CN103252569B - Portable minisize reserve energy spot welding machine - Google Patents

Abstract

The portable micro-energy storage spot welding machine provided by the invention includes a nickel-metal hydride battery pack (1) equipped with a charger, a spot welding control circuit module (2), an energy storage charging switch (3), and a farad-level energy storage capacitor (4 ), a spot welding discharge switch (5), a spot welding gun with a manual control switch (6), a grounding clip (7) connected to the welding machine through a cable, and an energy adjustment and display panel (8), wherein, (1) and (2) and (3) are connected to each other, (2) is also connected to (5)-(8), (3) is connected to (4), (4) is connected to (2), (3), (5) and ( 8) is connected, (5) is connected with (6), (6) is connected with (8), and (7) is connected with (8). The portable miniature energy storage spot welding machine of the present invention is designed for welding thin/ultra-thin steel plates or delicate micro-miniature parts, and can be used to solve the problem of rapid on-site installation of some sensors.

Description

Portable Micro Energy Storage Spot Welding Machine

technical field

The invention relates to the technical field of electromechanical control, in particular to a portable miniature energy storage spot welding machine.

Background technique

Spot welding connection is a commonly used connection relationship between metal materials at present, and the usual spot welding operations are welded by spot welding machines.

At present, in the safety monitoring system of large-scale engineering facilities such as railways, bridges and electric power, the installation of sensors is the key technology for obtaining monitoring signals. For example, stress sensors and shunt current sensors are generally fixed by bonding, riveting or bolts, the construction process is complicated, and sometimes it will cause damage to the measured point. And the installation equipment is not easy to carry, which limits the promotion in some fields.

The known spot welding technology is the basic principle of instantaneous heating of contact resistance to weld metal when a large current passes through the workpiece crimping point, which makes the spot welding process have unique advantages in some production fields. However, general industrial spot welding machines are powered by AC power supply, relying on step-down transformers or electronic converters to obtain low-voltage and high-current power supplies, and some energy storage welding machines also need to couple energy through the secondary iron core circuit to heat the solder joints. The power consumption efficiency is low, and the equipment is bulky and inconvenient to carry. Even if it can weld thin and light parts, the current regulation is not precise enough to meet the requirements of portable hand-held spot welding conditions such as the sensor installation mentioned above.

Therefore, a technical problem that needs to be solved urgently at present is: how to propose an effective measure to solve the problems existing in the prior art.

Contents of the invention

The technical problem to be solved by the present invention is to provide a portable miniature energy storage spot welder, which is designed for welding thin/ultra-thin steel plates or exquisite micro-miniature parts, and can be used to solve the problem of rapid on-site installation of some sensors.

In order to solve the above problems, the present invention discloses a portable miniature energy storage spot welding machine, which includes a nickel-metal hydride battery pack (1) equipped with a charger, a spot welding control circuit module (2), an energy storage charging switch (3), Farad level energy storage capacitor (4), spot welding discharge switch (5), spot welding torch with manual control switch (6), grounding clamp (7) connected to the welding machine through cables, and energy adjustment and display panel (8) , wherein, the Ni-MH battery pack (1) equipped with a charger is connected to the spot welding control circuit module (2) and the energy storage charging switch (3), and the spot welding control circuit module (2) is connected to the Ni-MH battery pack (1), energy storage charging switch (3), spot welding discharge switch (5), spot welding gun with manual control switch (6), grounding clamp (7) connected to the welder by cable and energy The regulator is connected to the display panel (8), the energy storage charging switch (3) is connected to the Ni-MH battery pack (1) equipped with a charger, the spot welding control circuit module (2) and the farad-level energy storage capacitor (4), and the farad The level energy storage capacitor (4) is connected with the spot welding control circuit module (2), the energy storage charging switch (3) and the spot welding discharge switch (5), and the spot welding discharge switch (5) is connected with the spot welding control circuit module (2) , the farad-level energy storage capacitor (4) is connected to the spot welding gun (6) with a manual control switch, the spot welding gun (6) with a manual control switch is connected to the spot welding discharge switch (5) and the energy adjustment and display panel (8 ) connection, the grounding clip (7) connected to the welding machine and the energy adjustment are connected to the display panel (8) through cables.

Further, the portable miniature energy storage spot welding machine also includes a waterproof satchel-type engineering plastic sealed box (9), which is used to store the nickel-metal hydride battery pack (1) equipped with a charger, the spot welding control circuit Module (2), energy storage charging switch (3), Farad-level energy storage capacitor (4), spot welding discharge switch (5), spot welding gun with manual control switch (6), grounding connected to the welding machine through a cable Clip (7) and energy adjustment and display panel (8) are contained in it.

Further, the portable micro-energy storage spot welding machine also includes a solar charger (10), the solar charger (10) is equipped with a Ni-MH battery pack (1) equipped with a charger, an energy adjustment and display panel ( 8) It is connected with the waterproof satchel type engineering plastic sealing box (9).

Further, the spot welding control circuit module (2) includes a voltage stabilizing circuit (2a) that converts the battery voltage into a module power supply, a charging control circuit (2b) that automatically adjusts the charging current according to the charging voltage, and automatically adjusts the charging current by comparing the reference voltage. The energy setting circuit (2c) to stop charging, the spot welding discharge control circuit (2d) triggered by the button, and the charging and discharging working state indicating circuit (2e).

Further, the energy storage charging switch (3) and the spot welding discharge switch (5) are composed of automotive-grade FET electronic switches with on-off control, and the control input terminal of the energy storage charging switch (3) is connected to the charging control The output terminals of the circuit (2b) are connected; the control input terminals of the spot welding discharge switch (5) are connected with the output terminals of the spot welding discharge control circuit (2d).

Further, the energy adjustment and display panel (8) includes a power conversion switch (8a), an energy adjustment knob (8b), an energy storage digital display (8c), a battery charging socket (8d), a spot welding trigger signal socket (8e ), the working status indicator light (8f) and the high current output terminal (8g) connected to the welding torch, among which, the power conversion switch (8a) is connected to the Ni-MH battery pack (1) equipped with a charger, and the energy adjustment knob (8b) It is connected with the spot welding control circuit module (2), the energy storage digital display (8c) is connected with the Ni-MH battery pack (1) equipped with a charger and the Farad-level energy storage capacitor (4), and the battery charging socket (8d) is connected with the accessory The Ni-MH battery pack (1) with charger is connected, the spot welding trigger signal socket (8e) is connected with the spot welding control circuit module (2) and the spot welding gun (6) with manual control switch, the working status indicator light (8f ) is connected to the spot welding control circuit module (2), and the large current output terminal (8g) of the welding gun is connected to the spot welding control circuit module (2), the spot welding gun (6) with a manual control switch and the welding machine through a cable connected to the ground clip (7).

Further, the spot welding gun (6) with a manual control switch includes a spot welding gun head (6a) with a locking screw, a plastic pistol handle (6b) for installing the spot welding gun head and connecting the cable of the spot welding machine, and connecting Go to the welding trigger switch (6c) of the trigger socket on the panel of the spot welding machine. After entering the welding preparation state, pull the trigger button to implement spot welding.

In summary, this scheme directly adopts capacitor energy storage control, which simplifies the circuit structure, improves energy utilization rate, reduces power supply voltage, reduces volume, weight and product cost while meeting the welding energy requirements of the sensor fixed bracket, and is safe to use. Reliable, used for single-sided thin plate spot welding process, especially the parts to be welded are easy to disassemble and assemble, and will not affect the working surface. Experiments prove that the present invention realizes the expected design function and the application purpose, can be used to solve the problem of on-site quick installation of the sensor, and becomes a practical device suitable for field construction.

Description of drawings

Fig. 1 is the structural representation of portable miniature energy storage spot welding machine of the present invention;

Fig. 2 is a block diagram of the circuit structure of the portable miniature energy storage spot welding machine of the present invention;

Fig. 3 is the operating panel diagram of the portable miniature energy storage spot welding machine of the present invention;

Fig. 4 is a schematic diagram of a typical application of the portable mini energy storage spot welding machine according to the present invention.

detailed description

In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and examples. However, the examples given are not intended to limit the present invention.

As shown in Figure 1, it is a schematic structural view of the portable miniature energy storage spot welding machine of the present invention, which specifically includes a nickel-metal hydride battery pack (1) equipped with a charger, a spot welding control circuit module (2), and an energy storage charging switch ( 3), Farad level energy storage capacitor (4), spot welding discharge switch (5), spot welding torch with manual control switch (6), grounding clamp (7) connected to the welding machine through cables, and energy adjustment and display panel (8), wherein, the Ni-MH battery pack (1) equipped with a charger is connected to the spot welding control circuit module (2) and the energy storage charging switch (3), and the spot welding control circuit module (2) is connected to the Ni-MH battery pack for the charger (1), energy storage charging switch (3), spot welding discharge switch (5), spot welding gun with manual control switch (6), grounding clip connected to the welder via cable (7 ) and energy regulation are connected with the display panel (8), the energy storage charging switch (3) is connected with the Ni-MH battery pack (1) equipped with a charger, the spot welding control circuit module (2) and the farad level energy storage capacitor (4) connection, the farad-level energy storage capacitor (4) is connected to the spot welding control circuit module (2), the energy storage charging switch (3) and the spot welding discharge switch (5), and the spot welding discharge switch (5) is connected to the spot welding control circuit module (2), the farad-level energy storage capacitor (4) is connected to the spot welding gun (6) with a manual control switch, the spot welding gun (6) with a manual control switch and the spot welding discharge switch (5) and energy adjustment and display The panel (8) is connected, and the grounding clamp (7) connected to the welding machine and the energy adjustment are connected to the display panel (8) through cables.

Preferably, the portable miniature energy storage spot welding machine also includes a waterproof satchel-type engineering plastic sealed box (9), which is used to store the nickel-metal hydride battery pack (1) equipped with a charger, spot welding control Circuit module (2), energy storage charging switch (3), farad level energy storage capacitor (4), spot welding discharge switch (5), spot welding gun with manual control switch (6), and welding machine connected by cable The ground clip (7) and the energy adjustment and display panel (8) are contained therein.

Preferably, the portable mini energy storage spot welding machine also includes a solar charger (10), the solar charger (10) is equipped with a Ni-MH battery pack (1) equipped with a charger, an energy adjustment and a display panel (8) is connected with the waterproof satchel type engineering plastics sealing box (9).

Preferably, the spot welding control circuit module (2) includes a voltage stabilizing circuit (2a) that converts the battery voltage into a module power supply, a charging control circuit (2b) that automatically adjusts the charging current according to the charging voltage, and automatically adjusts the charging current by comparing the reference voltage. The energy setting circuit (2c) to stop charging, the spot welding discharge control circuit (2d) triggered by the button, and the charging and discharging working state indicating circuit (2e).

Preferably, the energy storage charging switch (3) and the spot welding discharge switch (5) are composed of automotive-grade FET electronic switches with on-off control, and the control input terminal of the energy storage charging switch (3) is connected to the charging control The output terminals of the circuit (2b) are connected; the control input terminals of the spot welding discharge switch (5) are connected with the output terminals of the spot welding discharge control circuit (2d).

Preferably, the energy adjustment and display panel (8) includes a power conversion switch (8a), an energy adjustment knob (8b), an energy storage digital display (8c), a battery charging socket (8d), a spot welding trigger signal socket (8e ), the working status indicator light (8f) and the high current output terminal (8g) connected to the welding torch, among which, the power conversion switch (8a) is connected to the Ni-MH battery pack (1) equipped with a charger, and the energy adjustment knob (8b) It is connected with the spot welding control circuit module (2), the energy storage digital display (8c) is connected with the Ni-MH battery pack (1) equipped with a charger and the Farad-level energy storage capacitor (4), and the battery charging socket (8d) is connected with the accessory The Ni-MH battery pack (1) with charger is connected, the spot welding trigger signal socket (8e) is connected with the spot welding control circuit module (2) and the spot welding gun (6) with manual control switch, the working status indicator light (8f ) is connected to the spot welding control circuit module (2), and the large current output terminal (8g) of the welding gun is connected to the spot welding control circuit module (2), the spot welding gun (6) with a manual control switch and the welding machine through a cable connected to the ground clip (7).

Preferably, the spot welding gun (6) with a manual control switch includes a spot welding gun head (6a) with a locking screw, a plastic pistol handle (6b) for installing the spot welding gun head and connecting the cable of the spot welding machine and connecting Go to the welding trigger switch (6c) of the trigger socket on the panel of the spot welding machine. After entering the welding preparation state, pull the trigger button to implement spot welding.

As shown in Figure 2, it is a schematic block diagram of the circuit structure of the portable miniature energy storage spot welding machine. The portable miniature energy storage spot welding machine is composed of a power supply (1), a control circuit module (2), and an energy storage charging switch (3) connected in series. , an energy storage capacitor (4), a spot welding discharge switch (5), a welding torch (6) with a spot welding trigger switch and a grounding clamp (7) connected to the welding machine through a cable. Each port of the control module (2) is connected with the above components to realize the spot welding control function.

After using the energy adjustment knob (8b) to adjust the voltage division of the potentiometer to set the reference voltage, the internal comparator of the energy storage control module starts to detect the charging voltage of the energy storage capacitor. When the charging voltage reaches the set reference, the comparator outputs a control signal to automatically stop charging. During the charging and discharging process, the control module will generate PWM pulses to be added to the control terminal of the charging and discharging switch, and the charging and discharging rate will be automatically adjusted.

As shown in Figure 3, it is the operation panel diagram of the portable miniature energy storage spot welding machine. The energy adjustment and display panel (8) of the portable miniature energy storage spot welding machine is equipped with a power conversion switch (8a) and an energy adjustment knob ( 8b), energy storage display (8c), battery charging socket (8d), welding trigger socket (8e), working status indicator light (8f) and output terminal (8g). The control circuit module (2) realizes the signal connection between energy regulation and the display panel (8) through a connector. Switching of the work changeover switch (8a) can make the whole spot welding machine be in the spot welding, shut-off and charging states respectively.

In the embodiment shown in Figure 4, the shell is a satchel-type engineering plastics sealed box (9). When it needs to be used, open the box cover of (9), clamp the grounding wire on the bottom workpiece to be welded, turn the switch (8a) to the "spot welding" position, adjust the energy (8b) so that (8c) displays the required voltage, and the indicator light (8f) After "ready" is displayed, press the welding torch head (6a) on the welding point of the sheet to be welded, and pull the trigger (6c) to complete a spot welding.

The above is where the key technology for the present invention to be practical.

Main Specifications:

Welding energy adjustment range: 10J—60J

Maximum output: 100J

Welding thickness: 0.05—0.3(mm)

Shell volume: 285×213×155(mm) ³

Machine weight: 3.5Kg

Working voltage: DC 24V

Number of spot welding after charging: >3000

To further illustrate, the technical requirements proposed by the present invention to the welding machine are:

1. The structural design of the welding machine should be compact, strong, easy to carry, and meet the requirements of outdoor environments.

2. Focus on low-consumption and high-efficiency circuit design to ensure that the carried battery will not be too large or heavy.

3. The circuit of the spot welding discharge switch has fast response speed and low loss, and can generate instantaneous high power output.

4. The working voltage must be lower than 36V to ensure the safety of users.

According to the above engineering application requirements, the present invention solves the following problems in realization:

1. In order to ensure safe voltage, the power supply described above directly uses a battery pack lower than 36V. For example, if you choose a 24V/4Ah Ni-MH battery, the energy stored in the battery is: 24V×4A×3600s=345600J, even if the spot welding efficiency is 50%, the average energy consumption per point is 50J, and the battery can be welded after each charge (345600× 50%)/50=3456 points. It can meet the requirements of spot welding 1000 times.

2. For the low-voltage energy storage capacitor (4), in order to make each discharge meet the welding energy requirements, the selected energy storage capacity and working voltage are estimated according to the capacitance energy storage formula W=C×V ² /2, which can be Meet the design requirements.

3. The non-contact discharge switch (5) that can pass through the instantaneous large current above KA, because the working voltage of the welding machine is very low, the special switch circuit module of high-power and low-voltage FET is selected, and the internal resistance is only 2mΩ. The use of multiple devices in parallel fully meets the technical requirements.

4. The safe and reliable charging and discharging control module adopts a special control chip, which can automatically generate a PWM signal to adjust the charging current according to the charging voltage, and solve the contradiction between charging efficiency and charging time. A reasonable circuit layout avoids being disturbed when a large current is discharged.

5. The spot welding machine is powered by a 24-volt standard Ni-MH battery. When the transfer switch is connected to an external AC or solar charger, the internal battery will be charged automatically.

According to the above technical requirements, the present invention adopts the Farad capacitor as the spot welding energy storage power supply, and is equipped with an adaptive fast charging and a low-voltage high-current discharging circuit to realize the above special spot welding function. According to welding theory and engineering experience, the energy of instantaneous welding of solder joints needs to be adjustable from 20 to 100 J (Joules) according to the thickness of the workpiece, and it must have sufficient energy density within milliseconds, so that the temperature rise can reach the weldment. melting point.

The product described in the present invention is small in size and light in weight, powered by a low-voltage battery, safe and reliable in use, and can be carried around for field use. It is a serialization specially designed for welding thin/ultra-thin steel plates or delicate and small parts. The new electromechanical product shows that the product of the present invention can be used to solve the problem of rapid installation of some sensors on site.

The portable miniature energy storage spot welding machine provided by the present invention and its use method have been introduced in detail above. The principles and implementation methods of the present invention have been explained by using specific examples in this paper. The description of the above embodiments is only used to help understanding The method of the present invention and its core idea; at the same time, for those of ordinary skill in the art, according to the idea of the present invention, there will be changes in the specific implementation and scope of application. In summary, the content of this specification should not be construed as a limitation of the invention.

Claims (6)

1. A portable miniature energy storage spot welding machine, comprising a Ni-MH battery pack (1) equipped with a charger, a spot welding control circuit module (2), an energy storage charging switch (3), and a farad-level energy storage capacitor (4 ), a spot welding discharge switch (5), a spot welding gun (6) with a manual control switch, a grounding clip (7) connected to the welding machine through a cable, and an energy adjustment and display panel (8), wherein the equipped The NiMH battery pack (1) of the charger is connected with the spot welding control circuit module (2) and the energy storage charging switch (3), and the spot welding control circuit module (2) is connected with the NiMH battery pack (1) equipped with the charger , energy storage charging switch (3), spot welding discharge switch (5), spot welding torch with manual control switch (6), grounding clamp (7) connected to the welding machine through a cable, and energy adjustment and display panel (8) Connection, the energy storage charging switch (3) is connected with the Ni-MH battery pack (1) equipped with a charger, the spot welding control circuit module (2) and the farad-level energy storage capacitor (4), and the farad-level energy storage capacitor (4) It is connected with the spot welding control circuit module (2), the energy storage charging switch (3) and the spot welding discharge switch (5), and the spot welding discharge switch (5) is connected with the spot welding control circuit module (2), the farad level energy storage capacitor ( 4) It is connected with the spot welding gun (6) with manual control switch, the spot welding gun (6) with manual control switch is connected with the spot welding discharge switch (5) and the energy adjustment and display panel (8), through the cable and welding The ground clip (7) connected to the machine and the energy adjustment are connected with the display panel (8), and a waterproof bag-type engineering plastics sealing box (9) is also included, which is used for the described Ni-MH battery pack (1 ), spot welding control circuit module (2), energy storage charging switch (3), farad level energy storage capacitor (4), spot welding discharge switch (5), spot welding gun with manual control switch (6), through cable The grounding clamp (7) connected to the welding machine and the energy adjustment and display panel (8) are contained in it. 2. portable miniature energy storage spot welder as claimed in claim 1, is characterized in that, also comprises solar charger (10), and described solar charger (10) is equipped with the nickel-metal hydride battery pack (1 of charger) ), the energy regulation is connected with the display panel (8) and the waterproof satchel type engineering plastics sealing box (9). 3. The portable miniature energy storage spot welding machine as claimed in claim 1, is characterized in that, described spot welding control circuit module (2) comprises the voltage stabilizing circuit (2a) that battery voltage is converted into module power supply, according to charging The charging control circuit (2b) which automatically adjusts the charging current by the voltage, the energy setting circuit (2c) which automatically stops charging by comparing the reference voltage, the spot welding discharge control circuit (2d) triggered by the button, and the charging and discharging working state indication circuit (2e ). 4. The portable miniature energy storage spot welding machine as claimed in claim 3, characterized in that, the described energy storage charging switch (3) and the spot welding discharge switch (5) are made of automotive grade FET with on-off control Composed of electronic switches, the control input end of the energy storage charging switch (3) is connected to the output end of the charging control circuit (2b); the control input end of the spot welding discharge switch (5) is connected to the output end of the spot welding discharge control circuit (2d) connect. 5. The portable miniature energy storage spot welding machine according to claim 3, characterized in that, said energy adjustment and display panel (8) includes a power conversion switch (8a), an energy adjustment knob (8b), an energy storage digital display (8c), battery charging socket (8d), spot welding trigger signal socket (8e), working status indicator light (8f) and high current output terminal (8g) connected to the welding torch, wherein, the power conversion switch (8a) is equipped with The NiMH battery pack (1) of the charger is connected, the energy adjustment knob (8b) is connected with the spot welding control circuit module (2), and the energy storage digital display (8c) is connected with the NiMH battery pack (1) and The farad level energy storage capacitor (4) is connected, the battery charging socket (8d) is connected with the Ni-MH battery pack (1) equipped with a charger, the spot welding trigger signal socket (8e) is connected with the spot welding control circuit module (2) and the The spot welding torch (6) with manual control switch is connected, the working state indicator light (8f) is connected with the spot welding control circuit module (2), and the large current output terminal (8g) of the welding torch is connected with the spot welding control circuit module (2), The spot welding torch (6) with manual control switch is connected to the ground clamp (7) which is connected to the welding machine by a cable. 6. the portable miniature energy storage spot welding machine as claimed in claim 3 is characterized in that, the described spot welding gun (6) that has manual control switch comprises the spot welding gun head (6a) that has locking screw, installs The spot welding torch head is connected to the plastic pistol handle (6b) of the spot welding machine cable and the welding trigger switch (6c) connected to the trigger socket of the spot welding machine panel. After entering the welding preparation state, pull the trigger button to implement spot welding.