Energy storage stud welding machine capable of accurately controlling welding time

Abstract

The utility model discloses an energy storage stud welding machine capable of accurately controlling welding time, which relates to the technical field of stud welding machines and comprises a casing, and an integrated power filter, a control transformer, an inverter charging board, a charging and discharging capacitor, an energy storage capacitor and a control board are fixed in the casing. The integrated power supply filter is fixed on the inner side of the power supply input port on the rear wall of the shell and connected with an external power supply through a copper bar; according to the energy storage stud welding machine, accurate control over welding time is achieved through control of the microprocessor, a perfect heat dissipation system and a safety protection module are arranged, efficient power supply filtering and inversion charging technologies are adopted, and the problems that an existing energy storage stud welding machine is inaccurate in welding time control, poor in heat dissipation performance and insufficient in safety protection are solved; and meanwhile, the adaptability of equipment to a complex power grid and the electric energy conversion efficiency are improved, the welding quality and the equipment reliability are remarkably improved, and the high-precision stud welding requirements of various industrial scenes are met.

Description

Technical Field

[0001] This utility model relates to the field of stud welding machine technology, specifically to an energy storage stud welding machine that precisely controls welding time. Background Technology

[0002] Energy storage stud welding machine is a special equipment that uses capacitor energy storage and instantaneous discharge to weld metal studs to substrates. It is widely used in building steel structures, shipbuilding and automotive industries. Its core principle is to use energy storage capacitors to pre-store electrical energy and release high-energy pulse current at the moment of triggering, so that the contact surface between the stud and the workpiece melts instantly and forms a metallurgical bond.

[0003] Existing energy storage stud welding machines typically include a charging circuit, an energy storage capacitor bank, and a mechanical triggering device. During operation, the external power supply is rectified and filtered to charge the capacitor to the set voltage. The operator triggers the discharge circuit via a foot switch, and the capacitor energy is instantly released to the stud and workpiece through the welding torch. The welding time is controlled by a mechanical relay or basic electronic circuit, and temperature protection mostly relies on a bimetallic strip temperature control switch. Fault detection is simply indicated by indicator lights. Although such equipment can meet basic welding needs, its control logic is simple and lacks real-time parameter monitoring and adaptive adjustment capabilities.

[0004] Current energy storage stud welding machines have the following shortcomings: First, the welding time control is not precise enough, mainly relying on manual adjustment of the charging voltage and discharge circuit resistance, making it difficult to achieve millisecond-level precise control, which affects welding quality and consistency; Second, the heat dissipation performance needs to be improved, as internal components are prone to overheating during long-term operation, affecting equipment stability and service life; Third, there is a lack of effective safety protection mechanisms, such as welding being triggered even when the welding torch is not positioned accurately, which can easily lead to welding defects or even safety accidents. Utility Model Content

[0005] The purpose of this invention is to provide an energy storage stud welding machine that can precisely control welding time, in order to solve the technical problem that the welding time control in the prior art is not precise enough, mainly relying on manual adjustment of charging voltage and discharge circuit resistance, which makes it difficult to achieve millisecond-level precise control and affects welding quality and consistency.

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

[0007] An energy storage stud welding machine for precise control of welding time includes a housing, inside which are fixed an integrated power filter, a control transformer, an inverter charging board, a charging / discharging capacitor, an energy storage capacitor, and a control board. The integrated power filter is fixed inside the power input port on the rear wall of the housing and connected to an external power source via a copper busbar. The control transformer is installed in front of the integrated power filter, and its primary coil is connected to the output terminal of the filter via a copper busbar. The inverter charging board is vertically fixed to the right side of the control transformer and mechanically connected to the secondary winding terminal of the transformer via bolts. The charging / discharging capacitor and the energy storage capacitor are horizontally arranged below the inverter charging board and connected in parallel to the output terminal of the inverter charging board via a stacked busbar. The control board is horizontally installed inside the operation panel on the front of the housing and integrates a microprocessor controller.

[0008] As a further embodiment of this utility model, it also includes a cooling fan structure, a temperature control module, a welding trigger locking module, and a digital display screen; the cooling fan structure is located behind the control board and its power terminals are connected to the V output winding of the control transformer via wires; the temperature control module is attached to the surface of the energy storage capacitor shell and connected to the ADC interface of the control board via a shielded cable; the welding trigger locking module is fixed at the welding gun interface on the top of the shell and connected to the communication interface of the control board via an RS bus; the digital display screen is embedded in the surface of the operation panel and connected to the data interface of the control board via a ribbon cable; the microprocessor controller is connected to the PWM control terminal of the inverter charging board and the speed control signal terminal of the cooling fan via a ribbon cable; and a voltage equalization resistor group is provided between the charging / discharging capacitor and the energy storage capacitor.

[0009] As a further embodiment of this utility model: the cooling fan structure includes a temperature sensor, a frequency converter, and a detachable dust filter. The temperature sensor is embedded in the heat sink surface of the inverter charging board, and the frequency converter is connected to the speed control port of the control board through a PWM signal line.

[0010] As a further embodiment of this utility model: the integrated power filter consists of an EMI filter and a transient voltage suppressor connected in series. The input terminal of the EMI filter is connected to an external power supply through a copper busbar, and the transient voltage suppressor is connected in parallel between the output terminal of the EMI filter and the primary coil of the control transformer.

[0011] As a further embodiment of this utility model: the welding trigger locking module includes an infrared positioning sensor, an electromagnetic locking mechanism and an LED warning light. The detection end of the infrared positioning sensor faces the welding gun outlet direction, the coil driving end of the electromagnetic locking mechanism is connected to the relay output end of the control board, and the LED warning light is embedded in the right panel of the digital display screen.

[0012] The beneficial effects of this utility model are as follows: This utility model achieves precise control of welding time through microprocessor control, is equipped with a complete heat dissipation system and safety protection module, and adopts efficient power filtering and inverter charging technology, which solves the problems of inaccurate welding time control, poor heat dissipation performance and insufficient safety protection of existing energy storage stud welding machines. At the same time, it improves the adaptability of the equipment to complex power grids and the power conversion efficiency, significantly improves welding quality and equipment reliability, and is suitable for high-precision stud welding needs in various industrial scenarios. 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 schematic diagram of the internal structure of the casing in this utility model;

[0016] Figure 3 This is a schematic diagram of the control board structure in this utility model;

[0017] In the diagram: 1. Housing; 2. Control board; 3. Inverter charging board; 4. Charging and discharging capacitor; 5. Energy storage capacitor; 6. Integrated power filter; 7. Control transformer; 8. Cooling fan structure; 9. Digital display screen. 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 energy storage stud welding machine for precise control of welding time includes a housing 1, inside which are fixed an integrated power filter 6, a control transformer 7, an inverter charging board 3, a charging / discharging capacitor 4, an energy storage capacitor 5, and a control board 2. The integrated power filter 6 is fixed inside the power input port on the rear wall of the housing and connected to an external power source via a copper busbar. The control transformer 7 is installed in front of the integrated power filter 6, and its primary coil is connected to the output terminal of the filter via a copper busbar. The inverter charging board 3 is vertically fixed to the right side of the control transformer 7 and mechanically connected to the secondary winding terminal of the transformer via bolts. The charging / discharging capacitor 4 and the energy storage capacitor 5 are horizontally arranged below the inverter charging board 3 and connected in parallel to the output terminal of the inverter charging board 3 via a stacked busbar. The control board 2 is horizontally installed inside the operation panel on the front of the housing and integrates a microprocessor controller.

[0020] During operation, the integrated power filter 6 is fixed inside the power input port on the rear wall of the housing and connected to the external power supply via a copper busbar. It performs preliminary filtering of the input power, suppressing electromagnetic interference and ensuring the stability of the welding machine's power supply. The control transformer 7 is installed directly in front of the integrated power filter 6. Its primary coil is connected to the filter output via a copper busbar, while its secondary winding is mechanically connected to the inverter charging board 3 via bolts. The inverter charging board 3 is vertically fixed to the right of the control transformer 7 and is responsible for converting the low-voltage AC output of the transformer into DC power, preparing for subsequent capacitor charging. The charging / discharging capacitor 4 and the energy storage capacitor 5 are horizontally arranged below the inverter charging board 3 and connected in parallel to the output of the inverter charging board 3 via a stacked busbar. The charging / discharging capacitor 4 is used for rapid energy storage and release, while the energy storage capacitor 5 is responsible for long-term energy storage. They work together to meet the instantaneous high current requirements during welding. The control board 2 is horizontally installed inside the operation panel on the front of the housing, integrating a microprocessor controller for precise control and real-time monitoring of the welding machine's operating parameters, enabling precise control of the welding time.

[0021] It also includes a cooling fan structure 8, a temperature control module, a welding trigger locking module, and a digital display screen 9; the cooling fan structure 8 is located behind the control board 2 and its power terminals are connected to the 12V output winding of the control transformer 7 via wires; the temperature control module is attached to the surface of the energy storage capacitor 5 and connected to the ADC interface of the control board 2 via a shielded cable; the welding trigger locking module is fixed at the welding gun interface on the top of the shell and connected to the communication interface of the control board 2 via an RS485 bus; the digital display screen 9 is embedded in the surface of the operation panel and connected to the data interface of the control board 2 via a ribbon cable; the microprocessor controller is connected to the PWM control terminal of the inverter charging board 3 and the speed control signal terminal of the cooling fan via a ribbon cable; and a voltage equalization resistor group is provided between the charging and discharging capacitor 4 and the energy storage capacitor 5.

[0022] The cooling fan structure 8 is located behind the control board 2. Its power terminals are connected to the 12V output winding of the control transformer 7 via wires, providing a stable power supply for the cooling fan. The temperature control module is attached to the surface of the energy storage capacitor 5 and is connected to the ADC interface of the control board 2 via a shielded cable. It monitors the operating temperature of the energy storage capacitor 5 in real time and feeds the temperature signal back to the control board 2 so that the microprocessor controller can adjust the heat dissipation accordingly based on temperature changes. The welding trigger locking module is fixed at the welding gun interface on the top of the casing and is connected to the communication interface of the control board 2 via an RS485 bus. It is used to achieve precise triggering and locking of the welding gun during the welding process, ensuring the stability and safety of the welding process. The digital display screen 9 is embedded in the surface of the operation panel and is connected to the data interface of the control board 2 via a ribbon cable. It is used to display the operating parameters and fault information of the welding machine, allowing the operator to intuitively understand the working status of the welding machine. At the same time, the microprocessor controller is connected to the PWM control terminal of the inverter charging board 3 and the speed control signal terminal of the cooling fan via a ribbon cable. It can achieve precise control of the charging and discharging process of the speed control signal terminal of the inverter charging board 3 and intelligent adjustment of the cooling fan speed to adapt to different welding needs and working environments. In addition, a voltage equalization resistor group is provided between the charging / discharging capacitor 4 and the energy storage capacitor 5 to balance the voltage between the two, prevent the capacitor from being damaged due to excessive voltage difference, extend the service life of the capacitor, and ensure the stable operation of the welding machine.

[0023] The cooling fan structure 8 includes a temperature sensor, a frequency converter, and a detachable dust filter. The temperature sensor is embedded in the heat sink surface of the inverter charging board 3, and the frequency converter is connected to the speed control port of the control board 2 through a PWM signal line.

[0024] The cooling fan structure includes a temperature sensor, a frequency converter, and a removable dust filter. The temperature sensor is embedded in the surface of the heat sink of the inverter charging board 3 to monitor the operating temperature of the inverter charging board 3 in real time. The frequency converter is connected to the speed control port of the control board 2 via a PWM signal line. Based on the PWM signal sent by the control board 2, the frequency converter can control the speed of the cooling fan, realizing stepless speed regulation. This allows for flexible adjustment of the cooling fan speed according to the actual temperature inside the welding machine, achieving energy-saving and efficient heat dissipation. Simultaneously, the removable dust filter design facilitates regular disassembly and cleaning, effectively preventing dust from entering the cooling fan and affecting its normal operation and heat dissipation effect. This further improves the service life and maintenance convenience of the cooling fan, ensuring stable and reliable heat dissipation performance of the welding machine during long-term operation.

[0025] The integrated power filter 6 consists of an EMI filter and a transient voltage suppressor connected in series. The input terminal of the EMI filter is connected to an external power supply through a copper busbar, and the transient voltage suppressor is connected in parallel between the output terminal of the EMI filter and the primary coil of the control transformer 7.

[0026] The integrated power filter 6 consists of a series-connected EMI filter and a transient voltage suppressor. The input of the EMI filter is connected to an external power supply via a copper busbar to filter out electromagnetic interference introduced by the external power supply, reducing electromagnetic pollution from the welding machine to surrounding electronic equipment and ensuring that the normal operation of the welding machine is not affected by external electromagnetic interference. The transient voltage suppressor is connected in parallel between the output of the EMI filter and the primary coil of the control transformer 7. Its main function is to protect the control transformer 7 and subsequent circuits from damage caused by transient overvoltages, such as those generated by lightning strikes or power switching. It can quickly respond to and clamp overvoltages, limiting the amplitude of the overvoltage to a safe range, ensuring the safety and reliability of the welding machine's internal circuits, extending the service life of the welding machine, and improving the adaptability and stability of the welding machine in complex power grid environments.

[0027] The welding trigger locking module includes an infrared positioning sensor, an electromagnetic locking mechanism, and an LED warning light. The detection end of the infrared positioning sensor faces the welding gun outlet direction, the coil drive end of the electromagnetic locking mechanism is connected to the relay output end of the control board 2, and the LED warning light is embedded in the right panel of the digital display screen 9.

[0028] This module includes an infrared positioning sensor, an electromagnetic locking mechanism, and an LED warning light. The infrared positioning sensor's detection end faces the welding torch exit direction, used to detect the welding torch's positioning before welding, ensuring that the distance and angle between the welding torch and the workpiece meet the welding process requirements. The coil drive end of the locking mechanism is connected to the relay output end of control board 2. When the welding torch is accurately positioned, control board 2 controls the coil of the electromagnetic locking mechanism to be energized through the relay output end, achieving reliable locking at the welding torch interface, preventing the welding torch from loosening during welding and ensuring the stability of welding quality. Simultaneously, the LED warning light is embedded in the right panel of the digital display screen 9. When the welding torch is not locked in place or an abnormality occurs during welding, the LED warning light will flash to alert the operator, effectively preventing welding accidents caused by insecure welding torch locking, improving the safety and reliability of welding operations, and ensuring precise control and safe operation of the welding process.

[0029] The working principle of this utility model is as follows: The cooling fan structure 8 is located behind the control board 2, and its power terminals are connected to the 12V output winding of the control transformer 7 via wires to provide a stable power supply for the cooling fan; the temperature control module is in close contact with the surface of the energy storage capacitor 5 shell and is connected to the ADC interface of the control board 2 via a shielded cable to monitor the operating temperature of the energy storage capacitor 5 in real time and feed the temperature signal back to the control board 2 so that the microprocessor controller can make corresponding heat dissipation adjustments according to temperature changes; the welding trigger locking module is fixed at the welding gun interface on the top of the shell and is connected to the communication interface of the control board 2 via an RS485 bus to realize welding during the welding process. The precise triggering and locking functions of the welding gun ensure the stability and safety of the welding process. The digital display screen 9, embedded in the operation panel and connected to the control board 2 via a ribbon cable, displays the welding machine's operating parameters and fault information, allowing operators to intuitively understand the machine's working status. Simultaneously, the microprocessor controller connects to the PWM control terminal of the inverter charging board 3 and the speed control signal terminal of the cooling fan via a ribbon cable, enabling precise control of the charging and discharging process of the inverter charging board 3 and intelligent adjustment of the cooling fan speed to adapt to different welding needs and working environments. Furthermore, a voltage equalization resistor is provided between the charging / discharging capacitor 4 and the energy storage capacitor 5. The cooling fan assembly is used to balance the voltage between the two components, preventing capacitor damage due to excessive voltage difference, extending capacitor lifespan, and ensuring stable operation of the welding machine. The cooling fan structure includes a temperature sensor, a frequency converter, and a removable dust filter. The temperature sensor is embedded in the heat sink surface of the inverter charging board 3 to monitor the operating temperature of the inverter charging board 3 in real time. The frequency converter is connected to the speed control port of the control board 2 via a PWM signal line. Based on the PWM signal sent by the control board 2, the frequency converter can control the speed of the cooling fan, achieving stepless speed regulation. This allows for flexible adjustment of the cooling fan speed according to the actual internal temperature of the welding machine. To achieve energy-saving and efficient heat dissipation; at the same time, the design of the detachable dustproof screen facilitates regular disassembly and cleaning, effectively preventing dust from entering the cooling fan and affecting its normal operation and heat dissipation effect, further improving the service life and maintenance convenience of the cooling fan, and ensuring the stable and reliable heat dissipation performance of the welding machine during long-term operation; the integrated power filter 6 consists of a series EMI filter and a transient voltage suppressor. The input end of the EMI filter is connected to the external power supply through a copper busbar to filter out electromagnetic interference brought in by the external power supply, reduce the electromagnetic pollution of the welding machine to the surrounding electronic equipment, and ensure that the normal operation of the welding machine is not affected by external electromagnetic interference;A transient voltage suppressor is connected in parallel between the output of the EMI filter and the primary winding of the control transformer 7. Its main function is to protect the control transformer 7 and subsequent circuits from damage caused by transient overvoltages, such as those generated by lightning strikes or power switching. It can quickly respond to and clamp overvoltages, limiting their amplitude to a safe range, ensuring the safety and reliability of the welding machine's internal circuitry, extending the welding machine's service life, and improving its adaptability and stability in complex power grid environments.

[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. A stud welding machine with energy storage for precise control of welding time, characterized in that, The device includes a housing (1), which contains an integrated power filter (6), a control transformer (7), an inverter charging board (3), a charging and discharging capacitor (4), an energy storage capacitor (5), and a control board (2). The integrated power filter (6) is fixed inside the power input port on the rear wall of the housing and connected to an external power source via a copper busbar. The control transformer (7) is installed in front of the integrated power filter (6) and its primary coil is connected to the output end of the filter via a copper busbar. The inverter charging board (3) is vertically fixed to the right side of the control transformer (7) and mechanically connected to the secondary winding terminal of the transformer via bolts. The charging and discharging capacitor (4) and the energy storage capacitor (5) are arranged horizontally below the inverter charging board (3) and connected in parallel to the output end of the inverter charging board (3) via a stacked busbar. The control board (2) is horizontally installed inside the operation panel at the front of the housing and integrates a microprocessor controller.

2. The energy storage stud welding machine according to claim 1, characterized in that, It also includes a cooling fan structure (8), a temperature control module, a welding trigger locking module, and a digital display screen (9); the cooling fan structure (8) is located behind the control board (2) and its power terminals are connected to the 12V output winding of the control transformer (7) via wires; the temperature control module is attached to the surface of the energy storage capacitor (5) and connected to the ADC interface of the control board (2) via a shielded cable; the welding trigger locking module is fixed at the welding gun interface on the top of the shell and connected to the communication interface of the control board (2) via an RS485 bus; the digital display screen (9) is embedded in the surface of the operation panel and connected to the data interface of the control board (2) via a ribbon cable; the microprocessor controller is connected to the PWM control terminal of the inverter charging board (3) and the speed control signal terminal of the cooling fan via a ribbon cable; and a voltage equalization resistor group is provided between the charging and discharging capacitor (4) and the energy storage capacitor (5).

3. The energy storage stud welding machine according to claim 2, characterized in that: The cooling fan structure (8) includes a temperature sensor, a frequency converter and a detachable dust filter. The temperature sensor is embedded on the heat sink surface of the inverter charging board (3), and the frequency converter is connected to the speed control port of the control board (2) through a PWM signal line.

4. The energy storage stud welding machine according to claim 1, characterized in that: The integrated power filter (6) consists of an EMI filter and a transient voltage suppressor connected in series. The input end of the EMI filter is connected to an external power supply through a copper busbar, and the transient voltage suppressor is connected in parallel between the output end of the EMI filter and the primary coil of the control transformer (7).

5. The energy storage stud welding machine according to claim 2, characterized in that: The welding trigger locking module includes an infrared positioning sensor, an electromagnetic locking mechanism and an LED warning light. The detection end of the infrared positioning sensor faces the welding gun outlet direction. The coil driving end of the electromagnetic locking mechanism is connected to the relay output end of the control board (2). The LED warning light is embedded on the right panel of the digital display screen (9).

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