Capacitive Welder Transformer Reset and Charging Circuit
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Solution Overview
Problem
Conventional capacitive welders face challenges in quickly charging welding transformers due to high inductance, leading to biased magnetism and prolonged charging times, and existing solutions either fail to provide sufficient reset current or waste energy through large resistors.
Innovation Solution
A capacitive welder design that includes a bypass switching element and control circuit to manage the flow of reset current through the primary winding of the welding transformer, allowing for efficient magnetism resetting and rapid capacitor charging by switching between the primary and bypass paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charging current flows through the welding transformer to perform magnetic resetting, then the bias magnetism is eliminated, but the large inductance of the welding transformer suppresses the charging current and extends the charging time
Solution Approach 1:
The charging process is segmented into two distinct phases: first, the charging current flows through the welding transformer primary winding to perform magnetic resetting; second, after resetting is complete, the charging current flows through the bypass circuit to quickly charge the capacitor. This segmentation allows each phase to optimize for its specific function without compromise.
Solution Approach 2:
The magnetic resetting action is performed preliminarily before the main capacitor charging process. By completing the magnetic resetting first through the transformer, the system eliminates bias magnetism that would otherwise interfere with subsequent welding operations, and then proceeds with rapid capacitor charging through the bypass circuit.
2Productivity
If a bypass circuit with low impedance is used to ensure sufficient charging current, then the charging time is reduced, but most of the charging current flows to the bypass circuit and insufficient reset current reaches the primary winding
Solution Approach 1:
The system dynamically switches between two charging paths based on the operational phase. During the initial phase, the charging current flows through the welding transformer primary winding to perform magnetic resetting. After resetting is complete, the system switches to the bypass circuit for rapid capacitor charging. This dynamic switching allows the system to optimize for magnetic resetting first, then for charging speed.
3Reliability
If a large resistor is connected in the bypass circuit to increase its impedance, then more reset current flows to the primary winding, but electricity is wasted and charging time is delayed
Solution Approach 1:
The bypass circuit with the large resistor is activated periodically only during the initial magnetic resetting phase, not during continuous operation. The charging control unit controls the switching element to connect the bypass circuit only when resetting is needed, and then disconnects it once resetting is complete. This periodic activation minimizes energy waste while ensuring adequate reset current flows to the primary winding when necessary.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively resets the magnetism of the welding transformer and quickly charges the capacitor, reducing charging time while minimizing energy wastage, thereby improving the overall efficiency and stability of the capacitive welding process.
Implementation Method 1
A pulse welding current, which is significantly greater than the primary winding current, flows to a secondary winding of the welding transformer. This welding current flows in the object to be welded, through welding electrodes
Implementation Method 2
the capacitive welder stores welding electric power in a welding capacitor in a longer time than a discharge time and discharges the electricity at once
Data Source
AI summary
The capacitive welder includes a charging circuit, a welding transformer, a capacitor, a discharging switching element connected in parallel with a primary winding of the welding transformer and the capacitor that are connected in series, a bypass switching element connected in parallel with the primary winding, welding electrodes connected in parallel with a secondary winding of the welding transformer, and a control circuit for bringing the welding transformer into a reset allowing state by allowing a reset current to flow in the primary winding using the input power introduced through the charging circuit without supplying an ON signal to the bypass switching element, and then supplying the ON signal to the bypass switching element such that the capacitor is charged through the bypass switching element by the input power introduced through the charging circuit.