Intelligent power supply method and device for lithium ion supercapacitor

Abstract

The invention provides an intelligent power supply method and device for a lithium ion supercapacitor, and belongs to the technical field of power supply of high-power energy storage equipment.The method comprises the steps that working condition categories are divided according to weldment data and welding types, and then a target power supply mode of the lithium ion supercapacitor is determined according to working conditions; the high energy density of the lithium super capacitor can cover different load welding requirements, and power supply waste or insufficiency is avoided. According to the method, the initial power and the power adjustment step length are set according to the target power supply mode, the initial power adaptive to the working condition is rapidly output by using the high power density of the lithium super capacitor, preheating is not needed, and meanwhile, the reasonable step length is preset to reserve space for subsequent adjustment. According to the method, welding current, arc voltage and welding speed data are collected in real time, and power is dynamically corrected according to the step length. The high-power response speed of the lithium super capacitor can adapt to welding parameter changes, continuous power supply stability is maintained through high energy, and the welding quality is improved through precise power adjustment.

Description

Technical Field

[0001] This application belongs to the field of power supply technology for high-power energy storage devices, and more specifically, it relates to an intelligent power supply method and device for lithium-ion supercapacitors. Background Technology

[0002] Lithium-ion supercapacitors are energy storage devices that combine the high energy density of lithium-ion batteries with the high power density of traditional supercapacitors. They enable rapid charging and discharging as well as long-term energy maintenance, making them suitable for power applications requiring both fast power response and sustained energy output. For welding equipment, a stable power supply is a core prerequisite for ensuring welding quality. Currently, the main power supply methods for welding equipment include traditional lead-acid battery power, ordinary supercapacitor power, and direct mains power.

[0003] However, existing power supply methods have obvious drawbacks. Traditional lead-acid batteries have high energy density but low power density, which cannot meet the instantaneous high power demand during the welding start-up phase. Moreover, their slow charging and discharging response makes it difficult to adapt to power changes during operating condition switching. Ordinary supercapacitors have high power density but low energy density, which cannot support long-term continuous welding and are prone to power outages. Although direct mains power supply can provide continuous energy, it is greatly affected by grid fluctuations and has poor flexibility, making it unsuitable for mobile welding scenarios. In addition, all of these methods lack the ability to dynamically adapt to real-time welding parameters, resulting in a mismatch between power supply and operating condition requirements, which can easily lead to quality problems such as incomplete welding and over-welding. Summary of the Invention

[0004] The purpose of this application is to provide a smart power supply method and device for lithium-ion supercapacitors, so as to improve the flexibility of smart power supply for lithium-ion supercapacitors and thus improve welding quality.

[0005] A first aspect of this application provides a smart power supply method for lithium-ion supercapacitors, comprising: Welding condition category is determined based on weldment data and welding equipment welding type, and target power supply mode of lithium-ion supercapacitor is determined based on the welding condition category; Based on the target power supply mode, determine the target initial power and target power adjustment step size for the lithium-ion supercapacitor to power the welding equipment; Based on the welding current, welding arc voltage, and welding speed of the welding equipment, the target initial power is adjusted according to the target power adjustment step size to obtain the target power supply.

[0006] A second aspect of this application provides an intelligent power supply device for a lithium-ion supercapacitor, comprising: The power supply mode determination module determines the welding condition category based on the weldment data and the welding type of the welding equipment, and determines the target power supply mode of the lithium-ion supercapacitor based on the welding condition category. The power determination module determines the target initial power and target power adjustment step size for the lithium-ion supercapacitor to supply power to the welding equipment based on the target power supply mode. The power adjustment module adjusts the target initial power according to the target power adjustment step size based on the welding current, welding arc voltage and welding speed of the welding equipment, to obtain the target power supply.

[0007] A third aspect of this application provides an electronic device, including a memory, a processor, and a computer program stored in the memory and running on the processor, wherein the processor executes the computer program to implement the steps of the above-described intelligent power supply method for a lithium-ion supercapacitor.

[0008] In a fourth aspect of this application, a computer-readable storage medium is provided, the computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the above-described intelligent power supply method for a lithium-ion supercapacitor.

[0009] The beneficial effects of the intelligent power supply method and device for lithium-ion supercapacitors provided in this application are as follows: This application determines the welding condition category by analyzing weldment data and welding type, and then matches the target power supply mode, accurately adapting to different welding scenarios and ensuring stable welding quality. This application determines the target initial power and power adjustment step size based on the target power supply mode, and adjusts the power in real time by combining welding current, arc voltage, and welding speed to achieve dynamic power optimization. This dynamic adjustment mechanism can flexibly adjust the power supply according to changes in the actual welding process and the operating conditions of the welding equipment, reducing unnecessary energy consumption, improving energy utilization efficiency, and lowering operating costs. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] Figure 1 A schematic flowchart illustrating an intelligent power supply method for a lithium-ion supercapacitor provided in an embodiment of this application; Figure 2 A structural block diagram of an intelligent power supply device for a lithium-ion supercapacitor provided in an embodiment of this application; Figure 3 This is a schematic block diagram of an electronic device provided in an embodiment of this application. Detailed Implementation

[0012] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0013] To make the objectives, technical solutions, and advantages of this application clearer, the following description will be provided in conjunction with the accompanying drawings and specific embodiments.

[0014] Please refer to Figure 1 , Figure 1 This is a flowchart illustrating an intelligent power supply method for a lithium-ion supercapacitor according to an embodiment of this application. The method can be executed by an electronic device, and specifically, the method may include steps S101 to S103.

[0015] S101: Determine the welding condition category based on the weldment data and the welding type of the welding equipment, and determine the target power supply mode of the lithium-ion supercapacitor based on the welding condition category.

[0016] In this embodiment, the weldment data includes the weldment material and weldment thickness; the welding condition category is determined based on the weldment data and the welding type of the welding equipment, specifically including: determining the welding energy threshold based on the weldment material and weldment thickness; determining the welding current characteristics based on the welding type of the welding equipment; the welding current characteristics include the power supply external characteristics, current range, and current mode; and determining the welding condition category based on the welding energy threshold and welding current characteristics.

[0017] In this embodiment, weldment data refers to the physical properties of the workpiece to be welded. Weldment data can include weldment thickness and material, such as stainless steel, aluminum alloy, and high-strength steel, which determine the material's melting point, thermal conductivity, and coefficient of thermal expansion. For example, aluminum alloys have high thermal conductivity and require more energy, while high-strength steel requires low heat input to prevent embrittlement. The welding type of the welding equipment refers to the specific equipment's (such as manual arc welding machine, submerged arc welding machine, or tungsten inert gas welding machine) process. Manual arc welding machines require a steep drop in external power supply characteristics to prevent wire sticking, while submerged arc welding machines require a flat characteristic for stable wire feeding. Different welding types of equipment correspond to different current characteristics (current range, power supply mode), which are the core basis for determining the operating condition category.

[0018] The welding energy threshold is the minimum energy input range determined by the material and thickness of the workpiece; that is, the energy required per unit length to complete a qualified weld. For example, the threshold for a 3mm stainless steel sheet is approximately 3-5 kJ / cm, and for a 20mm carbon steel sheet, it is approximately 15-20 kJ / cm. Welding current characteristics are the power output characteristics determined by the welding type. These characteristics can include external power supply characteristics, current range, and current mode. For example, external power supply characteristics refer to the current-voltage output curve; for instance, manual welding requires a steep drop to prevent wire sticking, while gas shielded welding requires a flat curve for stable wire feeding. The current range refers to the current interval suitable for the welding type; for example, tungsten inert gas (TIG) welding is typically 50-300A, while submerged arc (SAG) welding can reach 400-1500A. Current mode refers to constant current, pulse, dual pulse, etc. Welding condition categories are classification labels that comprehensively consider the workpiece requirements and process characteristics. These categories directly relate to the power supply strategy of lithium-ion supercapacitors. Welding condition categories can include thin-plate precision welding conditions, thick-plate high-current welding conditions, etc.

[0019] This embodiment determines the working condition category by integrating and analyzing weldment data and welding type information. The material and thickness of the weldment determine the required welding energy; for example, high-melting-point alloy steel and thicker weldments require higher energy, thus determining the welding energy threshold. The welding type is associated with different welding current characteristics. For example, shielded metal arc welding (SMAW) requires a steeply sloping external power supply characteristic to stabilize the arc, while gas metal arc welding (GMAW) requires a flat and hard external characteristic to achieve constant wire feed. Different welding types correspond to specific current ranges and current modes. By combining the welding energy threshold with the welding current characteristics, the welding working condition category can be determined, and a suitable power supply mode can be matched.

[0020] In this embodiment, relying on the high energy density (≥150Wh / kg) characteristics of lithium-ion supercapacitors, it can cover the full-condition energy requirements of thin plate precision welding (low heat input 3-5kJ / cm) and thick plate high-current welding (high heat input 15-20kJ / cm), avoiding power outages caused by insufficient energy of ordinary supercapacitors (energy density ≤50Wh / kg). For example, when welding automotive frames, which are typically made of high-strength steel with considerable thickness, a high welding energy threshold is required. The method employs gas metal arc welding (GMAW), characterized by a flat, hard external current characteristic, a specific current range, and a pulsed current mode. By integrating this information and determining the operating condition, the lithium-ion supercapacitor utilizes an appropriate constant-voltage power supply mode to ensure a stable and efficient welding process, thereby guaranteeing the quality of the frame welding.

[0021] In this embodiment, the welding current characteristics include the current range; the welding condition category is determined based on the welding energy threshold and the welding current characteristics, specifically including: If the welding energy threshold is less than or equal to the target threshold and the current range is within the first current range, then the welding condition category is determined to be a thin plate precision welding condition. If the welding energy threshold is greater than the target threshold, and / or the current range is within the second current range, then the welding condition category is determined to be a thick plate high-current welding condition.

[0022] In this embodiment, the target threshold is a critical value that distinguishes the energy requirements of thin and thick plates. Based on the target threshold, welding below the target threshold is initially classified as a precision scenario for thin plates, while welding above the target threshold is classified as a high-current scenario for thick plates. The first current range refers to the low-current range suitable for thin plates (e.g., 50-200A). The second current range refers to the high-current range suitable for thick plates (e.g., 300-600A). This embodiment identifies the welding condition category through welding energy threshold and welding current characteristics.

[0023] For example, when the welding energy threshold is less than or equal to the target threshold and the current range falls within the first interval, it indicates that the workpiece needs low heat input and low current control to avoid burn-through or deformation. This type of welding can be classified as a thin plate precision welding condition.

[0024] When the welding energy threshold is greater than the target threshold, or the current range falls within the second interval, it indicates that the workpiece requires high heat input and high current penetration to ensure that the penetration depth meets the standard. This type of welding can be classified as a thick plate high current welding condition.

[0025] S102: Determine the target initial power and target power adjustment step size for the lithium-ion supercapacitor to power the welding equipment based on the target power supply mode.

[0026] In this embodiment, the target power supply mode refers to the specific operating mode of the lithium-ion supercapacitor's power output for different welding conditions, such as low-power mode and high-power mode. The target initial power is the basic power provided by the lithium-ion supercapacitor at the start of welding; for example, the initial power requirement is higher when welding thick steel plates. The target power adjustment step size represents the magnitude of each power change when adjusting the power according to actual needs during the welding process, and is related to the stability of the welding process and the sensitivity to current and voltage fluctuations. This embodiment first determines the target power supply mode, and then, based on the parameter characteristics adapted to the target power supply mode and combined with the information on the weldment and welding type, determines the appropriate target initial power and target power adjustment step size. The lithium supercapacitor with high power density (≥3000W / kg) supports rapid initial power output without preheating. For example, the first initial power of 3kW (thin plate condition) can reach the rated value within 0.1 seconds, and the second initial power of 20kW (thick plate condition) can achieve an instantaneous current peak of 300A, far faster than the preheating start-up time of traditional power banks.

[0027] For example, in shipbuilding, when welding thick steel plates for the hull, a constant current power supply mode is adopted. Based on the thickness of the steel plate and the type of welding, a higher target initial power is set to ensure stable arc initiation. Considering that hull welding requires continuous and stable output, a smaller target power adjustment step is set to avoid large power fluctuations and ensure welding quality and efficiency.

[0028] For example, in the welding of steel structure bridges, Q345 steel of varying thicknesses needs to be welded using gas metal arc welding (GMAW). First, the welding energy requirement is determined based on the thickness of the workpiece (e.g., 20mm steel plate) and its material, and a constant voltage power supply mode is matched. The target initial power needs to be set to a base value that can stably penetrate the gap between thick plates and form a molten pool. For example, it can be preset to a medium-to-high power suitable for thick plates based on process experience, ensuring that the penetration depth meets the standard after arc ignition. During welding, due to potential assembly errors or thermal deformation at the butt joints of the steel plates, the power needs to be adjusted in real time. At this time, the target power adjustment step is set to a small range, such as adjusting the power by ±5% each time based on arc voltage feedback, to avoid spatter or incomplete fusion due to excessively large step sizes. This precise setting allows the lithium-ion supercapacitor to maintain stable output during bridge welding on-site, ensuring both the penetration of thick plate welding and adapting to complex working conditions through dynamic fine-tuning, thereby improving weld uniformity and overall structural strength.

[0029] S103: Based on the welding current, welding arc voltage and welding speed of the welding equipment, the target initial power is adjusted according to the target power adjustment step size to obtain the target power supply.

[0030] In this embodiment, the welding current is the current intensity that directly affects the penetration depth and weld formation, and is related to the thickness and material of the workpiece. The welding arc voltage is the voltage value reflecting the arc length and stability, affecting the weld width and spatter rate. The welding speed is the rate at which the weld advances per unit time, determining the heat input and production efficiency. The target power adjustment step size is the power adjustment range preset according to the working conditions, avoiding frequent and large fluctuations. The target power supply is the real-time output power that dynamically matches the welding requirements.

[0031] This embodiment collects welding current, voltage, and speed data in real time, calculates the real-time heat input during the welding process based on these three data points, and compares it with the preset target heat input. When the current is detected to be below the threshold (e.g., due to incomplete fusion of a thick plate) or the voltage is detected to be too high (e.g., due to an excessively long arc), resulting in the actual heat input being lower than the target heat input, the power is increased step by step according to the target power; conversely, the power is reduced. When the welding current suddenly fluctuates (e.g., from 120A to 180A), the lithium supercapacitor can achieve instantaneous current replenishment through its fast charging and discharging characteristics, shortening the response time and avoiding incomplete welding caused by arc extinction; at the same time, the wide voltage range (220V-360V) can reduce voltage fluctuation errors, which is superior to the fluctuation range of traditional power banks.

[0032] For example, in on-site welding operations for pipeline engineering, manual arc welding is required for X70 pipeline steel with a diameter of 508 mm and a wall thickness of 12 mm. The target initial power can be set to a suitable medium power based on the pipe thickness and welding type. After arc ignition, the welding current, arc voltage, and welding speed are monitored in real time. If the current is found to be slightly low, resulting in insufficient molten pool temperature (shallow penetration), the power supply is gradually increased in preset small increments, with each increase being approximately 3% of the current power, until the current stabilizes within a suitable range and the penetration depth meets the requirements. If the welding speed slows down due to changes in the gap between the pipe ends, to prevent excessive heat input from causing coarse grains, this embodiment automatically reduces the power in increments to maintain a stable arc voltage. Throughout the welding process, by continuously collecting the three parameters and dynamically adjusting the power, uniform weld formation and good fusion are ensured, avoiding incomplete penetration or burn-through problems caused by improper power, thus guaranteeing the welding quality and operational safety of long-distance pipelines.

[0033] As can be seen from the above, this embodiment determines the welding condition category by analyzing the weldment data and welding type, and then matches the target power supply mode. This allows for precise adaptation to the needs of different welding scenarios, avoiding power waste or insufficient power caused by fixed power supply in traditional power supply modes, and ensuring stable welding quality. This embodiment determines the target initial power and power adjustment step size based on the target power supply mode, and adjusts the power in real time by combining welding current, arc voltage, and welding speed to achieve dynamic power optimization. This dynamic adjustment mechanism can flexibly adjust the power supply according to the actual welding process, reducing unnecessary energy consumption, improving energy utilization efficiency, and lowering operating costs. Furthermore, this embodiment monitors load data changes during the welding process and adjusts the power supply in real time, effectively avoiding equipment overload or performance degradation caused by power supply mismatch, extending the service life of welding equipment and lithium-ion supercapacitors, improving the reliability and stability of equipment operation, and providing efficient, energy-saving, and safe power supply for welding operations.

[0034] In one embodiment of this application, determining the target power supply mode of the lithium-ion supercapacitor based on the welding condition category includes: If the welding condition is a thin plate precision welding condition, then the target power supply mode for the lithium-ion supercapacitor is determined to be the first power supply mode. If the welding condition is a thick plate high current welding condition, then the target power supply mode of the lithium-ion supercapacitor is determined to be the second power supply mode. The power supply power of the first power supply mode is less than that of the second power supply mode.

[0035] In this embodiment, determining the target initial power and target power adjustment step size for the lithium-ion supercapacitor to power the welding equipment based on the target power supply mode includes: If the target power supply mode is the first power supply mode, then the target initial power of the lithium-ion supercapacitor for powering the welding equipment is determined as the first initial power, and the target power adjustment step size is the first power adjustment step size. If the target power supply mode is the second power supply mode, then the target initial power of the lithium-ion supercapacitor for powering the welding equipment is determined to be the second initial power, and the target power adjustment step size is the second power adjustment step size. Wherein, the first initial power is less than the second initial power, and the first power adjustment step size is less than the second power adjustment step size.

[0036] In this embodiment, the precision welding condition for thin plates can refer to scenarios requiring precise thermal control, such as when the workpiece thickness is less than a preset thickness threshold and the welding process is TIG welding or micro-plasma welding. The characteristics of this precision welding condition for thin plates are that they are sensitive to heat input, prone to burn-through or deformation, and require low-power, high-precision adjustment. The high-current welding condition for thick plates can refer to scenarios where the workpiece thickness is greater than a preset thickness threshold and the welding process is submerged arc welding or... This is suitable for applications requiring deep penetration, such as gas shielded welding. Thick plate welding with high current is characterized by high heat input requirements, the need to penetrate thick materials, and the need for high power and rapid response adjustment. The first power supply mode is suitable for thin plate precision applications, with lower power output (e.g., 2-8kW). The lithium-ion supercapacitor has a rated output voltage of 220V (voltage range 210V-230V) and a rated current of 13.6A. There is no instantaneous current peak requirement (due to small current fluctuations in thin plate applications), and the focus is on controlling the stability and accuracy of heat input. The second power supply mode is suitable for thick plate high current applications, with higher power output (e.g., 15-30kW). The lithium-ion supercapacitor has a rated output voltage of 360V (voltage range 350V-370V), and the instantaneous current peak can reach 300A (suitable for the instantaneous high current requirements during arc initiation in thick plates), focusing on meeting the energy requirements and dynamic response for deep penetration.

[0037] The first initial power is set based on the minimum penetration requirement of thin plates (e.g., 3kW) to avoid burn-through due to excessive initial energy. The second initial power is set based on the penetration requirement of thick plates (e.g., 20kW). Leveraging the high energy density (≥150Wh / kg) of lithium-ion supercapacitors, this power provides continuous power for 5 hours, far exceeding the power requirements of traditional lead-acid batteries (only 2-3 hours at 20kW) and ordinary supercapacitors (only 1-2 hours at 20kW), ensuring uninterrupted continuous welding of thick plates. The first initial power is also set based on the minimum penetration requirement of thin plates (e.g., 3kW), providing continuous power for 12 hours, suitable for batch precision welding of thin plates. The first power adjustment step is typically small (e.g., 0.5kW / time) to prevent sudden power fluctuations causing heat input volatility, such as adjusting the current by only 5A or the voltage by 0.5V each time. The second power adjustment step is typically larger (e.g., 2kW / time), allowing for rapid power increases to meet penetration requirements (e.g., adjusting the current by 20A or the voltage by 2V each time).

[0038] This embodiment determines the welding condition category based on the material, thickness, and welding type of the weldment. If the weldment is 15mm carbon steel and is submerged arc welded, it is determined to be a thick plate high-current welding condition. The thin plate condition triggers the first power supply mode; the thick plate condition triggers the second power supply mode. In the first power supply mode, the initial power is set to 3kW to match the minimum penetration requirement of the thin plate, and the adjustment step is 0.5kW / time to prevent heat input overshoot. In the second power supply mode, the initial power is set to 20kW to match the penetration requirement of the thick plate, and the adjustment step is 2kW / time to quickly compensate for insufficient energy.

[0039] For example, the weldment data is as follows: a 2mm aluminum alloy sheet with high thermal conductivity and prone to burn-through; the welding type is TIG welding, requiring constant current characteristics and low current. This embodiment, based on the material (aluminum alloy), thickness (2mm), and process (TIG welding), comprehensively determines it as a precision welding condition for thin plates, triggering the determination of the target power supply mode as the first power supply mode. In this embodiment, the initial target power can be set to 3kW, corresponding to a TIG welding current of 100A, a voltage of 30V, and a heat input of approximately 5kJ / cm, to avoid burn-through. In this embodiment, the target power adjustment step can be set to 0.5kW / time, corresponding to a current ±5A and a voltage ±0.5V, ensuring that the heat input fluctuation is less than or equal to 10%.

[0040] If the temperature of the molten pool is detected to rise during the welding process, such as exceeding 500°C, this embodiment can reduce the power to 2.5kW (current 90A, voltage 28V) in 0.5kW increments, reducing the heat input to 4.5kJ / cm, effectively preventing burn-through.

[0041] As can be seen from the above, this embodiment can achieve a dual improvement in welding quality and efficiency by accurately matching working conditions and power supply modes. Addressing the characteristics of thin plates being prone to burn-through and thick plates requiring greater penetration, differentiated power settings and adjustment steps reduce the rate of defects such as burn-through and incomplete fusion. Automated mode switching and parameter presets reduce manual debugging time, significantly improving operational efficiency. Furthermore, the method of this embodiment is adaptable to welding scenarios involving multiple materials and processes, reducing the risk of equipment overload, extending the lifespan of lithium-ion supercapacitors, and effectively meeting the diverse needs of industrial welding.

[0042] In one embodiment of this application, the target initial power is adjusted according to the target power adjustment step size based on the welding current, welding arc voltage, and welding speed of the welding equipment to obtain the target power supply, including: Calculate welding heat input based on welding current, welding arc voltage, and welding speed of welding equipment; Obtain the target welding heat input of the weldment, calculate the heat input difference between the welding heat input and the target welding heat input, and base the calculation on the heat input difference; The target initial power is adjusted based on the heat input difference and the target power adjustment step size to obtain the target power supply.

[0043] In this embodiment, the welding heat input is calculated based on the welding current, welding arc voltage, and welding speed of the welding equipment. Specifically, this includes: calculating the welding heat input based on the welding current, welding arc voltage, and welding speed of the welding equipment and using the heat input calculation formula. The formula for calculating heat input is as follows:

[0044] Where E is the welding heat input, U is the welding arc voltage, I is the welding current, and v is the welding speed. This represents the thermal efficiency coefficient of the welding method.

[0045] In this embodiment, welding heat input refers to the heat absorbed per unit length of weld. Welding heat input directly affects weld penetration, microstructure, and welding deformation. The target welding heat input is an ideal heat input value preset based on the workpiece material, thickness, and welding method; it is a core process parameter for welding quality. For example, the target heat input for TIG welding of 1mm stainless steel plate is typically set at 80-120 kJ / m, while for 20mm carbon steel submerged arc welding it requires 500-800 kJ / m. The heat input difference is the deviation between the actual welding heat input and the target value, used to determine whether power supply adjustment is necessary. For example, power adjustment is triggered when the difference exceeds ±5%. For thin-plate welding requiring higher precision, the difference threshold can be set to ±3%.

[0046] In this embodiment, the product of the welding arc voltage and the welding current is the total arc power, reflecting the energy output intensity; the welding method thermal efficiency coefficient refers to the energy utilization rate of different welding processes, used to correct the actual effective energy; the welding speed refers to the welding length per unit time, and the speed is introduced into the denominator of the formula to calculate the energy per unit length. The higher the welding speed, the lower the heat input; the formula is divided by 1000 at the end as a constant conversion, used to convert the power unit (W) to kJ and adapt the speed unit, such as cm / min to cm / s.

[0047] For example, this embodiment can calculate the actual heat input based on real-time monitoring data of welding current, arc voltage, and welding speed, according to a preset heat input calculation formula. This embodiment compares the actual heat input with the target heat input value: if the welding speed is too fast, resulting in insufficient energy and the actual value being lower than the target value, it is determined that the power supply needs to be increased; if the current is too large, resulting in overheating and the actual value being higher than the target value, it is determined that the power supply needs to be reduced. This embodiment can adjust the output power of the lithium-ion supercapacitor proportionally according to the magnitude of the heat input difference and the preset target power adjustment step size: for example, when the difference is +10%, the number of steps required to complete the adjustment is calculated based on the specific value of the target power adjustment step size, such as reducing the power in four steps, to avoid excessively large single adjustments that could cause arc instability.

[0048] For example, assuming the workpiece parameters are a 1.5mm thick TC4 titanium alloy plate, using pulsed TIG welding, the target heat input is set to 150kJ / m. This embodiment obtains real-time monitoring data: welding current: 80A, arc voltage: 12V, welding speed: 20cm / min. Actual heat input calculation: Through voltage, current, and speed conversion, the actual value is found to be 135kJ / m, which is 10% lower than the target heat input. This embodiment determines that additional energy is needed, and the power is increased from the initial 10kW to 11kW in 5 steps, increasing by 2% each time (approximately 0.5kW / time). The heat input difference gradually decreases to ±2%, the weld penetration depth stabilizes at 0.8-1.0mm, and the heat-affected zone width is controlled within 1.2mm, meeting the requirement of no deformation for aerospace parts.

[0049] As can be seen from the above, this embodiment calculates the welding heat input and compares it with the target value. Based on the difference and the adjustment step size, the power is dynamically adjusted, which can accurately control the heat input, match the welding requirements in real time, avoid defects such as incomplete fusion and burn-through, and improve the quality of the weld. It also achieves dynamic power optimization, reduces energy waste, and improves welding stability and production efficiency.

[0050] In one embodiment of this application, after determining the target power supply mode of the lithium-ion supercapacitor based on the welding condition category, the method further includes: If the target power supply mode is the first power supply mode, in response to the welding current data of the welding equipment meeting the first condition, the target power supply mode is switched to the second power supply mode; the first condition is that the welding current data of the welding equipment exceeds the first current threshold and the duration reaches the first duration. If the target power supply mode is the second power supply mode, in response to the temperature data of the welding area meeting the second condition, the target power supply mode is switched to the first power supply mode; the second condition is that the temperature data of the welding area exceeds the safe temperature threshold of the weldment and the duration reaches the second duration.

[0051] In this embodiment, the first current threshold refers to the maximum allowable welding current critical value in the thin-plate precision welding mode, such as 150A, reflecting the upper limit of power carrying capacity under the current operating condition. The first duration refers to the shortest time that the current must remain above the threshold, such as 2 seconds, to avoid instantaneous fluctuations triggering erroneous switching. The safe temperature threshold refers to the highest temperature that the weldment material can withstand, such as 300℃ for aluminum alloys, to prevent overheating from causing grain coarsening or deformation. The second duration refers to the shortest time that the temperature must remain above the threshold, such as 5 seconds, to ensure that abnormal temperature rise is not caused by accidental factors.

[0052] This embodiment can adaptively switch modes by triggering dynamic data in real time. For the switch from thin plate welding to thick plate welding: when the current in thin plate welding continuously exceeds the threshold, such as when the weld points overlap and the energy required for the molten pool increases, it is determined that the actual working condition is switched to thick plate welding, the upper limit of power is automatically increased and the high current mode is switched to enhance the penetration ability.

[0053] For switching from thick plate welding to thin plate welding: If the temperature continues to exceed the safe value during thick plate welding, such as due to poor heat dissipation causing local overheating, it is determined that the heat input needs to be reduced, the mode should be switched to low power and pulse output should be enabled to reduce the range of heat-affected zone.

[0054] For example, the workpiece is a 2mm low-carbon steel plate (classified as a thin plate welding condition), and a gas metal arc welding (GMAW) is used. During the welding process, due to workpiece assembly errors, the local gap of the weld reaches 3mm, far exceeding the suitable range for thin plate welding. The welding current continuously increases from the preset 120A to 180A, exceeding the first threshold of 150A for 3 seconds. In this embodiment, the actual working condition is determined to be a thick plate condition, and the system automatically switches to the second power supply mode, increasing the initial power from 10kW to 18kW, while simultaneously increasing the adjustment step size from 1kW / time to 3kW / time. After adjustment, the weld pool depth increases from 1.2mm to 2.5mm, ensuring complete fusion at the gap and avoiding incomplete penetration defects caused by delayed manual intervention.

[0055] As can be seen from the above, this embodiment can dynamically switch the power supply mode by monitoring current and temperature data in real time: the current exceeding the limit for thin plates can be switched to the thick plate mode to compensate for insufficient fusion; the temperature exceeding the limit for thick plates can be switched to the thin plate mode to control heat and prevent deformation. This achieves adaptive operation, reduces manual intervention, improves welding quality stability, avoids defects such as overheating or insufficient penetration, and is suitable for scenarios with assembly errors or changes in heat dissipation, thereby improving production efficiency.

[0056] The intelligent power supply method for lithium-ion supercapacitors in this embodiment can be extended to the following scenarios in addition to welding equipment: (1) Emergency start-up of construction machinery: Provide high-power instantaneous power start-up for excavators and loaders, quickly reach the rated current, and solve the problem of difficult low-temperature start-up of traditional lead-acid batteries; (2) Energy replenishment for new energy vehicles: As a mobile energy replenishment device, the fast charging feature is compatible with the 300V-800V automotive voltage platform, and a single energy replenishment supports ultra-long range; (3) Power replenishment for port cranes: Real-time replenishment of the ultra-large power gap at the moment of crane lifting, shortening the response time and avoiding grid overload.

[0057] A smart power supply method for a lithium-ion supercapacitor corresponding to the above embodiment, Figure 2 This is a structural block diagram of an intelligent power supply device for a lithium-ion supercapacitor, provided as an embodiment of this application. For ease of explanation, only the parts relevant to the embodiment of this application are shown. References Figure 2 The intelligent power supply device 20 for a lithium-ion supercapacitor includes: a power supply mode determination module 21, a power determination module 22, and a power adjustment module 23.

[0058] Among them, the power supply mode determination module 21 is used to determine the welding condition category based on the weldment data and the welding type of the welding equipment, and to determine the target power supply mode of the lithium-ion supercapacitor based on the welding condition category. The power determination module 22 is used to determine the target initial power and target power adjustment step size of the lithium-ion supercapacitor for powering the welding equipment based on the target power supply mode. The power adjustment module 23 is used to adjust the target initial power according to the target power adjustment step size based on the welding current, welding arc voltage and welding speed of the welding equipment, so as to obtain the target power supply.

[0059] In one embodiment of this application, the weldment data includes the weldment material and the weldment thickness; the power supply mode determination module 21 is specifically used to determine the welding energy threshold based on the weldment material and the weldment thickness; Welding current characteristics are determined based on welding type; welding current characteristics include power source external characteristics, current range, and current mode. Welding condition categories are determined based on welding energy thresholds and welding current characteristics.

[0060] In one embodiment of this application, the power supply mode determination module 22 is specifically used to determine the target power supply mode of the lithium-ion supercapacitor as the first power supply mode if the welding condition category is thin plate precision welding condition. If the welding condition is a thick plate high current welding condition, then the target power supply mode of the lithium-ion supercapacitor is determined to be the second power supply mode. The power supply power of the first power supply mode is less than that of the second power supply mode.

[0061] In one embodiment of this application, the power determination module 22 is specifically used to determine the target initial power of the lithium-ion supercapacitor for powering the welding equipment as the first initial power and the target power adjustment step size as the first power adjustment step size if the target power supply mode is the first power supply mode. If the target power supply mode is the second power supply mode, then the target initial power of the lithium-ion supercapacitor for powering the welding equipment is determined to be the second initial power, and the target power adjustment step size is the second power adjustment step size. The first initial power is less than the second initial power, and the first power adjustment step size is less than the second power adjustment step size.

[0062] In one embodiment of this application, the power adjustment module 23 is specifically used to calculate the welding heat input based on the welding current, welding arc voltage and welding speed of the welding equipment; obtain the target welding heat input of the workpiece; and calculate the heat input difference between the welding heat input and the target welding heat input. The target initial power is adjusted based on the heat input difference and the target power adjustment step size to obtain the target power supply.

[0063] In one embodiment of this application, the power adjustment module 23 is further configured to calculate the welding heat input based on the welding current, welding arc voltage and welding speed of the welding equipment and through a heat input calculation formula; The formula for calculating heat input is as follows:

[0064] Where E is the welding heat input, U is the welding arc voltage, I is the welding current, and v is the welding speed. This represents the thermal efficiency coefficient of the welding method.

[0065] In one embodiment of this application, a smart power supply device 20 for a lithium-ion supercapacitor further includes: The power supply mode switching module is used to switch the target power supply mode to the second power supply mode if the target power supply mode is the first power supply mode and the welding current data of the welding equipment meets the first condition; the first condition is that the welding current data of the welding equipment exceeds the first current threshold and the duration reaches the first duration. If the target power supply mode is the second power supply mode, in response to the temperature data of the welding area meeting the second condition, the target power supply mode is switched to the first power supply mode; the second condition is that the temperature data of the welding area exceeds the safe temperature threshold of the weldment and the duration reaches the second duration.

[0066] See Figure 3 , Figure 3 This is a schematic block diagram of an electronic device provided according to an embodiment of this application. Figure 3 The electronic device 300 in this embodiment may include one or more processors 301, one or more input devices 302, one or more output devices 303, and one or more memories 304. The processors 301, input devices 302, output devices 303, and memories 304 communicate with each other via a communication bus 305. The memories 304 store computer programs, including program instructions. The processors 301 execute the program instructions stored in the memories 304. Specifically, the processors 301 are configured to invoke the program instructions to perform the functions of the modules in the aforementioned device embodiments, for example... Figure 2 The functions of the power supply mode determination module 21, power determination module 22, and power adjustment module 23 are shown.

[0067] It should be understood that, in the embodiments of this application, the processor 301 may be a central processing unit (CPU), but it may also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or any conventional processor.

[0068] Input device 302 may include a touchpad, a fingerprint sensor (for collecting the user's fingerprint information and fingerprint orientation information), a microphone, etc., and output device 303 may include a display (LCD, etc.), a speaker, etc.

[0069] The memory 304 may include read-only memory and random access memory, and provides instructions and data to the processor 301. A portion of the memory 304 may also include non-volatile random access memory. For example, the memory 304 may also store information about the type of welding equipment.

[0070] In specific implementations, the processor 301, input device 302, and output device 303 described in the embodiments of this application can execute the implementation methods described in the embodiments of the intelligent power supply method for lithium-ion supercapacitors provided in this application, or they can execute the implementation methods of the electronic device 300 described in the embodiments of this application, which will not be repeated here.

[0071] In another embodiment of this application, a computer-readable storage medium is provided. This computer-readable storage medium stores a computer program, which includes program instructions. When executed by a processor, the program instructions implement all or part of the processes in the methods described above. Alternatively, the computer program can instruct related hardware to complete the process. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include any entity or device capable of carrying computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, etc.

[0072] The computer-readable storage medium can be an internal storage unit of the electronic device in any of the foregoing embodiments, such as a hard disk or memory of the electronic device. The computer-readable storage medium can also be an external storage device of the electronic device, such as a plug-in hard disk, smart media card (SMC), secure digital card (SD), flash card, etc., equipped on the electronic device. Furthermore, the computer-readable storage medium can include both internal and external storage units of the electronic device. The computer-readable storage medium is used to store computer programs and other programs and data required by the electronic device. The computer-readable storage medium can also be used to temporarily store data that has been output or will be output.

[0073] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this application.

[0074] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the electronic devices and units described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0075] In the several embodiments provided in this application, it should be understood that the disclosed electronic devices and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. In addition, the mutual coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces or units, or it may be an electrical, mechanical, or other form of connection.

[0076] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments of this application, depending on actual needs.

[0077] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0078] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A smart power supply method for lithium-ion supercapacitors, characterized in that, include: Welding condition category is determined based on weldment data and welding equipment welding type, and target power supply mode of lithium-ion supercapacitor is determined based on the welding condition category; Based on the target power supply mode, determine the target initial power and target power adjustment step size for the lithium-ion supercapacitor to power the welding equipment; Based on the welding current, welding arc voltage, and welding speed of the welding equipment, the target initial power is adjusted according to the target power adjustment step size to obtain the target power supply.

2. The intelligent power supply method for a lithium-ion supercapacitor as described in claim 1, characterized in that, The weldment data includes the weldment material and weldment thickness; The determination of welding condition categories based on weldment data and welding equipment type includes: The welding energy threshold is determined based on the material and thickness of the weldment. The welding current characteristics are determined based on the welding type; the welding current characteristics include power supply external characteristics, current range, and current mode. The welding condition category is determined based on the welding energy threshold and the welding current characteristics.

3. The intelligent power supply method for a lithium-ion supercapacitor as described in claim 1, characterized in that, The determination of the target power supply mode for the lithium-ion supercapacitor based on the welding condition category includes: If the welding condition category is thin plate precision welding condition, then the target power supply mode of the lithium-ion supercapacitor is determined to be the first power supply mode. If the welding condition category is a thick plate high current welding condition, then the target power supply mode of the lithium-ion supercapacitor is determined to be the second power supply mode. The power supply power of the first power supply mode is less than that of the second power supply mode.

4. The intelligent power supply method for a lithium-ion supercapacitor as described in claim 3, characterized in that, The determination of the target initial power and target power adjustment step size for the lithium-ion supercapacitor to power the welding equipment based on the target power supply mode includes: If the target power supply mode is the first power supply mode, then the target initial power of the lithium-ion supercapacitor for supplying power to the welding equipment is determined to be the first initial power, and the target power adjustment step size is the first power adjustment step size. If the target power supply mode is the second power supply mode, then the target initial power of the lithium-ion supercapacitor for supplying power to the welding equipment is determined to be the second initial power, and the target power adjustment step size is the second power adjustment step size. The first initial power is less than the second initial power, and the first power adjustment step size is less than the second power adjustment step size.

5. The intelligent power supply method for a lithium-ion supercapacitor as described in claim 1, characterized in that, The target power supply is obtained by adjusting the target initial power according to the target power adjustment step size based on the welding current, welding arc voltage, and welding speed of the welding equipment, including: The welding heat input is calculated based on the welding current, welding arc voltage, and welding speed of the welding equipment. Obtain the target welding heat input of the weldment, and calculate the heat input difference between the welding heat input and the target welding heat input; The target initial power is adjusted based on the heat input difference and the target power adjustment step size to obtain the target power supply.

6. The intelligent power supply method for a lithium-ion supercapacitor as described in claim 5, characterized in that, The calculation of welding heat input based on the welding current, welding arc voltage, and welding speed of the welding equipment includes: The welding heat input is calculated based on the welding current, the welding arc voltage, and the welding speed of the welding equipment, using a heat input calculation formula. The formula for calculating heat input is as follows: Where E is the welding heat input, U is the welding arc voltage, I is the welding current, and v is the welding speed. This represents the thermal efficiency coefficient of the welding method.

7. The intelligent power supply method for a lithium-ion supercapacitor as described in claim 1, characterized in that, After determining the target power supply mode of the lithium-ion supercapacitor based on the welding condition category, the method further includes: If the target power supply mode is the first power supply mode, in response to the welding current data of the welding equipment meeting the first condition, the target power supply mode is switched to the second power supply mode; the first condition is that the welding current data of the welding equipment exceeds the first current threshold and the duration reaches the first duration. If the target power supply mode is the second power supply mode, in response to the temperature data of the welding area meeting the second condition, the target power supply mode is switched to the first power supply mode; the second condition is that the temperature data of the welding area exceeds the safe temperature threshold of the weldment and the duration reaches the second duration.

8. An intelligent power supply device for a lithium-ion supercapacitor, characterized in that, include: The power supply mode determination module is used to determine the welding condition category based on the weldment data and the welding type of the welding equipment, and to determine the target power supply mode of the lithium-ion supercapacitor based on the welding condition category. A power determination module is used to determine the target initial power and target power adjustment step size for the lithium-ion supercapacitor to supply power to the welding equipment based on the target power supply mode. The power adjustment module is used to adjust the target initial power according to the target power adjustment step size based on the welding current, welding arc voltage and welding speed of the welding equipment, to obtain the target power supply.

9. An electronic device comprising a memory, a processor, and a computer program stored in the memory and running on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the method as described in any one of claims 1 to 7.

10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by a processor, it implements the steps of the method as described in any one of claims 1 to 7.

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