A standby automatic energy-saving circuit and electric welding machine

Abstract

The utility model discloses a kind of standby automatic energy-saving circuit and electric welding machine, including power switch circuit, switch control circuit, power-on delay circuit, isolation control circuit, safety indicating circuit, isolation shaping circuit, welding machine MCU and operation display circuit;The first input end of the power switch circuit is used to access power supply, the output end of the power switch circuit is connected with the input end of welding machine MCU by isolation shaping circuit, the first output end of the welding machine MCU is connected with the input end of switch control circuit, and the output end of the switch control circuit is connected with the second input end of the power switch circuit.The utility model makes that electric welding machine can automatically enter deep energy-saving mode, avoid power consumption, improve electrical device life and reliability.

Description

Technical Field

[0001] This utility model belongs to the field of electric welding machine technology, specifically relating to a standby automatic energy-saving circuit and an electric welding machine. Background Technology

[0002] In the welding industry, with the continuous improvement of digitalization and intelligence, and the increasing demand for remote operations, the power consumption of welding machines and their systems in standby mode is also increasing. This continuously rising standby power consumption will first cause serious energy waste and inefficiency. Although the basic power of digital welding equipment seems low, considering that welding operations are often accompanied by frequent start-ups and shutdowns, the daily standby time may reach 4-8 hours. Over the long term, the average annual additional power consumption of a single piece of equipment can reach hundreds of kilowatt-hours. If a company has multiple pieces of equipment running at the same time, the total energy waste will directly increase production costs.

[0003] Secondly, standby power consumption accelerates the aging of core components and shortens their lifespan. In standby mode, internal components such as power modules, capacitors, and transformers operate at full load but remain continuously heated. Issues arise such as the drying of electrolyte in electrolytic capacitors under prolonged low heat, and the accelerated electron migration of digital modules leading to decreased chip accuracy and increased probability of failure due to prolonged power supply. Similarly, prolonged data display increases the likelihood of malfunctions and maintenance costs, impacting production schedules. Furthermore, standby power consumption weakens the energy efficiency advantage of digital welding systems, negating the efficiency advantage of the welding machine during operation. Currently, most welding machine manufacturers have implemented energy-saving solutions that stop fan rotation during standby, significantly reducing additional power consumption caused by fan rotation. However, even after addressing the fan as the primary source of standby power consumption, other aspects of damage become apparent, with some components still consuming tens of watts.

[0004] Even after optimizing the standby power consumption (fan off in standby mode), the static power consumption of the display module and core chip, as well as leakage current and magnetic flux leakage in the power supply circuit, still account for a significant proportion. In standby mode, the welding machine's display module, such as an LCD, LED digital tube, or OLED screen, needs to continuously display device status such as "standby" or "voltage," and its power consumption typically accounts for 20% of the total standby power consumption, approximately 7W. The core chips of the digital welding machine, such as the main control MCU, power management chip PMIC, and signal processing chip DSP, are the "hidden giants" of standby power consumption, with their static current and peripheral circuit leakage current accounting for approximately 40% of the total standby power consumption, about 13W. Even with optimized display and chip power consumption, leakage current (approximately 10W) ​​still exists in the welding machine's main power supply circuit (e.g., losses in the rectifier bridge, filter capacitors, auxiliary power supply, and control transformer).

[0005] Therefore, this utility model addresses the special needs of industrial welding equipment during standby, aiming to solve the problem that traditional welding machines cannot automatically save energy during standby, resulting in additional losses. It provides a technical solution for standby energy saving of welding equipment, which is of great significance for improving the energy saving and emission reduction effect of welding machines in standby mode. The more welding machines are used, the more prominent the advantages of this automatic energy saving solution will be. Utility Model Content

[0006] To address the aforementioned problems, this utility model proposes a standby automatic energy-saving circuit and a welding machine, enabling the welding machine to automatically enter a deep energy-saving mode, avoiding power consumption and improving the lifespan and reliability of electrical components.

[0007] To achieve the above-mentioned technical objectives and effects, this utility model is implemented through the following technical solution:

[0008] In a first aspect, this utility model provides a standby automatic energy-saving circuit, including: a power switch circuit, a switch control circuit, a power-on delay circuit, an isolation control circuit, a safety indicator circuit, an isolation shaping circuit, a welding machine MCU, and an operation display circuit;

[0009] The first input terminal of the power switch circuit is used to connect to the power supply. The output terminal of the power switch circuit is connected to the input terminal of the welding machine MCU through an isolation shaping circuit. The first output terminal of the welding machine MCU is connected to the input terminal of the switch control circuit. The output terminal of the switch control circuit is connected to the second input terminal of the power switch circuit.

[0010] The above technical solution allows the welding machine MCU to control the power switch circuit through the switch control circuit, enabling the welding machine to automatically enter a deep energy-saving mode, avoiding power consumption and improving the lifespan and reliability of electrical components.

[0011] In conjunction with the first aspect, optionally, when the welding machine enters standby mode for a set time, the welding machine MCU turns off the power switch circuit through the switch control circuit, and the welding machine enters deep energy-saving mode.

[0012] The above technical solution allows the welding machine's MCU to control the welding machine into a deep energy-saving mode, which improves the lifespan and reliability of power-consuming components during standby operation, reduces the failure rate, lowers the power consumption cost during standby, and also reduces the maintenance and repair costs of the equipment.

[0013] In conjunction with the first aspect, optionally, the standby automatic energy-saving circuit further includes an operation display circuit, the input terminal of which is connected to the second output terminal of the welding machine MCU.

[0014] The above technical solution allows the operation display circuit to display all parameter information, such as welding machine standby status, current, voltage, process specifications, and alarm information, under the control of the welding machine MCU, making it easy for users to identify the welding machine status.

[0015] In conjunction with the first aspect, optionally, the operation display circuit includes a standby indicator light, which illuminates when the welding machine enters standby mode.

[0016] In conjunction with the first aspect, optionally, the standby automatic energy-saving circuit further includes a power-on delay circuit, wherein the input terminal of the power-on delay circuit is used to connect to a power supply, and its output terminal is connected to the isolation shaping circuit.

[0017] The above technical solution involves a power-on delay circuit that temporarily supplies power to the subsequent isolation and shaping circuit when the welding machine is first powered on. The conduction time of this circuit can be set; after the set time, the circuit automatically disconnects, preventing malfunctions caused by unstable power-on conditions. The isolation and shaping circuit isolates the AC power transmitted from the power-on delay circuit and power switch circuit from the subsequent circuits, while simultaneously converting the AC power to DC power to supply the welding machine MCU and other circuits, ensuring stable and safe operation of the welding machine MCU.

[0018] In conjunction with the first aspect, optionally, the standby automatic energy-saving circuit further includes an isolation control circuit, wherein the first input terminal of the isolation control circuit is used to connect to the power supply, the second input terminal is connected to the third output terminal of the welding machine MCU, and the output terminal of the isolation control circuit is connected to the safety indicator circuit.

[0019] The above technical solution allows the isolation control circuit to isolate the welding machine MCU from the standby indicator circuit, while simultaneously executing the welding machine MCU's control over the safety indicator circuit.

[0020] In conjunction with the first aspect, optionally, the safety indicator circuit includes a safety indicator light that illuminates when the welding machine enters deep energy-saving mode.

[0021] In the above technical solution, the indicator light is off when the welding machine is working normally, in standby mode, or in self-recovery energy-saving mode. When the welding machine enters deep energy-saving mode, the indicator light is on for status indication and safety reminder.

[0022] In conjunction with the first aspect, optionally, a filter is connected to the input terminal of the welding machine MCU.

[0023] The above technical solution, through interference filtering, can prevent misjudgment when the welding machine MCU performs operation monitoring, standby timing, and command transmission.

[0024] Secondly, this utility model provides a welding machine, including the standby automatic energy-saving circuit described in any one of the first aspects.

[0025] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0026] This utility model provides an automatic standby energy-saving circuit and a welding machine, which enables the welding machine to automatically enter a deep energy-saving mode, achieving deeper energy saving and making standby more energy-efficient; users can also customize the standby time according to their own working conditions, making the operation flexible.

[0027] After the welding machine enters deep energy-saving mode, it has energy-saving status and safety indication functions to prevent electric shock due to misjudgment in energy-saving mode. This improves the lifespan and reliability of power-consuming components during standby operation, reducing the failure rate; it increases the production efficiency of equipment users, reducing the probability of inefficiency caused by welding machine damage requiring replacement and repair; it lowers the power consumption cost during standby, while also reducing equipment maintenance and repair costs.

[0028] Energy efficiency standards only specify the rated efficiency, power factor, and no-load current of welding machines, without regulating losses during standby. Energy savings during standby are equivalent to further improving welding machine efficiency, thus contributing to energy conservation and environmental protection. Attached Figure Description

[0029] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein:

[0030] Figure 1 This is a circuit system block diagram of a standby automatic energy-saving circuit according to the present invention;

[0031] Figure 2 This is a circuit timing diagram of a standby automatic energy-saving circuit in self-recovery energy-saving mode according to the present invention;

[0032] Figure 3 This is a circuit timing diagram of a standby automatic energy-saving circuit of the present invention in deep energy-saving mode. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the utility model and are not intended to limit the scope of protection of this utility model.

[0034] In the description of this utility model patent, it should be noted that the terms "upper", "lower", "left", "right", "horizontal", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model patent and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model patent.

[0035] In the description of this utility model patent, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0036] The application principle of this utility model will be described in detail below with reference to the accompanying drawings.

[0037] Example 1

[0038] like Figure 1 As shown, this embodiment provides a standby automatic energy-saving circuit, including: a power switch circuit, a switch control circuit, a power-on delay circuit, an isolation control circuit, a safety indicator circuit, an isolation shaping circuit, a welding machine MCU, and an operation display circuit;

[0039] In one specific embodiment of this example, the first input terminal of the power switch circuit is used to connect to a power source, the output terminal of the power switch circuit is connected to the input terminal of the welding machine MCU through an isolation shaping circuit, the first output terminal of the welding machine MCU is connected to the input terminal of the switch control circuit, and the output terminal of the switch control circuit is connected to the second input terminal of the power switch circuit.

[0040] In one specific embodiment of this invention, after the welding machine has entered standby mode for a set time, the welding machine MCU turns off the power switch circuit through the switch control circuit, and the welding machine enters a deep energy-saving mode. In specific implementation, standby refers to a working mode in which the welding machine does not receive any external operation commands (such as parameter setting, manual wire feeding, gas detection), does not perform any program loading, remote communication (such as dedicated machines, IoT, robots), or other operations, and the welding machine's automatic control components enter a long-term stable state (such as fan stoppage) without any commands. When the welding machine has entered standby mode for the set time, the welding machine MCU issues a power-off command, and the welding machine MCU turns off the power switch circuit through the switch control circuit. At this time, the system is completely powered off and enters the deep energy-saving mode. The data interaction process between the welding machine MCU and the switch control circuit in this invention is implemented using existing technology.

[0041] In one specific embodiment of this example, the standby automatic energy-saving circuit further includes an operation display circuit, the input terminal of which is connected to the second output terminal of the welding machine MCU.

[0042] In one specific embodiment of this example, the operation display circuit includes a standby indicator light, which illuminates when the welding machine enters standby mode.

[0043] In one specific embodiment of this invention, the standby automatic energy-saving circuit further includes a power-on delay circuit. The input terminal of the power-on delay circuit is used to connect to a power supply, and its output terminal is connected to the isolation shaping circuit. In a specific implementation, when the welding machine is powered on, the power-on delay circuit supplies power to the isolation power module and subsequent circuits. After power-on, the welding machine MCU performs a power-on self-test and enters the default standby state. The power switch circuit is activated and engaged. After the power-on delay circuit reaches the preset delay time, it automatically disconnects, and the welding machine power-on is complete.

[0044] In one specific embodiment of this example, the standby automatic energy-saving circuit further includes an isolation control circuit. The first input terminal of the isolation control circuit is used to connect to the power supply, the second input terminal is connected to the third output terminal of the welding machine MCU, and the output terminal of the isolation control circuit is connected to the safety indicator circuit.

[0045] In one specific embodiment of this invention, the safety indicator circuit includes a safety indicator light, which illuminates when the welding machine enters deep energy-saving mode. In practice, when the system is powered off, the isolation control circuit will activate the safety indicator light to alert the user to the welding machine's status.

[0046] In one specific embodiment of this example, a filter is connected to the input terminal of the welding machine MCU. During implementation, to prevent misjudgment, interference filtering is performed on the welding machine MCU, and the filtered judgment result is used as the standard for whether to enter or resume standby mode.

[0047] The standby automatic energy-saving circuit of the present invention will be described in detail below with reference to a specific embodiment:

[0048] When the welding machine enters standby mode, the welding machine MCU enters automatic timing mode:

[0049] 1. The welding machine MCU starts standby timing when the standby conditions are met according to the defined standby criteria.

[0050] 2. The welding machine MCU starts timing and, when the user-designed standby time is met, makes a final check to see if an operation or communication signal has been received. If no signal is received, it enters energy-saving mode; if a signal is received, it restarts timing when the standby conditions are met again.

[0051] 3. To prevent misjudgment, the software performs interference filtering, and the filtered judgment result is used as the standard for whether to enter or resume standby mode;

[0052] 4. The welding machine can be designed with multiple energy-saving modes. The deep energy-saving mode is the final energy-saving mode, which adds two more energy-saving modes on top of the existing standby fan stopping.

[0053] The two-stage energy saving system has different standby time points. When the conditions are met at the first time point, such as... Figure 2 As shown, the welding machine first enters the self-recovery energy-saving mode. At this time, the welding machine MCU will control the operation display circuit to turn off all indicator lights except for the standby indicator light, which is a digital tube used for standby indication. At the same time, the communication circuit will be controlled to reduce the communication frequency as much as possible without affecting the wake-up speed, so as to reduce the power consumption of related circuit chips. If a wake-up signal such as a button or communication is received during this period, the system will return to the normal operating state without affecting the operation rhythm.

[0054] 5. For example Figure 3 As shown, based on the self-recovery energy-saving mode, the welding machine MCU will continue to automatically accumulate the time. When the total time reaches the second standby time, after the welding machine completes one test, the welding machine MCU will turn off the power switch circuit through the switch control circuit, and the welding machine will enter the deep energy-saving mode. After entering this energy-saving mode, the circuit will be completely powered off.

[0055] After the system is powered off, the isolation control circuit will activate the safety indicator light.

[0056] 6. For welding machines that have entered deep energy-saving mode, the main switch of the welding machine must be turned back on before they can be used normally.

[0057] 7. When the welding machine starts up, it first supplies power to the isolation shaping and subsequent welding machine MCU circuits through the power-on delay circuit. After the welding machine MCU starts up normally, it controls the power switch circuit to turn on. The power-on delay circuit automatically enters the disconnect mode after the set delay time ends. After that, the welding machine enters the standby or normal use mode.

[0058] Example 2

[0059] This utility model provides a welding machine, including the standby automatic energy-saving circuit described in any one of Embodiment 1.

[0060] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A standby automatic energy-saving circuit, characterized in that, include: Power switch circuit, switch control circuit, power-on delay circuit, isolation control circuit, safety indicator circuit, isolation shaping circuit, welding machine MCU and operation display circuit; The first input terminal of the power switch circuit is used to connect to the power supply. The output terminal of the power switch circuit is connected to the input terminal of the welding machine MCU through an isolation shaping circuit. The first output terminal of the welding machine MCU is connected to the input terminal of the switch control circuit. The output terminal of the switch control circuit is connected to the second input terminal of the power switch circuit.

2. The standby automatic energy-saving circuit according to claim 1, characterized in that, When the welding machine enters standby mode for a set time, the welding machine MCU turns off the power switch circuit through the switch control circuit, and the welding machine enters deep energy-saving mode.

3. The standby automatic energy-saving circuit according to claim 1, characterized in that, The standby automatic energy-saving circuit also includes an operation display circuit, the input of which is connected to the second output of the welding machine MCU.

4. The standby automatic energy-saving circuit according to claim 3, characterized in that, The operation display circuit includes a standby indicator light, which illuminates when the welding machine enters standby mode.

5. The standby automatic energy-saving circuit according to claim 1, characterized in that, The standby automatic energy-saving circuit also includes a power-on delay circuit, the input of which is used to connect to a power supply, and its output is connected to the isolation shaping circuit.

6. The standby automatic energy-saving circuit according to claim 1, characterized in that, The standby automatic energy-saving circuit also includes an isolation control circuit. The first input terminal of the isolation control circuit is used to connect to the power supply, the second input terminal is connected to the third output terminal of the welding machine MCU, and the output terminal of the isolation control circuit is connected to the safety indicator circuit.

7. The standby automatic energy-saving circuit according to claim 6, characterized in that, The safety indicator circuit includes a safety indicator light, which illuminates when the welding machine enters deep energy-saving mode.

8. The standby automatic energy-saving circuit according to claim 1, characterized in that, A filter is connected to the input terminal of the welding machine MCU.

9. An electric welding machine, characterized in that, Includes the standby automatic energy-saving circuit as described in any one of claims 1-8.

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