Dual power circuit fused welder circuit and welding system

Abstract

This utility model discloses a welding machine circuit and welding system with integrated dual-power circuits. The welding machine circuit includes a rectifier module, an inverter module, a transformer, and a battery power supply circuit connected in sequence. The input side of the rectifier module is connected to an external AC power source. The secondary side of the transformer consists of a first winding coil and a second winding coil connected in series. One end of the secondary side is connected to the anode of a first diode, and the other end is connected to the anode of a second diode. The cathodes of the first and second diodes are connected to one end of an output inductor. The connection point of the first and second winding coils and the other end of the output inductor constitute the output terminal of the welding machine circuit. The battery power supply circuit includes a battery and a power switch transistor. The battery power supply circuit reuses the first diode, the second diode, and the output inductor, forming a BUCK circuit with the battery and the power switch transistor. Deep integration of the AC power supply circuit and the DC power supply circuit is achieved by using high-power devices.

Description

Technical Field

[0001] This utility model relates to the field of welding machines, and in particular to a welding machine circuit and welding system with dual power supply circuit integration. Background Technology

[0002] Currently, some welding equipment has begun to use both batteries and mains power as power sources. In scenarios where there is no mains power, batteries can be used for temporary construction, and when mains power is available, it can be connected to mains power for long-term operation, which brings certain conveniences.

[0003] However, the two power supply systems are independent of each other, and the power design is relatively redundant. When one system is working, the other system is completely shut down, and the power stage components cannot be reused. It is more of a combination of the two power supplies. This results in disadvantages such as large size, heavy weight, and significantly increased cost.

[0004] The disclosure of the above background information is only for the purpose of assisting in understanding the concept and technical solution of this application, and does not necessarily provide technical instruction. Utility Model Content

[0005] The purpose of this invention is to provide a welding machine circuit that deeply integrates AC power circuit and DC power circuit, thereby saving space, reducing weight, and lowering costs.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A welding machine circuit with integrated dual-power supply circuits includes a bridge rectifier module, an H-bridge inverter module, and a transformer connected in sequence. The input side of the bridge rectifier module is configured to be connected to an external AC power source. The welding machine circuit also includes a battery power supply circuit.

[0008] The secondary side of the transformer consists of a first winding coil and a second winding coil connected in series. One end of the secondary side is connected to the positive terminal of the first diode, and the other end is connected to the positive terminal of the second diode. The negative terminals of the first diode and the second diode are connected to one end of the output inductor.

[0009] The connection point between the first winding coil and the second winding coil, and the other end of the output inductor constitute the output terminal of the welding machine circuit;

[0010] The battery power supply circuit includes a battery and a power switch transistor, and the battery power supply circuit reuses the first diode, the second diode, and the output inductor to form a BUCK circuit with the battery and the power switch transistor.

[0011] Furthermore, in accordance with any or a combination of the aforementioned technical solutions, the drain of the power switch is connected to the positive terminal of the battery, and the source of the power switch is connected to one end of the output inductor.

[0012] The connection point between the first winding coil and the second winding coil is connected to the negative terminal of the battery.

[0013] Furthermore, based on any or a combination of the aforementioned technical solutions, the welding machine circuit with integrated dual power supply circuits provided by this utility model also includes a PWM signal source switch, which is connected to the gate of the power switch transistor.

[0014] The power switch is equipped with a body diode, the anode of which is connected to the source of the power switch, and the cathode of which is connected to the drain of the power switch.

[0015] Furthermore, following any one or a combination of the aforementioned technical solutions, the PWM signal source switch is configured to control the output or shutdown of the PWM signal, and to adjust the duty cycle of the PWM signal.

[0016] Furthermore, based on any or a combination of the aforementioned technical solutions, the power switch is an N-channel MOSFET.

[0017] Furthermore, based on any one or a combination of the aforementioned technical solutions, the turns ratio of the first winding coil to the second winding coil is 1:1.

[0018] Furthermore, based on any or a combination of the aforementioned technical solutions, the welding machine circuit with dual power supply circuit integration provided by this utility model also includes a filter module disposed between the bridge rectifier module and the H-bridge inverter module, wherein the filter module is an RC filter circuit or an LC filter circuit.

[0019] Furthermore, based on any or a combination of the aforementioned technical solutions, the bridge rectifier module is a full-wave rectifier circuit composed of four diodes;

[0020] The H-bridge inverter module includes two sets of bridge arms, each consisting of four power switching devices.

[0021] Furthermore, based on any or a combination of the aforementioned technical solutions, the welding machine circuit with integrated dual power supply circuits provided by this utility model also includes a heat sink.

[0022] According to another aspect of the present invention, the present invention provides a welding system, including welding equipment and a welding machine circuit with dual power supply circuits as described above, wherein the welding equipment is connected to the output terminal of the welding machine circuit.

[0023] The beneficial effects of the technical solution provided by this utility model are as follows:

[0024] a. The AC power circuit and DC power circuit of the welding machine reuse high-power devices to achieve deep integration, thereby saving space, reducing weight and reducing cost;

[0025] b. The power rating of reused devices typically reaches 5kW, generating a large amount of heat. The reused circuit structure not only saves on the number of devices but also saves on the corresponding heat dissipation device, resulting in a comprehensive reduction of at least half the volume and weight, thus achieving miniaturization of the welding machine circuit. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 A conceptual block diagram of dual-power circuit multiplexing and fusion in a single-channel welding machine provided as an exemplary embodiment of the present invention;

[0028] Figure 2 A circuit diagram of a welding machine circuit with integrated dual power supply circuits provided as an exemplary embodiment of the present invention. Detailed Implementation

[0029] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention 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 invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0030] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, apparatus, product, or device that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or devices.

[0031] In one embodiment of this utility model, a welding machine circuit with integrated dual-power supply circuits is provided, wherein the dual power supplies are AC power and DC power, such as... Figure 1 As shown, the AC power supply circuit includes a bridge rectifier module, an H-bridge inverter module, a transformer, and an AC power circuit connected in sequence, wherein the input side of the bridge rectifier module is configured to be connected to an external AC power source.

[0032] The DC power supply for the welding machine circuit is a battery, and its corresponding battery power supply circuit is the DC power supply circuit, which includes the battery and some components reused with the AC power supply circuit. The specific description of the reused components is as follows:

[0033] like Figure 2 As shown, the secondary side of transformer T1 consists of a first winding coil and a second winding coil connected in series, with one end of the secondary side connected to a first diode. Figure 2 The positive terminal of D5 is connected to the second diode (D5), and the other end is connected to the positive terminal of the second diode (D5). Figure 2 The positive terminal of diode D6 is connected to the output inductor, and the negative terminals of the first diode D5 and the second diode D6 are connected together. Figure 2 One end of L1);

[0034] The connection point between the first winding coil and the second winding coil, and the other end of the output inductor L1 constitute the two endpoints of the output terminal of the welding machine circuit.

[0035] The battery power supply circuit includes the battery and the power switching transistor ( Figure 2 In the battery power supply circuit, the first diode D5, the second diode D6, and the output inductor L1 are reused to form a BUCK circuit with the battery and the power switch Q5.

[0036] like Figure 2As shown, the drain of the power switch Q5 is connected to the positive terminal of the battery, and the source of the power switch Q5 is connected to one end of the output inductor L1.

[0037] The connection point between the first winding coil and the second winding coil is connected to the negative terminal of the battery, which constitutes one of the output terminals of the welding machine circuit.

[0038] The welding machine circuit with integrated dual-power supply circuits provided by this utility model also includes a PWM signal source switch, which is connected to the gate of the power switch Q5. The power switch Q5 is preferably an N-channel MOSFET and is equipped with a body diode. The anode of the body diode is connected to the source of the power switch Q5, and the cathode of the body diode is connected to the drain of the power switch Q5. Further, the PWM signal source switch is configured to control the output or shutdown of the PWM signal and to adjust the duty cycle of the PWM signal.

[0039] In one specific embodiment, the turns ratio of the first winding coil to the second winding coil is 1:1.

[0040] See further Figure 2 The AC power supply circuit provided by this utility model also includes a filter module disposed between the bridge rectifier module and the H-bridge inverter module. The filter module is an RC filter circuit, which includes a capacitor C1 and a resistor R1 connected in parallel; the filter module can also be an LC filter circuit (not shown). Figure 2 As shown, the bridge rectifier module is a full-wave rectifier circuit composed of four diodes (D1, D2, D3, D4); the H-bridge inverter module includes two bridge arms obtained by grouping four power switching devices, including the first bridge arm containing power transistors Q1 and Q2 and the second bridge arm containing power transistors Q3 and Q4.

[0041] In one embodiment of this utility model, a welding system is provided, including welding equipment and a welding machine circuit with dual power supply circuits fused as described above, such as... Figure 1 As shown, the welding equipment is connected to the output terminal of the welding machine circuit.

[0042] The welding machine circuit in this embodiment operates in the following two modes:

[0043] When using AC power, the power switch Q5 is not working. At this time, the overall circuit scheme is the same as that of a traditional AC welding machine: the AC input is rectified and filtered by diodes D1, D2, D3, D4 and capacitor C1 and converted into DC power; then it is inverted into AC power by a full-bridge circuit composed of switches Q1, Q2, Q3, Q4 and transformer T1; finally, the DC welding power is output by diodes D5 and D6; the output inductor L1 is connected in series in the DC output circuit to maintain the stability of the electric arc.

[0044] When a DC power supply (battery) is used, the switching transistors Q1, Q2, Q3, and Q4 are not working. At this time, the power switching transistor Q5, inductor L1, and diodes D5 and D6 form a typical DC chopper (BUCK) circuit. The output inductor L1 serves as the output inductor of the BUCK circuit, and the diodes D5 and D6 serve as the rectifier diodes of the BUCK circuit. The DC power supply (battery) is converted by the BUCK circuit to output DC welding power.

[0045] In summary, the output inductor L1, diodes D5 and D6 are key components when the two power supplies operate independently, and can also be reused when powered by either power supply. These reused components are high-power devices. In addition to reusing power devices, corresponding heat sinks are also reused, resulting in a reduction in cost, significant savings in size and weight, and miniaturization of the welding machine circuit.

[0046] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0047] The above description is only a specific embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A welding machine circuit with integrated dual-power supply circuits, comprising a bridge rectifier module, an H-bridge inverter module, and a transformer connected in sequence, wherein, The input side of the bridge rectifier module is configured to be connected to an external AC power supply; the welding machine circuit further includes a battery power supply circuit. The secondary side of the transformer consists of a first winding coil and a second winding coil connected in series. One end of the secondary side is connected to the positive terminal of the first diode, and the other end is connected to the positive terminal of the second diode. The negative terminals of the first diode and the second diode are connected to one end of the output inductor. The connection point between the first winding coil and the second winding coil, and the other end of the output inductor constitute the output terminal of the welding machine circuit; The battery power supply circuit includes a battery and a power switch transistor, and the battery power supply circuit reuses the first diode, the second diode, and the output inductor to form a BUCK circuit with the battery and the power switch transistor.

2. The welding machine circuit with integrated dual power supply circuits according to claim 1, characterized in that, The drain of the power switch is connected to the positive terminal of the battery, and the source of the power switch is connected to one end of the output inductor. The connection point between the first winding coil and the second winding coil is connected to the negative terminal of the battery.

3. The welding machine circuit with integrated dual power supply circuits according to claim 2, characterized in that, It also includes a PWM signal source switch, which is connected to the gate of the power switch transistor; The power switch is equipped with a body diode, the anode of which is connected to the source of the power switch, and the cathode of which is connected to the drain of the power switch.

4. The welding machine circuit with integrated dual power supply circuits according to claim 3, characterized in that, The PWM signal source switch is configured to control the output or shutdown of the PWM signal, and to adjust the duty cycle of the PWM signal.

5. The welding machine circuit with dual power supply circuit fusion according to any one of claims 2 to 4, characterized in that, The power switch is an N-channel MOSFET.

6. The welding machine circuit with integrated dual power supply circuits according to claim 1, characterized in that, The turns ratio of the first winding coil to the second winding coil is 1:

1.

7. The welding machine circuit with integrated dual power supply circuits according to claim 1, characterized in that, It also includes a filter module disposed between the bridge rectifier module and the H-bridge inverter module, wherein the filter module is an RC filter circuit or an LC filter circuit.

8. The welding machine circuit with integrated dual power supply circuits according to claim 1, characterized in that, The bridge rectifier module is a full-wave rectifier circuit composed of four diodes; The H-bridge inverter module includes two sets of bridge arms, each consisting of four power switching devices.

9. The welding machine circuit with integrated dual power supply circuits according to claim 1, characterized in that, It also includes the heat sink.

10. A welding system, characterized in that, It includes welding equipment and a welding machine circuit with dual power supply circuits fused as described in any one of claims 1 to 9, wherein the welding equipment is connected to the output terminal of the welding machine circuit.

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