Dual station hand arc welding module for generators

Abstract

The application discloses a double-station manual arc welding module for a generator and relates to the technical field of electric welders, which comprises a power distribution module, is used for generating power through a magneto and outputting electric power, distributing the electric power into one or multiple independent power outputs, rectifying three-phase power of the power outputs respectively, providing one or multiple independent direct-current welding power sources, and combining the multiple independent direct-current welding power sources in parallel. Compared with the prior art, the application has the beneficial effects that the double-station manual arc welding module for the generator realizes flexible switching between single-station high-current welding and multiple-station or double-station simultaneous welding, meets the demand of high-current welding, replaces multiple electric welding machines with different power specifications by one device, greatly shortens the construction period, reduces the number of equipment purchases, reduces the labor cost and equipment expenditure, utilizes the electric energy generated by the magneto, has high electric energy utilization efficiency, and saves the long-term use cost for users.

Description

Technical Field

[0001] This invention relates to the field of electric welding machine technology, specifically a dual-station manual arc welding module for generators. Background Technology

[0002] A generator-based welding machine, also known as an engine welding machine, is a multi-functional machine that integrates a welding machine into a generator. It is primarily used in environments where there is no power grid or where installing a power grid is inconvenient. It provides power for general electrical appliances while also enabling welding operations. Currently available generator-based welding machines, regardless of power rating, only have one welding torch interface and one ground wire interface. One generator-based welding machine can only power one welder at a time. For low-power generator-based welding machines, the output current is limited and cannot meet the demands of high-current welding (such as welding rods with a diameter of 5 mm or more). They are mainly suitable for scenarios requiring frequent movement and single-person welding operations. Furthermore, high-power generator-based welding machines are bulky and heavy (generally exceeding 50 kg), making them difficult for a single person to move and usually requiring two or more people to work together. However, once transported to the work site… Because the equipment only supports single-station welding, only one welder can work on it, while other collaborators have to wait or be reassigned, resulting in a waste of human resources and increased labor costs. Especially when the welding schedule is tight, multiple generator welding machines must be added to speed up the process, further increasing equipment costs. There is an urgent need for a dual-station manual arc welding module for generator welding machines to solve the technical problems of existing generator welding machines only supporting single-station welding, high-power equipment requiring multiple people to move but only one person can work on it, resulting in a waste of human resources, and a single machine being unable to handle both high-current single-station welding and multi-station collaborative welding. Summary of the Invention

[0003] This invention provides a dual-station manual arc welding module for generators to solve the problems mentioned in the background art.

[0004] According to an embodiment of the present invention, a dual-station manual arc welding module for a generator is provided, comprising:

[0005] The power distribution module is used to generate electricity and output electrical power through a magneto, distribute the electrical power into one or more independent power outputs, rectify the three-phase power output separately, provide one or more independent DC welding power supplies, and combine multiple independent DC welding power supplies in parallel.

[0006] The mode control module, connected to the power distribution module, is used for the operation of corresponding external devices. It provides the power distribution module with the working power required for power distribution and controls the power distribution module to perform rectification. When the power distribution module provides multiple independent DC welding power sources, it switches the parallel combination state of the multiple DC welding power sources in the power distribution module according to the welding current requirements of the welding rod.

[0007] As a further aspect of the present invention: the power distribution module includes a magneto G1, wherein the motor windings of the magneto G1 are star-shaped or delta-shaped and the motor windings are connected in parallel in three or more groups.

[0008] As a further embodiment of the present invention: the U1, V1 and W1 terminals of the winding 1 of the magneto G1 are respectively connected to the stationary terminal of the relay switch of relay K1, the first input terminal of rectifier T1 and the moving terminal of the relay switch of relay K2. The first terminals of the electromagnetic coils of relay K1 and relay K2 are both connected to a DC 12V power supply. The moving terminal of the relay switch of relay K1 and the stationary terminal of the relay switch of relay K2 are respectively connected to the second input terminal and the third input terminal of rectifier T1. The first output terminal and the second output terminal of rectifier T1 are respectively connected to the positive and negative terminals of station 1.

[0009] As a further embodiment of the present invention: the U2, V2 and W2 terminals of the winding 2 of the magneto G1 are respectively connected to the stationary terminal of the relay switch of relay K3, the first input terminal of rectifier T2 and the moving terminal of the relay switch of relay K4. The first terminals of the electromagnetic coils of relay K3 and relay K4 are both connected to a DC 12V power supply. The moving terminal of the relay switch of relay K3 and the stationary terminal of the relay switch of relay K4 are respectively connected to the second input terminal and the third input terminal of rectifier T2. The first output terminal and the second output terminal of rectifier T2 are respectively connected to the positive and negative terminals of the 2-position.

[0010] As a further embodiment of the present invention: the U3, V3 and W3 terminals of the winding 3 of the magneto G1 are respectively connected to the stationary terminal of the relay switch of relay K5, the first input terminal of rectifier T3 and the moving terminal of the relay switch of relay K6. The first terminals of the electromagnetic coils of relay K5 and relay K6 are both connected to a DC12V power supply. The moving terminal of the relay switch of relay K5 and the stationary terminal of the relay switch of relay K6 are respectively connected to the second input terminal and the third input terminal of rectifier T3. The first output terminal and the second output terminal of rectifier T3 are respectively connected to the positive and negative terminals of the 4-position circuit.

[0011] As a further embodiment of the present invention: the mode control module includes a control device, which is equipped with an operation panel for selecting workstations, adjusting current, and displaying current. The A, B, C, D, E, and F control terminals of the control device are respectively connected to the second terminals of the electromagnetic coils of relays K1, K2, K3, K4, K5, and K6.

[0012] As a further embodiment of the present invention: the power distribution module further includes six sets of welding output interfaces, which are respectively connected to the positive terminal of position 1, the negative terminal of position 1, the positive terminal of position 2, the negative terminal of position 2, the positive terminal of position 4, and the negative terminal of position 4. The positive terminal of position 1 and the positive terminal of position 2 are connected through the corresponding welding output interfaces to obtain the positive terminal of position 3, and the negative terminal of position 1 and the negative terminal of position 2 are connected through the corresponding welding output interfaces to obtain the negative terminal of position 3.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: The dual-station manual arc welding module for generators of the present invention realizes flexible switching between single-station high-current welding and multi-station or dual-station simultaneous welding. In single-station mode, it can meet the high-current welding requirements of welding rods with a diameter of 5 mm and above. In multi-station or dual-station mode, it can support two welders to work simultaneously without interference, welding welding rods with a diameter of 4 mm and below respectively. One device replaces multiple generator welding machines of different power specifications. The multi-station or dual-station mode greatly shortens the construction period, which is especially suitable for welding tasks with tight schedules. At the same time, the cooperating personnel can directly participate in the welding operation, avoiding idle human resources, reducing the number of equipment purchased and the frequency of handling, reducing labor costs and equipment expenditures. It directly utilizes the electrical energy generated by the magneto, with high electrical energy utilization efficiency, saving users long-term operating costs. Attached Figure Description

[0014] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 The circuit diagram of a dual-station manual arc welding module for a generator provided in an embodiment of the present invention.

[0016] Figure 2 The circuit diagram for parallel output of station 1 and station 2 provided in an embodiment of the present invention.

[0017] Figure 3 Wiring diagram of the multi-station manual arc welding module for a generator provided in an embodiment of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figure 1 A dual-station manual arc welding module for generators, comprising:

[0020] The power distribution module is used to generate electricity and output electrical power through a magneto, distribute the electrical power into one or more independent power outputs, rectify the three-phase power output separately, provide one or more independent DC welding power supplies, and combine multiple independent DC welding power supplies in parallel.

[0021] The mode control module, connected to the power distribution module, is used for the operation of corresponding external devices. It provides the power distribution module with the working power required for power distribution and controls the power distribution module to perform rectification. When the power distribution module provides multiple independent DC welding power sources, it switches the parallel combination state of the multiple DC welding power sources in the power distribution module according to the welding current requirements of the welding rod.

[0022] Furthermore, the power distribution module includes a magneto G1, the motor windings of which are star-shaped or delta-shaped and the motor windings are connected in parallel in three or more groups.

[0023] In a specific embodiment, the no-load output voltage of the magneto G1 at its rated speed is determined by the no-load voltage described in the welding, and can be AC30V to AC80V.

[0024] Furthermore, the U1, V1, and W1 terminals of winding 1 of magneto G1 are respectively connected to the stationary terminal of relay switch K1, the first input terminal of rectifier T1, and the moving terminal of relay switch K2. The first terminals of electromagnetic coils of relay K1 and K2 are both connected to a DC 12V power supply. The moving terminal of relay switch K1 and the stationary terminal of relay switch K2 are respectively connected to the second and third input terminals of rectifier T1. The first and second output terminals of rectifier T1 are respectively connected to the positive and negative terminals of station 1.

[0025] Furthermore, the U2, V2, and W2 terminals of winding 2 of magneto G1 are respectively connected to the stationary terminal of relay switch K3, the first input terminal of rectifier T2, and the moving terminal of relay switch K4. The first terminals of the electromagnetic coils of relay K3 and K4 are both connected to a DC 12V power supply. The moving terminal of relay switch K3 and the stationary terminal of relay switch K4 are respectively connected to the second and third input terminals of rectifier T2. The first and second output terminals of rectifier T2 are respectively connected to the positive and negative terminals of position 2.

[0026] Furthermore, the U3, V3, and W3 terminals of winding 3 of magneto G1 are respectively connected to the stationary terminal of relay switch K5, the first input terminal of rectifier T3, and the moving terminal of relay switch K6. The first terminals of electromagnetic coils of relay K5 and K6 are both connected to a DC12V power supply. The moving terminal of relay switch K5 and the stationary terminal of relay switch K6 are respectively connected to the second and third input terminals of rectifier T3. The first and second output terminals of rectifier T3 are respectively connected to the positive and negative terminals of the 4-position circuit.

[0027] In a specific embodiment, rectifiers T1, T2, and T3 are all three-phase rectifiers; relays K1, K2, K3, K4, K5, and K6 are selected in the same way, and the electromagnetic coils of the relays change the state of the relay switches by magnetic attraction; the DC12V power supply can be obtained by stepping down and regulating DC8V-DC150V through a DC-DC step-down circuit composed of PW2153, and the DC8V-DC150V can be obtained by rectifying the AC power supplied by the U3 and V3 terminals of the winding of the magneto G1 by the rectifier.

[0028] Furthermore, the mode control module includes a control device, which is equipped with an operation panel for station selection, current adjustment, and current display. The A, B, C, D, E, and F control terminals of the control device are respectively connected to the second terminals of the electromagnetic coils of relays K1, K2, K3, K4, K5, and K6.

[0029] In a specific embodiment, the operation panel of the aforementioned control device features both a multi-station selector switch and a single-station selector switch. When welding electrodes with a diameter of 5 mm or more is required, the single-station selector switch is selected. When multiple people are required to weld electrodes with a diameter of 4 mm or less, the multi-station selector switch is selected. The control device uses an LM324 as a comparator to achieve segmented adjustment of the current magnitude. The current adjustment function on the operation panel can be achieved through a current adjustment potentiometer, which is a sliding rheostat. Clockwise rotation increases the resistance value, and counterclockwise rotation decreases the resistance value. The DC 12V power supply is distributed through a 10K resistor. After being pressed, the voltage is connected to the current adjustment potentiometer. When the potentiometer is rotated, the voltage at the slider of the current adjustment potentiometer changes continuously with the change in resistance. This voltage serves as the given signal. After voltage division, it provides a signal to the ammeter, which then changes with the given voltage. When the current is given, six sets of fixed voltages are preset, such as DC1V / 2V / 3V / 4V / 5V / 6V. These are compared with the given current signal. If the given current signal is greater than the preset signal, the control device controls the relay to switch between different current levels. This process continues. As long as the given signal is greater than DC6V, relays K1-K6 are all energized, outputting the maximum current, thus achieving the purpose of segmented current adjustment. Figure 3 This is the wiring diagram for the multi-station manual arc welding module of the generator. The current can be preset and displayed via a current display meter.

[0030] In another embodiment, since the more workstations there are, the smaller the maximum welding current that a single workstation can provide, the limited welding rods that can be used, and the practicality is not high, considering practicality and cost, the number of workstations is only two, that is, a dual-workstation generator welding machine. The workstation selection on the operation panel of the dual-workstation generator welding machine is a dual-workstation switch and a single-workstation switch.

[0031] In this embodiment, please refer to Figure 2 The power distribution module also includes six sets of welding output interfaces. The six sets of welding output interfaces are respectively connected to the positive terminal of station 1, the negative terminal of station 1, the positive terminal of station 2, the negative terminal of station 2, the positive terminal of station 4, and the negative terminal of station 4. The positive terminal of station 1 and the positive terminal of station 2 are connected through the corresponding welding output interfaces to obtain the positive terminal of station 3. The negative terminal of station 1 and the negative terminal of station 2 are connected through the corresponding welding output interfaces to obtain the negative terminal of station 3.

[0032] In a specific embodiment, the above-mentioned 3-station can weld welding rods with a diameter of 4 mm. The positive and negative terminals of the 3-station can be connected to the positive and negative terminals of the 4-station respectively through the welding output interface, thereby obtaining a brand-new welding station, increasing the welding current, and then welding welding rods with a diameter of 5 mm or more.

[0033] The working principle of the dual-station manual arc welding module for generators in this invention is as follows: The engine burns fuel, driving the magneto to rotate, causing the magneto G1 to generate power. The magneto G1 has three or more independent low-voltage, high-current windings. The magneto G1 windings are either star-shaped or delta-shaped. At rated engine speed, the no-load output voltage is AC30V-AC80V (depending on the no-load voltage required for welding). Each winding, after rectification by a three-phase rectifier bridge, outputs a DC voltage, which is the no-load voltage of the welding module. Generally, it is DC50V-DC100V, mainly used for arc ignition at the start of welding. Specifically, the three-phase AC power output from windings 1, 2, and 3 of the magneto G1 is transmitted through corresponding relays K1 to K6. The power distribution can be controlled by adjusting the closing status of the relay switches from K1 to K6. The distributed power is then rectified by rectifiers T1, T2, and T3 in the corresponding branches, providing independent DC welding power to positions 1, 2, and 4 respectively. One position... The welding current can be up to 90A. When welding is required, simply set the current according to your needs and connect the welding torch and grounding clamp to the corresponding station. For high-current welding (i.e., welding electrodes with a diameter of 5mm or larger), use the single-station switch on the control panel to connect stations 1 and 2 in parallel to create station 3. Then connect stations 3 and 4 in parallel to create a new high-current station. For welding electrodes with a diameter of 4mm or smaller by multiple people, select the multi-station switch. The control panel for dual-station generator-welded machines uses the dual-station switch. The switch allows for dual-station welding via 3 or 4 stations. When adjusting the current, if the required current is below 90A, the current can be reduced via the control panel. Stations 1, 2, and 4 can be selected. Once the maximum output current of stations 1, 2, and 4 exceeds 90A, station 3 can be selected. Station 3 outputs 180A, and the current can be reduced again. The maximum current provided by the parallel connection of stations 3 and 4 is 270A. When the required current is within the range of 180A to 270A, welding can be performed at the new station, making the current of the welding module adjustable within 270A.

[0034] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0035] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider 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 dual-station manual arc welding module for generators, characterized in that, The dual-station manual arc welding module for generators includes: The power distribution module is used to generate electricity and output electrical power through a magneto, distribute the electrical power into one or more independent power outputs, rectify the three-phase power output separately, provide one or more independent DC welding power supplies, and combine multiple independent DC welding power supplies in parallel. The mode control module, connected to the power distribution module, is used for the operation of corresponding external devices. It provides the power distribution module with the working power required for power distribution and controls the power distribution module to perform rectification. When the power distribution module provides multiple independent DC welding power sources, it switches the parallel combination state of the multiple DC welding power sources in the power distribution module according to the welding current requirements of the welding rod.

2. The dual-station manual arc welding module for generators according to claim 1, characterized in that, The power distribution module includes a magneto G1, whose motor windings are star-shaped or delta-shaped and the motor windings are connected in parallel in three or more groups.

3. The dual-station manual arc welding module for generators according to claim 2, characterized in that, The U1, V1, and W1 terminals of winding 1 of the magneto G1 are respectively connected to the stationary terminal of the relay switch of relay K1, the first input terminal of rectifier T1, and the moving terminal of the relay switch of relay K2. The first terminals of the electromagnetic coils of relay K1 and relay K2 are both connected to a DC 12V power supply. The moving terminal of the relay switch of relay K1 and the stationary terminal of the relay switch of relay K2 are respectively connected to the second and third input terminals of rectifier T1. The first and second output terminals of rectifier T1 are respectively connected to the positive and negative terminals of station 1.

4. The dual-station manual arc welding module for generators according to claim 3, characterized in that, The U2, V2, and W2 terminals of winding 2 of the magneto G1 are respectively connected to the stationary terminal of the relay switch of relay K3, the first input terminal of rectifier T2, and the moving terminal of the relay switch of relay K4. The first terminals of the electromagnetic coils of relay K3 and relay K4 are both connected to a DC 12V power supply. The moving terminal of the relay switch of relay K3 and the stationary terminal of the relay switch of relay K4 are respectively connected to the second and third input terminals of rectifier T2. The first and second output terminals of rectifier T2 are respectively connected to the positive and negative terminals of position 2.

5. The dual-station manual arc welding module for generators according to claim 4, characterized in that, The U3, V3, and W3 terminals of winding 3 of the magneto G1 are respectively connected to the stationary terminal of the relay switch of relay K5, the first input terminal of rectifier T3, and the moving terminal of the relay switch of relay K6. The first terminals of the electromagnetic coils of relay K5 and relay K6 are both connected to a DC 12V power supply. The moving terminal of the relay switch of relay K5 and the stationary terminal of the relay switch of relay K6 are respectively connected to the second and third input terminals of rectifier T3. The first and second output terminals of rectifier T3 are respectively connected to the positive and negative terminals of the 4-position circuit.

6. The dual-station manual arc welding module for generators according to claim 5, characterized in that, The mode control module includes a control device with an operation panel for selecting workstations, adjusting current, and displaying current. The A, B, C, D, E, and F control terminals of the control device are respectively connected to the second terminals of the electromagnetic coils of relays K1, K2, K3, K4, K5, and K6.

7. The dual-station manual arc welding module for generators according to claim 6, characterized in that, The power distribution module also includes six sets of welding output interfaces. The six sets of welding output interfaces are respectively connected to the positive terminal of station 1, the negative terminal of station 1, the positive terminal of station 2, the negative terminal of station 2, the positive terminal of station 4, and the negative terminal of station 4. The positive terminal of station 1 and the positive terminal of station 2 are connected through the corresponding welding output interfaces to obtain the positive terminal of station 3. The negative terminal of station 1 and the negative terminal of station 2 are connected through the corresponding welding output interfaces to obtain the negative terminal of station 3.

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