A megawatt high-power plasma torch power supply complete machine
By introducing a soft-start unit and a rectifier unit into the plasma torch power supply, combined with a closed-loop cooling system and an emergency stop circuit, the problems of excessive starting current and unstable arc were solved, achieving stable operation of the equipment and high-temperature plasma generation, which facilitates maintenance and safe operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 安徽省金屹等离子体电源科技有限公司
- Filing Date
- 2025-07-22
- Publication Date
- 2026-07-21
AI Technical Summary
Existing plasma torch power supplies lack soft-start units and rectifier units, resulting in excessive inrush current during startup, which may burn out the devices. Furthermore, AC drive leads to arc instability, making it impossible to form a sustained high-temperature plasma.
A plasma torch power supply unit was designed, comprising a transformer, a soft-start unit, a rectifier unit, a PDSM module, a DSP control unit, a PLC control system, and a touch screen. The soft-start unit gradually increases the voltage/current, the rectifier unit adjusts the output voltage/current, and a closed-loop cooling system and an emergency stop circuit are combined to ensure the safe and stable operation of the equipment.
It effectively protects circuit components, limits starting current, ensures stable operation of the plasma torch, provides high-temperature plasma, extends equipment life, facilitates maintenance and transportation, and enables safe operation.
Smart Images
Figure CN224538387U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of power supply equipment technology, specifically to a megawatt-level high-power plasma torch power supply unit. Background Technology
[0002] Plasma torch power supplies are characterized by their small size, high efficiency, fast feedback control, low noise, and easy maintenance. They also feature comprehensive protection functions to ensure long-term stable operation. They can be used in fields such as solid waste treatment, plasma melting and smelting, and plasma material processing.
[0003] Currently, many plasma torch power supplies do not have soft-start units and rectifier units. During startup, the inrush current is too large, which may burn out the rectifier, power devices (such as IGBTs) or electrodes, shortening the equipment life. In addition, if the plasma torch is driven directly by AC power, the arc will frequently extinguish / reignite with the AC cycle, resulting in extremely unstable plasma and the inability to form a continuous and effective high-temperature plasma. Utility Model Content
[0004] To address the problems existing in current technical solutions, the purpose of this utility model is to provide a complete megawatt-level high-power plasma torch power supply.
[0005] To achieve the above objectives, this utility model provides the following technical solution:
[0006] A megawatt-level high-power plasma torch power supply unit includes a transformer, a soft-start unit, a rectifier unit, a PDSM module, a DSP control unit, a PLC control system, and a touch screen;
[0007] Three-phase 10kV AC power input passes through a high-voltage switchgear and is connected to a transformer;
[0008] The transformer transforms the three-phase 10kV AC power and then connects it to the soft starter unit.
[0009] The soft-start unit is connected to the rectifier unit, and the rectifier unit is connected to the PDSM module; the PDSM module is connected to an inductor, and the other end of the inductor is the output circuit.
[0010] The PLC control system is connected to the DSP control unit, and the DSP control unit is connected to the PDSM module.
[0011] The PDSM module is connected to the inductor output circuit, which outputs a plasma torch power supply with a voltage of 250V / 500V and a current of 4000A / 2000A.
[0012] Furthermore, the plasma torch power supply also includes a transformer; the rectifier transformer is a three-phase, two-winding transformer with an operating frequency of 50±3Hz. The winding connection is Y / Y, with one winding and a voltage of 10kV / 430V; or Y / D, with one winding and a voltage of 10kV / 430V. The two windings have evenly distributed capacities, each 600kVA. The transformer's short-circuit impedance is no greater than 5%. Under a 50Hz input, the transformer's leakage inductance is 5%. The transformer can withstand 100% overload for a short period (less than 1 second each time, no more than 100 times per day) while maintaining the integrity of the transformer winding structure. The rectifier transformer adopts a fully insulated structure, epoxy-cast, and wound with aluminum material; the input and output terminals use copper-aluminum transitions.
[0013] Furthermore, the plasma torch power supply also includes a cooling unit, which is installed in a dedicated compartment within the cabinet. The cooling unit can be manually filled with an appropriate amount of coolant, and the cooling medium of the cooling unit is water, with a conductivity maintained below 100 S / cm for at least a 3-year target lifespan.
[0014] Furthermore, the cooling unit is a complete closed-loop cooling system, with pumps, expansion tanks, and temperature monitoring, which circulates the coolant through all the necessary components.
[0015] Furthermore, the plasma torch power supply unit includes a power supply enclosure, constructed using a single cabinet and access doors to all available equipment for easy maintenance. All enclosures are IP54 rated, and all access doors are integrated into the emergency stop circuit, allowing access to high-power equipment via safety switches. The power supply enclosure is equipped with safety locks to ensure safe entry, and forklift access points are provided for convenient transport.
[0016] Furthermore, the power supply employs an emergency stop circuit to safely interrupt and disable the DC output. The emergency stop circuit features a dual-channel stop circuit as part of the program, with the medium-voltage circuit breaker immediately tripping upon emergency stop. Safety relays also form part of the external dual-channel emergency stop system, shutting down the system and providing indication to the HMI (and main PLC) upon emergency stop.
[0017] Furthermore, the control panel provides process data and soft buttons to the operator, facilitating local operation of the PPS. Local functions are only allowed when the power supply is in local mode. The control panel provides functions such as local / remote control switching buttons, a charging button to charge the bus and turn off the main circuit breaker, a discharging button to open the circuit breaker and discharge through a resistor, running the PPS, stopping the PPS, opening and closing the DC output grounding switch, and setting the DC output current and DC output power limit settings.
[0018] Compared with the prior art, the beneficial effects of this utility model are as follows: This novel plasma torch power supply uses a high-voltage switchgear, transformer, soft start system; the soft start system, rectifier module, PDSM module, inductor, and outputs a plasma torch power supply with a voltage of 250V / 500V and a current of 4000A / 2000A; it supplies energy to the torch through the plasma power supply, uses an electric arc to generate high-temperature gas, and smelts and recovers precious metals; it has a short time, large capacity, and is easy to use; the power supply is built using a single cabinet and access doors to all available equipment, facilitating maintenance; the power supply casing is equipped with a safety lock, making operation safer; the power supply casing provides a forklift point for convenient transportation.
[0019] The soft-start unit uses a gradual increase in voltage / current (such as linear boost or stepped boost) to limit the starting current within a safe range, protecting circuit components and loads and avoiding arc instability caused by instantaneous high voltage / high current. Secondly, the rectifier unit's controllable rectifier (such as thyristor rectifier) can adjust the output DC voltage / current to adapt to the power changes of the plasma torch under different operating conditions (such as low-power preheating and high-power operation). Attached Figure Description
[0020] The present invention will be further described below with reference to the accompanying drawings:
[0021] Figure 1 This is a schematic diagram of the power supply circuit principle of the plasma torch of this utility model;
[0022] Figure 2 This is a schematic diagram of the overall structure of the plasma torch power supply of this utility model;
[0023] Figure 3 This is a schematic diagram of the structure of the plasma torch power supply cooling unit of this utility model;
[0024] Figure 4 This is a schematic diagram of the plasma torch power control panel of this utility model; Detailed Implementation
[0025] 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 of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0026] Example 1
[0027] like Figures 1-4 As shown, this embodiment provides a plasma torch power supply, including a transformer, a soft-start unit, a rectifier unit, a PDSM module, a DSP control unit, a PLC control system, and a touch screen;
[0028] Three-phase 10kV AC power input passes through a high-voltage switchgear and is connected to a transformer;
[0029] The transformer transforms the three-phase 10kV AC power and then connects it to the soft starter unit.
[0030] The soft-start unit is connected to the rectifier unit, which in turn is connected to the PDSM module. The PDSM module is connected to an inductor, and the other end of the inductor is the output circuit.
[0031] The PLC control system is connected to the DSP control unit, and the DSP control unit is connected to the PDSM module.
[0032] The PDSM module is connected to the inductor output circuit, which outputs a plasma torch power supply with a voltage of 250V / 500V and a current of 4000A / 2000A.
[0033] Furthermore, the plasma torch power supply also includes a transformer; the rectifier transformer is a three-phase, two-winding transformer with an operating frequency of 50±3Hz. The winding connection is Y / Y, with one winding and a voltage of 10kV / 430V; and Y / D, with one winding and a voltage of 10kV / 430V. The two windings have evenly distributed capacities, each 600kVA. The transformer's short-circuit impedance is no greater than 5%. Under a 50Hz input, the transformer's leakage inductance is 5%. The transformer can withstand 100% overload for a short period (less than 1 second each time, no more than 100 times per day) without the winding structure remaining intact. The rectifier transformer adopts a fully insulated structure, epoxy-cast, and wound with aluminum material; the input and output terminals use copper-aluminum transitions.
[0034] Furthermore, the plasma torch power supply also includes a cooling unit, which is installed in a dedicated compartment within the cabinet. The cooling unit can be manually filled with an appropriate amount of coolant. The cooling medium of the cooling unit is water, and its conductivity remains below 100 S / cm for at least a 3-year target lifespan.
[0035] Furthermore, the cooling unit is a complete closed-loop cooling system, with pumps, expansion tanks, and temperature monitoring, which circulates the coolant through all the necessary components.
[0036] Furthermore, the plasma torch power supply unit comprises a power supply enclosure, constructed using a single cabinet and access doors to all available equipment for easy maintenance. All enclosures are IP54 rated, and all access doors are integrated into the emergency stop circuit, allowing access to high-power equipment via safety switches. The power supply enclosure is equipped with safety locks to ensure safe entry, and forklift access points are provided for convenient transport.
[0037] Furthermore, the power supply employs an emergency stop circuit to safely interrupt and disable the DC output. The emergency stop circuit features a dual-channel stop circuit as part of the program, with the medium-voltage circuit breaker immediately tripping upon emergency stop. Safety relays also form part of the external dual-channel emergency stop system, shutting down the system and providing indication to the HMI (and main PLC) upon emergency stop.
[0038] Furthermore, the control panel provides process data and soft buttons to the operator, facilitating local operation of the PPS. Local functions are only allowed when the power supply is in local mode. The control panel provides functions such as local / remote control switching buttons, a charging button to charge the bus and turn off the main circuit breaker, a discharging button to open the circuit breaker and discharge through a resistor, running the PPS, stopping the PPS, opening and closing the DC output grounding switch, and setting the DC output current and DC output power limit settings.
[0039] The above description is merely an illustrative example of the structure of this utility model. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of this utility model or exceed the scope defined in the claims, all of which should fall within the protection scope of this utility model.
Claims
1. A megawatt-class high-power plasma torch power supply system, characterized in that, Includes transformer, soft starter unit, rectifier unit, PDSM module, DSP control unit, PLC control system, and touch screen; Three-phase 10kV AC power input passes through a high-voltage switchgear and is connected to a transformer; The transformer transforms the three-phase 10kV AC power and then connects it to the soft starter unit. The soft-start unit is connected to the rectifier unit, and the rectifier unit is connected to the PDSM module; the PDSM module is connected to an inductor, and the other end of the inductor is the output circuit. The PLC control system is connected to the DSP control unit, and the DSP control unit is connected to the PDSM module.
2. The megawatt-level high-power plasma torch power supply according to claim 1, characterized in that, The transformer is a three-phase two-winding transformer. The short-circuit impedance of the transformer is not greater than 5%. The leakage inductance of the transformer is 5% under 50Hz input conditions.
3. The megawatt-level high-power plasma torch power supply system according to claim 1, characterized in that, It also includes a cooling unit and a water tank, wherein the cooling medium of the cooling unit is water.
4. The megawatt-level high-power plasma torch power supply according to claim 3, characterized in that, It also includes a power supply housing and a cabinet, wherein the power supply housing is installed inside the cabinet, and the cabinet is equipped with an access door and a safety lock. The water tank is installed inside the cabinet.
5. The megawatt-level high-power plasma torch power supply according to claim 3, characterized in that, The cooling unit includes three cooling water outlet pipes and one cooling water return pipe installed on the water tank. A liquid filling port is provided on the side wall of the water tank near the top, and a liquid drain port is provided on the side wall of the water tank near the bottom. A liquid level display window is installed on the side wall of the water tank.
6. The megawatt-level high-power plasma torch power supply according to claim 5, characterized in that, An emergency stop circuit is installed on the access door.