analysis. If there is a deviation between the actual amplitude and the set value, the DSP immediately adjusts the control signal to ensure that the pulse amplitude is always stable within the set range.

[0076] Power supply mode switching stage:

[0077] During the welding process, the voltage sensor and the current sensor collect the electrical signals on the connection lines between the bidirectional inverter and the power grid and the energy storage output lines in real time and transmit them to the single-chip microcomputer. The single-chip microcomputer analyzes the signals based on the preset control algorithm. When detecting power supply fluctuations of the power grid or changes in load demand, it controls the drive circuit of the bidirectional inverter to adjust the switching frequency and duty cycle of the bidirectional inverter, realizes the charge and discharge control of the energy storage device, and the smooth switching between power grid power supply and energy storage power supply, ensuring the stable and reliable operation of the welding inverter power supply.

[0078] The voltage sensor and current sensor collect electrical signals in real time and transmit the analog signals to the analog-to-digital conversion module built into the single-chip microcomputer for digital processing. The single-chip microcomputer analyzes the digitized signals according to the preset control algorithm to judge information such as the current power supply state, load demand, and state of charge of the energy storage device. When detecting power grid power supply fluctuations or load demand changes, the single-chip microcomputer controls the drive circuit of the bidirectional inverter to adjust the switching frequency and duty cycle of the bidirectional inverter, realizing the charge and discharge control of the energy storage device and the smooth switching between power grid power supply and energy storage power supply, ensuring the stable and reliable operation of the welding inverter power supply.

[0079] Heat dissipation stage:

[0080] During the operation of the device, the supercapacitor module 10 and the lithium phosphate battery module 12 will generate heat. The hot end of the thermoelectric cooler 1104 in the protective shell 1101 is in contact with the heat sink plate 1105, and the cold end is in contact with the water tank 1106. The thermoelectric cooler 1104 works to transfer heat to the heat sink plate 1105, and the heat sink plate 1105 distributes the heat evenly and dissipates heat through the first heat exchange fins 501. The coolant in the water tank 1106 circulates under the action of the circulation pump in the cavity between the water tank 1106, the heat exchange tube 1102, and the outer shell 1202 of the lithium phosphate battery module 12 and the sealing shell, taking away the heat. The fan 1107 drives the low-temperature air flow to cool the supercapacitor module 10, forming a complete heat dissipation cycle to ensure the device operates at an appropriate temperature. At the same time, the cooling power of the thermoelectric cooler 1104 is adaptively adjusted according to the temperature in the power supply box 5. Multiple high-precision temperature sensors collect temperature data in real time, which is preprocessed by the signal conditioning circuit and then sent to the microcontroller. The microcontroller adjusts the cooling power of the thermoelectric cooler 1104 according to the preset temperature-power adjustment algorithm to maintain an appropriate temperature in the power supply box 5.

[0081] The sealing case of the lithium phosphate battery module 12 is made of insulating and heat-insulating materials to prevent electrical interference and heat transfer between the battery cells and the outer shell 1202. At the same time, the cavity between the sealing case and the outer shell 1202 is communicated with the water tank 1106 through the connecting pipe 1108, providing a basis for the heat dissipation cycle. The hot end of the thermoelectric cooler 1104 in the protective case 1101 is in contact with the heat sink plate 1105, and the cold end is in contact with the water tank 1106. The heat exchange pipe 1102, the second heat exchange fin 1103 and the fan 1107 above the water tank 1106 together constitute a heat dissipation system. The fan 1107 drives the low-temperature air flow to cool the supercapacitor module 10. One end of the heat exchange pipe 1102 is communicated with the water tank 1106, and the other end is communicated with the cavity of the lithium phosphate battery module 12, forming a complete heat dissipation cycle. The water tank 1106 is internally provided with a circulation pump, and a coolant with good heat dissipation performance and chemical stability is filled. The coolant circulates under the action of the circulation pump, continuously taking away heat. The cooling power of the thermoelectric cooler 1104 is adaptively adjusted according to the temperature in the power supply box 5. Multiple high-precision temperature sensors collect temperature data in real time, which is preprocessed by the signal conditioning circuit and then sent to the microcontroller. The microcontroller judges the temperature condition according to the preset temperature-power adjustment algorithm and adjusts the cooling power of the thermoelectric cooler 1104 to ensure that the power supply box 5 always maintains an appropriate working temperature range.

[0082] The foregoing has shown and described the basic principles, main features and advantages of the present invention. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above-described exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, in any regard, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to embrace all changes within the meaning and scope of the equivalent elements of the claims in the present invention. Any reference signs in the claims should not be regarded as limiting the claimed claims.

[0083] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative manner of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A hybrid energy storage welding inverter power supply, comprising a power supply box (5), a power supply controller (4) being installed at the upper end of the power supply box (5), and a control panel (401) being provided on the power supply controller (4), characterized in that: The power supply box (5) is mounted on a sliding seat (8), rollers (6) are mounted on both sides of the sliding seat (8), and the sliding seat (8) moves via the rollers (6); a telescopic rod (2) is mounted on the sliding seat (8), a pull rod (1) is mounted on the top of the telescopic rod (2), an input power supply seat (9) is provided on one side of the power supply box (5), and the input power supply seat (9) is sleeved and mounted on one end of the pull rod (1) close to the sliding seat (8); The power controller (4) has a built-in bidirectional inverter, an adaptive switching circuit module, a high-frequency inverter module and a DC pulse welding module. One end of the bidirectional inverter is connected to the power grid via an input power supply socket (9), and the other end is respectively connected to a super capacitor module (10) and a lithium phosphate battery module (12) for coordinating the bidirectional flow of energy in each part. The high-frequency inverter module and the DC pulse welding module are connected in series via an electrical circuit and are connected to a welding output interface. The two work together to provide a composite welding output. The high-frequency inverter module and the DC pulse welding module are arranged adjacent to each other on the circuit board to reduce signal interference. The adaptive switching circuit module includes a voltage sensor, a current sensor and a single-chip microcomputer. The voltage sensor and the current sensor are installed on the connection line between the bidirectional inverter and the power grid and the energy storage output line to collect electrical signals in real time. The single-chip microcomputer is connected to the voltage and current sensors and the bidirectional inverter through a data line to receive sensor signals and control the bidirectional inverter to switch the working mode. A bidirectional smart meter is connected in series between the power grid and the bidirectional inverter through an electrical line to collect power grid electricity prices and electricity consumption data, and is connected to the single-chip microcomputer through a data line to realize data interaction. A heat dissipation module (11) is installed inside the power supply box (5), and the heat dissipation module (11) is provided with a protective shell (1101). A super capacitor module (10) and a lithium phosphate battery module (12) are respectively installed on both sides of the heat dissipation module (11) in the power supply box (5). A heat spreader (1105) is embedded at the bottom end of the heat dissipation module (11) of the power supply box (5), and a first heat exchange fin (501) is provided on a surface of one side of the heat spreader (1105) located outside the power supply box (5). A support foot (502) is installed on the side of the bottom end of the power supply box (5) away from the sliding seat (8); The power controller (4) is provided with a handle (3), and lock buckles (7) are provided on both sides of the power controller (4) and the power supply box (5), and the power controller (4) and the power supply box (5) are locked and fixed by the lock buckles (7).

2. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: The telescopic rod (2) can be adjusted in length, and the height of the pull rod (1) can be adjusted according to usage requirements.

3. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: The bidirectional inverter adopts a full-bridge topology structure, and has high energy conversion efficiency and stable output performance; the full-bridge topology structure of the bidirectional inverter is composed of four power switch tubes, which are connected to form bridge arms in pairs, and the power switch tubes are selected from insulated gate bipolar transistors IGBT or metal oxide semiconductor field effect transistors MOSFET; in the forward energy conversion process, that is, the inversion process from the DC side to the AC side, the DC power is converted into AC power output by controlling the two switch tubes on the diagonal to be alternately turned on and off; specifically, when one pair of switch tubes on the diagonal is turned on, the current flows from the positive electrode of the DC power supply through the turned-on switch tube to the AC load, and then returns to the negative electrode of the DC power supply through the other pair of turned-on switch tubes, forming a complete loop, and outputting the positive half cycle of the AC voltage; in the other half cycle, the output of the negative half cycle of the AC voltage is realized by controlling the turn-on of the switch tubes on the other pair of diagonals; in the reverse energy conversion, that is, the rectification process from the AC side to the DC side, the turn-on sequence of the four switch tubes is reasonably controlled according to the phase of the AC input voltage, and the AC power is converted into DC power and stored in the energy storage device; This full-bridge topology can fully utilize the voltage of the DC power supply in each switching cycle, which reduces energy loss and improves energy conversion efficiency compared to other topologies. At the same time, by adopting advanced pulse width modulation technology, the conduction time and frequency of the switch tube are accurately controlled, effectively reducing the harmonic content of the output voltage and current, making the output AC power purer, ensuring stable output performance, and meeting the strict requirements of the hybrid energy storage welding inverter power supply for power conversion and output under different working conditions.

4. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: The single-chip microcomputer of the adaptive switching circuit module adopts a high-performance, low-power microcontroller, which can quickly and accurately process the electrical signals collected by the sensor and control the bidirectional inverter. Specifically, when the sensor collects electrical signals such as voltage and current on the input side, these analog signals will be transmitted to the analog-to-digital conversion module built into the single-chip microcomputer for digital processing. The single-chip microcomputer analyzes the digitized signals according to a preset control algorithm to determine the current power supply status, load demand, and charge state of the energy storage device. When a grid power supply fluctuation or a load demand change is detected, the single-chip microcomputer controls the driving circuit of the bidirectional inverter to adjust the switching frequency and duty cycle of the bidirectional inverter, thereby realizing the charging and discharging control of the energy storage device and smooth switching between grid power supply and energy storage power supply, thereby ensuring stable and reliable operation of the welding inverter power supply.

5. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: The high-frequency inverter module adopts soft switching technology to reduce switching losses and improve inverter efficiency. Specifically, the high-frequency inverter module forms a resonant circuit by adding a resonant inductor and a resonant capacitor in the main circuit. In the process of switching on and off the switch tube, the resonance phenomenon generated by the resonant circuit is used to make the voltage at both ends of the switch tube or the current flowing through the switch tube approach zero at the moment of switching action. Specifically, in the zero voltage switching mode, before the switch tube is turned on, the voltage at both ends of the switch tube is reduced to zero through the resonant circuit. At this time, the switch tube is turned on to avoid the conduction loss caused by the existence of voltage. In the zero current switching mode, before the switch tube is turned off, the current flowing through the switch tube is reduced to zero by resonance, thereby eliminating the current tailing phenomenon during shutdown and reducing the shutdown loss. At the same time, the soft switching technology increases the switching frequency, reduces the volume and weight of the filter element under the same power output, reduces the harmonic content in the circuit, improves the power quality, and significantly improves the inverter efficiency under the comprehensive effect, ensuring the efficient and stable operation of the hybrid energy storage welding inverter power supply.

6. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: The DC pulse welding module can accurately control the frequency, width and amplitude of the pulse to meet the requirements of different welding processes; the DC pulse welding module has a built-in high-performance digital signal processor as the control core; in terms of controlling the pulse frequency, the DSP generates a precise clock signal through an internal timer based on the preset welding process parameters to determine the pulse repetition period, thereby achieving precise adjustment of the pulse frequency, and can be flexibly switched within a wider frequency range, specifically, 10Hz-1000Hz, to meet the requirements of thin plate welding for high-frequency pulses and thick plate welding for low-frequency pulses; when controlling the pulse width, the DSP uses pulse width modulation technology to change the PWM signal according to the requirements of the welding process for droplet transition, weld formation, etc. The duty cycle of the pulse can be precisely controlled to control the on-time of the pulse. The pulse width can be within the microsecond range, specifically, 10μs-1000μs, with fine adjustment to ensure precise control of energy input during welding. For the control of pulse amplitude, the DC pulse welding module is equipped with a high-performance power amplifier and a closed-loop feedback circuit. According to the requirements of different welding materials and welding positions for current amplitude, the DSP outputs the corresponding control signal to the power amplifier and adjusts its amplification factor, thereby changing the pulse output amplitude. At the same time, the output current signal is collected in real time through the sampling resistor and fed back to the DSP for comparative analysis. If there is a deviation between the actual amplitude and the set value, the DSP immediately adjusts the control signal to ensure that the pulse amplitude is always stable within the set range, effectively improving the welding quality and adaptability.

7. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: The lithium phosphate battery module (12) is provided with an outer shell (1202), a battery cell is installed in the outer shell (1202) via a sealed shell, a cavity is provided between the sealed shell and the outer shell (1202), and the cavity between the sealed shell and the outer shell (1202) is connected to the water tank (1106) via a connecting pipe (1108), and a wiring electrode (1201) is provided at the top of the outer shell (1202); the sealed shell is made of insulating and heat-insulating materials to prevent electrical interference and heat transfer between the battery cell and the outer shell (1202).

8. A hybrid energy storage welding inverter power supply according to claim 1, characterized in that: A semiconductor refrigeration sheet (1104) is installed on the upper surface of the heat spreader (1105) in the protective shell (1101); the hot end of the semiconductor refrigeration sheet (1104) is in contact with the heat spreader (1105); the cold end of the semiconductor refrigeration sheet (1104) is in contact with the water tank (1106); a heat exchange tube (1102) is arranged above the water tank (1106); a second heat exchange fin (1103) is arranged on the outer side of the heat exchange tube (1102); a fan (1107) is arranged behind the heat exchange tube (1102); a low-temperature airflow is driven by the fan (1107) to cool the supercapacitor module (10); one end of the heat exchange tube (1102) is connected to the water tank (1106) via a connecting tube (1108); and the other end of the heat exchange tube (1102) is connected to the cavity between the shell (1202) and the battery cell via the connecting tube (1108).

9. A hybrid energy storage welding inverter power supply according to claim 8, characterized in that: The water tank (1106) has a built-in circulation pump, and the water tank (1106) is filled with a cooling medium, and the cooling medium circulates through the water tank (1106), the heat exchange tube (1102), and the cavity between the sealing shell and the outer shell (1202) through the circulation pump; the cooling medium is a coolant, which has good heat dissipation performance and chemical stability.

10. A hybrid energy storage welding inverter power supply according to claim 8, characterized in that: The cooling power of the semiconductor cooling sheet (1104) can be adaptively adjusted according to the temperature in the power supply box (5); specifically, a plurality of high-precision temperature sensors are evenly distributed in the power supply box (5) to collect temperature data at different positions in the box in real time; these temperature sensors transmit the collected analog temperature signals to the signal conditioning circuit connected thereto, perform pre-processing such as filtering and amplification on the signals, and then send them to the microcontroller; the microcontroller pre-stores a temperature-power adjustment algorithm formulated according to the normal working temperature range of the electronic components in the power supply box (5); after receiving the processed temperature signal, the microcontroller performs calculation analysis based on the algorithm to determine the current temperature condition in the power supply box (5); if the temperature is higher than the set upper threshold value, the microcontroller outputs a control signal to the drive circuit of the semiconductor cooling sheet (1104), and increases the working current of the semiconductor cooling sheet (1104) by adjusting the pulse width modulation signal of the drive circuit, thereby improving its cooling power; On the contrary, if the temperature is lower than the set lower threshold value, the microcontroller reduces the operating current of the semiconductor cooling plate (1104) through the driving circuit, thereby reducing the cooling power, thereby ensuring that the power supply box (5) is always maintained within a suitable operating temperature range, thereby ensuring the stable operation of the hybrid energy storage welding inverter power supply.

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