Steel barrel welding machine adopts the advantage of medium frequency inverter power supply
Resistance welding is a welding process that uses electric current to generate heat through the resistance of the workpiece and the welding contact surface, and at the same time applies pressure to the welding place. It has the characteristics of high production efficiency, low cost, material saving and easy automation, and is widely used. Including the industrial sector of steel drum production. According to the nature of the power supply can be divided into power frequency AC welding machine, secondary rectification welding machine, three-phase low-frequency welding machine, DC shock wave welding machine, capacitor storage welding machine and inverter welding machine. As a new type of control power supply, inverter resistance welding power supply has become the development direction of resistance welding power source with its remarkable high quality and low consumption.
1 Introduction to the control system
1.1 Power frequency AC resistance welding control power supply
The two thyristors in reverse parallel connection are connected in series with the primary winding of the welding transformer, and then connected to the power grid by using the trigger control device, so that the two thyristors are respectively connected to the power supply in the positive and negative half cycles of the alternating current. By adjusting the conduction angle of the thyristor, the secondary output current of the welding transformer can be adjusted.
The power frequency AC power supply has the largest share in the resistance welding power supply due to the relatively simple design principle, mature component production technology, and low manufacturing cost.
1.2 Zhongdun inverter DC resistance welding control power supply
The intermediate frequency inverter DC resistance welding control power supply is made up of three-phase alternating current through the rectifier circuit to become pulsating direct current, and then the inverter circuit composed of the power switching device becomes the intermediate frequency square wave accessing transformer, and is rectified into a pulsating little DC power supply after the step-down. The electrode welds the workpiece. The inverter usually uses current feedback pulse width modulation (PWM) to obtain a stable constant current output.
Figure 1 and Figure 2 show the comparison of the schematic diagram of power frequency AC and IF inverter DC welding.
figure 1
figure 2
2 Advantage comparison
2.1 One of the advantages of IF inverter welding
2.1.1 Three-phase balanced load
The three-phase balanced load can reduce the power requirement of the power supply system, and does not cause any bee overload on any single phase, and meets the preferential power rate requirement.
2.1.2 Power factor close to 1
There is no inductance component, no need to adjust the power factor, which is much higher than the traditional 50Hz thyristor resistance welder. Therefore, the energy cost of welding the product is significantly reduced.
2.3.3 Eliminate pollution to the power supply, it is clean welding
It does not have to be powered separately and can be used with the robotic welding tooling control system.
2.1.4 Reduce power consumption, save energy and reduce consumption
The power demand for the workshop is low, only 2/3 of the traditional thyristor secondary rectification resistance welder, reducing the need and cost of the cable. Since the effective value of the welding current is greatly increased, the actual welding time can be reduced by more than 20%, and the welding pressure can be greatly reduced.
2.2 Advantages of IF Inverter Welding
2.2.1 As long as the quality and volume of the AC transformer 1/3, light and fast
2.2.2 Improve heat input efficiency
The output of the welding transformer is DC voltage, and there is no trouble with the inductance.
Pure DC has no zero-crossing annoyance, and the efficiency of heat is greatly improved.
2.2.3 Unique circuit for protection of inverters and transformers
2.3 Advantages of IF Inverter Welding
2.3.1 Welding control current is more accurate
The inverter system is almost unaffected by the power supply system. Even in the case of ±15% of the network voltage fluctuation, the welding current accuracy can be controlled below 2%.
Not affected by the shape of the workpiece and the material of the workpiece (no loss of inductance),
Adjustment accuracy and monitoring accuracy are 20 times higher than AC systems.
2.3.2 Increase the stability of the welding process
DC welding is technically friendly and has a much broader prospect of use than communication.
The secondary current can really maintain a constant current.
2.3.3 Digital Control Improves Current Control and Measurement Accuracy
2.3.4 Welding time accuracy is ms, which can control the welding time arbitrarily
3 Conclusion
The traditional 50Hz thyristor resistance welding controller, in addition to the price advantage, can not achieve the ideal welding stability for the high quality requirements. The quality of welded products cannot be compared with the intermediate frequency welding system. The use of energy-saving intermediate frequency inverter soldering products will greatly promote and promote the protection of the environment and ecological balance as well as the regional economic development. Have a deeper meaning. Therefore, from a long-term perspective, the application prospect of medium frequency inverter welding in the steel drum industry is promising, and it will become the development trend of steel barrel resistance welding research.
(Jiangyin Wuxing Welding Copper Co., Ltd.)
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