Simple induction heating power supply for welding preheating dehydrogenation

Abstract

The utility model relates to a simple induction heating power supply for welding preheating dehydrogenation, which comprises a main circuit and a control circuit, the main circuit is used for realizing induction heating, converting external three-phase alternating current into intermediate-frequency alternating current for induction heating, and realizing heating of an induction heating load; the control circuit is used for controlling and monitoring the main circuit, and the induction heating power supply is controlled and managed through the main control board. According to the utility model, the aims of simplicity in operation, cost reduction and light weight of equipment are fulfilled, the control precision and efficiency are improved, the protection function is enhanced, the energy consumption and noise are reduced, and the requirements of conventional preheating hydrogen elimination application occasions are better met.

Description

TECHNICAL FIELD

[0001] The utility model relates to a simple induction heating power supply for welding preheating and hydrogen removal belongs to induction heating power supply field. BACKGROUND

[0002] Induction heating power supply has a wide range of applications in industrial welding, its main role is to preheat and hydrogen removal treatment to workpiece through the induction heating mode, to improve the welding quality and efficiency. At present, induction heating power supply is mainly divided into analog circuit control and digital circuit control two categories. The induction heating power supply of analog circuit control usually can only realize the basic power and current mode control, can satisfy some simple heating demand. However, the control parameter of this kind of power supply is not easy to modify, lacks flexibility, is difficult to adapt to the complex and changeable welding process requirement.

[0003] With the development of digital technology, the induction heating power supply of digital circuit control gradually rises. This kind of power supply has higher control precision, and the software design is also more flexible, can better satisfy various complex welding process demand. However, the existing digital circuit control induction heating power supply usually adopts multiple chips to control, leading to its function is too complex, cost is higher, and due to the large number of components, the weight of equipment is also relatively heavy, is not conducive to the installation and maintenance in practical application.

[0004] In the conventional preheating and hydrogen removal application occasion, although the digital control mode is required, its function demand is relatively simple, and does not need complex heat treatment process and excessive temperature control point. Therefore, the existing induction heating power supply has certain mismatch in function and cost, and cannot satisfy the demand of conventional preheating and hydrogen removal application well. INVENTION CONTENTS

[0005] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present scheme proposes a digital induction heating power supply based on single ARM control structure, aiming at solving the problem of lack of digital control of analog power supply, and overcoming the deficiencies of complex control system, high cost, many components and heavy equipment weight of the existing induction heating power supply.

[0006] The utility model provides a simple induction heating power supply for welding preheating and hydrogen removal, the technical scheme of the utility model is:

[0007] A simple induction heating power supply for welding preheating and hydrogen removal, including main circuit and control circuit, the main circuit is used for realizing induction heating, and the external three-phase alternating current is converted into the intermediate frequency alternating current of induction heating, and the heating of induction heating load is realized, the control circuit is used for controlling and monitoring main circuit, and the control and management of induction heating power supply are realized through main control board;

[0008] The main circuit comprises a molded case circuit breaker QF, an anti-interference magnetic ring L3, an anti-interference magnetic ring L4, an anti-interference magnetic ring L5, a rectifier bridge BD1, a high-frequency filter capacitor C1, a discharge porcelain tube resistor R1, an IGBT module, a voltage division sampling resistor R5, a medium-frequency transformer TR1, a filter capacitor group C2, an absorption capacitor C3, an absorption capacitor C4, a current transformer CT1 and a voltage transformer VT1, an input end of the molded case circuit breaker QF is used for connecting external three-phase alternating current; input ends of the anti-interference magnetic ring L3, the anti-interference magnetic ring L4 and the anti-interference magnetic ring L5 are connected to an output end of the molded case circuit breaker QF, and are used for reducing electromagnetic interference; the rectifier bridge BD1 is connected to output ends of the anti-interference magnetic ring L3, the anti-interference magnetic ring L4 and the anti-interference magnetic ring L5; the high-frequency filter capacitor C1 and the discharge porcelain tube resistor R1 are connected in parallel at two ends of the rectifier bridge BD1; one end of the voltage division sampling resistor R5 is connected between the high-frequency filter capacitor C1 and the discharge porcelain tube resistor R1, and the other end is connected to a main control board of a control circuit, and is used for collecting a direct-current bus voltage signal; the IGBT module comprises an IGBT1 module and an IGBT2 module, positive poles of the IGBT1 module and the IGBT2 module are connected to a positive pole of the rectifier bridge BD1, and negative poles of the IGBT1 module and the IGBT2 module are connected to a negative pole of the rectifier bridge BD1;

[0009] One end of a primary side of the medium-frequency transformer TR1 is connected to an output end of the IGBT1 module, and the other end is connected to an output end of the IGBT2 module through a direct-current blocking capacitor C5;

[0010] An absorption capacitor C3 is connected in parallel at two ends of the IGBT1 module, and an absorption capacitor C4 is connected in parallel at two ends of the IGBT2 module; the filter capacitor group C2 is connected in parallel between the discharge porcelain tube resistor R1 and the IGBT1 module; one end of a secondary side of the transformer TR1 is connected to a resonant capacitor group C6, and the other end of the resonant capacitor group C6 is connected to an induction heating load; the other end of the induction heating load is connected to the other end of the secondary side of the transformer TR1, and the resonant capacitor group C6 and the induction heating load form a resonant loop;

[0011] The current transformer CT1 is sleeved on an output end connecting line of the IGBT1, is used for acquiring a resonant output current signal, and an output end of the current transformer CT1 is connected to the main control board U1; input ends of the voltage transformer VT1 are connected at two ends of the resonant capacitor group C6, an output end of the voltage transformer VT1 is connected to the main control board U1, and the voltage transformer VT1 is used for acquiring a resonant output voltage signal;

[0012] The switching power supply P1 is connected to an output end of the molded case circuit breaker QF, and is used for providing 24V power supply for the control circuit; an output end A of the molded case circuit breaker QF and an input zero line are connected to an input end of the switching power supply P1, an output end of the switching power supply P1 outputs 24V+ and GND, and the switching power supply P1 supplies power to the control circuit;

[0013] The output end A, output end B and output end C of the molded case circuit breaker QF are connected to the fan FAN through the AC contactor KM3.1.

[0014] The control circuit comprises a signal acquisition control circuit and a main control system, the signal acquisition control circuit is used for monitoring and controlling the running state of the power supply; the main control system is used for controlling and managing the inductive heating power supply; the signal acquisition control circuit comprises a power supply indicator lamp HL10, a running indicator lamp HL8, an alarm indicator lamp HL9, a fan relay K3, a start-stop switch SB5 and an emergency stop switch SB6, one end of the power supply indicator lamp HL10 is connected to GND, and the other end is connected to 24V+; one end of the running indicator lamp HL8 is connected to 24V+, and the other end is connected to GND through a control switch K1; wherein the control switch K1 is controlled by the main control board U1; one end of the alarm indicator lamp HL9 is connected to 24V+, and the other end is connected to GND through a control switch K2, wherein the control switch K2 is controlled by the main control board U1; one end of the coil of the fan relay KM3.2 is connected to 24V+, and the other end is connected to GND through a control switch K3, wherein the control switch K3 is controlled by the main control board; one end of the start-stop switch SB5 is connected to 24V+, and the other end is connected to the main control board U1; one end of the emergency stop switch SB6 is connected to 24V+, and the other end is connected to the main control board U1.

[0015] The main control system comprises a main control board, an LCD screen and a drive board, the main control board is used for processing signals such as acquisition and calculation of AC voltage, temperature, IO, resonant output current and voltage and PWM output; the LCD screen is a medical-grade touch configuration screen, communicates with the main control board through RS485 and is used for displaying and setting various parameters; the drive board is used for amplifying and driving the PWM signal sent by the main control board and inverting output of the IGBT module.

[0016] The main control board comprises a direct-current voltage signal processing unit, a temperature signal processing unit, a communication processing unit, an indicator lamp / relay output signal processing unit and a switch input signal processing unit, the direct-current voltage signal processing unit is used for acquiring and processing the direct-current bus voltage signal transmitted by the voltage dividing sampling resistor R5; the temperature signal processing unit is used for acquiring and processing temperature signals; the communication processing unit is used for communication between the main control board and the LCD screen; the indicator lamp / relay output signal processing unit is used for controlling the on-off of the running indicator lamp HL8, the alarm indicator lamp HL9 and the fan relay KM3.2; the switch input signal processing unit is used for processing input signals of the start-stop switch SB5 and the emergency stop switch SB6.

[0017] Resonant output voltage processing unit for collecting and processing the resonant output voltage signal transmitted by the voltage transformer VT1; Resonant output current processing unit for collecting and processing the resonant output current signal transmitted by the current transformer CT1; PWM drive output control unit for generating PWM drive signal and outputting to the drive board; Protection control unit for protection processing according to the feedback signal of the drive board; DC / DC power supply unit for converting 24V power supply to power the ARM control unit; ARM control unit, the direct current voltage signal processing unit, temperature signal processing unit, communication processing unit, indicator light / relay output signal processing unit, switch input signal processing unit, resonant output voltage processing unit, resonant output current processing unit, PWM drive output control unit, protection control unit and DC / DC power supply unit are connected to the ARM control unit.

[0018] The absorption capacitor C3 and the absorption capacitor C4 are selected as 80uf capacitors.

[0019] The filter capacitor group C2 selects a 30uf DC filter capacitor, which realizes filtering and energy storage together with the absorption capacitor C3 and the absorption capacitor C4.

[0020] The utility model discloses the advantages are:

[0021] Reduce the number of components: through the optimization main circuit design, reduced unnecessary components, make the circuit structure more simple.

[0022] Reduce the weight of equipment: the reduction of components directly leads to the reduction of the overall weight of equipment, is convenient for installation and maintenance, especially in the industrial field environment, lighter equipment can improve work efficiency.

[0023] Single ARM control: adopt single ARM chip as the main control unit, integrates multiple functions, such as the collection and calculation of alternating voltage, temperature, IO, resonant output current, voltage and the processing of PWM output signal.The integrated design simplifies the structure of control system, improves the stability and reliability of system.

[0024] Easy to operate and manage: through the parameter display and setting of LCD screen, operation is more intuitive and convenient.The use of medical-grade touch configuration screen improves the human-computer interaction experience, so that the operator can quickly get started, reduces the training cost.

[0025] Anti-interference magnetic ring: set anti-interference magnetic ring in main circuit, effectively reduces electromagnetic interference, improves the anti-interference ability of power supply, ensures the stable operation of equipment in complex electromagnetic environment.

[0026] Filtering capacitor group: through the use of filtering capacitor group and absorption capacitor, further realizes filtering and energy storage effect, reduces voltage glitch and bus voltage fluctuation, improves the output quality of power supply.

[0027] Accurate signal acquisition and processing: the main control board integrates various signal processing units, which can accurately acquire and process DC bus voltage, temperature, resonance output current and voltage and other signals, realize real-time monitoring and accurate control of power supply running state.

[0028] The utility model realizes simple operation, cost reduction and equipment light weight target, improves control precision and efficiency simultaneously, strengthens protection function, reduces energy consumption and noise, better satisfies the demand of conventional preheating hydrogen elimination application occasion. BRIEF DESCRIPTION OF DRAWINGS

[0029] Fig. 1 It is the structure schematic drawing of main circuit of the utility model.

[0030] Fig. 2 It is the structure schematic drawing of signal acquisition control circuit of the utility model.

[0031] Fig. 3 It is the structure schematic drawing of main control system of the utility model.

[0032] Fig. 4 It is the structure schematic drawing of main control board of the utility model. DETAILED DESCRIPTION

[0033] The utility model will be more clear with the description of the advantages and characteristics of the utility model will be more clear with the description of the advantages and characteristics of the utility model. But these examples are only exemplary, and do not constitute any limitation on the scope of the utility model. Those skilled in the art should understand that the details and forms of the technical scheme of the utility model can be modified or replaced without departing from the spirit and scope of the utility model, but these modifications and replacements all fall within the protection scope of the utility model.

[0034] Referring to Figs. 1 to 4The utility model relates to a simple induction heating power supply for welding preheating hydrogen removal, including main circuit and control circuit, the main circuit be used for realizing induction heating, convert external three -phase alternating current into induction heating's intermediate frequency alternating current, realize the heating of induction heating load, the control circuit be used for controlling and monitoring to main circuit, realize the control and management of induction heating power supply through main control board, the main circuit includes plastic -shell circuit breaker QF, anti -interference magnetic ring L3, anti -interference magnetic ring L4, anti -interference magnetic ring L5, rectifier bridge BD1, high -frequency filter capacitor C1, discharge porcelain pipe resistance R1, IGBT module, voltage -division sampling resistance R5, intermediate frequency transformer TR1, filter capacitor group C2, absorption capacitor C3, absorption capacitor C4, current transformer CT1 and voltage transformer VT1, the input of plastic -shell circuit breaker QF be used for connecting external three -phase alternating current, the input of anti -interference magnetic ring L3, anti -interference magnetic ring L4 and anti -interference magnetic ring L5 be connected in the output of plastic -shell circuit breaker QF, be used for reducing electromagnetic interference, the rectifier bridge BD1 be connected in the output of anti -interference magnetic ring L3, anti -interference magnetic ring L4, anti -interference magnetic ring L5, high -frequency filter capacitor C1 and discharge porcelain pipe resistance R1 are connected in both ends of rectifier bridge BD1, one end of voltage -division sampling resistance R5 is connected between high -frequency filter capacitor C1 with discharge porcelain pipe resistance R1, and the other end is connected to the main control board of control circuit, be used for gathering direct current bus voltage signal, the IGBT module includes IGBT1 module and IGBT2 module, the positive pole of IGBT1 module and IGBT2 module is connected to the positive pole of rectifier bridge BD1, and the negative pole is connected the negative pole of rectifier bridge BD1, the primary side one end of intermediate frequency transformer TR1 is connected to the output of IGBT1 module, and the other end is connected to the output of IGBT2 module through the direct current -isolating capacitor C5, and the absorption capacitor C3 is connected in both ends of IGBT1 module, and the absorption capacitor C4 is connected in both ends of IGBT2 module, the filter capacitor group C2 is connected in between discharge porcelain pipe resistance R1 and IGBT1 module, one end of transformer TR1's secondary side is connected to resonance capacitor group C6, the other end of resonance capacitor group C6 is connected induction heating load, and the other end of induction heating load is connected the other end of transformer TR1's secondary side, and this resonance capacitor group C6 and induction heating load form resonance loop, the current transformer CT1 is set up on the output connection line of IGBT1, be used for obtaining resonance output current signal, and the output of current transformer CT1 is connected to main control board U1, the input of voltage transformer VT1 is connected in both ends of resonance capacitor group C6, the output of voltage transformer VT1 is connected to main control board U1, be used for obtaining resonance output voltage signal, the switching power supply P1 is connected in the output of plastic -shell circuit breaker QF, be used for providing 24V power supply for control circuit,The output end A and the input zero line of the molded case circuit breaker QF are connected to the input end of the switching power supply P1, the output end of the switching power supply P1 outputs 24V+ and GND to power the control circuit; the output end A, the output end B and the output end C of the molded case circuit breaker QF are connected to the fan FAN through the AC contactor KM3.1. Among them, the absorption capacitor C3 and the absorption capacitor C4 select 80uf capacitors; the filter capacitor group C2 selects a 30uf DC filter capacitor, which realizes filtering and energy storage together with the absorption capacitor C3 and the absorption capacitor C4.

[0035] Based on the configuration of the main circuit and the control circuit, the following advantages are realized:

[0036] 1. Reduced electromagnetic interference

[0037] Anti-interference magnetic ring: By setting anti-interference magnetic ring L3, anti-interference magnetic ring L4 and anti-interference magnetic ring L5 in the main circuit, electromagnetic interference can be effectively reduced, the anti-interference ability of the power supply can be improved, and the stable operation of the equipment in complex electromagnetic environment can be ensured.

[0038] High-frequency filter capacitor: High-frequency filter capacitor C1 is connected in parallel across rectifier bridge BD1, further filtering out high-frequency interference and improving the output quality of the power supply.

[0039] 2. Accurate signal acquisition and control

[0040] Voltage division sampling resistor: Voltage division sampling resistor R5 is connected between high-frequency filter capacitor C1 and discharge porcelain tube resistor R1, used to collect DC bus voltage signal and provide accurate voltage feedback for the control circuit.

[0041] Current transformer and voltage transformer: Current transformer CT1 and voltage transformer VT1 are used to obtain resonance output current signal and voltage signal respectively, which are transmitted to main control board U1 to realize real-time monitoring and accurate control of the power supply running state.

[0042] 3. High-efficiency inverter output

[0043] IGBT module: IGBT module (including IGBT1 and IGBT2) as the core switching device can efficiently convert DC power into intermediate frequency AC power to realize heating of the induction heating load.

[0044] Intermediate frequency transformer and resonance capacitor group: The combination of intermediate frequency transformer TR1 and resonance capacitor group C6 forms a resonance circuit to improve energy conversion efficiency and realize efficient heating of the induction heating load.

[0045] 4. Enhanced protection function

[0046] Absorption capacitor: The absorption capacitor C3 and the absorption capacitor C4 are connected in parallel across the IGBT module, which can absorb voltage glitches in the switching process, reduce the voltage stress of the IGBT, and improve the reliability and life of the device.

[0047] Filter capacitor group: The filter capacitor group C2 and the absorption capacitor jointly realize the functions of filtering and energy storage, further improving the output quality and stability of the power supply.

[0048] 5. Power management and control

[0049] Switching power supply: The switching power supply P1 provides a 24V power supply for the control circuit to ensure stable operation of the control circuit.

[0050] Fan control: The start and stop of the fan FAN are controlled by the AC contactor KM3.1 to realize the heat dissipation management of the device and improve the reliability and life of the device.

[0051] Simplified main circuit components: By optimizing the design of the main circuit, unnecessary components are reduced, the cost and weight of the device are reduced, and the installation and maintenance are facilitated.

[0052] By optimizing the design of the main circuit and the control circuit, the reduction of electromagnetic interference, accurate signal acquisition and control, efficient inverter output, enhanced protection function, convenient power management and control, easy operation, cost reduction and device lightweight, and strong adaptability are achieved, which better meets the needs of conventional preheating and hydrogen removal applications.

[0053] The control circuit includes a signal acquisition control circuit and a main control system. The signal acquisition control circuit is used for monitoring and controlling the running state of the power supply. The main control system is used for inductive heating power control and management. The signal acquisition control circuit includes a power indicator HL10, a running indicator HL8, an alarm indicator HL9, a fan relay K3, a start-stop switch SB5, and an emergency stop switch SB6. One end of the power indicator HL10 is connected to GND, and the other end is connected to 24V+. One end of the running indicator HL8 is connected to 24V+, and the other end is connected to GND through a control switch K1. The control switch K1 is controlled by the main control board U1. One end of the alarm indicator HL9 is connected to 24V+, and the other end is connected to GND through a control switch K2. The control switch K2 is controlled by the main control board U1. One end of the coil of the fan relay KM is connected to 24V+, and the other end is connected to GND through a control switch K3. The control switch K3 is controlled by the main control board. One end of the start-stop switch SB5 is connected to 24V+, and the other end is connected to the main control board U1. One end of the emergency stop switch SB6 is connected to 24V+, and the other end is connected to the main control board U1.

[0054] The control circuit structure has the following advantages:

[0055] 1. Intuitive operation status indication

[0056] Power indicator: The power indicator HL10 can intuitively determine whether the power is on. One end is connected to GND and the other end is connected to 24V+. When the power supply is normal, the indicator lights up, providing clear visual feedback.

[0057] Running indicator: The running indicator HL8 is connected to the main control board U1 through the control switch K1. When the device is running, the main control board controls K1 to close, and the indicator lights up, showing that the device is in working condition. When it stops, K1 is disconnected, and the indicator is turned off, making it convenient for operators to quickly judge the running status of the device.

[0058] Alarm indicator: The alarm indicator HL9 is connected to the main control board U1 through the control switch K2. When the device fails, the main control board controls K2 to close, and the indicator lights up, reminding the operator to handle it in time to ensure the safe operation of the device.

[0059] 2. Precise control and feedback

[0060] Fan relay: One end of the coil of the fan relay KM3.2 is connected to 24V+, and the other end is connected to GND through the control switch K3, which is controlled by the main control board.

[0061] When the device is running, the main control board controls K3 to close, and the fan runs to provide cooling for the device. When the device stops and the internal temperature is normal, K3 is disconnected, and the fan stops, achieving precise cooling control and reducing energy consumption and noise.

[0062] Start-stop switch: One end of the start-stop switch SB5 is connected to 24V+, and the other end is connected to the main control board U1. The operator presses SB5 to input 24V+ to the main control board, and the device runs. SB5 is reset, 24V+ is disconnected from the main control board, and the device stops running, achieving precise start-stop control of the device and easy operation.

[0063] Emergency stop switch: One end of the emergency stop switch SB6 is connected to 24V+, and the other end is connected to the main control board U1. In an emergency, the operator presses SB6, 24V+ is disconnected from the main control board, and the device stops running, ensuring the safety of the operator and the device.

[0064] 3. High integration and simplified design

[0065] Signal acquisition and control integration: The signal acquisition and control circuit integrates the power indicator, running indicator, alarm indicator, fan relay, start-stop switch, and emergency stop switch, and controls and manages them through the main control board U1, simplifying the circuit design, reducing the number of components, and reducing the cost and weight of the device.

[0066] Master system integration: The master system includes a master board, an LCD screen, and a driver board. The master board is responsible for the collection and calculation of AC voltage, temperature, IO, resonant output current, and voltage, as well as the processing of PWM output signals. The LCD screen is used for displaying and setting various parameters. The driver board is used to amplify and drive the PWM signals sent by the master board to the IGBT module for inverter output, achieving comprehensive control and management of the induction heating power supply, and improving the stability and reliability of the system.

[0067] Through the coordinated work of the signal acquisition control circuit and the master system, precise control and management of the induction heating power supply are achieved, with intuitive operation status indication, precise control and feedback, highly integrated and simplified design, flexible parameter setting and adjustment, enhanced safety and reliability, and reduced energy consumption and noise, etc. It better meets the needs of conventional preheating and hydrogen removal applications.

[0068] The master system includes a master board, an LCD screen, and a driver board. The master board is used for the collection and calculation of AC voltage, temperature, IO, resonant output current, and voltage, as well as the processing of PWM output signals. The LCD screen is a medical-grade touch configuration screen that communicates with the master board through RS485 and is used for displaying and setting various parameters. The driver board is used to amplify and drive the PWM signals sent by the master board to the IGBT module for inverter output.

[0069] The master system has the following advantages:

[0070] Master board: The master board integrates the functions of AC voltage, temperature, IO, resonant output current, and voltage collection and calculation, as well as PWM output signal processing, achieving comprehensive control and management of the induction heating power supply. This highly integrated design reduces the number of components, simplifies the circuit structure, and improves the reliability and stability of the system.

[0071] LCD screen: The medical-grade touch configuration screen communicates with the master board through RS485 and can display various operating parameters and status information in real time, such as output current, output power, output voltage, DC bus voltage, resonant frequency, system temperature, etc. At the same time, the operator can flexibly set and modify parameters such as working mode, target current, target power, target temperature, etc. through the screen, meeting the needs of different welding processes.

[0072] Driver board: The driver board is responsible for amplifying the PWM signals sent by the master board and driving the IGBT module for inverter output, ensuring the efficiency and stability of the inverter process. This specialized driver board design improves the efficiency and reliability of signal transmission, further enhancing the performance of the system.

[0073] Precise Signal Acquisition and Processing: The main control board can accurately acquire and process various signals such as AC voltage, temperature, IO, resonance output current and voltage, etc., realizing real-time monitoring and precise control of the power supply operating state. This helps to discover and handle abnormal situations in time, ensuring the safe operation of the equipment.

[0074] Efficient PWM Output: The PWM signal generated by the main control board is amplified by the drive board and can efficiently drive the IGBT module for inverter output, improving energy conversion efficiency and reducing energy consumption. At the same time, precise PWM control helps to improve the stability of output voltage and current, further improving heating quality.

[0075] Intelligent System Management: Through the LCD screen, operators can easily set and adjust parameters, realizing intelligent management of the induction heating power supply. The design of this human-machine interface improves the convenience and efficiency of operation, reducing the possibility of human error.

[0076] Diversified Parameter Setting: Operators can set and modify various parameters such as working mode, target current, target power, target temperature, etc. through the LCD screen, meeting the needs of different welding processes. This flexible parameter setting function enables the device to adapt to various complex welding scenarios, improving the versatility and adaptability of the device.

[0077] Real-time Parameter Adjustment: During the welding process, operators can adjust parameters such as temperature and power in real time according to actual needs, ensuring the stability and quality of the welding process. This real-time adjustment function improves the flexibility and response speed of the device, further improving welding efficiency and quality.

[0078] Reliable Drive Function: The drive board can accurately amplify and drive the IGBT module with the PWM signal from the main control board, ensuring the stability and reliability of inverter output. This reliable drive function helps to improve the operating efficiency and life of the device, reducing the possibility of device failure. Perfect protection function: The main control board also has protection control function, which can perform real-time protection processing according to the feedback signal of the drive board, ensuring that the device can cut off the power supply in time in abnormal conditions to avoid damage. This perfect protection function improves the safety and reliability of the device, ensuring the safety of operators and equipment.

[0079] The main control system structure realizes efficient management and control of the induction heating power supply through the advantages of high integration, precise control, flexible parameter setting, improved system stability and reliability, and reduced energy consumption, etc., meeting the needs of different welding processes, improving welding quality and efficiency, reducing operating costs, and having wide application prospects.

[0080] The main control board includes a DC voltage signal processing unit 1 for collecting and processing the DC bus voltage signal transmitted by the voltage sampling resistor R5; a temperature signal processing unit 2 for collecting and processing the temperature signal; a communication processing unit 3 for communication between the main control board and the LCD screen; an indicator light / relay output signal processing unit 4 for controlling the on-off of the operation indicator light HL8, the alarm indicator light HL9, and the fan relay KM3.2; a switch input signal processing unit 5 for processing the input signals of the start-stop switch SB5 and the emergency stop switch SB6; a resonance output voltage processing unit 6 for collecting and processing the resonance output voltage signal transmitted by the voltage transformer VT1; a resonance output current processing unit 7 for collecting and processing the resonance output current signal transmitted by the current transformer CT1; a PWM drive output control unit 8 for generating PWM drive signals and outputting to the drive board; a protection control unit 9 for protection processing according to the feedback signals of the drive board; a DC / DC power supply unit 10 for converting the 24V power supply to power the ARM control unit; and an ARM control unit 11, wherein the DC voltage signal processing unit, the temperature signal processing unit, the communication processing unit, the indicator light / relay output signal processing unit, the switch input signal processing unit, the resonance output voltage processing unit, the resonance output current processing unit, the PWM drive output control unit, the protection control unit, and the DC / DC power supply unit are all connected to the ARM control unit.

[0081] The main control board has the following advantages:

[0082] 1. High integration and modular design

[0083] Functional integration: The main control board integrates multiple functional units, including DC voltage signal processing, temperature signal processing, communication processing, indicator light / relay output signal processing, switch input signal processing, resonance output voltage processing, resonance output current processing, PWM drive output control, protection control, and DC / DC power supply unit, etc., realizing comprehensive control and management of the induction heating power supply. This highly integrated design reduces the number of components, simplifies the circuit structure, and improves the reliability and stability of the system.

[0084] Modular design: Each functional unit is designed and integrated in a modular manner, facilitating maintenance and upgrading. When a unit fails, it can be replaced or repaired individually, reducing maintenance costs and downtime. At the same time, modular design also makes the system more expandable, allowing easy addition or modification of functional modules according to actual needs.

[0085] 2. Precise signal collection and processing

[0086] DC voltage signal processing: The DC voltage signal processing unit 1 is responsible for collecting and processing the DC bus voltage signal transmitted by the sampling resistor R5, providing accurate voltage feedback to the main control board, ensuring stable operation of the system under different load conditions.

[0087] Temperature signal processing: The temperature signal processing unit 2 collects and processes temperature signals, real-time monitors the temperature state of the device, prevents overheating caused by device damage, and improves the safety and reliability of the device.

[0088] Resonant output signal processing: The resonant output voltage processing unit 6 and the resonant output current processing unit 7 respectively collect and process the resonant output signals transmitted by the voltage transformer VT1 and the current transformer CT1, providing accurate output feedback to the main control board, achieving precise control of the induction heating process, and improving heating efficiency and quality.

[0089] 3. Flexible control and feedback

[0090] Indicator light / relay output signal processing: The indicator light / relay output signal processing unit 4 controls the on-off of the running indicator light HL8, the alarm indicator light HL9 and the fan relay KM3.2, achieving intuitive indication of the device running state and precise control of the fan, improving the operability and safety of the device.

[0091] Switch input signal processing: The switch input signal processing unit 5 processes the input signals of the start-stop switch SB5 and the emergency stop switch SB6, achieving flexible start-stop control and emergency stop function of the device, ensuring the safety of the operator and the device.

[0092] PWM drive output control: The PWM drive output control unit 8 generates PWM drive signals and outputs to the drive board, achieving precise control of the IGBT module, improving the efficiency and stability of the inverter output.

[0093] 4. Reliable protection and power management

[0094] Protection control: The protection control unit 9 performs protection processing according to the feedback signals of the drive board, and can take protective measures such as cutting off the power or reducing the power output when the system appears abnormal, preventing device damage, and improving the reliability and safety of the system.

[0095] DC / DC power management: The DC / DC power supply unit 10 converts the 24V power supply to power the ARM control unit, ensuring that the main control board can work stably under different power conditions, improving the power adaptability and reliability of the system.

[0096] 5. Core control capability

[0097] ARM control unit: The ARM control unit 11 is the core of the main control board, integrating the control and management functions of all functional units, with powerful data processing and control capabilities. Through the ARM control unit, the main control board can implement complex control algorithms and logic, improving the intelligent level and control precision of the system.

[0098] 6. Improve system stability and reliability

[0099] Stable signal transmission and processing: The signal transmission and processing between various functional units is realized through the high-speed bus inside the main control board, ensuring the accuracy and real-time performance of the data, and improving the overall performance and reliability of the system.

[0100] 7. Reduce energy consumption and improve efficiency

[0101] Precise control and management: Through the precise control and management of the main control board, the induction heating power supply can realize efficient energy conversion and output, reducing energy consumption and improving the overall efficiency of the system. Optimized power management: The high-efficiency power conversion and management of the DC / DC power supply unit 10 ensure that the main control board can work stably under different power conditions, further improving the power utilization efficiency of the system.

[0102] The main control board structure realizes efficient management and control of the induction heating power supply through the advantages of high integration, precise control, flexible feedback, reliable protection, and powerful core control capabilities, improving the stability, reliability, and efficiency of the system, reducing energy consumption and maintenance costs, meeting the needs of different welding processes, and having wide application prospects.

[0103] The working principle of the utility model is as follows:

[0104] (1) Power input and anti-interference

[0105] Moulded case circuit breaker QF: Connects external three-phase alternating current to provide power for the entire system.

[0106] Anti-interference magnetic ring L3, L4, L5: Connected to the output end of the molded case circuit breaker QF, used to reduce electromagnetic interference and ensure stable operation of the power supply in complex electromagnetic environments.

[0107] (2) Rectification and filtering

[0108] Rectifier bridge BD1: Rectifies three-phase alternating current to direct current to provide stable direct current power for subsequent circuits.

[0109] High-frequency filter capacitor C1: Connected in parallel across the rectifier bridge BD1 to further filter out high-frequency interference and improve the output quality of the power supply.

[0110] (3) DC bus voltage sampling

[0111] Voltage division sampling resistor R5: connected between high-frequency filter capacitor C1 and discharge porcelain tube resistor R1, used to collect DC bus voltage signal and transmit the signal to main control board U1.

[0112] (4) Inverter output

[0113] IGBT module: including IGBT1 module and IGBT2 module, positive connected to the positive of rectifier bridge BD1, negative connected to the negative of rectifier bridge BD1. IGBT module as the core switching device, converts DC to intermediate frequency AC.

[0114] Intermediate frequency transformer TR1: one end of the primary side is connected to the output end of IGBT1 module, the other end is connected to the output end of IGBT2 module through the DC blocking capacitor C5. Intermediate frequency transformer steps up or steps down the intermediate frequency AC to meet the demand of induction heating load.

[0115] Absorption capacitor C3 and C4: connected in parallel across the IGBT module, used to absorb voltage glitch in switching process, reduce voltage stress of IGBT, improve reliability and life of the device. Filter capacitor group C2: connected in parallel between discharge porcelain tube resistor R1 and IGBT1 module, together with absorption capacitor to realize filtering and energy storage, further improve the output quality and stability of the power supply.

[0116] (5) Resonant circuit

[0117] Resonant capacitor group C6: connected to the secondary side of intermediate frequency transformer TR1, forms a resonant circuit with induction heating load, improves energy conversion efficiency, realizes efficient heating of induction heating load.

[0118] (6) Signal acquisition

[0119] Current transformer CT1: set on the output connection line of IGBT1, used to obtain resonant output current signal and transmit the signal to main control board U1.

[0120] Voltage transformer VT1: connected across resonant capacitor group C6, used to obtain resonant output voltage signal and transmit the signal to main control board U1.

[0121] (7) Power management

[0122] Switching power supply P1: connected to the output of molded case circuit breaker QF, provides 24V power supply for control circuit, ensures stable operation of control circuit.

[0123] Fan control: controls the start and stop of fan FAN through AC contactor KM3.1, realizes heat dissipation management of the device, improves the reliability and life of the device.

[0124] (8) Signal acquisition control circuit:

[0125] Power indicator HL10: one end connected to GND, the other end connected to 24V+, used to indicate whether the power is on.

[0126] Running indicator HL8: one end connected to 24V+, the other end connected to GND through control switch K1, controlled by the main control board U1, used to indicate the running state of the device.

[0127] Alarm indicator HL9: one end connected to 24V+, the other end connected to GND through control switch K2, controlled by the main control board U1, used to indicate the fault state of the device.

[0128] Fan relay K3.2: one end of the coil connected to 24V+, the other end connected to GND through control switch K3, controlled by the main control board U1, used to control the start and stop of the fan.

[0129] Start-stop switch SB5: one end connected to 24V+, the other end connected to the main control board U1, used to control the start and stop of the device.

[0130] Emergency stop switch SB6: one end connected to 24V+, the other end connected to the main control board U1, used to emergency stop the device in emergency situations.

[0131] Main control board: responsible for the collection and calculation of AC voltage, temperature, IO, resonant output current, voltage, and the processing of PWM output signals, to realize the overall control and management of the induction heating power supply.

[0132] LCD screen: medical-grade touch configuration screen, communicates with the main control board through RS485, used to display and set various parameters such as output current, output power, output voltage, DC bus voltage, resonant frequency, system temperature, etc.

[0133] Drive board: amplifies the PWM signal sent by the main control board and drives the IGBT module to perform inverter output, ensuring the efficiency and stability of the inverter process.

[0134] (9) DC voltage signal processing unit 1: collects and processes the DC bus voltage signal transmitted by the sampling resistor R5, providing accurate voltage feedback for the main control board.

[0135] Temperature signal processing unit 2: collects and processes temperature signals, real-time monitors the temperature state of the device, prevents overheating caused by device damage.

[0136] Resonant output voltage processing unit 6: collects and processes the resonant output voltage signal transmitted by the voltage transformer VT1, providing accurate output feedback for the main control board.

[0137] Resonant output current processing unit 7: collect and process the resonant output current signal transmitted by current transformer CT1, and provide accurate output feedback for the main control board.

[0138] Indicator light / relay output signal processing unit 4: controls the on-off of operation indicator light HL8, alarm indicator light HL9 and fan relay K3, and realizes intuitive indication of the running state of the equipment and accurate control of the fan.

[0139] Switch input signal processing unit 5: processes the input signals of start-stop switch SB5 and emergency stop switch SB6, and realizes flexible start-stop control and emergency stop function of the equipment.

[0140] PWM drive output control unit 8: generates PWM drive signal and outputs to the drive board, realizes accurate control of IGBT module, and improves the efficiency and stability of inverter output.

[0141] Protection and power management:

[0142] Protection control unit 9: performs protection processing according to the feedback signal of the drive board, and can take protection measures such as cutting off the power supply or reducing the power output in time when the system appears abnormal, to prevent the equipment from being damaged.

[0143] DC / DC power supply unit 10: converts 24V power supply to power supply for ARM control unit, to ensure that the main control board can work stably under different power supply conditions.

[0144] ARM control unit 11: as the core of the main control board, integrates the control and management functions of all functional units, has powerful data processing and control ability, realizes complex control algorithm and logic, and improves the intelligent level and control precision of the system.

[0145] The utility model discloses a design of optimizing main circuit and control circuit, realizes the reduction of electromagnetic interference, accurate signal acquisition and control, efficient inverter output, enhanced protection function, convenient power management and control, simple operation, cost reduction and equipment light weight and strong adaptability and other advantages, better satisfy the demand of conventional preheating hydrogen elimination application occasion.

[0146] The above is only the preferred specific embodiment of the utility model, but the protection scope of the utility model does not limit to this, any skilled person in the art in the technical range disclosed by the utility model, according to the technical scheme and utility model concept of the utility model, carries out equivalent replacement or change, all should be covered in the protection scope of the utility model.

Claims

1. A simple induction heating power source for welding preheating dehydrogenation, characterized by, The induction heating power supply comprises a main circuit and a control circuit, the main circuit is used for realizing induction heating, converting external three-phase alternating current into induction heating intermediate frequency alternating current, and realizing heating of an induction heating load; the control circuit is used for controlling and monitoring the main circuit, and the control and management of the induction heating power supply are realized through a main control board; The main circuit comprises a molded case circuit breaker QF, anti-interference magnetic rings L3, L4 and L5, a rectifier bridge BD1, a high-frequency filter capacitor C1, a discharge porcelain tube resistor R1, IGBT modules, a voltage division sampling resistor R5, an intermediate frequency transformer TR1, a filter capacitor group C2, absorption capacitors C3 and C4, a current transformer CT1 and a voltage transformer VT1; an input end of the molded case circuit breaker QF is used for connecting external three-phase alternating current; input ends of the anti-interference magnetic rings L3, L4 and L5 are connected to an output end of the molded case circuit breaker QF, and are used for reducing electromagnetic interference; the rectifier bridge BD1 is connected to output ends of the anti-interference magnetic rings L3, L4 and L5; the high-frequency filter capacitor C1 and the discharge porcelain tube resistor R1 are connected in parallel at two ends of the rectifier bridge BD1; one end of the voltage division sampling resistor R5 is connected between the high-frequency filter capacitor C1 and the discharge porcelain tube resistor R1, and the other end is connected to a main control board of the control circuit, and is used for collecting a direct current bus voltage signal; the IGBT modules comprise IGBT1 modules and IGBT2 modules; positive poles of the IGBT1 modules and the IGBT2 modules are connected to a positive pole of the rectifier bridge BD1, and negative poles of the IGBT1 modules and the IGBT2 modules are connected to a negative pole of the rectifier bridge BD1; One end of a primary side of the intermediate frequency transformer TR1 is connected to an output end of the IGBT1 module, and the other end is connected to an output end of the IGBT2 module through a direct current blocking capacitor C5; Absorption capacitors C3 and C4 are connected in parallel at two ends of the IGBT1 module and the IGBT2 module respectively; the filter capacitor group C2 is connected in parallel between the discharge porcelain tube resistor R1 and the IGBT1 module; one end of a secondary side of the transformer TR1 is connected to a resonance capacitor group C6, the other end of the resonance capacitor group C6 is connected to an induction heating load, and the other end of the induction heating load is connected to the other end of the secondary side of the transformer TR1, and the resonance capacitor group C6 and the induction heating load form a resonance loop; The current transformer CT1 is sleeved on an output end connecting line of the IGBT1, and is used for acquiring a resonance output current signal; an output end of the current transformer CT1 is connected to the main control board U1; An input end of the voltage transformer VT1 is connected at two ends of the resonance capacitor group C6; an output end of the voltage transformer VT1 is connected to the main control board U1, and is used for acquiring a resonance output voltage signal; The switching power supply P1 is connected to an output end of the molded case circuit breaker QF, and is used for providing a 24V power supply for the control circuit; an output end A and an input zero line of the molded case circuit breaker QF are connected to an input end of the switching power supply P1; an output end of the switching power supply P1 outputs 24V+ and GND, and supplies power to the control circuit. The output end A, the output end B and the output end C of the molded case circuit breaker QF are connected to the fan FAN through the AC contactor KM3.

1.

2. The simple induction heating power source for welding preheating dehydrogenation according to claim 1, characterized by, The control circuit comprises a signal acquisition control circuit and a main control system, The signal acquisition control circuit is used for monitoring and controlling the operation state of the power supply; the main control system is used for controlling and managing the inductive heating power supply; the signal acquisition control circuit comprises a power supply indicator lamp HL10, an operation indicator lamp HL8, an alarm indicator lamp HL9, a fan relay K3, a start-stop switch SB5 and an emergency stop switch SB6, one end of the power supply indicator lamp HL10 is connected to GND, and the other end is connected to 24V+; one end of the operation indicator lamp HL8 is connected to 24V+, and the other end is connected to GND through a control switch K1; wherein the control switch K1 is controlled by the main control board U1; one end of the alarm indicator lamp HL9 is connected to 24V+, and the other end is connected to GND through a control switch K2; wherein the control switch K2 is controlled by the main control board U1; one end of the coil of the fan relay KM3.2 is connected to 24V+, and the other end is connected to GND through a control switch K3; wherein the control switch K3 is controlled by the main control board; one end of the start-stop switch SB5 is connected to 24V+, and the other end is connected to the main control board U1; one end of the emergency stop switch SB6 is connected to 24V+, and the other end is connected to the main control board U1.

3. The simple induction heating power source for welding preheating dehydrogenation according to claim 2, characterized by, The main control system comprises a main control board, an LCD screen and a drive board, the main control board is used for processing signals such as AC voltage, temperature, IO, resonant output current, voltage acquisition and calculation and PWM output; the LCD screen is a medical-grade touch configuration screen, communicates with the main control board through RS485, and is used for displaying and setting various parameters; the drive board is used for amplifying and driving the PWM signal sent by the main control board to output inversely by the IGBT module.

4. The simple induction heating power source for welding preheating dehydrogenation according to claim 3, characterized by, The main control board comprises: a DC voltage signal processing unit for acquiring and processing the DC bus voltage signal transmitted by the voltage dividing sampling resistor R5; a temperature signal processing unit for acquiring and processing temperature signals; a communication processing unit for communication between the main control board and the LCD screen; an indicator lamp / relay output signal processing unit for controlling the on-off of the operation indicator lamp HL8, the alarm indicator lamp HL9 and the fan relay KM3; a switch input signal processing unit for processing the input signals of the start-stop switch SB5 and the emergency stop switch SB6; a resonant output voltage processing unit for acquiring and processing the resonant output voltage signal transmitted by the voltage transformer VT1; a resonant output current processing unit for acquiring and processing the resonant output current signal transmitted by the current transformer CT1; a PWM drive output control unit for generating a PWM drive signal and outputting to the drive board; a protection control unit for protection processing according to the feedback signal of the drive board; a DC / DC power supply unit for converting the 24V power supply to supply power to the ARM control unit. An ARM control unit, the direct current voltage signal processing unit, temperature signal processing unit, communication processing unit, indicator light / relay output signal processing unit, switch input signal processing unit, resonance output voltage processing unit, resonance output current processing unit, PWM drive output control unit, protection control unit and DC / DC power supply unit are all connected to the ARM control unit.

5. The simple induction heating power supply for preheating and dehydrogenation of welding according to claim 1, characterized in that, The absorption capacitor C3 and the absorption capacitor C4 are 80uf capacitors.

6. The simple induction heating power supply for welding preheat dehydrogenation according to claim 1, characterized in that, The filter capacitor group C2 is a 30uf direct current filter capacitor, which, together with the absorption capacitor C3 and the absorption capacitor C4, realizes filtering and energy storage.

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