Inverter type stud welding machine for arc stud welding

Abstract

The utility model discloses an inverter type stud welding machine for arc discharge stud welding, and relates to the technical field of inverter type stud welding machines. A display screen is fixedly connected to the interior of the shell; a control panel is fixedly connected to one side of the display screen in the shell; a PLC (Programmable Logic Controller) is fixedly connected to the control panel; welding parameters, gas circuit on-off and pressure feedback are managed and controlled in a centralized mode through the PLC all-in-one machine, the operation process is greatly simplified in combination with a man-machine interaction touch interface, and the manual intervention requirement is remarkably reduced; the equipment adopts an industrial-grade heat dissipation framework and an electromagnetic compatibility enhanced design, supports large-current long-time continuous operation, highly integrates a power supply, a control unit and a cooling system through a modular integration technology, thoroughly abandons redundant peripherals of a traditional split type structure, and improves the reliability of the equipment. And the reliability is improved, and meanwhile the core requirement of an industrial automatic production line for efficient and compact welding equipment is met.

Description

Technical Field

[0001] This utility model relates to the technical field of inverter stud welding machines, specifically to an inverter stud welding machine for arc stud welding. Background Technology

[0002] Inverter stud welding machines are a new type of welding equipment based on high-frequency inverter technology. By converting industrial frequency AC power into high-frequency DC pulses, they achieve efficient welding of studs and substrates. Compared with traditional industrial frequency welding machines, their core advantages are small size, low energy consumption, and high output current stability. They can be adapted to the welding needs of studs made of various materials such as stainless steel and aluminum alloys. This technology is widely used in fields such as building steel structures, shipbuilding, and the automotive industry, and has become a mainstream solution for improving welding efficiency and precision.

[0003] Existing inverter stud welding machines typically consist of an inverter circuit module, a control unit, a welding power supply, and an operating interface. Their workflow is as follows: the inverter circuit rectifies, filters, and modulates the input AC power using a high-frequency switch to output a controllable DC pulse; the control unit adjusts parameters such as pulse frequency, current peak value, and welding time through a preset program; the operating interface uses physical buttons or a basic touchscreen for parameter input, and some devices are equipped with simple status indicator lights; in terms of functionality, existing technologies mostly support manual and semi-automatic welding modes, and some high-end models integrate basic safety functions such as overcurrent protection and temperature monitoring.

[0004] Existing traditional inverter stud welding machines generally suffer from the following technical defects: the equipment's functional modules are scattered, such as the power supply, controller, and pneumatic circuit unit, which are independently set up. The operation interface is complex and relies on manual experience to adjust parameters, resulting in cumbersome wiring, a high rate of misoperation, and difficulty in meeting the needs of high-intensity continuous operation. The traditional split structure has low heat dissipation efficiency and poor electromagnetic compatibility, which limits the increase of rated current and makes it difficult to balance high current output and equipment reliability. At the same time, the external cooling and pneumatic circuit system further increases the size of the equipment and the cost of troubleshooting, and cannot meet the high integration requirements of integrated and intelligent systems in industrial automation scenarios. The above defects seriously restrict the further improvement of welding efficiency and quality. Utility Model Content

[0005] The purpose of this invention is to provide an inverter stud welding machine for arc stud welding, so as to solve the technical problem that the existing technology cannot meet the high integration requirements of integration and intelligence in industrial automation scenarios.

[0006] The technical problem to be solved by this utility model can be achieved through the following technical solution:

[0007] An inverter-type stud welding machine for arc stud welding includes a housing; a display screen is fixedly mounted inside the housing; a control board is fixedly mounted to one side of the display screen inside the housing; a PLC is fixedly mounted on the control board; an IGBT drive board is fixedly mounted inside the housing; a leakage protection device is fixedly mounted inside the housing on the side of the IGBT drive board; a control transformer is fixedly mounted inside the housing; a drive transformer is fixedly mounted inside the housing on the side of the control transformer; and a high-frequency transformer is fixedly mounted inside the housing.

[0008] As a further embodiment of this utility model: an IGBT inverter and rectifier module is fixedly connected inside the housing; the IGBT inverter and rectifier module is located below the drive transformer.

[0009] As a further embodiment of this utility model: the high-frequency transformer is located on the side closest to the IGBT inverter and rectifier module.

[0010] As a further embodiment of this utility model: a reactor is fixedly connected inside the housing; the reactor is located on the side closest to the high-frequency transformer.

[0011] As a further embodiment of this utility model, the bottom end of the housing is provided with multiple sets of universal wheels.

[0012] The beneficial effects of this utility model are as follows: Welding parameters, gas path on / off, and pressure feedback are centrally controlled by a PLC integrated machine, and the operation process is greatly simplified by combining a human-machine interactive touch interface, significantly reducing the need for manual intervention. Based on high-frequency inverter technology optimization and dynamic parameter compensation algorithms, it can achieve precise control of the rated welding current, effectively suppressing welding spatter and improving the stability of the molten pool, ensuring weld consistency in challenging scenarios such as thin plates and dissimilar metals. Simultaneously, the equipment adopts an industrial-grade heat dissipation architecture and electromagnetic compatibility enhancement design, supporting high-current, long-term continuous operation. Furthermore, through modular integration technology, the power supply, control unit, and cooling system are highly integrated, completely eliminating the redundant peripherals of traditional split structures, improving reliability while meeting the core requirements of industrial automated production lines for efficient and compact welding equipment. Attached Figure Description

[0013] The present invention will be further described below with reference to the accompanying drawings.

[0014] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0015] Figure 2 This is a three-dimensional view of the control board structure in this utility model;

[0016] Figure 3 This is a three-dimensional structural view of the IGBT inverter and rectifier module in this utility model;

[0017] In the diagram: 1. Housing; 2. Display screen; 3. Control board; 4. IGBT driver board; 5. Residual current device; 6. Control transformer; 7. Drive transformer; 8. IGBT inverter and rectifier module; 9. High-frequency transformer; 10. Reactor; 11. Caster wheel. Detailed Implementation

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

[0019] like Figures 1-3 As shown, an inverter stud welding machine for arc stud welding includes a housing 1; a display screen 2 is fixedly connected inside the housing 1; a control board 3 is fixedly connected to one side of the display screen 2 inside the housing 1; a PLC is fixedly connected to the control board 3; an IGBT drive board 4 is fixedly connected inside the housing 1; a leakage protection device 5 is fixedly connected to the side of the IGBT drive board 4 inside the housing 1; a control transformer 6 is fixedly connected inside the housing 1; a drive transformer 7 is fixedly connected to the side of the control transformer 6 inside the housing 1; and a high-frequency transformer 9 is fixedly connected inside the housing 1.

[0020] The housing 1 houses an IGBT high-frequency protective gas solenoid valve. During operation, the PLC first outputs a current control signal, which is then activated by the IGBT driver board 4. The voltage is stepped down by the high-frequency transformer 9 via the IGBT high-frequency switch, and then rectified by a high-frequency high-current diode. Simultaneously, the PLC outputs an action control signal to the control board 3, which sequentially opens the protective gas solenoid valve, releases the arc-ignition current, energizes the welding torch lifting coil, releases the main arc current, de-energizes the welding torch lifting coil, releases the arc-terminating current, and finally closes the protective gas solenoid valve, thus completing the entire welding process control. The PLC integrated machine centrally manages welding parameters, gas path on / off, and pressure feedback. Combined with a human-machine interactive touch interface, the operation process is greatly simplified, significantly reducing the need for manual intervention. Based on high-frequency inverter technology optimization and dynamic parameter compensation algorithms, it can achieve precise control of the rated welding current, effectively suppressing welding spatter and improving the stability of the molten pool, ensuring the weld seam stability in challenging scenarios such as thin plates and dissimilar metals. Consistency is ensured; simultaneously, the equipment adopts an industrial-grade heat dissipation architecture and electromagnetic compatibility enhancement design, supporting high-current, long-term continuous operation. Furthermore, through modular integration technology, the power supply, control unit, and cooling system are highly integrated, completely eliminating the cumbersome peripherals of traditional split structures. This improves reliability while meeting the core requirements of industrial automated production lines for efficient and compact welding equipment. The leakage protection device (RCD5) can monitor the welding machine's leakage in real time. Once the leakage current reaches its tripping current value, the RCD will quickly cut off the power supply to prevent electric shock to operators, ensuring personal safety. It also prevents equipment damage caused by leakage, improving the reliability and stability of the welding machine's operation, reducing welding defects, optimizing welding parameter control, further improving welding quality, and ensuring that welding operations comply with relevant safety regulations and standards.

[0021] An IGBT inverter and rectifier module 8 is fixedly connected inside the housing 1; the IGBT inverter and rectifier module 8 is located below the drive transformer 7.

[0022] The IGBT inverter and rectifier module 8 inverts DC power into high-frequency AC power of 15-100kHz. Within the housing 1, the IGBT acts as a switching device, controlled by a pulse-width modulation (PWM) control signal generated by the DSP, controlling its on / off state to achieve the conversion from DC to high-frequency AC power. This process is crucial for the welding machine to output a suitable high-frequency current for welding, providing the foundation for subsequent transformation and rectification. The IGBT inverter and rectifier module 8 can also precisely adjust the output current magnitude and waveform according to welding requirements through the control circuit. During welding, by changing parameters such as the IGBT's conduction time, the welding current can be flexibly adjusted to adapt to welding studs of different diameters and materials, ensuring the stability and reliability of the welding quality.

[0023] The high-frequency transformer 9 is located on the side closest to the IGBT inverter and rectifier module 8.

[0024] One of the main functions of the high-frequency transformer 9 is to step down the high-frequency AC power after inversion. Through the electromagnetic induction principle of the transformer, the high-voltage high-frequency AC power obtained from the previous inversion is converted into a lower voltage AC power suitable for welding, generally reduced to tens of volts. This step-down process makes the output current more suitable for the needs of stud welding, preparing for subsequent rectification and filtering. Due to the high operating frequency, the core cross-sectional area and the number of coil turns of the high-frequency transformer are greatly reduced. Compared with the traditional power frequency transformer, its size and weight are significantly reduced. This makes the size and weight of the entire welding machine much smaller, making it easier to carry and move. It also reduces the use of manufacturing materials, giving it the advantages of energy saving and environmental protection.

[0025] A reactor 10 is fixedly connected inside the housing 1; the reactor 10 is located on the side near the high-frequency transformer 9.

[0026] Reactor 10 in housing 1 is mainly used for filtering. After the high-frequency AC power is stepped down by the transformer and then rectified again, there may still be some ripple and fluctuation in the DC power. The reactor, used in conjunction with the capacitor, can effectively smooth and stabilize the output current, eliminate high-frequency fluctuations and spikes in the current, make the output DC current more stable, improve the stability of the welding process, and reduce the generation of welding defects. The reactor can also play a role in storing and exchanging energy in the circuit. During the IGBT switching process, the reactor can absorb and release energy, and work together with components such as the filter capacitor to realize the rational distribution and transmission of energy in the circuit, improve the energy conversion efficiency of the entire welding machine, and reduce energy loss.

[0027] The bottom of the housing 1 is provided with multiple sets of universal wheels 11.

[0028] The housing 1 can be easily moved by the casters 11. The staff can push the housing 1 to rotate the casters 11 and move it to a designated position, thus improving the portability of the housing 1.

[0029] The working principle of this utility model is as follows: The housing 1 contains an IGBT high-frequency protective gas solenoid valve. During operation, the PLC first outputs a current control signal, which is then activated by the IGBT driver board 4. The voltage is stepped down by the high-frequency transformer 9 via the IGBT high-frequency switch, and then rectified by a high-frequency high-current diode. Simultaneously, the PLC outputs an action control signal to the control board 3, sequentially opening the protective gas solenoid valve, releasing the arc-igniting current, energizing the welding torch lifting coil, releasing the main arc current, de-energizing the welding torch lifting coil, releasing the arc-extinguishing current, and finally closing the protective gas solenoid valve, thus completing the entire welding process control. The PLC integrated machine centrally manages welding parameters, gas path on / off, and pressure feedback. Combined with a human-machine interactive touch interface, the operation process is greatly simplified, significantly reducing the need for manual intervention. Based on high-frequency inverter technology optimization and dynamic parameter compensation algorithms, it can achieve precise control of the rated welding current, effectively suppressing welding spatter and improving the stability of the molten pool, ensuring weld quality in challenging scenarios such as thin plates and dissimilar metals. Consistency is ensured; simultaneously, the equipment adopts an industrial-grade heat dissipation architecture and electromagnetic compatibility enhancement design, supporting high-current, long-term continuous operation. Furthermore, through modular integration technology, the power supply, control unit, and cooling system are highly integrated, completely eliminating the cumbersome peripherals of traditional split structures. This improves reliability while meeting the core requirements of industrial automated production lines for efficient and compact welding equipment. The leakage protection device (RCD5) can monitor the welding machine's leakage in real time. Once the leakage current reaches its tripping current value, the RCD will quickly cut off the power supply to prevent electric shock to operators, ensuring personal safety. It also prevents equipment damage caused by leakage, improving the reliability and stability of the welding machine's operation, reducing welding defects, optimizing welding parameter control, further improving welding quality, and ensuring that welding operations comply with relevant safety regulations and standards.

[0030] The above description provides a detailed account of one embodiment of the present invention. However, this description is merely a preferred embodiment and should not be construed as limiting the scope of the present invention. All equivalent variations and improvements made within the scope of the claims of the present invention should still fall within the patent coverage of the present invention.

Claims

1. An inverter stud welder for pull arc stud welding, characterized in that, It includes a shell (1); the inside of the shell (1) is fixedly connected with a display screen (2); the inside of the shell (1) is fixedly connected with a control panel (3) on one side of the display screen (2); the control panel (3) is fixedly connected with a PLC; the inside of the shell (1) is fixedly connected with an IGBT drive board (4); the inside of the shell (1) is fixedly connected with a leakage protector (5) on one side of the IGBT drive board (4); the inside of the shell (1) is fixedly connected with a control transformer (6); the inside of the shell (1) is fixedly connected with a drive transformer (7) on one side of the control transformer (6); the inside of the shell (1) is fixedly connected with a high-frequency transformer (9).

2. The stud welding machine according to claim 1, wherein The inside of the shell (1) is fixedly connected with an IGBT inverter and rectifier module (8); the IGBT inverter and rectifier module (8) is arranged below the drive transformer (7).

3. The stud welding machine of claim 1, wherein the stud welding machine is a stud arc welding machine. The high-frequency transformer (9) is arranged on one side of the IGBT inverter and rectifier module (8).

4. The stud welding machine of claim 1, wherein the stud welding machine is a stud arc welding machine. The inside of the shell (1) is fixedly connected with a reactance (10); the reactance (10) is arranged on one side of the high-frequency transformer (9).

5. The stud welding machine of claim 1, wherein the stud welding machine is a stud arc welding machine. The bottom end of the shell (1) is provided with a plurality of universal wheels (11).

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