Lithium battery energy storage stud welding machine circuit

Abstract

The utility model discloses a lithium electricity energy storage stud welding machine circuit belongs to welding machine circuit technical field, and the battery voltage is controlled through Q001, and the turns ratio of T001 transformer is boosted, and D1 rectifier bridge, L1 inductance filter charges voltage for energy storage capacitor C005, C006, is called " given voltage", and the voltage characteristic is, no matter how the battery voltage changes, this voltage is stable, and through the control of Q002 thyristor, the energy stored on C005, C006 electrolytic capacitor is outputted, and the large current is formed instantaneously, thereby the technical effect of high stability given voltage is realized.

Description

Technical Field

[0001] This utility model relates to a welding machine circuit, and more particularly to a lithium battery energy storage stud welding machine circuit, belonging to the technical field of welding machine circuits. Background Technology

[0002] Currently, there are two types of energy storage stud welding:

[0003] One type is the power frequency transformer step-up charging scheme energy storage stud welding machine. Because it involves the use of a high-power power frequency transformer, it is large in size, heavy in weight, inconvenient to move and carry, and has high cost, which is not conducive to market competition. Currently, there are only a few users in the market using it.

[0004] Another type is the inverter constant current charging solution stud welder. Inverter welders are small in size, light in weight, easy to move and carry, and highly efficient. They are currently widely used in the market.

[0005] Both types of energy storage stud welding machines mentioned above require grid power to operate. For stud welding operations in some remote areas without grid power, generators are needed, which is quite cumbersome. Therefore, a lithium battery energy storage stud welding machine circuit was designed to solve the above problems. Utility Model Content

[0006] The main purpose of this utility model is to provide a circuit for a lithium battery energy storage stud welding machine.

[0007] The objective of this utility model can be achieved by adopting the following technical solution:

[0008] The lithium battery energy storage stud welding machine circuit includes a MOSFET drive module. Terminal 1 of the MOSFET drive module is electrically connected to terminal 1 of power device Q001. Terminal 2 of power device Q001 is electrically connected to one end of resistor R001. Terminal 3 of power device Q001 is electrically connected to terminal 2 of transformer T001.

[0009] The PWM and control module is coupled to the MOSFET driver module;

[0010] The other end of resistor R001 is electrically connected to one end of resistor R002, and the other end of resistor R002 is electrically connected to terminal 1 of transformer T001.

[0011] Preferably, the other end of resistor R002 is electrically connected to capacitor C004 and the cathode of polarized capacitor C002 and the negative terminal of battery J1.

[0012] The other end of capacitor C004 is electrically connected to one end of capacitor C003. The other end of capacitor C003 is electrically connected to one end of resistor F1. The other end of resistor F1 is electrically connected to the positive terminal of battery J2 and the anode of polarized capacitor C001. The negative terminal of polarized capacitor C001 is electrically connected to the anode of polarized capacitor C002.

[0013] Preferably, terminal 6 of transformer T001 is electrically connected to terminal 2 of rectifier D1, and terminal 4 of rectifier D1 is electrically connected to one end of resistor R003 and the input terminal of PWM and control module.

[0014] Preferably, terminal 3 of rectifier D1 is electrically connected to terminal 7 of transformer T001, terminal 1 of rectifier D1 is electrically connected to one end of inductor L001, and the other end of inductor L001 is electrically connected to one end of resistor R005, the anode of polarized capacitor C005, the anode of polarized capacitor C006, and the cathode of diode D2.

[0015] Preferably, the anode of the polarized capacitor C005 is electrically connected to one end of the resistor R005, the cathode of the polarized capacitor C005 is electrically connected to one end of the resistor R004, and the other end of the resistor R003.

[0016] Preferably, the anode of diode D2 is electrically connected to the cathode of polarized capacitor C006, the cathode of polarized capacitor C005, and the other end of resistor R003.

[0017] Preferably, terminal 1 of the high-power thyristor Q002 is electrically connected to the other end of resistor R003, terminal 2 of the high-power thyristor Q002 is wired to output J3, terminal G of the high-power thyristor Q002 is electrically connected to the PWM and control module, and the other end of resistor R005 is electrically connected to the PWM and control module.

[0018] The beneficial technical effects of this utility model are as follows:

[0019] The lithium battery energy storage stud welding machine circuit provided by this utility model has the following steps before lithium battery stud welding (preparation stage): The battery pack voltage is controlled by Q001, the turns ratio of the T001 transformer is increased, and the D1 rectifier bridge and L1 inductor filter provide the charging voltage for the energy storage capacitors C005 and C006, which is called the "given voltage". The characteristic of this voltage is that it is stable no matter how the battery voltage changes. By controlling the Q002 thyristor, the energy stored on the C005 and C006 electrolytic capacitors is output, instantly forming a large current, thus achieving the technical effect of a highly stable given voltage. Attached Figure Description

[0020] Figure 1 This is a main circuit diagram of a lithium battery storage stud welding machine according to a preferred embodiment of the lithium battery storage stud welding machine circuit of this utility model. Detailed Implementation

[0021] To enable those skilled in the art to understand the technical solution of this utility model more clearly, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings, but the implementation of this utility model is not limited thereto.

[0022] Example 1

[0023] like Figure 1 J1 and J2 are connected to the positive and negative terminals of the battery pack. A boost circuit is used, and the battery pack voltage is between 16V and 24V.

[0024] F1 is a battery forward power supply protection resistor to prevent a sudden large current from forming and protecting the battery pack in the event of a short circuit caused by damage to the boost MOSFET or output power device.

[0025] C001 and C002 are electrolytic capacitors, which are large-capacity capacitors and serve as low-frequency filters and energy storage.

[0026] C003 and C004 are high-frequency filter capacitors;

[0027] Q001 is a power device that boosts voltage and controls energy output. Q001 can be a MOSFET, a single IGBT, or a silicon carbide MOSFET. Depending on the power requirement, multiple Q001 devices can be connected in parallel.

[0028] T001 is a transformer that boosts the battery pack voltage to a set value by calculating the turns ratio.

[0029] D1 is the rectifier bridge, used to rectify and step up the transformer's output voltage;

[0030] L1 is the output filter inductor, which smooths and stabilizes the output current;

[0031] R003 is a current feedback resistor used to detect the magnitude of the output current;

[0032] R004 and R005 are voltage feedback resistors used to detect the output voltage.

[0033] C005 and C006 are large-capacity electrolytic capacitors for energy storage.

[0034] D2 is a freewheeling diode that provides a freewheeling path for the energy stored in L1 and the load circuit inductance during the pulse output period, and during the gap period.

[0035] Q002 is a high-power thyristor that controls the energy output of the energy storage capacitor.

[0036] J3 and J4 are the output terminals of the welding machine;

[0037] Working principle: Before lithium battery stud welding (preparation stage): The battery pack voltage is controlled by Q001, the turns ratio of the T001 transformer is increased, and the D1 rectifier bridge and L1 inductor filter provide the charging voltage for the energy storage capacitors C005 and C006, which is called the "given voltage". The characteristic of this voltage is that it is stable no matter how the battery voltage changes.

[0038] Lithium-ion battery stud welding process: By controlling the Q002 thyristor, the energy stored in the C005 and C006 electrolytic capacitors is output, instantly forming a large current.

[0039] Example 2

[0040] This embodiment uses the actual fabrication of a lithium battery energy storage stud welding machine as an example to illustrate the implementation process of the circuit in detail.

[0041] A lithium battery pack with a nominal voltage of 24V and a capacity of 10Ah is selected, which can meet the frequent use requirements of the welding machine within a certain period of time.

[0042] This battery pack features overcharge and over-discharge protection, which can effectively extend battery life and ensure safe use.

[0043] Considering the power requirements of the welding machine, the power device Q001 is a MOSFET of model IRFP460.

[0044] Its drain-source breakdown voltage is 500V and its continuous drain current is 20A, which is fully capable of handling the voltage boosting work of this welding machine.

[0045] If the power requirement is greater in actual applications, multiple IRFP460 units can be connected in parallel.

[0046] Transformer T001 was customized with a turns ratio of 1:10 based on the battery pack voltage of 16V-24V and the desired boost output. Its primary winding has 100 turns, and its secondary winding has 1000 turns. The core material is made of silicon steel sheets with high magnetic permeability to improve energy conversion efficiency.

[0047] The rectifier bridge D1 is selected as the KBPC3510 type rectifier bridge, which has a rated current of 35A and a withstand voltage of 1000V, and can reliably rectify the AC voltage after the transformer is stepped up.

[0048] Inductor L1 is a self-made hollow inductor with an inductance of 10mH, wound with enameled wire with a wire diameter of 1mm.

[0049] This inductor can effectively smooth and stabilize the output current, reducing current fluctuations.

[0050] C001 and C002 are 4700μF / 50V electrolytic capacitors used for low-frequency filtering and energy storage; C003 and C004 are 0.1μF ceramic capacitors used for high-frequency filtering; C005 and C006 are 10000μF / 450V high-capacity electrolytic capacitors used as energy storage capacitors.

[0051] R001 and R002 are 10Ω / 2W metal film resistors; R003 is a 0.1Ω / 5W constantan wire resistor as the current feedback resistor; R004 and R005 are 100kΩ / 1W metal film resistors as the voltage feedback resistors.

[0052] A high-power thyristor of model BT151 was selected, with an average on-state current of 100A and a withstand voltage of 600V, which can meet the requirements for controlling the energy output of the energy storage capacitor.

[0053] Based on the circuit schematic, a printed circuit board (PCB) is designed using professional PCB design software (such as Altium Designer). During the design process, the layout of each component is carefully considered, separating power components from control components to reduce interference. Simultaneously, wiring is rationally planned to ensure short and low-impedance current paths.

[0054] Solder the prepared components according to the PCB design drawings. During the soldering process, strictly control the soldering temperature and time to ensure soldering quality. For temperature-sensitive components such as MOSFETs and SCRs, adopt heat dissipation measures to prevent damage to the components due to overheating during soldering.

[0055] After assembling the circuit, static debugging is performed first. Check the soldering of each component to ensure it is correct and to check for any issues such as cold solder joints or short circuits. Use a multimeter to measure the voltage at key points, such as the battery voltage, the primary and secondary voltages of the transformer, and the output voltage of the rectifier bridge, to ensure that the voltage values ​​meet design requirements. If any abnormal voltage is found, carefully inspect the relevant components and wiring to troubleshoot the problem.

[0056] After confirming that the static debugging is correct, proceed with dynamic debugging. Connect the battery pack and start the welding machine. Observe the control signals output by the PWM and control module using an oscilloscope to ensure that their frequency and duty cycle meet the design requirements. At the same time, observe the charging process of the energy storage capacitor and the triggering of the thyristor to check whether the output current and voltage of the welding machine are stable. During the debugging process, fine-tune the value of the feedback resistor according to the actual situation to optimize the performance of the welding machine.

[0057] Perform stud welding tests using a properly calibrated welding machine. Select suitable studs and base materials, adjust the welding machine parameters (such as welding time and welding current), and conduct multiple welding tests. Observe the welding effect and check the bond strength between the stud and the base material, as well as the weld surface quality. Based on the welding test results, further optimize the welding machine parameters until satisfactory welding results are obtained.

[0058] Through the above embodiments, a stable lithium-ion battery storage stud welding machine was successfully manufactured and debugged, meeting the needs of actual production and application. In practical applications, the circuit parameters and component selection can be appropriately adjusted and optimized according to different welding requirements and working conditions.

[0059] The above description is only a further embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the scope disclosed by the present utility model, based on the technical solution and concept of the present utility model, shall fall within the protection scope of the present utility model.

Claims

1. A lithium battery energy storage stud welder circuit, characterized by: It includes a MOSFET driver module, whose terminal 1 is electrically connected to terminal 1 of power device Q001, terminal 2 of power device Q001 is electrically connected to one end of resistor R001, and terminal 3 of power device Q001 is electrically connected to terminal 2 of transformer T001. The PWM and control module is coupled to the MOSFET driver module; The other end of resistor R001 is electrically connected to one end of resistor R002, and the other end of resistor R002 is electrically connected to terminal 1 of transformer T001.

2. The lithium battery energy storage stud welder circuit of claim 1, wherein: The other end of resistor R002 is electrically connected to capacitor C004 and the cathode of polarized capacitor C002 and the negative terminal of battery J1. The other end of capacitor C004 is electrically connected to one end of capacitor C003. The other end of capacitor C003 is electrically connected to one end of resistor F1. The other end of resistor F1 is electrically connected to the positive terminal of battery J2 and the anode of polarized capacitor C001. The negative terminal of polarized capacitor C001 is electrically connected to the anode of polarized capacitor C002.

3. The lithium battery energy storage stud welder circuit of claim 2, wherein: The 6th terminal of transformer T001 is electrically connected to the 2nd terminal of rectifier D1, and the 4th terminal of rectifier D1 is electrically connected to one end of resistor R003 and the input terminal of PWM and control module.

4. The lithium battery energy storage stud welder circuit of claim 3, wherein: The 3rd terminal of rectifier D1 is electrically connected to the 7th terminal of transformer T001. The 1st terminal of rectifier D1 is electrically connected to one end of inductor L001. The other end of inductor L001 is electrically connected to one end of resistor R005, the anode of polarized capacitor C005, the anode of polarized capacitor C006, and the cathode of diode D2.

5. The lithium battery energy storage stud welder circuit of claim 4, wherein: The anode of the polarized capacitor C005 is electrically connected to one end of the resistor R005, the cathode of the polarized capacitor C005 is electrically connected to one end of the resistor R004, and the other end of the resistor R003.

6. The lithium battery energy storage stud welder circuit of claim 5, wherein: The anode of diode D2 is electrically connected to the cathode of polarized capacitor C006, the cathode of polarized capacitor C005, and the other end of resistor R003.

7. The lithium battery energy storage stud welder circuit of claim 6, wherein: The high-power thyristor Q002's terminal 1 is electrically connected to the other end of resistor R003, the high-power thyristor Q002's terminal 2 is connected to the J3 output, the high-power thyristor Q002's terminal G is electrically connected to the PWM and control module, and the other end of resistor R005 is electrically connected to the PWM and control module.

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