Multilayer distributed super-capacitor steel rail flash welding machine power supply system and flash welding machine

Abstract

The invention relates to a steel rail flash welding technology, in particular to a multilayer distributed super-capacitor steel rail flash welding machine power supply system and a flash welding machine. The multilayer distributed super-capacitor steel rail flash welding machine power supply system comprises a super-capacitor bank, the super-capacitor bank comprises a plurality of super-capacitors which are connected in series and in parallel, and the output end of the super-capacitor bank is used for being connected with a direct-current flash welding machine and providing direct-current voltage and instantaneous power needed by welding. The system can provide stable direct current, gives full play to the advantages and characteristics of high power density and large instantaneous discharge current of the super capacitor, reduces the size of the whole power supply system, avoids redundancy, and improves the use efficiency of equipment.

Description

Technical Field

[0001] This invention relates to rail flash welding technology, specifically to a multi-layer distributed supercapacitor rail flash welding machine power supply system and flash welding machine. Background Technology

[0002] The rail flash welding machine is a core piece of equipment for manufacturing seamless railway tracks, and the performance of its power supply system directly determines the welding quality, work efficiency, and operating costs. Currently in service, welding machines mainly use both AC and DC welding power sources.

[0003] There are three main types of power supply for AC welding: (1) using a high-power generator set as the source to directly output AC power at the power frequency; (2) using an AC system with lithium batteries as the source to convert DC power to AC power at the power frequency through a power storage converter (PCS); and (3) using a supercapacitor bank as the source to convert DC power to AC power at the power frequency through a high-power inverter. The ultimate load of these three modes is the power frequency welding transformer. As a high-power load, when the transformer is connected, it will cause serious three-phase load imbalance. This not only reduces the capacity utilization and voltage quality of the power supply system, but also causes harmonic interference to other three-phase electrical equipment in the grid and increases line losses. In addition, the power frequency welding transformer itself has a large leakage inductance, which leads to a low power factor in the system, increases reactive power demand, and causes energy waste. If a diesel generator set is used as the primary power source, it is also accompanied by significant noise and exhaust pollution.

[0004] There are two main types of power supply for DC welding: (1) DC systems with high-power generator sets as the source, which undergo an energy conversion path of "rectification (AC-DC) → high-frequency inverter (DC-AC) → high-frequency transformer step-down → secondary side rectification (DC)" and finally adopt DC welding; (2) DC systems with lithium batteries as the source, which generate medium- and high-frequency AC power through a high-power inverter, which is then rectified into DC welding current after being isolated and stepped down by a medium-frequency transformer. When using generator sets, the multi-stage energy conversion path increases reactive power and harmonic losses, and the generator sets themselves have pollution and noise problems. The entire system is large in size and weight and has poor mobility. When using lithium battery packs, in order to meet the extremely high instantaneous power (pulse) requirements of flash welding, high discharge rate cells must be used and a complex battery management system must be configured. This greatly increases the system cost, design and safety control difficulty, and often requires redundant capacity, resulting in reduced energy density and a bulky system. At present, the above two power supply systems are mostly integrated in a containerized manner, relying on heavy vehicles for transportation and hoisting, with poor deployment flexibility and high operating costs.

[0005] Therefore, there is an urgent need to provide a new power supply system for rail flash welding machines to solve the problems existing in the current power supply systems for rail flash welding machines. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a multi-layer distributed supercapacitor rail flash welding machine power supply system. It can provide stable DC power, give full play to the advantages of high power density and large instantaneous discharge current of supercapacitors, reduce the overall power supply system volume, avoid redundancy, and improve equipment utilization efficiency.

[0007] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: a multi-layer distributed supercapacitor rail flash welding machine power supply system, including a supercapacitor bank, wherein the supercapacitor bank includes multiple supercapacitors connected in series and parallel, and the output terminal of the supercapacitor bank is used to connect to a DC flash welding machine to provide DC voltage and instantaneous power required for welding.

[0008] Furthermore, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes a discharge soft-start circuit connected between the supercapacitor bank and the DC flash welding machine.

[0009] Furthermore, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes a charging device connected to the supercapacitor bank for charging the supercapacitor bank.

[0010] Furthermore, the supercapacitor bank is equipped with a water-cooled busbar inside or at its output end.

[0011] Furthermore, the supercapacitor bank includes at least two supercapacitor modules, each supercapacitor module includes at least two parallel supercapacitor strings, and each supercapacitor string includes at least two supercapacitors connected in series.

[0012] Furthermore, the power supply system for the multi-layer distributed supercapacitor rail flash welding machine also includes a multi-layer distributed control system, which is used to achieve voltage and current balance among the various supercapacitors.

[0013] Furthermore, the multi-layer distributed control system includes a supercapacitor control layer, a supercapacitor module control layer, and a complete supercapacitor control layer.

[0014] Furthermore, the multi-layer distributed control system also includes an overvoltage protection circuit, an overcurrent protection circuit, and an overtemperature protection circuit.

[0015] The present invention also relates to a flash welding machine, including a multi-layer distributed supercapacitor rail flash welding machine power supply system.

[0016] By adopting the above technical solution, the present invention has the following beneficial effects:

[0017] 1. This invention provides stable DC power through a supercapacitor bank formed by supercapacitors connected in series and parallel. It can fully utilize the advantages of supercapacitors, such as high power density and large instantaneous discharge current, thereby reducing the overall power supply system size, avoiding redundancy, and improving equipment utilization efficiency.

[0018] 2. This invention abandons the previous voltage conversion technology and uses a supercapacitor to directly discharge the rail, which greatly reduces redundancy, significantly improves power efficiency, reduces energy waste, and improves energy utilization.

[0019] 3. The welding process adopts DC flash welding technology, which has low circuit impedance and high output power, resulting in a low explosion threshold voltage for the welded beam, preventing the formation of large fire pits and improving the welding quality of the rails. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the connection structure between the multi-layer distributed supercapacitor rail flash welding machine power supply system and the DC flash welding machine of the present invention.

[0021] Figure 2 This is a schematic diagram of the power supply system for the multi-layer distributed supercapacitor rail flash welding machine of the present invention;

[0022] In the diagram, 1 is a supercapacitor bank; 11 is a supercapacitor module; 111 is a supercapacitor string; 1111 is a supercapacitor; and 2 is a DC flash welder. Detailed Implementation

[0023] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0024] like Figure 1 and Figure 2 As shown, a multi-layer distributed supercapacitor rail flash welding machine power supply system includes a supercapacitor bank 1, which includes multiple supercapacitors 1111 connected in series and parallel. The output terminal of the supercapacitor bank 1 is used to connect to a DC flash welding machine 2 to provide DC voltage and instantaneous power required for welding.

[0025] Specifically, supercapacitor bank 1 generates direct current (DC) and inputs it to both ends of the rail to complete the DC flash welding of the rail. Compared to the discharge characteristics of batteries, supercapacitors 1111, with their high power density, are well-suited to the intermittent high-power discharge characteristics of flash welding, enabling low-voltage, high-current discharge characteristics without voltage transformation. In this embodiment, supercapacitor bank 1, formed by connecting supercapacitors 1111 in series and parallel, provides stable DC power, fully utilizing the advantages of high power density and large instantaneous discharge current of supercapacitors 1111. This reduces the overall power supply system size, avoids redundancy, and improves equipment utilization efficiency.

[0026] Furthermore, this embodiment abandons the previous voltage conversion technology and directly discharges the rail through the supercapacitor 1111, which greatly reduces redundancy, significantly improves power efficiency, reduces energy waste, and enhances energy utilization.

[0027] Furthermore, the welding process employs DC flash welding technology, which has low circuit impedance and high output power, resulting in a low explosion threshold voltage for the welded beam and preventing the formation of large fire pits, thus improving the quality of rail welding.

[0028] In some examples, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes a discharge soft-start circuit connected between the supercapacitor bank 1 and the DC flash welding machine 2.

[0029] The discharge soft-start circuit can reduce inrush current and overvoltage caused by sudden changes in voltage and current during the start-up transition phase, thus protecting the circuit.

[0030] In some examples, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes a charging device connected to the supercapacitor bank 1 for charging the supercapacitor bank 1.

[0031] In some examples, the supercapacitor bank 1 is equipped with a water-cooled busbar inside or at its output.

[0032] In this way, the supercapacitor bank 1 can be cooled, ensuring its lifespan and performance.

[0033] In some examples, such as Figure 2 As shown, the supercapacitor bank 1 includes at least two supercapacitor modules 11, each supercapacitor module includes at least two parallel supercapacitor strings 111, and each supercapacitor string 111 includes at least two supercapacitors 1111 connected in series.

[0034] Specifically, the application of a multi-layer distributed supercapacitor bank 1 greatly reduces spatial redundancy to about one-quarter of that of traditional methods, eliminating the need for container loading powered by generator sets or lithium batteries, making the transportation process more convenient and efficient. Furthermore, this multi-layer distributed supercapacitor bank 1 itself has redundancy; even if some supercapacitors 1111 malfunction, it will not affect the power supply to the DC flash welder 2.

[0035] Preferably, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes a multi-layer distributed control system for achieving voltage and current balance among the various supercapacitors 1111.

[0036] More preferably, the multi-layer distributed control system includes a supercapacitor control layer, a supercapacitor module control layer, and a complete supercapacitor control layer. The supercapacitor control layer collects voltage, current, and temperature information of each individual supercapacitor; the supercapacitor module control layer collects voltage and current information of each module; and the complete supercapacitor control layer collects voltage and current information of the entire system. Based on the voltage and current feedback information of the modules and individual units, it completes the self-equalizing voltage process of the supercapacitors.

[0037] By employing a multi-layered distributed control method that balances voltage between individual cells and current across modules, the supercapacitor bank 1 maintains stable voltage and instantaneous high power output throughout its operation. Furthermore, the multi-layered distributed control of individual supercapacitors 1111, individual supercapacitor modules 11, and the supercapacitor bank 1 ensures the independence and compatibility of each supercapacitor 1111 and supercapacitor module 11.

[0038] In some examples, such as Figure 1 As shown, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes a welding machine control system, which is used to control the rail flash welding process.

[0039] In some examples, the multi-layer distributed supercapacitor rail flash welding machine power supply system also includes overvoltage protection circuits, overcurrent protection circuits, and overtemperature protection circuits.

[0040] like Figure 1 As shown, a flash welding machine includes the aforementioned multi-layer distributed supercapacitor rail flash welding machine power supply system.

[0041] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A multi-layer distributed supercapacitor rail flash welding machine power supply system, characterized in that, It includes a supercapacitor bank (1), which includes multiple supercapacitors (1111) connected in series and parallel. The output terminal of the supercapacitor bank (1) is used to connect to a DC flash welder (2) to provide DC voltage and instantaneous power required for welding.

2. The multi-layer distributed supercapacitor rail flash welding machine according to claim 1, characterized in that, It also includes a discharge soft-start circuit connected between the supercapacitor bank (1) and the DC flash welder (2).

3. The multi-layer distributed supercapacitor rail flash welding machine power supply system according to claim 1, characterized in that, It also includes a charging device connected to the supercapacitor bank (1) for charging the supercapacitor bank (1).

4. The multi-layer distributed supercapacitor rail flash welding machine power supply system according to claim 1, characterized in that, The supercapacitor bank (1) is equipped with a water-cooled busbar inside or at its output end.

5. The multi-layer distributed supercapacitor rail flash welding machine power supply system according to claim 1, characterized in that, The supercapacitor bank (1) includes at least two supercapacitor modules (11), each supercapacitor module includes at least two parallel supercapacitor strings (111), and each supercapacitor string (111) includes at least two series-connected supercapacitors (1111).

6. The multi-layer distributed supercapacitor rail flash welding machine power supply system according to claim 5, characterized in that, It also includes a multi-layer distributed control system for achieving voltage and current balancing of each supercapacitor (1111).

7. The multi-layer distributed supercapacitor rail flash welding machine power supply system according to claim 6, characterized in that, The multi-layer distributed control system includes a supercapacitor control layer, a supercapacitor module control layer, and a complete supercapacitor control layer.

8. The multi-layer distributed supercapacitor rail flash welding machine power supply system according to claim 1, characterized in that, It also includes overvoltage protection circuit, overcurrent protection circuit and overtemperature protection circuit.

9. A flash welding machine, characterized in that, The system includes the multi-layer distributed supercapacitor rail flash welding machine power supply system as described in any one of claims 1-8.

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