A silicon carbide digital pulse industrial gas shielded welding machine

Abstract

This invention provides a silicon carbide digital pulse industrial gas shielded welding machine, including a housing and a main circuit. Employing digital control, it features excellent static characteristics and rapid dynamic response, resulting in a stable welding arc and aesthetically pleasing weld formation. The panel uses a digital display screen, which provides clearer and more intuitive parameter adjustments compared to conventional digital tube displays. Communication utilizes a 485 digital interface, offering more precise data transmission and faster response times compared to analog communication. The circuit board on the left side is located to the left and right of the upper support, rather than on top, reducing dust accumulation and increasing the reliability of the control unit. This invention boasts a reasonable and simple structure, improved duty cycle, and significantly enhanced reliability.

Description

Technical Field

[0001] This utility model belongs to the field of welding machine technology, specifically relating to a silicon carbide digital pulse industrial gas shielded welding machine. Background Technology

[0002] Traditional pulse gas shielded welding machines generally suffer from large size and complex circuitry, leading to difficult maintenance and low reliability. Their drive circuits often employ analog control, relying on analog signals for communication with the wire feeder, making them susceptible to interference and lacking sufficient adjustment precision, thus affecting welding stability. Furthermore, these machines have low duty cycles, making them unsuitable for high-intensity continuous operation, and their human-machine interfaces typically only feature simple digital displays, failing to intuitively show key welding parameters, further increasing operational difficulty and debugging costs.

[0003] Existing technologies have not fully solved key issues such as dynamic matching, precise wire feeding coordination control, and efficient heat dissipation of silicon carbide devices in high-frequency pulse welding, which limits their widespread application in the field of high-performance welding. Utility Model Content

[0004] The purpose of this invention is to provide a silicon carbide digital pulse industrial gas shielded welding machine with a reasonable and simple structure, improved duty cycle and reliability, and good static external characteristics and fast dynamic response due to digital control.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A silicon carbide digital pulse industrial gas shielded welding machine includes a housing and a main circuit section;

[0007] The casing adopts a six-sided rectangular structure, which includes a bottom plate, a front panel, a rear panel, a middle plate, and an outer shell. The middle plate is installed on the upper part, and the bottom plate supports the front panel, the rear panel, the middle plate, and the outer shell.

[0008] The front panel is symmetrically provided with a red assembled output socket positive terminal and a black assembled output socket negative terminal. Between the red assembled output socket positive terminal and the black assembled output socket negative terminal are a seven-pin aviation socket and a five-pin aviation socket. The seven-pin aviation socket is connected to the wire feeder motor and the air valve, and the five-pin aviation socket is connected to the gun switch and the 485 communication of the control box.

[0009] The front panel is also equipped with a digital display screen and an operation panel. The operation panel includes three adjustment knobs: a current knob, a voltage knob, and an electronic inductance knob, as well as four buttons: an operation method button, a welding method button, a welding type button, and a welding wire diameter selection button. The digital display screen is connected to the main control board to realize data display and parameter setting.

[0010] An air switch is located on the upper right side of the rear panel, and a three-phase input socket and a 36V heater socket are located on the left side. The three-phase input socket is connected to the air switch and then to the three-phase rectifier bridge through a power line clamping wire. The 36V heater socket provides power for the gas meter heating. An air vent is located at the lower part of the rear panel and an axial flow fan is installed there.

[0011] A heat sink bracket is installed on the left side of the base plate. A three-phase rectifier bridge, a power board, two silicon carbide modules, an IGBT absorption plate, and a capacitor board are mounted on the bracket. The input of the three-phase rectifier bridge is connected to an air switch, and the output is filtered by the capacitor board and then connected to the silicon carbide module. The output of the silicon carbide module is connected to the primary of the main transformer. A secondary heat sink is installed on the right side of the base plate. Four secondary rectifier boards are mounted on it. The input of the secondary rectifier boards is connected to the secondary of the main transformer, and the output is connected to the positive terminal of the assembled output socket via an aluminum strip connected to the output inductor.

[0012] The middle layer board has an upper bracket at the top, a power transformer is installed at the bottom of the upper bracket, the main control board is installed on the left side, and a drive board and a communication board are installed on the right side of the middle layer board. The output end of the drive board is connected to the drive box to drive the silicon carbide module, and the 485 communication board is connected to the five-pin aviation socket. The main transformer and the output absorption board are suspended at the bottom of the middle layer board, and the center tap of the main transformer is connected to the negative terminal of the assembled output socket.

[0013] Preferably, the bottom of the base plate is equipped with swivel casters and directional casters for quick movement of the housing.

[0014] Preferably, the main control board is connected to the digital display screen, the driver board and the 485 communication board to realize parameter adjustment, display and communication functions.

[0015] Preferably, the 485 communication uses a digital interface to improve data transmission accuracy and response speed.

[0016] Preferably, the upper support adopts a left-right layout to reduce dust accumulation and improve control reliability.

[0017] Preferably, the main transformer is suspended to enhance heat dissipation performance.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] This utility model has a reasonable and simple structure, improved duty cycle, and enhanced reliability. In addition, the adoption of digital control provides excellent static characteristics and rapid dynamic response, resulting in a stable welding arc and aesthetically pleasing weld formation. The panel uses a digital display screen, which provides clearer and more intuitive parameter display compared to conventional digital tube displays. Communication is achieved through a 485 digital interface, which offers more precise data transmission and faster response compared to analog communication. The circuit board on the left side is located to the left and right of the upper bracket, rather than on top, making it less prone to dust accumulation and increasing the reliability of the control section. Attached Figure Description

[0020] Figure 1 This is a three-dimensional view of a silicon carbide digital pulse industrial gas shielded welding device according to this utility model.

[0021] Figure 2 This is a front view of a silicon carbide digital pulse industrial gas shielded welding device according to this utility model.

[0022] Figure 3 This is a rear view of a silicon carbide digital pulse industrial gas shielded welding device according to this utility model.

[0023] Figure 4 This is a left view of a silicon carbide digital pulse industrial gas shielded welding device according to this utility model (left and right side cover plates omitted).

[0024] Figure 5 This is a right view of a silicon carbide digital pulse industrial gas shielded welding device according to this utility model (left and right side cover plates omitted).

[0025] Figure 6 This is a top view of a silicon carbide digital pulse industrial gas shielded welding device according to this utility model (top cover plate omitted).

[0026] Figure 7 This is a schematic diagram of the structure of a silicon carbide digital pulse industrial gas shielded welding base plate according to the present invention.

[0027] Figure 8 This is a schematic diagram of the main circuit for silicon carbide digital pulse industrial gas shielded welding according to this utility model.

[0028] The serial numbers in the diagram are as follows:

[0029] 1. Operation method button; 2. Welding method button; 3. Current knob; 4. Welding type button; 5. Welding wire diameter selection button; 6. Electronic inductance knob; 7. Voltage knob; 8. Display screen; 9. Front panel vent; 10. Assembled output socket positive terminal; 11. Five-pin aviation socket; 12. Seven-pin aviation socket; 13. Assembled output socket negative terminal; 14. Universal casters; 15. Fixed casters; 16. Three-phase input socket; 17. Power cord clamp; 18. 19. Air switch; 20. 36V heater base; 21. Vent; 22. Driver box; 23. Three-phase rectifier bridge; 24. Power board; 25. Silicon carbide module; 26. Upper bracket; 27. IGBT absorption board; 28. Capacitor board; 29. ​​Main transformer; 30. Bracket; 31. Main control board; 32. Driver board; 33. 485 communication board; 34. Output absorption board; 35. Output inductor; 36. Aluminum strip; 37. Secondary heat sink; 38. Secondary rectifier board. Detailed Implementation

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0031] like Figures 1 to 7 As shown, this embodiment provides a silicon carbide digital pulse industrial gas shielded welding machine, which includes a housing and a main circuit. The housing includes a base plate, a front panel, a rear panel, a middle layer plate, left and right side panels, and a cover plate; the base plate, left and right side panels, rear panel, top cover plate, and front panel form the six sides of the housing; the middle layer plate is installed at the upper position; the base plate supports the left and right side panels, rear panel, middle layer plate, front panel, and top cover plate; the front panel... Figure 2 The front panel is equipped with a prefabricated output socket positive terminal 10 and a prefabricated output socket negative terminal 13. The positive output socket is located on the lower right side of the front panel, and the negative prefabricated output socket 13 is located on the lower left side of the front panel. When welding manually, the ground wire is connected to the negative terminal, and the welding clamp is connected to the positive terminal. When welding with gas shielded metal, the ground wire is connected to the negative output socket, and the positive output socket is connected to the wire feeder output end. The front panel is also equipped with a display panel, operation method button 1, welding method button 2, current adjustment knob 3, welding type button 4, welding wire diameter selection button 5, electronic inductance knob 6, voltage adjustment knob 7, display screen 8, front panel vent 9, prefabricated output socket positive terminal 10, five-pin aviation connector 11, seven-pin aviation connector 12, prefabricated output socket negative terminal 13, swivel casters 14, and fixed casters 15.

[0032] like Figure 3 As shown, the rear panel is equipped with 16, a three-phase input socket; used for power input, its power cord enters the waterproof connector and connects to the air switch, and the lower end connects to the three-phase rectifier bridge of the main circuit to provide AC power to the main circuit; 17, a pressure line; used to press the power input line to prevent loosening; 18, an air switch; used to control the power on and off, located on the upper right side of the rear panel. Above the rear panel is also a 36V heater socket 19, used to provide power for gas meter heating, and below is an external air vent 20, inside which an axial fan dissipates heat for the internal power devices.

[0033] like Figure 4 As shown, a heat sink with a bracket is installed on the left side of the base plate, on which a three-phase rectifier bridge 23 is mounted. A power board 24 is mounted on the bracket to supply power to the fan and power transformer. A primary inverter silicon carbide module 25 and an IGBT absorption plate 27 are mounted on the heat sink to absorb voltage spikes. A capacitor plate 28 is mounted above the silicon carbide module and the three-phase rectifier bridge to filter the voltage after rectification by the three-phase rectifier bridge and provide stable DC power to the silicon carbide module. After the silicon carbide module is inverted, it provides high-frequency AC power to the primary winding of the main transformer 29.

[0034] like Figure 5 As shown, a secondary rectifier heat sink 37 is installed on the right side of the base plate. Four secondary rectifier boards 38 are mounted on the secondary heat sink. The input of the rectifier board is connected to the secondary of the main transformer. After rectification, the signal is transmitted to the output inductor via the aluminum strip 36 and then connected to the output positive terminal assembly output socket. In addition, an output absorption plate 34 is installed below the middle layer plate on the right side for filtering out glitch in the output voltage signal.

[0035] like Figure 6 As shown, the upper bracket 26 for mounting circuit boards is located above the rear panel of the middle layer board. The upper bracket 26 is used to fix the main control board, the 485 communication board, and the driver board. Placing the circuit boards on the left and right sides helps to prevent dust accumulation. A power transformer is installed below the bracket to provide AC power to each board.

[0036] like Figure 7 As shown, in this embodiment, four casters, including swivel casters 14 and directional casters 15, are provided under the base plate to facilitate the movement of the machine.

[0037] The working principle of the whole machine is as follows Figure 8 As shown, in specific implementation, the main power supply of 380V is input from the three-phase input terminal, and the other end is connected to the air switch. The output terminal of the air switch is connected to the three-phase rectifier bridge. After rectification, it is filtered into DC power by the filter capacitor board, and then provides stable DC power to the left and right silicon carbide modules. After being inverted into AC power by the silicon carbide modules, it is output to the primary of the main transformer. The voltage after the secondary step-down is rectified by four secondary rectifier boards, and then filtered by the output inductor before being output.

[0038] The control panel is used for parameter adjustment, switching, display, and sending / receiving signals. The signals are transmitted to the main control board, which sends a given signal to the driver board, the 485 communication board, and the front display board. In addition, the main control board sends motor drive and solenoid valve drive voltages to the seven-pin aviation connector for driving the external wire feeder motor and air valve. The driver board outputs a PWM signal to the driver box, which then shapes the signal to drive the silicon carbide module. The IGBT absorption board is used to absorb the voltage spikes on the silicon carbide module and stabilize it. The 485 communication board is used for transmitting digital signals for the wire feeder display and button control.

[0039] This utility model has a reasonable and simple structure, improved duty cycle, and enhanced reliability. Furthermore, the adoption of digital control provides excellent static characteristics and rapid dynamic response, resulting in a stable welding arc and aesthetically pleasing weld formation. The panel uses a digital display screen, which provides clearer and more intuitive parameter adjustments compared to conventional digital tube displays. Communication utilizes a 485 digital interface, offering more precise data transmission and faster response compared to analog communication. The circuit board on the left side is located to the left and right of the upper bracket, rather than on top, reducing dust accumulation and increasing the reliability of the control section.

[0040] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0041] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0042] The above are merely preferred embodiments of this utility model, but the scope of protection of this utility model is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in this utility model, based on the technical solution and inventive concept of this utility model, should be included within the scope of protection of this utility model.

Claims

1. A silicon carbide digital pulse industrial gas arc welder characterized by, Including the casing and main circuitry; The casing adopts a six-sided rectangular structure, which includes a bottom plate, a front panel, a rear panel, a middle plate, and an outer shell. The middle plate is installed on the upper part, and the bottom plate supports the front panel, the rear panel, the middle plate, and the outer shell. The front panel is symmetrically provided with a red assembled output socket positive terminal (10) and a black assembled output socket negative terminal (13). Between the red assembled output socket positive terminal (10) and the black assembled output socket negative terminal (13) are a seven-pin aviation socket (12) and a five-pin aviation socket (11). The seven-pin aviation socket (12) is connected to the wire feeder motor and the air valve. The five-pin aviation socket (11) is connected to the gun switch and the 485 communication of the control box. The front panel is also equipped with a digital display screen (8) and an operation panel. The operation panel includes three adjustment knobs: a current knob (3), a voltage knob (7), and an electronic inductance knob (6), as well as four buttons: an operation method button (1), a welding method button (2), a welding type button (4), and a welding wire diameter selection button (5). The digital display screen (8) is connected to the main control board (31) to realize data display and parameter setting. An air switch (18) is provided on the upper right side of the rear panel, and a three-phase input socket (16) and a 36V heater socket (19) are provided on the left side. The three-phase input socket (16) is connected to the air switch (18) through the power line clamping wire (17) and then connected to the three-phase rectifier bridge (23). The 36V heater socket (19) provides power for the gas meter heating. A vent (20) is provided at the lower part of the rear panel and an axial flow fan is installed. A heat sink bracket is installed on the left side of the base plate. A three-phase rectifier bridge (23), a power board (24), two silicon carbide modules (25), an IGBT absorption plate (27), and a capacitor plate (28) are installed on the bracket. The input end of the three-phase rectifier bridge (23) is connected to an air switch (18), and the output end is connected to the silicon carbide module (25) after being filtered by the capacitor plate (28). The output end of the silicon carbide module (25) is connected to the primary of the main transformer (29). A secondary heat sink (37) is installed on the right side of the base plate. Four secondary rectifier boards (38) are installed on it. The input end of the secondary rectifier board is connected to the secondary of the main transformer (29), and the output end is connected to the positive terminal (10) of the assembled output socket after being connected to the output inductor (35) through an aluminum strip (36). Due to the use of silicon carbide modules, the heat dissipation effect is better than that of traditional models. The use of a heat sink smaller than that of traditional welding machines reduces the overall size of the machine. The upper part of the middle layer board is provided with an upper bracket (26), the bottom of the upper bracket (26) is equipped with a power transformer, the left side is equipped with a main control board (31), the right side of the middle layer board is equipped with a drive board (32) and a 485 communication board (33), the output end of the drive board (32) is connected to the drive box (22) to drive the silicon carbide module (25), and the 485 communication board (33) is connected to the five-pin aviation socket (11); the lower part of the middle layer board is suspended and installed with a main transformer (29) and an output absorption board (34), and the center tap of the main transformer (29) is connected to the negative terminal (13) of the assembled output socket.

2. The silicon carbide digital pulse industrial gas shielded welding machine according to claim 1, characterized in that, The bottom of the base plate is equipped with swivel casters (14) and directional casters (15).

3. The silicon carbide digital pulse industrial gas shielded welding machine according to claim 1, characterized in that, The main control board (31) is connected to the digital display screen (8), the driver board (32) and the 485 communication board (33) to realize parameter adjustment, display and communication functions.

4. A silicon carbide digital pulse industrial gas shielded welding machine according to claim 1, characterized in that, The 485 communication uses a digital interface, which improves data transmission accuracy and response speed compared to welding machines with analog interfaces.

5. A silicon carbide digital pulse industrial gas shielded welding machine according to claim 1, characterized in that, The upper support (26) adopts a left-right layout for isolation, which reduces dust accumulation and improves control reliability.

6. A silicon carbide digital pulse industrial gas shielded welding machine according to claim 1, characterized in that, The main transformer (29) is suspended to enhance heat dissipation.

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