Split type welding power supply

Abstract

The utility model belongs to the technical field of welding power sources, and discloses a split type welding power source which comprises an input module, a rectification inversion module, a voltage transformation module, an output module and a main control unit module. The rectification and inversion module comprises a rectification and inversion unit and a secondary rectification unit; the input module, the rectification inversion module, the transformation module, the output module and the main control unit module are all independent modules, and the independent modules are connected through quick connectors. According to the utility model, a completely independent modular design is adopted, and the modules are connected through the quick connectors, so that the split structure design of the welding power supply is realized. Independent modules are assembled, so that the division of labor in a factory is clearer; the independent module design is beneficial to construction of universal modules, types are reduced, and the cost of large-scale customization of parts is lower; the independent module design can distinguish a vulnerable module and an eternal module, the vulnerable module is placed in a dustless environment, the service life is prolonged, the eternal module does not need to be disassembled, and the vulnerable module is more convenient to maintain and replace due to the existence of the quick connector.

Description

Technical Field

[0001] The utility model belongs to the technical field of welding power supplies, and in particular relates to a split welding power supply. Background Art

[0002] At present, the main circuit and control circuit of the digital inverter DC welding power supply on the market are connected through many complex lines and are assembled and sold as a whole.

[0003] Although some welding power supplies can implement basic modular design, this design is only for the purpose of achieving automated assembly and fails to achieve complete independence of the modules, resulting in many complex circuits within the welding power supply.

[0004] Since there are still many complex circuits interspersed inside the welding power supply, the welding power supply needs ventilation and heat dissipation, and often a large amount of dust carried during ventilation will accumulate on the semiconductors and circuit boards, causing power failure.

[0005] When a welding power source fails and parts need to be replaced, due to the complex circuit structure inside the welding power source, the circuit disassembly, repair and replacement can only be performed by professionals, which leads to the following problems:

[0006] 1. The overall power supply needs to be returned to the factory for repair, which takes a long time, delays production and causes losses; 2. The power supply is heavy when returned to the factory, and the transportation cost is high; 3. Replacing the welding power supply is cumbersome, and connecting various input and output lines takes a lot of time.

[0007] The inventors have found through analysis that many parts of the current welding power supply are actually difficult to damage. Through the summary and analysis of the maintenance records in the factory, it can be seen that the two parts with the largest proportion of failures are semiconductors and circuit boards. Utility Model Content

[0008] The utility model aims to provide a split type welding power source, which is conducive to realizing the split structure design of the welding power source by adopting a completely independent modular design for the components in the welding power source and connecting the modules through a quick connector.

[0009] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0010] A split welding power source includes an input module, a rectifier inverter module, a transformer module, an output module and a main control unit module; the rectifier inverter module includes a rectifier inverter unit and a secondary rectifier unit;

[0011] Among them, the input module, rectifier inverter module, transformer module, output module and main control unit module are all independent modules, and each independent module is connected through a quick connector.

[0012] Preferably, the input module has two output ends, one of which is connected to the main control unit module through a quick connector, and the other is connected to the rectifier inverter unit in the rectifier inverter module through a quick connector;

[0013] The output end of the rectifier inverter unit is connected to the input end of the transformer module through a quick connector;

[0014] The transformer module has two output terminals, one of which is connected to the secondary rectifier unit in the rectifier inverter module through a quick connector, and the other is connected to the output module through a quick connector;

[0015] The output end of the secondary rectifier unit is connected to the output module via a quick connector;

[0016] The main control unit module and the rectifier inverter unit, the main control unit module and the transformer module, the main control unit module and the secondary rectifier unit, and the main control unit module and the output module are connected respectively through quick connectors.

[0017] Preferably, the input module has N groups of output terminals, and correspondingly supplies power to N groups of split welding power source units consisting of a rectifier inverter module, a transformer module, an output module and a main control unit module; wherein N is a natural number, and N≥2;

[0018] Each group of output terminals of the input module has two, and each is used to supply power to a group of split welding power source monomers;

[0019] The connection relationship between the independent modules in each group of split welding power source monomers is as follows:

[0020] The output end of the rectifier inverter unit is connected to the input end of the transformer module through a quick connector;

[0021] The transformer module has two output terminals, one of which is connected to the secondary rectifier unit in the rectifier inverter module through a quick connector, and the other is connected to the output module through a quick connector;

[0022] The output end of the secondary rectifier unit is connected to the output module via a quick connector;

[0023] The main control unit module and the rectifier inverter unit, the main control unit module and the transformer module, the main control unit module and the secondary rectifier unit, and the main control unit module and the output module are connected respectively through quick connectors.

[0024] The utility model has the following advantages:

[0025] As described above, the utility model relates to a split welding power source, the components of which adopt a completely independent modular design, and the modules are connected by quick connectors, thus realizing the split structural design of the welding power source. The independent module assembly makes the division of labor in the factory clearer; the independent module design is conducive to the construction of general modules, reducing the types, and the cost of mass customization of parts is lower; the independent module design can distinguish between vulnerable modules and permanent modules, and the vulnerable modules can be placed in a dust-free environment, which is conducive to extending the service life. The permanent modules do not need to be disassembled, and the existence of quick connectors makes the maintenance and replacement of vulnerable modules faster. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the structural principle of a split welding power source in Embodiment 1 of the present utility model;

[0027] Figure 2 This is a signal flow diagram of the split welding power supply in Example 1 of the utility model;

[0028] Figure 3 This is a schematic diagram of the structure of the input module in Embodiment 1 of the present utility model;

[0029] Figure 4 This is a schematic diagram of the structural principle of the rectifier inverter module in Example 1 of the utility model;

[0030] Figure 5 This is a schematic diagram of the structural principle of the voltage transformer module in Example 1 of the utility model;

[0031] Figure 6 This is a schematic diagram of the structural principle of the output module in Example 1 of the utility model;

[0032] Figure 7 This is a schematic diagram of the structural principle of the main control unit module in Example 1 of the utility model;

[0033] Figure 8 This is a schematic diagram of the structure of the high-power connector in Embodiment 1 of the utility model; wherein, Figure 8 (a) in the figure shows the schematic diagram of the connection line. Figure 8 (b) in the figure shows a schematic diagram of a connection seat;

[0034] Fig. 9 This is a schematic diagram of the structure of the low-power connector in Embodiment 1 of the utility model; wherein, Fig. 9 (a) in the figure shows the schematic diagram of the connection line. Fig. 9 (b) in the figure shows a schematic diagram of a connection seat;

[0035] Fig.10 This is a schematic diagram of the structural principle of a split welding power supply in Example 2 of the utility model. DETAILED DESCRIPTION

[0036] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments:

[0037] Example 1

[0038] This embodiment describes a split welding power source, the internal components of which adopt a completely independent modular design, and each independent module is connected by a quick connector to solve the technical defects of the traditional integral power source.

[0039] In order to realize the split structure design of the welding power supply, the utility model composes the easily damaged parts in the power supply into a vulnerable module, and the parts with long service life and not easy to be damaged into a permanent module, and the modules are connected by quick connectors such as quick plugs.

[0040] The vulnerable modules include the main control unit module and the rectifier inverter module, and the eternal modules include the transformer module, input module and output module.

[0041] like Figure 1 and Figure 2 As shown, the split welding power supply in this embodiment includes an input module, a rectifier inverter module, a transformer module, an output module and a main control unit module.

[0042] Among them, the input module, rectifier inverter module, transformer module, output module and main control unit module are all independent modules, and each independent module is connected through a quick connector.

[0043] The rectifier-inverter module includes a rectifier-inverter unit and a secondary rectifier unit.

[0044] In the figure, the rectifier inverter unit and the secondary rectifier unit are shown separately only to more clearly illustrate the connection and working process of the utility model. In fact, the two constitute an independent module, namely the rectifier inverter module.

[0045] Each independent module adopts a closed structure, that is, each independent module is configured with an independent shell, wherein, in order to facilitate grounding, each independent module uses sheet metal as a shell.

[0046] like Figure 1 As shown, the input module has two output terminals, one of which is connected to the main control unit module through a quick connector CON1, and the other is connected to the rectifier inverter unit in the rectifier inverter module through a quick connector TM1.

[0047] The output end of the rectifier inverter unit is connected to the input end of the transformer module through a quick connector TM2.

[0048] The transformer module has two output ends, one of which is connected to the secondary rectifier unit in the rectifier inverter module through a quick connector TM3, and the other is connected to the output module through a quick connector TM5.

[0049] The output end of the secondary rectifier unit is connected to the output module via a quick connector TM4.

[0050] The main control unit module is connected to the rectifier inverter unit and the secondary rectifier unit through the quick connector CON2. The main control unit module is connected to the transformer module and the output module through the quick connectors CON3 and CON4 respectively.

[0051] The quick connector comprises a connecting seat and a connecting line for realizing quick connection between the connecting seats.

[0052] Each independent module is provided with a connection socket.

[0053] like Figure 8 and Fig. 9 As shown, there are two types of quick connectors in this embodiment:

[0054] The first type is high-power connectors, such as Figure 1 The connection wires and connectors of TM1, TM2, TM3, TM4 and TM5 are as follows: Figure 8 The second type is a low-power connector, such as Figure 1 The connection wires and connectors of CON1, CON2, CON3, and CON4 are as follows: Fig. 9 As shown in (a) and (b) in .

[0055] like Figure 2 As shown, the signal flow of the split welding power supply in this embodiment is as follows:

[0056] The input module uses TM1 to connect to the rectifier inverter unit to provide AC380V, the main control unit module uses CON1 to connect to the input module to obtain AC200V, and the high-frequency AC power after primary rectification and inversion is transmitted to the transformer module using TM2. After the transformer module is transformed, it returns to the secondary rectifier unit of the rectifier inverter module through TM3. The inverter frequency control, temperature alarm control, radiator power supply, etc. of the rectifier inverter module are fed back to the main control unit module through CON2. The current after secondary rectification is connected to the output module through TM4, and the voltage feedback of the transformer module and the fan power supply line are connected to the main control unit through CON3. The common end of the transformer in the transformer module is connected to the output module using TM5, and the wire feeding control signal in the main control unit is connected to the output module through CON4.

[0057] The following is combined with Figure 3 To Attachment Figure 7The structure of each independent module of the split type welding power source is explained.

[0058] like Figure 3 As shown, the input module includes an input terminal block, a varistor, a filter coil, an indicator light, an air switch and an auxiliary transformer, wherein the connection relationship between the various parts in the input module is relatively conventional and will not be repeated here.

[0059] A connection socket TM1-OUT is provided at the output end of the air switch and is used to connect to the rectifier inverter unit. A connection socket CON1-OUT is provided at the output end of the auxiliary transformer and is used to connect to the main control unit module.

[0060] like Figure 4 As shown, the rectifier-inverter unit includes a rectifier, a filter capacitor coil, an inverter and a first current detector.

[0061] The input end of the rectifier is provided with a connection socket TM1-IN, and is used to connect with the input module. Specifically, the connection socket TM1-IN is connected to the connection socket TM1-OUT through a corresponding connecting line to form a quick connector TM1.

[0062] The rectifier, the filter capacitor coil and the inverter are connected in sequence.

[0063] The output end of the inverter is provided with a connection socket TM2-OUT, and is used to connect to the transformer module. Specifically, the connection socket TM2-OUT is connected to the following TM2-IN through a connecting line to form a quick connector TM2.

[0064] The first current detector is arranged at the output end of the inverter and is used for detecting the current signal output by the inverter.

[0065] like Figure 4 As shown, the secondary rectifying unit includes a buffer filter, a secondary rectifier and a second current detector.

[0066] The input end of the buffer filter is provided with a connector TM3-IN, and is used to be connected to the transformer module. Specifically, the connector TM3-IN is connected to the following connector TM3-OUT through a connecting line to form a quick connector TM3.

[0067] A snubber filter is connected to the secondary rectifier.

[0068] A connection socket TM4-OUT is provided at the output end of the secondary rectifier and is used to be connected to the output module; specifically, the connection socket TM4-OUT is connected to the following connection socket TM4-IN via a connecting line to form a quick connector TM4.

[0069] The second current detector is arranged at the output end of the secondary rectifier and is used for detecting the current signal output by the secondary rectifier.

[0070] The rectifier inverter module also includes a connector CON2-OUT connected to the inverter, the first current detector, the secondary rectifier and the second current detector, and communication with the main control unit module is achieved through the connector CON2-OUT.

[0071] Specifically, the connection socket CON2-OUT is connected to the following connection socket CON2-IN through a connection line to form a quick connector CON2.

[0072] In addition, the rectifier inverter module also includes a heat sink, such as Figure 4 As shown. The connector TM1-IN is also connected to the heat sink and supplies power to the heat sink. The rectifier inverter unit and the secondary rectifier unit are located on both sides of the heat sink.

[0073] The independent module design allows the primary rectifier inverter and the secondary rectifier to be placed on both sides of the heat sink, making the dust-proof design simpler.

[0074] like Figure 5 As shown, the transformer module includes a high-frequency transformer.

[0075] A connection socket TM2-IN is provided at the input end of the high-frequency transformer and is used to connect to the rectifier inverter unit. Specifically, the connection socket TM2-IN is connected to the connection socket TM2-OUT through a signal line to form a quick connector TM2.

[0076] The output end of the high-frequency transformer is provided with two connectors, namely connector TM3-OUT and connector TM5-OUT.

[0077] The connection socket TM3-OUT is connected to the connection socket TM3-IN in the secondary rectifier unit through a connecting line to form a quick connector TM3. Similarly, the connection socket TM5-OUT is connected to the TM5-IN in the output module through a connecting line to form a quick connector TM5.

[0078] The signal end of the high-frequency transformer is provided with a connection socket CON3-OUT, and is used to connect to the main control unit module. Specifically, the connection socket CON3-OUT is connected to CON3-IN of the main control unit module through a connecting line to form a quick connector CON3.

[0079] like Figure 5 As shown, the transformer module also includes a fan, and the main control unit module supplies power to the fan through the quick connector CON3.

[0080] like Figure 6 As shown, the output module includes a reactor, an external output terminal and a fan.

[0081] The reactor is connected to the external output terminal; the input end of the reactor is provided with a connector TM4-IN, and is used to connect to the secondary rectifier unit. Specifically, the connector TM4-IN is connected to the connector TM4-OUT through a connecting line to form a quick connector TM4.

[0082] The input end of the external output terminal is provided with a connection socket TM5-IN, and is used to be connected to the transformer module. Specifically, the connection socket TM5-IN is connected to the connection socket TM5-OUT through a connecting line to form a quick connector TM5.

[0083] The signal end of the external output terminal is provided with a connector CON4-OUT, and is used to connect to the main control unit module. Specifically, the connector CON4-OUT is connected to the following connector CON4-IN through a connecting line to form a quick connector CON4.

[0084] like Figure 6 As shown, the main control unit module can supply power to the fan in the output module through the quick connector CON4.

[0085] like Figure 7 As shown, the main control unit module includes a power board, a main control board, an inverter drive board, a filter board, a power distribution board, a wire feeding drive board and a communication board; wherein the power board is connected to the main control board and is used to supply power to the main control board.

[0086] The inverter drive board, the filter board, the power distribution board, the wire feeding drive board and the communication board are respectively connected to the main control board.

[0087] A connection socket CON1-IN is provided at the input end of the power board and is used to connect to the input module. Specifically, the connection socket CON1-IN is connected to the connection socket CON1-OUT through a connecting line to form a quick connector CON1.

[0088] A connection socket CON2-IN is provided at the output end of the inverter drive board and the input end of the filter board, and is used to connect to the rectifier inverter module. Specifically, the connection socket CON2-IN is connected to CON2-OUT to form a quick connector CON2.

[0089] A connection socket CON3-IN is provided at the output end of the power distribution board and is used to connect to the transformer module. Specifically, the connection socket CON3-IN is connected to the connection socket CON3-OUT to form a quick connector CON3.

[0090] A connection socket CON4-IN is provided at the output end of the wire feeding drive board and is used to connect with the output module. Specifically, the connection socket CON4-IN is connected with the connection socket CON4-OUT to form a quick connector CON4.

[0091] The following is an analysis of the advantages of split welding power supplies over traditional integrated power supplies:

[0092] 1. Each module is an independent individual, and the assembly is realized by using quick connectors, which is convenient for plug-in, maintenance and replacement.

[0093] 2. Each module becomes an independent entity, so that the input module, output module, main control unit module, and transformer module can all be used as universal modules for multiple welding power sources, reducing the number of module types and designs. This is specifically reflected in the following aspects:

[0094] For input modules, welding power sources with the same input voltage can use the same input module;

[0095] The same output module can be used for power supplies with the same wire feeder interface and the same output current;

[0096] The main control unit module can be designed as a broadband control module, with a low frequency matched with a hard-switch rectifier inverter module and a high frequency matched with a soft-switch rectifier inverter module.

[0097] The transformer module can become a component of the welding power source with the same transformer requirement.

[0098] 3. The input module can be customized to be a shared input module for multiple split-type welding power supply units, as shown in the following embodiment 2.

[0099] 4. The split structure design of each independent module of the welding power supply allows the use of an extension cord of a quick connector between the rectifier inverter module and the main control unit module, which can be placed separately in a low-temperature dust-free space, thereby extending its life and reducing the failure rate.

[0100] 5. Quick-plug connectors are used between independent modules to make disassembly and assembly between modules easier.

[0101] Example 2

[0102] like Fig.10 As shown, this embodiment 2 describes a split welding power supply, which is different from the above-mentioned embodiment 1 in that the same input module in this embodiment can supply power to multiple groups of split welding power supply units.

[0103] Specifically, the input module has N groups of output terminals, and corresponds to N groups of split welding power supply units consisting of a rectifier inverter module, a transformer module, an output module and a main control unit module for power supply; wherein N is a natural number, and N≥2.

[0104] Among them, each group of split welding power supply units can complete the welding operation relatively independently.

[0105] like Fig.10 As shown, each group of output terminals of the input module has two, which are used to supply power to a group of split welding power source monomers. The two output terminals in each group are respectively connected to the main control unit module and the rectifier inverter unit in the same split welding power source.

[0106] You can refer to Figure 2 One output end in each group is connected to the main control unit module through a quick connector CON1, and the other output end is connected to the rectifier inverter unit in the rectifier inverter module through a quick connector TM1.

[0107] The connection relationship between the independent modules in each group of split welding power source monomers is as follows:

[0108] The output end of the rectifier inverter unit is connected to the input end of the transformer module through a quick connector TM2.

[0109] The transformer module has two output ends, one of which is connected to the secondary rectifier unit in the rectifier inverter module through a quick connector TM3, and the other is connected to the output module through a quick connector TM5.

[0110] The output end of the secondary rectifier unit is connected to the output module via a quick connector TM4.

[0111] The main control unit module is connected to the rectifier inverter unit and the secondary rectifier unit through the quick connector CON2. The main control unit module is connected to the transformer module and the output module through the quick connectors CON3 and CON4 respectively.

[0112] In this embodiment 2, the same input module can be used when multiple power sources are welding in the same process. Since the input module is not easily damaged, the input module can be used as a fixed base and installed near the factory power distribution cabinet. When installing and disassembling, only one power supply line needs to be installed or removed, which is convenient for disassembly and makes the factory line layout more beautiful.

[0113] Of course, the above description is only a preferred embodiment of the present invention, and the present invention is not limited to the above embodiments. It should be noted that all equivalent substitutions and obvious deformation forms made by any technician familiar with the field under the guidance of this specification fall within the substantive scope of this specification and should be protected by the present invention.

Claims

1. A split welding power source, characterized in that: include: Input module, rectifier inverter module, transformer module, output module and main control unit module; The rectifier-inverter module comprises a rectifier-inverter unit and a secondary rectifier unit; The input module, the rectifier inverter module, the transformer module, the output module and the main control unit module are all independent modules, and each of the independent modules is connected via a quick connector.

2. The split welding power source according to claim 1, characterized in that: Each of the independent modules adopts a closed structure, that is, each of the independent modules is configured with an independent shell.

3. The split welding power source according to claim 1, characterized in that: The input module has two output ends, one of which is connected to the main control unit module through a quick connector, and the other is connected to the rectifier inverter unit in the rectifier inverter module through a quick connector; The output end of the rectifier inverter unit is connected to the input end of the transformer module via a quick connector; The transformer module has two output ends, one of which is connected to the secondary rectifier unit in the rectifier inverter module through a quick connector, and the other is connected to the output module through a quick connector; The output end of the secondary rectifier unit is connected to the output module via a quick connector; The main control unit module and the rectifier inverter unit, the main control unit module and the transformer module, the main control unit module and the secondary rectifier unit, and the main control unit module and the output module are connected respectively through quick connectors.

4. The split welding power source according to claim 1, characterized in that: The input module has N groups of output terminals, and correspondingly supplies power to N groups of split welding power source monomers consisting of a rectifier inverter module, a transformer module, an output module and a main control unit module; wherein N is a natural number, and N≥2; Each group of output terminals of the input module has two, and each is used to supply power to a group of split welding power source monomers; The connection relationship between the independent modules in each group of split welding power source monomers is as follows: The output end of the rectifier inverter unit is connected to the input end of the transformer module via a quick connector; The transformer module has two output ends, one of which is connected to the secondary rectifier unit in the rectifier inverter module through a quick connector, and the other is connected to the output module through a quick connector; The output end of the secondary rectifier unit is connected to the output module via a quick connector; The main control unit module and the rectifier inverter unit, the main control unit module and the transformer module, the main control unit module and the secondary rectifier unit, and the main control unit module and the output module are connected respectively through quick connectors.

5. The split welding power source according to claim 3 or 4, characterized in that: The quick connector includes a connection seat and a connection line for realizing a quick connection between the connection seats; Each of the independent modules is provided with a connection socket.

6. The split welding power source according to claim 3, characterized in that: The input module includes an input terminal block, a varistor, a filter coil, an indicator light, an air switch and an auxiliary transformer; A connection socket is provided at the output end of the air switch and is used to connect with the rectifier inverter unit; A connection socket is provided at the output end of the auxiliary transformer and is used to be connected to the main control unit module.

7. The split welding power source according to claim 5, characterized in that: The rectifier and inverter unit comprises a rectifier, a filter capacitor coil, an inverter and a first current detector; The input end of the rectifier is provided with a connection socket, and is used to connect to the input module; the rectifier, the filter capacitor coil and the inverter are connected in sequence, and the output end of the inverter is provided with a connection socket, and is used to connect to the transformer module; The first current detector is arranged at the output end of the inverter; The secondary rectifying unit comprises a buffer filter, a secondary rectifier and a second current detector; The input end of the buffer filter is provided with a connection socket, and is used to be connected to the transformer module. The buffer filter is connected to the secondary rectifier. The output end of the secondary rectifier is provided with a connection socket, and is used to be connected to the output module. The second current detector is arranged at the output end of the secondary rectifier; The rectifier-inverter module also includes a connection socket connected to the inverter, the first current detector, the secondary rectifier and the second current detector, and communication with the main control unit module is achieved through the connection socket.

8. The split welding power source according to claim 5, characterized in that: The transformer module includes a high-frequency transformer; The input end of the high-frequency transformer is provided with a connection socket, and is used to be connected to the rectifier inverter unit; The output end of the high-frequency transformer is provided with two connection sockets, which are used to connect to the secondary rectifier unit and the output module respectively; A connection socket is provided at the signal end of the high-frequency transformer and is used to be connected to the main control unit module.

9. The split welding power source according to claim 5, characterized in that: The output module includes a reactor and an external output terminal; The reactor is connected to the external output terminal; the input end of the reactor is provided with a connection seat, and is used to be connected to the secondary rectifier unit; the input end of the external output terminal is provided with a connection seat, and is used to be connected to the transformer module; The signal end of the external output terminal is provided with a connection socket and is used to be connected to the main control unit module.

10. The split welding power source according to claim 5, characterized in that: The main control unit module includes a power board, a main control board, an inverter drive board, a filter board, a power distribution board, a wire feeding drive board and a communication board; wherein the power board is connected to the main control board and is used to supply power to the main control board; The inverter drive board, the filter board, the power distribution board, the wire feeding drive board and the communication board are respectively connected to the main control board; A connection socket is provided at the input end of the power board and is used to connect with the input module; Connecting sockets are respectively provided at the output end of the inverter drive board and the input end of the filter board, and are used to connect to the rectifier inverter module; A connection socket is provided at the output end of the power distribution board and is used to connect to the transformer module; A connecting socket is provided at the output end of the wire feeding drive plate and is used to be connected to the output module.

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