Welding Device Dynamic Inverter Frequency Control
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Solution Overview
Problem
Conventional welding devices using inverter control face challenges in maintaining high inverter frequencies while minimizing switching losses and heat generation, which affects welding performance due to increased ripple factors and heat issues.
Innovation Solution
A welding device with a frequency controller that dynamically adjusts inverter frequencies based on the output-on period, using a combination of switching elements and feedback control to optimize inverter frequencies for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inverter frequency is increased to reduce ripple factor of welding voltage, then welding performance is improved, but switching loss and heat generation in switching section increase
Solution Approach 1:
The inverter frequency is made dynamically adjustable rather than fixed. The control device changes the inverter frequency based on the output-on period, allowing the system to adapt to different operating conditions. This dynamic adjustment enables the system to maintain high frequency for low ripple when needed while reducing frequency to minimize switching losses in other conditions.
Solution Approach 2:
The patent changes the inverter frequency parameter according to the output-on period. By varying this key parameter, the system optimizes the balance between ripple reduction and switching loss minimization. The frequency is set to a first value when output-on period is a first ratio, and to a second value when output-on period is a second ratio smaller than the first ratio.
2Manufacturing precision
If inverter frequency is increased to reduce ripple factor, then welding voltage quality is improved, but heat generation in switching section increases requiring more heat countermeasures
Solution Approach 1:
The system dynamically adjusts inverter frequency based on operating conditions (output-on period). This allows the system to maintain high frequency for improved welding voltage quality when the output-on period is appropriate, while reducing frequency under other conditions to minimize heat generation in the switching section.
Solution Approach 2:
The inverter frequency parameter is changed according to the output-on period ratio. When the output-on period is a first ratio, the frequency is set to a first value that provides good welding voltage quality. When the output-on period is a second ratio (smaller than the first), the frequency is reduced to a second value that minimizes heat generation.
3Stability of the object's composition
If fixed inverter frequency is used for stable operation, then control simplicity is maintained, but adaptability to different output-on periods is reduced
Solution Approach 1:
The system transitions from fixed frequency operation to dynamic frequency adjustment. The inverter frequency is automatically changed based on the detected output-on period, enabling the system to adapt to different operating conditions while maintaining stable control through automated frequency selection.
Solution Approach 2:
The control device detects the output-on period and uses this feedback information to determine the appropriate inverter frequency. This closed-loop feedback mechanism ensures the system automatically adapts to different output-on period conditions while maintaining stable and optimal operation.
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 allows for high-quality welding by reducing Joule heat generation and stabilizing heat in the switching section, minimizing countermeasures against heat and maintaining low ripple factors in welding voltage.
Implementation Method 1
Switching section 102 is formed of first switching element TR1 through fourth switching element TR4 of IGBT. First switching element TR1 through fourth switching element TR4 are switched on/off on PWM method in response to an instruction from driver 107.
Implementation Method 2
The DC voltage fed from smoothing capacitor 119 is further converted, through inverter driving by switching section 102, into high-frequency AC voltage suitable for welding.
Implementation Method 3
The high-frequency AC voltage fed from transformer 120 is rectified by secondary rectifier 121 formed of, for example, a diode.
Implementation Method 4
Welding device 101 supplies electrode 124 and base metal 122 with welding output to generate arc 125 between them, by which welding is performed on base metal 122.
Implementation Method 5
The greater the output-on period, the greater the amount of Joule heat generated in switching section 102.
Data Source
AI summary
The welding device of the present disclosure has a switching section, a setting section, an output detector, a controller, a frequency controller, and a driver. The switching section is formed of a switching element. The setting section determines setting output. The output detector detects welding output. The controller calculates an output-on period of the switching section according to the setting output and the welding output. The frequency controller determines an inverter frequency based on the output-on period. The driver controls on/off operation of a switching element of the switching section based on the inverter frequency and the output-on period. When the output-on period is calculated using a first ratio, the inverter frequency is determined to a first frequency, and when the output-on period is calculated using a second ratio smaller than the first ratio, the inverter frequency is determined to a second frequency higher than the first frequency.