Battery welding machine

Abstract

To accurately grasp how many welding rods can be welded more in a current battery state.SOLUTION: A battery welding machine comprises: a welding output part with which welding rods are connected; a welding control part which controls welding output by a set welding current value; a battery device which supplies power to the welding output part via the welding control part; and a display arithmetic processing part which performs arithmetic processing of a battery state of the battery device to display an arithmetic processing result, wherein the display arithmetic processing part calculates the number of weldable welding rods from the welding output for every set welding current value on the basis of the battery remaining capacity obtained from the battery device.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a battery welder.

Background Art

[0002] Conventionally, a battery welder includes a transformer connected to an AC power supply, a rectifier circuit that converts the output of the transformer into a phase-controlled full-wave rectified waveform, and a battery connected in series with the rectifier circuit, and takes out a welding output from both ends of the battery charged by the AC power supply. Further, in addition to the above-described configuration, a conventional battery welder has a liquid level sensor that detects a decrease in the battery liquid, a charging voltage sensing circuit, a charging current sensing circuit, a phase angle control circuit that controls the rectifier circuit, and a state display unit that displays the state of the battery. It is known that there is one having (see Patent Document 1 below).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] According to the above-described conventional technology, a warning display indicating that the battery liquid has decreased and a remaining battery capacity display are performed by a state display unit that displays the state of the battery. Regarding the remaining battery capacity display, color-coded display by an indicator and display by a percentage numerical value of the charging rate have generally been performed.

[0005] According to such a conventional technology, in a battery welder that needs to change the setting of the welding current according to the usage situation, since the power consumption varies depending on the change, it is difficult to intuitively and accurately grasp how much work can be continued with the current remaining battery capacity. There was a problem.

[0006] In particular, in a battery welder that uses welding rods, the welding current setting is changed according to the diameter of the welding rod. However, with the conventional remaining capacity display, it is not possible to accurately grasp how many more welds can be performed with the current battery remaining capacity, and there is a problem that a detailed plan cannot be made for continuing the welding operation.

[0007] The present invention has been proposed to address such problems. That is, in a battery welder, to enable intuitive and accurate understanding of how much more work can be continued in the current battery state, and to accurately grasp how many more welding rods can be welded in the current battery state, so that a detailed plan can be made for continuing the welding operation, etc. are the problems of the present invention.

Means for Solving the Problems

[0008] To solve such problems, the present invention has the following configuration. A battery welder comprising a welding output unit to which a welding rod is connected, a welding control unit that controls the welding output according to a set welding current value, a battery device that supplies power to the welding output unit via the welding control unit, and a display arithmetic processing unit that calculates the battery state of the battery device and displays the calculation result, wherein the display arithmetic processing unit obtains the remaining battery capacity from the information obtained from the battery device, and obtains and displays the number of weldable welding rods from the welding output for each set welding current value.

Effects of the Invention

[0009] With such features, the present invention can intuitively and accurately grasp, in a battery welder, how much work can be continued in the current battery state. Also, it can accurately grasp how many welding rods can be welded in the current battery state. Thereby, a detailed plan can be made regarding the continuation of the welding work, and in particular, it is possible to accurately determine whether to continue the welding work or to charge the battery device.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0011] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, the same reference numerals in different figures indicate parts having the same function, and duplicate descriptions in each figure will be omitted as appropriate.

[0012] As shown in FIG. 1, the battery welder 1 includes a welding output unit 10, a welding control unit 20, a battery device 30, and a display operation processing unit 40.

[0013] The welding output unit 10 to which the welding rod 2 is connected is provided with output terminals 10A and 10B. One end of the welding rod connection cable 11 is connected to the output terminal 10A, and one end of the work connection cable 12 is connected to the output terminal 10B. The other end of the welding rod connection cable 11 is connected to the welding rod 2 via the welding rod holder 13. Also, the other end of the work connection cable 12 is connected to the work W via the work clamp 14.

[0014] The welding control unit 20 controls the welding output in the welding output unit 10 according to the set welding current, and supplies the set welding current to the welding output unit 10 by controlling the power supplied from the battery device 30 by the gate drive 21.

[0015] The battery device 30 is provided with a battery 31 for supplying power to the welding output unit 10 via the welding control unit 20. The battery 31 is, for example, a lithium ion battery, and may be a single battery cell or a plurality of connected battery cells. The battery 31 is connected to the charger (AC / DC converter) 3 via the diode 3A and can be charged by an AC power source (not shown) connected to the charger 3.

[0016] Also, the battery device 30 is provided with a battery management unit (BMS: Battery Management System) 32 for managing the state of the battery. The battery management unit 32 recognizes the battery capacity (rated capacity) of the battery 31 and sequentially monitors the state of the battery 31, outputting the battery voltage, charge / discharge current, integrated value of the charge / discharge current, etc. as sequential information, and recording when a charge / discharge stop trigger occurs.

[0017] The display arithmetic processing unit 40 includes a welding current setting unit 41 that sets a welding current for the welding control unit 20, an arithmetic processing unit 42 that performs arithmetic processing based on information from the battery management unit 32 and information from a current detection unit 15 that detects the welding current output from the welding control unit 20, and a display unit 43 that displays the processing result of the arithmetic processing unit.

[0018] The display arithmetic processing unit 40 can be constituted by a control board. The welding current setting unit 41 can be constituted by a voltage adjustment circuit or the like for adjusting the input voltage of the gate drive 21 of the welding control unit 20. The arithmetic processing unit 42 can be constituted by a processor such as a CPU (Central Processing Unit) or MPU (Micro Processing Unit) mounted on the control board and storage elements such as a RAM (Random Access Memory) and a ROM (Read Only Memory). The display unit 43 can be constituted by software incorporated in a processor such as a CPU (Central Processing Unit) or MPU (Micro Processing Unit) mounted on the control board or an electronic circuit (monitor circuit) mounted on the control board and a display device (display panel) driven thereby.

[0019] The welding current setting unit 41 of the display arithmetic processing unit 40 sets the welding current (welding current value) output by the welding control unit through an adjustment operation of the current adjustment circuit by the user. The welding current value is set to an appropriate value according to the type and diameter of the welding rod, the welding posture, and the like. More specifically, as an example, the welding current value can be determined as shown in the following table. Note that the following table shows the case where the welding posture is limited to downward, and shows the appropriate welding current values for each type of coating system of the welding rod (illuminite type, low hydrogen type) and the thickness of the welding rod (diameter: 2.6 to 8.0φ).

[0020]

Table 1

[0021] The arithmetic processing unit 42 of the arithmetic processing unit 40 calculates the "number of weldable electrodes", which represents how many electrodes can be welded later, based on the current battery state of the battery 31 and the set value of the welding current (welding current value) obtained from the battery management unit 32, and outputs it to the display unit 43.

[0022] The arithmetic processing unit 42 obtains the remaining battery capacity from the information obtained from the battery management unit 32 of the battery device 30, and obtains and displays the number of weldable electrodes from the welding output for each set welding current value. In FIG. 2, the arithmetic processing steps performed by the arithmetic processing unit 42 will be specifically described.

[0023] In step S01 of FIG. 2, the arithmetic processing unit 42 calculates the remaining battery capacity [A·h] from the battery capacity (rated capacity) [A·h] obtained from the battery management unit 32 and the charge and discharge current integrated value (time integral value) [A·h] of the battery 31. The remaining battery capacity (FCC_cal) is obtained by the following formula (1) from the battery capacity (FCC) and the charge and discharge current integrated value (current_sum). FCC_cal = FCC - current_sum (1)

[0024] In step S02 of FIG. 2, the arithmetic processing unit 42 recognizes the welding current [A] set by the welding current setting unit 41 of the display arithmetic processing unit 40 as the welding current value (preset).

[0025] In step S03 of FIG. 2, the arithmetic processing unit 42 calculates the welding output [W (A·V)] (weld_w) by the following formula (2) using the set welding current value (preset) and the rated voltage (output voltage: weld_v) for the welding current value. weld_w = preset × weld_v (2)

[0026] In step S04 of FIG. 2, the arithmetic processing unit 42 sets the conversion efficiency through the welding control unit 20 to a predetermined value (as an example, 80%), and calculates the battery output [W] (battery_out) by the following formula (3). battery_out=weld_w / 0.8 (3)

[0027] In step S05 of FIG. 2, the arithmetic processing unit 42 calculates a correction value (charge-discharge ratio). This correction value (conv_eff) is obtained by the correction line m shown in FIG. 3. The correction line m is a straight line for obtaining the correction value for each set welding current value (preset). The correction value (conv_eff) here is the charge-discharge ratio (0 < conv_eff < 1) based on the internal resistance of the battery 31. As the welding current value (preset) increases, the correction value (conv_eff) becomes a lower value. In the illustrated example, if the correction value at the welding current value I1 is R1 and the correction value at the welding current value I2 is R2, when I1 < I2, then R2 < R1. The correction value (conv_eff) is obtained by the following formula (4) using constants (S and T) preset in advance by a preliminary test or the like. conv_eff=preset×S+T (4)

[0028] In step S06 of FIG. 2, the arithmetic processing unit 42 calculates the welding output capacity [W·h] per welding rod. The welding output capacity per welding rod (one_weld_out) is obtained by converting the welding output (weld_w) for each set welding current value (preset) into the battery output (battery_out) using the above formula (3), and then correcting the converted battery output (battery_out) with the correction value (conv_eff) obtained for each welding current value (preset). As an example, for one welding rod, assuming that the welding output is continuously performed for 1 minute, the welding output capacity can be obtained by the following formula (5) as the value obtained by converting the welding output capacity obtained by multiplying the battery output [W] (battery_out) by the correction value (conv_eff) into 1 minute. one_weld_out=battery_out×conv_eff / 60 (5)

[0029] In step S07 of FIG. 2, the arithmetic processing unit 42 calculates the battery output capacity [W·h] (FCC_w) based on the remaining battery capacity (FCC_cal). The battery output capacity (FCC_w) here is obtained by multiplying the battery voltage (battery_v) obtained from the battery management unit 32 by the remaining battery capacity (FCC_cal), and is obtained by the following formula (6). FCC_w = battery_v × FCC_cal (6)

[0030] In step S08 of FIG. 2, the arithmetic processing unit 42 calculates the number of welds possible [pieces]. The number of welds possible (weld_number) can be obtained by dividing the battery output capacity (FCC_w) by the welding output capacity per welding rod (one_weld_out), and is obtained by the following formula (7). weld_number = FCC_w / one_weld_out (7)

[0031] The number of welds possible obtained in steps S01 to S08 in this way is a value obtained according to each set welding current value, and is obtained in consideration of a correction value (charge-discharge ratio) that changes for each set welding current value. Therefore, it is a highly accurate value with respect to the current remaining battery capacity. Also, the fact that the remaining battery capacity itself is obtained from the integrated value of the charge-discharge current managed by the battery management unit 32 is also a factor contributing to the highly accurate calculation of the number of welds possible.

[0032] Figures 4 and 5 show an example of the external configuration of the display calculation processing unit 40 in the battery welder 1. In this example, the display calculation processing unit 40 includes two display panels 40A and 40B. The display panel 40A can selectively display the number of welds possible and the charge rate (SOC: State Of Charge) of the battery 31. Also, the display panel 40B is configured to display the set welding current value. The display switching of the display panel 40A is performed by switching the display switch 40C between on (Figure 4) and off (Figure 5). The adjustment volume 40D can be used to change the setting of the welding current value by operating it, and the changed welding current value is displayed on the display panel 40B. Here, an example of switching the display of the display panel 40A is shown, but the number of welds possible and the charge rate may be displayed in parallel on a plurality of display panels.

[0033] Figure 6 shows an example of the operation of the battery welder 1. When the operation is started, the display calculation processing unit 40 obtains information from the battery device 30 to obtain the battery capacity of the battery 31 (step S10) and grasps the battery state of the battery 31 (step S11). Then, the sub-processes of steps S01 to S08 described above are executed to calculate the number of welds possible in the current state of the battery 31 (step S12). When the welding current is set in step S02 described above, the set welding current value is displayed on the display panel 40B.

[0034] Then, the selection state of the display switch 40C described above is confirmed (step S13). If the on state is selected (the state shown in Figure 4: step S13 "ON"), the calculated number of welds possible is displayed on the display panel 40A (step S14). When the display switch 40C is in the off state (the state shown in Figure 5: step S13 "OFF"), the charge rate (SOC) is calculated based on the information obtained from the battery device 30 and displayed on the display panel 40A (step S15). The charge rate (SOC) can be obtained by the following formula (8) using the battery remaining capacity (FCC_cal) and the battery capacity (FCC) described above. SOC = (FCC_cal / FCC) × 100 (8)

[0035] And, when it is determined that there is charging or discharging of the battery 31 based on the information acquired from the battery device 30 (step S16 "NO"), the above-described steps S11 to S14 or steps S11 to S15 are executed to perform the display on the above-described display panel 40A. When there is no charging or discharging of the battery 31 (step S16 "YES"), it is confirmed whether the power is off (step S17 "YES"), the process is terminated, and when the power off cannot be confirmed (step S17 "NO"), the display from step S13 onward is continued to be maintained.

[0036] According to such a battery welder 1, by accurately displaying the number of welds that can be made, it is possible to intuitively and accurately grasp to what extent work can be continued in the current battery state. Thereby, a detailed plan can be made regarding the continuation of the welding work, and in particular, it is possible to accurately determine whether to continue the welding work or to charge the battery device 30.

Explanation of Reference Numerals

[0037] 1: Battery welder, 2: Welding rod, 3: Charger, 3A: Diode, 10: Welding output section, 10A, 10B: Output terminals, 11: Welding rod connection cable, 12: Work connection cable, 13: Welding rod holder, 14: Work clamp, 15: Current detection section, 20: Welding control section, 21: Gate drive, 30: Battery device, 31: Battery, 32: Battery management unit (BMS), 40: Display arithmetic processing section, 40A, 40B: Display panels, 40C: Display changeover switch, 40D: Adjustment volume, 41: Welding current setting section, 42: Arithmetic processing section, 43: Display section, m: Correction line, W: Work

Claims

1. A welding output unit to which a welding rod is connected, A welding control unit that controls the welding output according to a set welding current value, A battery device that supplies power to the welding output unit via the welding control unit, A battery welder comprising a display arithmetic processing unit that calculates the battery state of the battery device and displays the calculation result, The display arithmetic processing unit, is characterized in that it obtains the remaining battery capacity from the information obtained from the battery device, and obtains and displays the number of weldable welding rods from the welding output for each set welding current value.

2. The battery welder according to claim 1, characterized in that the remaining battery capacity is obtained from the integrated value of the charge and discharge current in the battery device.

3. The battery welder according to claim 2, characterized in that the number of weldable rods is obtained by obtaining the welding output capacity per welding rod and dividing the battery output capacity based on the remaining battery capacity by the welding output capacity per welding rod.

4. The battery welder according to claim 3, characterized in that the welding output capacity per welding rod is obtained by converting the welding output for each welding current value into battery output and correcting the converted battery output with a correction value obtained in advance for each welding current value.

5. The battery welder according to claim 4, characterized in that the correction value is a charge and discharge ratio with respect to the welding current value, and the charge and discharge ratio decreases as the welding current value increases.

6. The battery welder according to claim 1, characterized in that in addition to displaying the number of weldable rods, the display arithmetic processing unit can display the charge rate obtained from the remaining battery capacity.

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