Multifunctional welding comprehensive training system

Abstract

The application discloses a multifunctional welding comprehensive training system, which splits electrical elements of a welding machine according to functions, places the electrical elements apart from each other, connects the electrical elements according to welding machine electrical working principles, places weak current electrical elements in a weak current area in a welding machine control circuit, places high voltage electrical elements in a high voltage area in a welding machine primary circuit, and places low voltage electrical elements in a low voltage area in a welding machine secondary circuit, wherein the weak current area, the high voltage area and the low voltage area are three separated areas. By setting an equipment frame, each electrical element can be installed separately, and an observation window is used, so that the whole welding system becomes visualized, has high safety, students can intuitively and closely understand and learn internal structures of the welding system and working states of each element in a welding process, lays a sufficient knowledge accumulation for students to understand welding machine circuits and subsequent work, and promotes material discipline professional construction.

Description

Technical Field

[0001] This invention relates to the field of practical training equipment technology. Specifically, it relates to a multifunctional integrated welding training system. Background Technology

[0002] When teaching courses on arc welding equipment and welding processes, industrial welding machines are generally used. However, existing industrial welding machines have a high degree of internal integration and adopt a closed structure, making it impossible to observe the internal structure. Disassembling the welding machine for teaching is also dangerous. Students cannot intuitively feel and learn about the working status of the main circuit, control circuit, and internal electrical equipment of the welding system. Furthermore, the existing welding machines are relatively simple in function, requiring the purchase of different types of welding machines for teaching, which increases the investment cost. Utility Model Content

[0003] Therefore, the technical problem to be solved by the present invention is to provide a multifunctional comprehensive welding training system that allows students to intuitively understand the working process of welding electrical equipment, adjust parameters, and simulate the output characteristics, wire feeding speed, current and voltage of different welding power sources.

[0004] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a multi-functional welding integrated training system, which separates the electrical components of the welding machine according to their functions, places each electrical component at intervals, and connects each electrical component to each other according to the electrical working principle of the welding machine.

[0005] The aforementioned multifunctional welding integrated training system places the low-voltage electrical components in the welding machine control circuit in the low-voltage area, the high-voltage electrical components in the welding machine primary circuit in the high-voltage area, and the low-voltage electrical components in the welding machine secondary circuit in the low-voltage area. The low-voltage area, the high-voltage area, and the low-voltage area are three separate regions.

[0006] The aforementioned multifunctional welding integrated training system includes a primary rectifier module, a primary capacitor, and an inverter module. The input terminal of the primary rectifier module is connected to a three-phase power supply, the output terminal of the primary rectifier module is connected to the input terminal of the inverter module, and the primary capacitor is connected in parallel to the output terminal of the primary rectifier module.

[0007] The aforementioned multifunctional welding integrated training system includes a transformer module, a secondary rectifier module, and an output inductor. The input terminal of the transformer module is connected to the output terminal of the inverter module, and the output terminal of the transformer module is connected to the input terminal of the secondary rectifier module. The first output terminal of the secondary rectifier module forms a positive output, and the second output terminal of the secondary rectifier module forms a negative output. The output inductor is connected in series with the negative output of the secondary rectifier module.

[0008] The aforementioned multifunctional welding integrated training system includes a switching power supply, a power frequency transformer, a main control board, and a wire feeding control board. The input terminal of the switching power supply is connected to a 220V AC mains power supply. The input terminal of the power frequency transformer is connected to the primary rectifier module. The output terminal of the power frequency transformer supplies power to the main control board through the primary power supply line. The output terminal of the power frequency transformer is connected to the main control board through the auxiliary transformer power supply line. The main control board is connected to the wire feeding control board through the wire feeding control line. The transformer module is connected to the main control board through the auxiliary wire feeding power supply line. The wire feeding control board is connected to the wire feeder connector through the wire feeder interface line.

[0009] In the aforementioned multifunctional welding integrated training system, the main control board is connected to the inverter module's drive board via a PWM drive line. A Hall sensor is installed at the output terminal of the secondary rectifier module, and this Hall sensor is connected to the main control board via an output current detection line. The output terminal of the secondary rectifier module is connected to the main control board via an output voltage sampling line, and the current transformer is connected to the main control board via a primary current sampling line. The current signal collected by the Hall sensor, the voltage signal collected by the voltage sampling line, and the current signal collected by the current transformer are all transmitted to the main control board via isolated linear optocouplers. The main control board calculates the corresponding control characteristics based on the sampled voltage and current signals and the set output mode. The main control board is connected to the PWM drive line via a DA interface, and after outputting the characteristic voltage, it transmits it to the inverter module's drive board via the PWM drive line.

[0010] In the aforementioned multifunctional welding integrated training system, the inverter module is equipped with a heat sink temperature switch, the main control board is connected to the first cooling fan via the heat sink temperature switch, the secondary rectifier module is equipped with a thermistor connected to the main control board, and the main control board is connected to a second cooling fan via a circuit. The first cooling fan is installed on one side of the inverter module, and the second cooling fan is installed on one side of the secondary rectifier module. The switching power supply provides power to the first cooling fan and the second cooling fan respectively.

[0011] The aforementioned multifunctional welding integrated training system also includes a data acquisition unit and a data control unit. The switching power supply outputs 24V DC power to power the data control unit, which is communicatively connected to the wire feeding control board. The data acquisition unit is also communicatively connected to the data control unit, which is powered by 220V AC mains power. The main control board receives control signals from the data control unit and adjusts the output voltage of the transformer module. The wire feeder is communicatively connected to the wire feeder connector. The data control unit sends control signals to the wire feeder through the wire feeding control board to adjust the wire feeding speed. After the protective gas cylinder is connected to the wire feeder, the data control unit outputs control signals to the wire feeder through the wire feeding control board to control the type, flow rate, and output time of the protective gas. The main control board receives output current, output voltage, and primary current, which are then sent to and displayed on the data acquisition unit. The data control unit controls the inverter module to output DC current or pulse current. The integrated data control unit collects data on the wire feeding speed, welding wire consumption, and shielding gas consumption of the wire feeder from the wire feeding control board in real time via the CAN communication protocol; the main control board receives the control signal sent by the integrated data control unit and controls the inverter module to output voltage and current.

[0012] In the aforementioned multifunctional welding integrated training system, a 380V power switch is provided on the input terminal of the primary rectifier module, a 220V power switch is provided on the switching power supply, and the positive output and the negative output are connected to an output port, which is connected to the welding torch.

[0013] The aforementioned multifunctional welding integrated training system also includes an equipment frame and an observation window. The platform of the equipment frame is divided into a low-voltage area, a high-voltage area, and a weak-voltage area. The weak-voltage area, the high-voltage area, and the low-voltage area are three independent partitioned areas, and the low-voltage area, the high-voltage area, and the weak-voltage area are painted with different colors. The platform of the frame is covered with a transparent protective cover, and the side wall of the protective cover has an opening and closing observation window.

[0014] The technical solution of the present invention achieves the following beneficial technical effects:

[0015] 1. By setting up the equipment frame, various electrical components can be installed separately. With the help of the observation window, the entire welding system becomes visible and has a high level of safety. Students can intuitively and closely understand and learn about the internal structure of the welding system and the working status of each component during the welding process. This lays a solid foundation for students to understand welding machine circuits and subsequent work, and promotes the development of materials science major.

[0016] 2. By adjusting various parameters, the output characteristics, current, voltage, and wire feed speed of different welding power sources can be simulated. Students can directly experience the influence of current and voltage on the welding arc state. One-on-one operation of welding power source experiments can not only meet the needs of welding teaching, but also enable students to fully participate in the teaching process and improve the quality of teaching.

[0017] 3. The multifunctional welding integrated training system of this invention, through a fully digital arc welding process development and teaching system, can meet the ever-growing demands of the welding industry for new processes. The system will provide a flexible and innovative platform for the research and development and manufacturing of arc welding equipment and new welding processes, used for researching, designing, and testing high-performance, high-efficiency arc welding equipment and new processes. This platform will improve the R&D capabilities of welding equipment and promote technological innovation; it can be used to research and test new welding processes and materials. Simultaneously, in welding professional courses and practical teaching, it helps welding students understand and master the composition, working principle, and key technologies for realizing arc welding processes of arc welding equipment. The system will provide a practical and intuitive arc welding environment, allowing students to practice relevant theories and arc welding processes by operating the system, helping them transform theoretical knowledge into practical skills. Attached Figure Description

[0018] Figure 1 A front view of the structure of the present invention;

[0019] Figure 2 A schematic diagram of the invention on the left side;

[0020] Figure 3 The right-hand side schematic diagram of the present invention;

[0021] Figure 4 A top view of the platform structure on the device frame of this invention;

[0022] Figure 5 Circuit diagram of the multifunctional welding integrated training system of this invention;

[0023] Figure 6 Electrical schematic diagram of the multifunctional welding integrated training system of this invention;

[0024] Figure 7 The principle block diagram of the multifunctional welding integrated training system of the present invention.

[0025] The reference numerals in the diagram are as follows: 1-Equipment frame; 2-Observation window; 3-Working indicator light; 4-Data acquisition unit; 5-Data control unit; 6-Operation button; 7-Output port; 8-220V power switch; 9-380V power switch; 10-Primary rectifier module; 11-Primary capacitor; 12-Inverter module; 13-Transformer module; 14-Secondary rectifier module; 15-Output inductor; 16-Switching power supply; 17-Power frequency transformer; 18-Main control board; 19-Wire feeding control board; 20-Wire feeder connector. Detailed Implementation

[0026] The multifunctional welding integrated training system in this embodiment, such as Figure 1-3 As shown, the equipment includes a frame 1 and an observation window 2. The platform of the frame 1 is divided into a low-voltage area, a high-voltage area, and a low-voltage area. These three areas are independent and are painted with different colors: red for the high-voltage area, yellow for the low-voltage area, and green for the low-voltage area. A transparent protective cover covers the platform of the frame 1. An observation window 2, which can be opened and closed, is installed on the side wall of the protective cover and is connected by hinges. A data acquisition unit 4, a data control unit 5, operation buttons 6, an output port 7, and a wire feeder connector 20 are installed on the side wall of the frame 1. The wire feeder, welding torch, and all cables are connected using standard interfaces. A 220V power switch 8 and a -380V power switch 9 are installed on the other side wall. The data control unit 5 contains a teaching software system, through which various welding parameters are set. The system uses an aluminum alloy platform and an acrylic enclosure, allowing direct observation of its structure from the outside to ensure student safety. Components are connected in a bus-like manner, and industrial interfaces are used to ensure safety. Furthermore, LED running lights can be installed on each group of wires and controlled by a microcontroller to simulate the inversion process of the circuit, facilitating students' understanding.

[0027] The data control integrated machine 5 is equipped with a teaching software system, which can adjust welding current, welding voltage, wire feed speed, arc length, arc thrust, jogging wire feed, and gas supply parameters, and can also adjust welding characteristics such as pulse frequency, pulse peak / base value, and slope through the teaching software. Employing a combination of hardware and software, it can display and control real-time current, voltage, and waveform. The stored program controller communicates with the microcontroller software to adjust the required parameters, achieving a maximum output current of 500A. The welding characteristic output can be adjusted to DC or pulse. The primary adjustment parameters are as follows: Current: maximum 500A; Arc length: ±30%; Arc thrust: ±30%; Early gas supply: 0-5S; Late gas supply: 0-5S; Arc ignition current: 0%-150%; Arc ignition time: 0-5S; Gradation time: 0-5S; Arc termination current: 0%-150%; Arc termination time: 0-5S. The secondary adjustment parameters are as follows: DC short-circuit current rise slope 1-300; DC short-circuit current rise amplitude 0-500A; Pulse peak current: 200-500A; Pulse peak current time: 0-200; Double pulse frequency: 0.2-10; Double pulse duty cycle: 1-99.

[0028] The teaching software system includes a welding characteristics software system and a controller operating system software system. Specifically, the software system takes the consumable electrode arc welding (MEA) process as the control object, adopts the mainstream single-chip microcomputer storage and operation, and is designed with programs including system initialization program, main program, interrupt service program, power characteristic control program, signal sampling and processing program, power output parameter adjustment and display program, fault diagnosis and alarm program, etc. The program can control the completion of the MEA process, including unified and non-unified characteristic adjustment programs. The above programs should have modification and refresh functions. It implements basic process control programs and reserves program storage space, including process timing control based on real-time current and voltage signals combined with solenoid valve opening and closing signals, and arc initiation and termination control based on real-time current and voltage signals combined with wire feed speed control, while providing program modification and refresh functions. A current and voltage data acquisition module is configured, which can intuitively display and record data in real time. It can be expanded for network use in the future. Through a host computer, the welding machine's working status can be monitored in real time, including welding parameter management and real-time welding data information monitoring.

[0029] like Figure 4 As shown, the electrical components of the welding system are arranged on the equipment frame 1 platform, with each electrical component placed at intervals and connected to each other according to the electrical working principle of the welding machine. The low-voltage electrical components in the welding machine control circuit are placed in the low-voltage area, the high-voltage electrical components in the primary circuit of the welding machine are placed in the high-voltage area, and the low-voltage electrical components in the secondary circuit of the welding machine are placed in the low-voltage area. The low-voltage area, the high-voltage area, and the low-voltage area are three separate areas.

[0030] like Figure 4-5 As shown, the high-voltage electrical components include a primary rectifier module 10, a primary capacitor 11, and an inverter module 12. The input terminal of the primary rectifier module 10 is connected to a three-phase power supply, and the output terminal of the primary rectifier module 10 is connected to the input terminal of the inverter module 12. The primary capacitor 11 is connected in parallel to the output terminal of the primary rectifier module 10. The high-voltage electrical components form the main circuit. In specific design, the main circuit is a full-bridge inverter hard-switching main circuit. The inverter module 12 uses a current-type PWM chip UC3846 as the core control chip. The UC3846 outputs two complementary PWM drive waveforms to control the alternating operation of two different bridge arms, inverting the DC voltage rectified by the primary rectifier module 10 into a 20kHz AC square wave voltage.

[0031] like Figure 4-5 As shown, the low-voltage electrical components include a transformer module 13, a secondary rectifier module 14, and an output inductor 15. The input terminal of the transformer module 13 is connected to the output terminal of the inverter module 12, and the output terminal of the transformer module 13 is connected to the input terminal of the secondary rectifier module 14. The output terminal of the secondary rectifier module 14 generates a positive output and a negative output. The output inductor 15 is connected in series with the negative output of the secondary rectifier module 14. A 20kHz AC square wave voltage is reduced and isolated by the amorphous transformer module 13 before being supplied to the output side. After rectification by the full-wave secondary rectifier module 14, the voltage is filtered by the output inductor 15 and supplied to the output terminal, where it can be soldered using a welding torch.

[0032] like Figure 4-5 As shown, the low-voltage electrical components include a switching power supply 16, a power frequency transformer 17, a main control board 18, and a wire feeding control board 19. The input terminal of the switching power supply 16 is connected to the 220V mains power. The input terminal of the power frequency transformer 17 is connected to the primary rectifier module 10. The output terminal of the power frequency transformer 17 supplies power to the main control board 18 through the primary power supply line. The output terminal of the power frequency transformer 17 is also connected to the main control board 18 through the auxiliary transformer power supply line. The main control board 18 is connected to the wire feeding control board 19 through the wire feeding control line. The transformer module 13 is connected to the main control board 18 via the wire feeding auxiliary power supply line. The wire feeding control board 19 is connected to the wire feeding machine connector 20 via the wire feeding machine interface line. The wire feeding machine is connected to the wire feeding machine connector 20 for communication. The data control unit 5 sends control signals to the wire feeding machine through the wire feeding control board 19 to regulate the wire feeding speed. After the protective gas cylinder is connected to the wire feeding machine, the data control unit 5 outputs control signals to the wire feeding machine through the wire feeding control board 19 to control the type, flow rate, and output time of the protective gas output by the wire feeding machine.

[0033] Both the main control board 18 and the wire feeding control board 19 use the GD32F303RCT6 series ARM chip manufactured by GigaDevice, featuring a 64-pin package, 32-bit architecture, support for external 32MHz crystal oscillators, 12-bit AD and DA converters, two 12-bit DA outputs, and CAN communication functionality for easy external expansion. Programming can be performed using an online GD-link programmer or an offline white box programmable module.

[0034] The main control board 18 uses an ARM chip to control the working logic and welding characteristics of the entire welding machine. The wire feeding control board 19 uses an ARM chip for wire feeding logic control, as well as the acquisition and control of signals such as the welding torch / gas valve, enabling the adjustment and acquisition of wire feeding speed, wire feeding method, gas supply volume, gas supply time, and gas type. The two ARM chips communicate with each other using CAN communication mode to ensure the timeliness of information transmission.

[0035] The wire feeding circuit employs a BUCK constant voltage design on the 24V output from the switching power supply 16, providing an adjustable 2.5-24V voltage to ensure precise and controllable wire feeding speed. During soldering, to reduce the workload on the 24V switching power supply 16, a tap is specifically provided from the transformer module 13 to supply auxiliary power to the wire feeding circuit, thus preventing a reduction in the switching power supply's lifespan. Wire feeding control utilizes an ARM chip, employing current and voltage feedback to perform software calculations and output the corresponding PWM pulse width, ultimately controlling the wire feeder's speed.

[0036] like Figure 4-5 As shown, the main control board 18 is connected to the drive board of the inverter module 12 via a PWM drive line; a Hall sensor is installed on the output terminal of the secondary rectifier module 14, and the Hall sensor is connected to the main control board 18 via an output current detection line; the output terminal of the secondary rectifier module 14 is connected to the main control board 18 via an output voltage sampling line; a current transformer is installed on the output terminal of the inverter module 12, and the current transformer is connected to the main control board 18 via a primary current sampling line. After receiving the control signal sent by the data control integrated machine 5, the main control board 18 adjusts the output voltage of the transformer module 13, and after receiving the control signal sent by the data control integrated machine 5, the main control board 18 adjusts the output current of the secondary rectifier module 14. The data control integrated machine 5 controls the inverter module 12 to output DC current or pulse current. The data control integrated machine 5 collects the wire feeding speed, welding wire consumption, and shielding gas consumption of the wire feeder obtained by the wire feeding control board 19 in real time via the CAN communication protocol; after receiving the control signal sent by the data control integrated machine 5, the main control board 18 controls the output voltage and current of the inverter module 12.

[0037] The control circuit, primarily based on the main control board 18, is a software control circuit designed around the GD32F303RCT6 chip. Output current and voltage control are software-controlled, outputting corresponding welding characteristics according to different preset modes. Both output current and voltage employ isolated sampling. The output current is sampled using a Hall effect sensor, while the output voltage is directly sampled. The current signal from the Hall effect sensor, the voltage signal from the voltage sampling line, and the current signal from the current transformer are all transmitted to the main control board 18 via isolated linear optocouplers. The main control board 18 calculates the corresponding control characteristics based on the sampled voltage and current signals and the preset output mode. The main control board 18 connects to the PWM drive line via a DA interface. After outputting the characteristic voltage, the main control board 18 transmits it to the driver board of the inverter module 12 via the PWM drive line. The signal is then transmitted to the ARM chip via isolated linear optocouplers. The ARM chip calculates the corresponding control characteristics based on the sampled current and voltage signals and the output mode set by the software program. It then outputs the characteristic voltage through the DA interface to the UC3846 PWM chip, completing the control of the output current and voltage.

[0038] like Figure 4-5 As shown, the inverter module 12 is equipped with a heat sink temperature switch, the main control board 18 is connected to the first cooling fan through the heat sink temperature switch, the secondary rectifier module 14 is equipped with a thermistor, the thermistor is connected to the main control board 18, the main control board 18 is connected to the second cooling fan through a line, the first cooling fan is installed on one side of the inverter module 12, the second cooling fan is installed on one side of the secondary rectifier module 14, and the switching power supply 16 supplies power to the first cooling fan and the second cooling fan respectively.

[0039] like Figure 4 As shown, the switching power supply 16 outputs 24V DC power to power the data control unit 5. The data control unit 5 is connected to the wire feeding control board 19. The data acquisition unit 4 is connected to the data control unit 5. The data acquisition unit 4 is powered by 220V AC mains power. The output current, output voltage and primary current received by the main control board 18 are sent to the data acquisition unit 4 and displayed on the data acquisition unit 4, and fed back to the data control unit 5.

[0040] In practical application, the wire feeder is connected to the wire feeder communication connector 20 using a 6-core cable to transmit power from the host to the wire feeder. The communication protocol is CAN communication. The positive and negative terminals of the welding torch are connected to the positive and negative terminals of the output port 7, respectively. The multi-functional welding integrated training system is equipped with software. The entire welding machine's working mode and output parameters are set through the touch screen of the data control integrated machine 5. The touch screen communicates with the welding machine via a network cable. The parameters of the entire welding machine are set by sending parameters through the touch screen. Different welding parameters, such as voltage, current, wire feed speed, and arc length, are adjusted through the data control integrated machine 5. The operation mode and parameters such as advance / retard gas supply are set, and the internal parameters of the characteristic curve are set: rise / fall slope and KP / KI value. After debugging, practical training can begin.

[0041] This solution's secondary development allows for the setting and modification of key parameters related to welding characteristics for welding performance optimization. Software upgrades and verification are performed via computer programming and flashing. For communication with other peripheral devices, the source code can be released for expansion through network cabling, CAN communication, or MAX232 communication.

[0042] By combining hardware and software, different needs can be met for different learners. The hardware component allows students to learn about the components of hardware, the functions, roles, and relationships between different hardware parts, and to conduct practical training in assembly, repair, and welding. The software component includes built-in learning courses and exam question banks, enabling daily practice and exams on welding-related professional knowledge. By manually setting relevant circuit faults, students' independent repair abilities can be cultivated, improving their problem-solving skills related to welding equipment and processes.

[0043] The system utilizes software for automatic or manual waveform control, enabling current waveform control based on process timing, arc initiation, arc termination, and different processes. As needed, intelligent detection algorithms and multi-mode selection modules can be added. For waveform control, adaptive adjustment and waveform reconstruction methods can be employed. Due to the system's openness, users can perform secondary development according to their requirements.

[0044] Specific applications:

[0045] 1. Vocational schools: Focus on fixed hardware circuits, mainly used by students to analyze welding machine power supply faults, and learn about the composition of various hardware components.

[0046] 2. Undergraduate institutions: The main focus is on demonstrating the principle of inverter power supply, and modular hardware replacement is implemented to enable more functional demonstrations. Arc welding power supply courseware is also installed to assist undergraduate teaching.

[0047] 3. Graduate student experiments: mainly software-based, which can optimize characteristic curves by writing code to achieve better welding characteristics, and can design welding characteristics in a targeted manner to weld some special metals.

[0048] 4. Competition Scenario: Design a hardware fault diagnosis and scoring system. The original competition only focused on welding techniques and processes. This equipment can be used to compete on equipment maintenance and usage.

[0049] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of the claims of this patent application.

Claims

1. A multifunctional welding comprehensive training system, characterized in that, The platform of the equipment frame (1) is divided into a low-voltage area, a high-voltage area and a weak-voltage area. The weak-voltage area, the high-voltage area and the low-voltage area are three independent partitioned areas. Different colors are painted in the low-voltage area, the high-voltage area and the weak-voltage area respectively. The electrical components of the welding machine are separated according to their functions, and the components are placed at intervals. The components are connected to each other according to the working principle of the welding machine. The low-voltage electrical components in the welding machine control circuit are placed in the low-voltage area, the high-voltage electrical components in the primary circuit of the welding machine are placed in the high-voltage area, and the low-voltage electrical components in the secondary circuit of the welding machine are placed in the low-voltage area. The platform of the equipment frame (1) is covered with a transparent protective cover, and an observation window (2) that can be opened and closed is installed on the side wall of the protective cover.

2. The multifunctional welding integrated training system according to claim 1, wherein, The high-voltage electrical components include a primary rectifier module (10), a primary capacitor (11), and an inverter module (12). The input terminal of the primary rectifier module (10) is connected to a three-phase power supply. The output terminal of the primary rectifier module (10) is connected to the input terminal of the inverter module (12). The primary capacitor (11) is connected in parallel to the output terminal of the primary rectifier module (10). The three-phase power supply is rectified into DC voltage by the primary rectifier module (10). The DC voltage output by the primary rectifier module (10) is inverted into AC square wave voltage by the inverter module (12).

3. The multifunctional welding integrated training system according to claim 2, wherein, The low-voltage electrical components include a transformer module (13), a secondary rectifier module (14), and an output inductor (15). The input terminal of the transformer module (13) is connected to the output terminal of the inverter module (12), and the output terminal of the transformer module (13) is connected to the input terminal of the secondary rectifier module (14). The output terminal of the secondary rectifier module (14) generates a positive output and a negative output. The output inductor (15) is connected in series on the negative output of the secondary rectifier module (14). The AC square wave voltage output by the inverter module (12) is reduced by the transformer module (13) and then rectified by the secondary rectifier module (14), and then filtered by the output inductor (15).

4. The multifunctional welding integrated training system according to claim 3, characterized in that, The low-voltage electrical components include a switching power supply (16), a power frequency transformer (17), a main control board (18), and a wire feeding control board (19). The input terminal of the switching power supply (16) is connected to the 220V mains power. The input terminal of the power frequency transformer (17) is connected to the primary rectifier module (10). The output terminal of the power frequency transformer (17) supplies power to the main control board (18) through the primary power supply line. The output terminal of the power frequency transformer (17) is connected to the main control board (18) through the auxiliary transformer power supply line. The main control board (18) is connected to the wire feeding control board (19) through the wire feeding control line. The transformer module (13) is connected to the main control board (18) through the wire feeding auxiliary power supply line. The wire feeding control board (19) is connected to the wire feeding machine connector (20) through the wire feeding machine interface line. The wire feeder and the wire feeding machine connector (20) are connected in communication.

5. The multifunctional welding integrated training system according to claim 4, characterized in that, The main control board (18) is connected to the drive board of the inverter module (12) via a PWM drive line; a Hall sensor is provided on the output end of the secondary rectifier module (14), and the Hall sensor is connected to the main control board (18) via an output current detection line; the output end of the secondary rectifier module (14) is connected to the main control board (18) via an output voltage sampling line; a current transformer is provided on the output end of the inverter module (12), and the current transformer is connected to the main control board (18) via a primary current sampling line; the current signal collected by the Hall sensor, the voltage signal collected by the voltage sampling line, and the current signal collected by the current transformer are all transmitted to the main control board (18) via isolated linear optocouplers. The main control board (18) calculates the corresponding control characteristics based on the sampled voltage and current signals and the set output mode. The main control board (18) is connected to the PWM drive line via a DA interface. After the main control board (18) outputs the characteristic voltage, it transmits it to the drive board of the inverter module (12) via the PWM drive line.

6. The multifunctional welding integrated training system according to claim 5, wherein, The inverter module (12) is equipped with a heat sink temperature switch. The main control board (18) is connected to the first cooling fan through the heat sink temperature switch. The secondary rectifier module (14) is equipped with a thermistor, which is connected to the main control board (18). The main control board (18) is connected to a second cooling fan through a line. The first cooling fan is installed on one side of the inverter module (12), and the second cooling fan is installed on one side of the secondary rectifier module (14). The switching power supply (16) supplies power to the first cooling fan and the second cooling fan respectively.

7. The multifunctional welding integrated training system according to claim 6, wherein, It also includes a data acquisition unit (4) and a data control unit (5). The switching power supply (16) outputs 24V DC power to power the data control unit (5). The data control unit (5) is communicatively connected to the wire feeding control board (19). The data acquisition unit (4) is communicatively connected to the data control unit (5). The data acquisition unit (4) is powered by 220V AC mains power. The main control board (18) receives the control signal sent by the data control unit (5) and controls the inverter module (12) to output voltage and current. The data control unit (5) sends a control signal to the wire feeder through the wire feeding control board (19) to regulate the wire feeding speed and protect the gas cylinder and the wire feeder. After the machine is connected, the data control unit (5) outputs control signals to the wire feeder through the wire feeding control board (19) to control the type, flow rate and output time of the protective gas output by the wire feeder; the output current, output voltage and primary current received by the main control board (18) are sent to the data acquisition unit (4) through the network cable or MAX232 mode and displayed on the data acquisition unit (4); the data control unit (5) sends control signals to control the inverter module (12) to output DC current or pulse current; the data control unit (5) collects the wire feeding speed, welding wire consumption and protective gas consumption of the wire feeder obtained by the wire feeding control board (19) in real time through the CAN communication protocol.

8. The multifunctional welding integrated training system according to claim 7, characterized in that, The primary rectifier module (10) is equipped with a 380V power switch (9) at its input terminal, and the switching power supply (16) is equipped with a 220V power switch (8). The positive output and the negative output are connected to an output port (7), which is connected to the welding torch.

Images