CN117697079A - Welding power supply suitable for continuous uninterrupted welding of ultra-long welding seam - Google Patents

Abstract

The application discloses a welding power supply suitable for continuous uninterrupted welding of overlength welding seam relates to welding equipment technical field. The power supply comprises a welding power supply control module, a control switch module, a high-frequency arcing module, a current balance module, a first single-pole double-throw switch, a second single-pole double-throw switch, a double-way driving module, a standby double-way driving module, a double-way IGBT module, a standby double-way IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation state feedback module, wherein the probability value of an arc stopping event occurring at the end of the next period can be periodically estimated after successful arcing through the connection relation and functional cooperation of the modules, and when the probability value is judged to be larger than or equal to a preset threshold value, the standby double-way driving module and the standby double-way IGBT module are switched and started to output direct current for maintaining an arc, so that the purpose of continuous uninterrupted welding can be realized in the ultra-long welding seam welding process.

Description

A welding power source suitable for continuous and uninterrupted welding of ultra-long welds

Technical field

The invention belongs to the technical field of welding equipment, and specifically relates to a welding power source suitable for continuous and uninterrupted welding of ultra-long weld seams.

Background technique

TIG (Tungsten Inert Gas Welding) welding, also known as non-melting extremely inert gas arc welding, is a mature welding method that is widely used in the welding field of carbon steel, stainless steel, aluminum alloy and non-ferrous metal materials. Ordinary TIG welding has a stable arc and good welding quality, but its penetration depth is shallow, the welding speed is slow, and the efficiency is low. It is generally used for thin plate welding or bottom penetration welding of important thick-walled components.

Titanium alloy welding is a difficult point in traditional welding, especially continuous and uninterrupted welding with a weld length of more than 6,000 to 12,000 meters, which means continuous and uninterrupted welding for more than 250 to 500 hours. Such an ultra-long weld and an extremely long time There is no precedent for titanium alloy welding to be completed in one go. This is mainly because the module used to maintain the arc in the welding power source will malfunction due to excessive use, which will accidentally trigger an arc stop event and require a second arc start. In addition, interference from external force majeure factors such as unexpected power outages can also cause unexpected arc stoppage accidents and affect the welding yield rate.

Contents of the invention

The purpose of the present invention is to provide a welding power source suitable for continuous and uninterrupted welding of ultra-long weld seams, so as to solve the problem that existing welding power sources are difficult to achieve continuous and uninterrupted welding during the welding process of ultra-long weld seams.

In order to achieve the above objects, the present invention adopts the following technical solutions:

In the first aspect, a welding power supply suitable for continuous and uninterrupted welding of ultra-long welds is provided, including a welding power supply control module, a control switch module, a high-frequency arc starting module, a current balancing module, a first single-pole double-throw switch, The second single-pole double-throw switch, the dual-channel drive module in use, the backup dual-channel drive module, the dual-channel IGBT module in use, the backup dual-channel IGBT module, the negative pole of the power output, the positive pole of the power output and the operating status feedback module, wherein, the The negative pole of the power output is used to connect the welding gun head, and the positive pole of the power output is used to connect the workpiece to be welded;

The first output end of the welding power control module is connected to the controlled end of the control switch module, the second output end of the welding power control module is connected to the first input end of the current balance module, and the welding power control module The third output end of the module is respectively connected to the controlled end of the first single-pole double-throw switch and the second single-pole double-throw switch, and the control switch module is connected to the high-frequency arc starting module. The output end of the module is connected to the negative output of the power supply;

The first PWM pulse signal output terminal of the current balancing module is connected to the common terminal of the first single pole double throw switch, and the second PWM pulse signal output terminal of the current balancing module is connected to the common terminal of the second single pole double throw switch. end, the normally closed end of the first single-pole double-throw switch is connected to the input end of the first current drive unit in the dual-channel drive module, and the first current drive unit in the dual-channel drive module is The output end of the unit is connected to the input end of the first IGBT unit in the in-use dual-channel IGBT module, and the normal end of the first single-pole double-throw switch is connected to the first current driver in the backup dual-channel drive module. The input end of the unit, the output end of the first current drive unit in the backup dual-channel drive module is connected to the input end of the first IGBT unit in the backup dual-channel IGBT module, and the dual-channel IGBT module in use The output end of the first IGBT unit in the spare dual IGBT module and the output end of the first IGBT unit in the backup dual IGBT module are respectively connected to the negative pole of the power output, and the normally closed end of the second single pole double throw switch is connected to the The input end of the second current drive unit in the dual-channel drive module is connected to the output end of the second current drive unit in the dual-channel drive module. The input end of the two-way IGBT unit, the normal open end of the second single-pole double-throw switch is connected to the input end of the second current drive unit in the backup dual-way drive module, and the second current drive unit in the backup dual-way drive module The output end of the current driving unit is connected to the input end of the second IGBT unit in the backup dual-circuit IGBT module, and the output end of the second IGBT unit in the in-use dual-circuit IGBT module is connected to the backup dual-circuit IGBT module. The output terminals of the second IGBT unit in the IGBT module are respectively connected to the positive output of the power supply;

The output end of the operating status feedback module is connected to the input end of the welding power supply control module;

The welding power supply control module, on the one hand, is used to perform start/stop actions on the high-frequency arc starting module through the control switch module according to the welding control sequence data, and output an excitation control signal to the current balance module, so as to The current balancing module is caused to output two balanced PWM pulse signals through two current fixed-frequency PWM pulse generator circuits that are internally connected in a master-slave manner and run in parallel, thereby making the dual-channel drive module in use and the The dual-channel IGBT module outputs DC current and superimposes it with the high-frequency pulse high-voltage signal generated by the high-frequency arc starting module and inputs it into the welding gun;

The welding power supply control module, on the other hand, is also used to periodically perform feature extraction processing on the real-time operating status data from the operating status feedback module after successful arc starting, to obtain multi-dimensional operating status features, and then extract all the features. The multi-dimensional operating status characteristics described above are imported into the arc-stop event prediction model that has been pre-trained based on the machine learning algorithm, and the probability value of the arc-stop event at the end of the next cycle is output. Finally, it is determined that the probability value is greater than or equal to the preset value. When the threshold value is reached, the common terminal and the normally open terminal corresponding to the first single-pole double throw switch are controlled to be turned on and the common terminal and the normally closed terminal corresponding to the cutoff are controlled, and the common terminal and the normally closed terminal corresponding to the second single-pole double throw switch are controlled to be turned on. Open and cut off the corresponding common terminal and normally closed terminal to enable the backup dual-channel drive module and the backup dual-channel IGBT module to output the DC current.

Based on the above invention, a new welding power supply solution that can automatically switch to use an arc maintenance module is provided, which includes a welding power supply control module, a control switch module, a high-frequency arc starting module, a current balancing module, and a first single-pole double throw switch, the second SPDT switch, the dual-channel drive module in use, the spare dual-channel drive module, the dual-channel IGBT module in use, the spare dual-channel IGBT module, the negative pole of the power output, the positive pole of the power output and the operating status feedback module, and pass The connection relationship and functional cooperation of these modules can periodically estimate the probability value of an arc stop event at the end of the next cycle after successful arc starting, and when it is determined that the probability value is greater than or equal to the preset threshold, switch to start using the backup dual circuit The drive module and the backup dual-channel IGBT module are used to output the DC current used to maintain the arc. This way, the arc maintenance module currently in use can be deactivated in time before it fails to avoid accidentally triggering an arc stop event, and thus can be used in ultra-long welds. The purpose of continuous and uninterrupted welding is achieved during the welding process, which facilitates practical application and promotion.

In a possible design, a UPS uninterruptible power supply is also included, wherein the power supply end of the UPS uninterruptible power supply is respectively connected to the welding power supply control module, the control switch module, the high-frequency arc starting module, and the The current balancing module, the first single-pole double-throw switch, the second single-pole double-throw switch, the dual-channel drive module in use, the backup dual-channel drive module, the dual-channel IGBT module in use, the The above-mentioned backup dual-channel IGBT module and the above-mentioned operating status feedback module.

In a possible design, it also includes a first electronically controlled switch, a second electronically controlled switch, a first capacitor and a second capacitor, wherein one end of the first electronically controlled switch is connected to the negative pole of the power output, and the The other end of the first electronically controlled switch is connected to one end of the first capacitor, the other end of the first capacitor is grounded, one end of the second electronically controlled switch is connected to the positive output of the power supply, and the second electronically controlled switch The other end of the second capacitor is connected to one end of the second capacitor, and the other end of the second capacitor is connected to ground;

The fourth output end of the welding power supply control module is respectively connected to the controlled end of the first electronically controlled switch and the second electronically controlled switch;

Control the common end corresponding to the first single-pole double throw switch to be turned on and the common end and normally closed end corresponding to the normally open and cut-off state, and control the common end and normally open end and cut-off corresponding to the second single-pole double throw switch to be turned on. The corresponding public terminals and normally closed terminals include:

Control the first electronically controlled switch and the second electronically controlled switch to switch from the off state to the on state respectively, and start a timer;

When the timer reaches a preset duration threshold, the first single-pole double-throw switch is controlled to turn on the corresponding common terminal and the normally open terminal and to turn off the corresponding common terminal and the normally closed terminal, and control the second single-pole double-throw switch. The double-throw switch conducts the corresponding common terminal and the normally open terminal and turns off the corresponding common terminal and the normally closed terminal, wherein the preset duration threshold is shorter than half of the cycle duration of the next cycle;

The first electronically controlled switch and the second electronically controlled switch are respectively controlled to return from the on state to the off state.

In a possible design, the first electronically controlled switch or the second electronically controlled switch uses a thyristor or a relay.

In a possible design, the welding power supply control module is also used after successful arc starting:

When the continuous use time of the in-use dual-channel drive module and the in-use dual-channel IGBT module reaches M cycles, the common terminal corresponding to the conduction of the first single-pole double-throw switch is controlled to correspond to the normally open and closed state. The common end and the normally closed end, and the common end and the normally closed end corresponding to the conduction and normally open end of the second single-pole double throw switch are controlled to enable the backup dual-way drive module and the The backup dual-channel IGBT module outputs the DC current, where M represents a positive integer greater than or equal to 5;

And when the continuous use time of the backup dual-channel drive module and the backup dual-channel IGBT module reaches N cycles, the common terminal corresponding to the first single-pole double-throw switch is controlled to be turned off and normally open and turned on. The common end and the normally closed end, and the common end and the normally closed end corresponding to the second single-pole double throw switch are controlled to be turned off and turned on, so as to enable the dual-channel drive module in use and all The dual-channel IGBT module is used to restore the output of the DC current, where N represents a positive integer greater than or equal to 5.

In a possible design, the machine learning algorithm uses a linear regression algorithm based on the Python sklearn library.

In a possible design, the arc-stop event prediction model is pre-trained as follows:

Acquire multiple copies of normal operating status data and multiple copies of previous operating status data corresponding to multiple historical arc stoppage events, wherein the normal operating status data refers to the time when no arc stoppage event occurs by the operating status feedback module. The real-time operating status data collected at the beginning of the K-hour historical period, K represents a positive integer, and the previous operating status data refers to the real-time operating status data collected by the operating status feedback module at a determined moment before the corresponding event occurs. Running status data, the determined time is equal to the time when the corresponding event occurs minus the duration of one cycle;

For each piece of normal operation status data in the plurality of pieces of normal operation status data, extract multi-dimensional operating status features from the corresponding data as the corresponding model input item, and use the value 0 as the corresponding model output item to obtain the corresponding And contains negative samples of the model input term and the model output term;

For each previous operating state data in the plurality of previous operating state data, extract the multi-dimensional operating state characteristics from the corresponding data as the corresponding model input item, and use the value 1 as the corresponding model output item, to obtain Corresponding positive samples that contain the model input and the model output;

Apply a plurality of the negative samples and a plurality of the positive samples to perform calibration verification modeling on the artificial intelligence model based on the machine learning algorithm to obtain the arc stop event prediction model, wherein the arc stop event prediction model The confidence of the model with an output value of 1 is used as the probability value of an arc stop event occurring at the end of the next period.

In a possible design, the first single-pole double-throw switch or the second single-pole double-throw switch uses a single-channel single-pole double-throw CMOS analog switch model LN3657.

In a possible design, the operating status feedback module includes a welding current feedback unit, an arc voltage feedback unit, a temperature signal feedback unit, a chiller operating status feedback unit, and two IGBT output feedback units.

In a possible design, the control switch module includes a welding gun protective gas valve switch, a chiller start-stop switch and an arc start-stop switch.

Beneficial effects of the above solution:

(1) The present invention creatively provides a new welding power supply solution that can automatically switch to use an arc maintenance module, which includes a welding power supply control module, a control switch module, a high-frequency arc starting module, a current balance module, a first single-pole dual throw switch, the second single-pole double-throw switch, the dual-channel drive module in use, the spare dual-channel drive module, the dual-channel IGBT module in use, the spare dual-channel IGBT module, the negative pole of the power output, the positive pole of the power output and the operating status feedback module, and Through the connection relationship and functional cooperation of these modules, it is possible to periodically estimate the probability value of an arc stop event at the end of the next cycle after successful arc starting, and when it is determined that the probability value is greater than or equal to the preset threshold, switch to start using the backup dual A circuit drive module and a backup dual-circuit IGBT module are used to output the DC current used to maintain the arc. This way, the arc maintenance module currently in use can be deactivated in time before it fails to avoid accidentally triggering an arc stop event, and thus can be used in ultra-long welding. The purpose of continuous and uninterrupted welding is achieved during the seam welding process, which facilitates practical application and promotion;

(2) UPS uninterruptible power supply can also be used to avoid accidental arc stoppage accidents due to unexpected power outages, and further ensure the purpose of continuous uninterrupted welding during the ultra-long welding seam welding process;

(3) By adopting the delayed power-off solution, the welding machine and welding gun can be cooled down first when the mains power is abnormal, effectively protecting the welding power source and welding gun, thereby effectively ensuring long-term stability of welding and reducing losses.

Description of the drawings

In order to explain the embodiments of the present invention or the technical solutions in the prior art more clearly, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are only These are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without exerting creative efforts.

Figure 1 is a schematic structural diagram of a welding power source suitable for continuous and uninterrupted welding of ultra-long weld seams provided by an embodiment of the present application.

Detailed ways

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the present invention will be briefly introduced below in conjunction with the accompanying drawings and the description of the embodiments or the prior art. Obviously, the following description of the structure of the drawings is only These are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without exerting creative efforts. It should be noted here that the description of these embodiments is used to help understand the present invention, but does not constitute a limitation of the present invention.

It should be understood that although the terms first, second, etc. may be used herein to describe various objects, these objects should not be limited by these terms. These terms are only used to distinguish one object from another. For example, a first object may be referred to as a second object, and similarly a second object may be referred to as a first object, without departing from the scope of example embodiments of the invention.

It should be understood that the term "and/or" that may appear in this article is only an association relationship describing related objects, indicating that there can be three relationships, for example, A and/or B, which can mean: A alone exists, The existence of B alone or the existence of A and B at the same time; for another example, A, B and/or C can mean the existence of any one of A, B and C or any combination of them; for what may appear in this article The term "/and" describes another type of associated object relationship, indicating that there can be two relationships, for example, A/and B, which can mean: A alone exists or A and B exist simultaneously; in addition, for The character "/" that may appear in this article generally indicates that the related objects are an "or" relationship.

Example

As shown in Figure 1, the welding power supply provided by the first aspect of this embodiment and suitable for continuous and uninterrupted welding of ultra-long welds includes but is not limited to a welding power supply control module, a control switch module, a high-frequency arc starting module, a current Balanced module, first SPDT switch, second SPDT switch, dual-channel drive module in use, backup dual-channel drive module, dual-channel IGBT (Insulate-Gate Bipolar Transistor) module in use, Standby dual-channel IGBT module, negative pole of power output, positive pole of power output and operating status feedback module, wherein the negative pole of power output is used to connect the welding gun head, and the positive pole of power output is used to connect the workpiece to be welded.

The first output end of the welding power control module is connected to the controlled end of the control switch module, the second output end of the welding power control module is connected to the first input end of the current balance module, and the welding power control module The third output end of the module is respectively connected to the controlled end of the first single-pole double-throw switch and the second single-pole double-throw switch, and the control switch module is connected to the high-frequency arc starting module. The output terminal of the module is connected to the negative output terminal of the power supply. The control switch module is used to complete the arc starting of the welding gun by controlling the operation of the high-frequency arc starting module; specifically, the control switch module includes but is not limited to a welding gun protective gas valve switch, a chiller start-stop switch and a start-stop switch. Arc start and stop switch, wherein the welding gun protective gas valve switch is used to control the opening/closing of the welding gun protective gas valve, so that the protective gas continues to flow from the welding gun nozzle when the gas valve is opened, and stops when the gas valve is closed. The protective gas flows out; the chiller start/stop switch is used to control the start/stop of the chiller to cool the welding gun when the chiller is started. In particular, the welding power supply control module can also monitor the welding gun in real time through conventional temperature measurement methods. temperature, and when the welding gun temperature is higher than the first preset temperature (for example, adding 10 degrees Celsius to room temperature, that is, 35 degrees Celsius), the start-stop switch of the chiller is triggered to start the chiller, and when the welding gun temperature When the chiller is continuously lower than the second preset temperature (which is lower than the first preset temperature, such as room temperature) within a preset period of time (for example, within 30 minutes), the start-stop switch of the chiller is triggered to stop the chiller. , in order to realize intelligent start and stop of the water chiller, which is conducive to saving electric energy; the arc start and stop switch is used to control the start/stop of the high-frequency arc starting module, so as to realize arc starting at startup.

The first PWM pulse signal output terminal of the current balancing module is connected to the common terminal of the first single pole double throw switch, and the second PWM pulse signal output terminal of the current balancing module is connected to the common terminal of the second single pole double throw switch. end, the normally closed end of the first single-pole double-throw switch is connected to the input end of the first current drive unit (i.e., the current drive unit A in Figure 1) in the dual-channel drive module in use. The output end of the first current drive unit in the dual-channel drive module is connected to the input end of the first IGBT unit (i.e. IGBT unit A in Figure 1) in the dual-channel IGBT module in use. The first single-pole The normally open end of the double-throw switch is connected to the input end of the first current drive unit in the backup dual-channel drive module (i.e., the current drive unit C in Figure 1). The first current drive unit in the backup dual-channel drive module The output end of the driving unit is connected to the input end of the first IGBT unit in the backup dual-channel IGBT module (i.e., IGBT unit C in Figure 1), and the first IGBT unit in the in-use dual-channel IGBT module is The output end and the output end of the first IGBT unit in the backup dual-channel IGBT module are respectively connected to the negative pole of the power output, and the normally closed end of the second single-pole double-throw switch is connected to the in-use dual-channel drive module. The input end of the second current drive unit (i.e., the current drive unit B in Figure 1), and the output end of the second current drive unit in the in-use dual-channel drive module is connected to the in-use dual-channel IGBT module. The input end of the second IGBT unit (i.e. IGBT unit B in Figure 1), the normal end of the second single pole double throw switch is connected to the second current drive unit (i.e. The input end of the current drive unit D) in Figure 1, and the output end of the second current drive unit in the backup dual-channel drive module are connected to the second IGBT unit in the backup dual-channel IGBT module (i.e. Figure 1 The input end of the IGBT unit D) in the dual-channel IGBT module, the output end of the second IGBT unit in the in-use dual-channel IGBT module and the output end of the second IGBT unit in the backup dual-channel IGBT module are respectively connected to the The power output is positive.

The output end of the operating status feedback module is connected to the input end of the welding power supply control module. The operating status feedback module is used to monitor signals such as welding current, welding voltage, temperature of power devices, and operating conditions of the chiller when the system is running, and feeds these signals back to the welding power supply control module after necessary electrical isolation. , so that the welding power supply control module can obtain real-time operating status data based on analog-to-digital conversion of these signals in real time; specifically, the operating status feedback module includes but is not limited to a welding current feedback unit, an arc voltage feedback unit, and a temperature signal feedback unit. unit, chiller operating status feedback unit and two-way IGBT output feedback unit, etc., wherein the welding current feedback unit is used to collect and feedback the welding current status, and the arc voltage feedback unit is used to collect and feedback the arc voltage status (also i.e. welding voltage state), the temperature signal feedback unit is used to collect and feedback the temperature state of the power device, the chiller operating status feedback unit is used to collect and feedback the operating status of the chiller, the two-way IGBT output feedback unit It is used to collect and feedback the status of output parameters such as output voltage, output current or output power of the in-use dual-channel IGBT module or the backup dual-channel IGBT module. They can all use existing circuit structures to implement corresponding functions.

The welding power supply control module, on the one hand, is used to perform start/stop actions on the high-frequency arc starting module through the control switch module according to the welding control sequence data, and output an excitation control signal to the current balance module, so as to The current balancing module is caused to output two balanced PWM pulse signals through two current fixed-frequency PWM pulse generator circuits that are internally connected in a master-slave manner and run in parallel, thereby making the dual-channel drive module in use and the The dual-channel IGBT module outputs a DC current and is superimposed with the high-frequency pulse high-voltage signal generated by the high-frequency arc starting module and input into the welding gun. The aforementioned functions are basic functions of existing welding power sources and can be conventionally implemented based on existing technologies. Specifically, they include but are not limited to: sequentially controlling the start-stop switch of the chiller and the protective gas of the welding gun based on accurate welding control timing data. The gas valve switch makes the welding gun circulate cooling water and causes the shielding gas to continuously flow out from the welding gun nozzle. After a certain period of time, the space between the tungsten needle and the workpiece to be welded is filled with shielding gas, and then the arc excitation current is output to the The current balance module generates two balanced PWM (Pulse width modulation, pulse width modulation) pulse signals to drive the dual-channel drive module and the dual-channel IGBT module in use, and then the tungsten electrode tip of the welding gun A stable DC voltage is formed with the surface of the workpiece, and then by turning on the arc starting and stopping switch, the high frequency arc starting module is controlled to output a high frequency and high voltage signal and loaded to the negative pole of the power supply output to excite the arc, causing the power supply to output The negative electrode is connected to the positive electrode of the power output. Finally, after the arc is generated, the high-frequency arc starting module is controlled to stop working immediately, and the base current (i.e., the DC current) output by the dual-channel IGBT module in use is maintained. arc.

The welding power supply control module, on the other hand, is also used to periodically perform feature extraction processing on the real-time operating status data from the operating status feedback module after successful arc starting, to obtain multi-dimensional operating status features, and then extract all the features. The multi-dimensional operating status characteristics described above are imported into the arc-stop event prediction model that has been pre-trained based on the machine learning algorithm, and the probability value of the arc-stop event at the end of the next cycle is output. Finally, it is determined that the probability value is greater than or equal to the preset value. When the threshold value (for example, is preset to 62.8%), the first single-pole double-throw switch is controlled to turn on the corresponding common terminal and the normally open terminal and to turn off the corresponding common terminal and the normally closed terminal, and to control the second single-pole double-throw switch. The corresponding common terminal and the normally open terminal are turned on and the corresponding common terminal and the normally closed terminal are turned off, so as to enable the backup dual-channel drive module and the backup dual-channel IGBT module to output the DC current. The cycle length of the aforementioned cycle may be, but is not limited to, 1 minute, for example. The specific method of feature extraction processing is the existing conventional method, for example, the welding current value, the welding voltage value, the temperature value of the power device, the operating status value of the chiller, etc. are extracted as multi-dimensional operating status features. The machine learning algorithm is an artificial intelligence core algorithm that specializes in studying how computers can simulate or implement human learning behavior to acquire new knowledge or skills and reorganize existing knowledge structures to continuously improve their own performance. It is an artificial intelligence core algorithm that enables computers to A fundamental approach to intelligence; specifically, the machine learning algorithm preferably uses a linear regression algorithm based on the Python sklearn library in order to quickly and accurately find patterns in the data. The arc-stop event occurrence prediction model may be, but is not limited to, pre-trained according to the following steps S101 to S104.

S101. Obtain multiple copies of normal operating status data and multiple copies of previous operating status data corresponding to multiple historical arc stoppage events. The normal operating status data refers to the operation status data generated by the operating status feedback module without arc stoppage. The real-time operating status data collected at the beginning of the K-hour historical period when the event occurs, K represents a positive integer, and the previous operating status data refers to the operating status feedback module collected at a certain moment before the corresponding event occurs. The real-time operating status data, the determined time is equal to the time when the corresponding event occurs minus the duration of one cycle.

In step S101, for example, if no arc stop event occurs within 4 hours from 8:00 to 12:00 (that is, the value of K is 4), the real-time operating status collected at 8:00 can be The data is regarded as the normal operating status data; and if an arc stop event occurs at 12:01, the real-time operation data collected at 12:00 (that is, the determined time, the cycle length is 1 minute) can be The status data is treated as a copy of the previous operating status data.

S102. For each piece of normal operating status data in the plurality of pieces of normal operating status data, extract the multidimensional operating status characteristics from the corresponding data as the corresponding model input item, and use the value 0 as the corresponding model output item, to obtain Corresponding negative samples that contain the model input and the model output.

S103. For each previous operating state data in the multiple previous operating state data, extract the multi-dimensional operating state characteristics from the corresponding data as the corresponding model input item, and use the value 1 as the corresponding model output item. , get the corresponding positive sample that contains the model input and the model output.

S104. Apply multiple negative samples and multiple positive samples to perform calibration verification modeling on the artificial intelligence model based on the machine learning algorithm to obtain the arc stop event prediction model, wherein the arc stop event The confidence level of the occurrence prediction model with an output value of 1 is used as the probability value of an arc stop event occurring at the end of the next period.

In the step S104, the specific process of the calibration verification modeling includes the calibration process and the calibration process of the model, that is, first comparing the model simulation results with the actual measured data, and then adjusting the model parameters according to the comparison results, so that The simulation results are consistent with the actual process, so the arc-stop event prediction model can be obtained through conventional calibration verification modeling methods. Preferably, during the calibration and verification modeling process of the artificial intelligence model, a Bayesian optimization algorithm based on a tree structure is used to tune model parameters. In addition, the artificial intelligence model can also use, but is not limited to, machine learning such as support vector machine, K nearest neighbor method, stochastic gradient descent method, multi-layer perceptron, decision tree, back propagation neural network or radial basis function network. algorithm to implement.

Based on the aforementioned welding power supply suitable for continuous and uninterrupted welding of ultra-long welds, a new welding power supply solution that can automatically switch to use the arc maintenance module is provided, which includes a welding power supply control module, a control switch module, and a high-voltage arc maintenance module. Frequency arc starting module, current balance module, first SPDT switch, second SPDT switch, dual-channel drive module in use, backup dual-channel drive module, dual-channel IGBT module in use, backup dual-channel IGBT module, power supply The output negative pole, the power supply output positive pole and the operating status feedback module, and through the connection relationship and functional cooperation of these modules, can periodically estimate the probability value of an arc stop event at the end of the next cycle after successful arc starting, and determine the probability When the value is greater than or equal to the preset threshold, the switch starts to use the backup dual-channel drive module and the backup dual-channel IGBT module to output the DC current for maintaining the arc. This can be deactivated in time before the arc maintenance module currently in use fails. It avoids accidental triggering of arc stop events and achieves continuous and uninterrupted welding during ultra-long welding seams.

Preferably, it also includes a UPS (Uninterruptible Power Supply) uninterruptible power supply, wherein the power supply end of the UPS uninterruptible power supply is respectively, but not limited to, connected to the welding power supply control module, the control switch module, and the high-frequency generator. arc module, the current balancing module, the first single-pole double-throw switch, the second single-pole double-throw switch, the in-use dual-channel drive module, the backup dual-channel drive module, the in-use dual-channel drive module IGBT module, the backup dual-channel IGBT module and the operating status feedback module, etc. The UPS uninterruptible power supply is an uninterruptible power supply containing an energy storage device, which can provide uninterrupted power supply to some equipment that requires high power supply stability. In this way, by using UPS uninterruptible power supply, accidental arc stoppage accidents caused by unexpected power outages can be effectively avoided. Specifically, the UPS uninterruptible power supply can be, but is not limited to, a passive backup UPS power supply (that is, an inverter is connected in parallel between the mains and the load and is simply used as a backup power supply; this kind of UPS power supply is used when the mains power supply When normal, the load is completely and directly powered by the mains, the inverter does not perform any power conversion, and the battery is powered by an independent charger; when the mains is abnormal, the load is completely powered by the inverter), online interactive UPS power supply (that is, the inverter is connected in parallel between the mains and the load to serve as a backup power supply. At the same time, the inverter serves as a charger to charge the battery; through the reversible operation mode of the inverter, it interacts with the mains, so It is called interactive; this kind of UPS power supply, when the mains power is normal, the load is powered by the improved mains power, and the inverter serves as a charger to charge the battery. At this time, the inverter acts as an AC/DC converter. function; when the mains fails, the load is completely powered by the inverter. At this time, the inverter functions as a DC/AC converter) or a double-conversion UPS power supply (referring to the inverter connected in series between the AC input and the load). During the period, the power supply continuously supplies power to the load through the inverter; the power supply method of this kind of UPS power supply is as follows: when the mains power is normal, the mains power supplies power to the load through the rectifier and inverter; when the mains power is abnormal, the storage battery passes through The inverter supplies power to the load). In addition, considering the limited energy storage of the UPS uninterruptible power supply and the large power required for welding, the UPS uninterruptible power supply cannot provide power for a long time. Therefore, it is preferable that the welding power supply control module is also used to monitor the The working status of the UPS uninterruptible power supply. When it is found according to the monitoring results that the UPS uninterruptible power supply activates the inverter to provide power due to abnormal mains power, the control switch module and/or the current balancing module are controlled to enable the UPS uninterruptible power supply. The welding machine enters the arc closing process or creates a weld that can be used for lap joint next time (the specific control process can be routinely implemented based on existing technical means), and after completion, it delays the operation for a preset time (for example, 10 minutes) before officially Power off and stop, or after completion, monitor the welding gun temperature in real time through conventional temperature measurement methods, and then restore the welding gun temperature to the third preset temperature (for example, add 10 degrees Celsius to room temperature, that is, 35 degrees Celsius) or reach other preset temperatures. The power is officially shut down only when the temperature conditions are set to avoid problems such as condensation water caused by the large gap between the welding gun temperature and room temperature, and effectively protect the welding power source and welding gun. In this way, through the aforementioned delayed power-off solution, the welding machine and welding gun can be cooled down when the mains power is abnormal, effectively protecting the welding power source and welding gun, thereby effectively ensuring long-term stability of welding and reducing losses.

Preferably, it also includes a first electronically controlled switch K1, a second electronically controlled switch K2, a first capacitor C1 and a second capacitor C2, wherein one end of the first electronically controlled switch K1 is connected to the negative pole of the power output, so The other end of the first electronically controlled switch K1 is connected to one end of the first capacitor C1, the other end of the first capacitor C1 is grounded, one end of the second electronically controlled switch K2 is connected to the positive output of the power supply, and the The other end of the second electronically controlled switch K2 is connected to one end of the second capacitor C2, and the other end of the second capacitor C2 is grounded; the fourth output end of the welding power supply control module is connected to the first electronically controlled switch respectively. K1 and the controlled end of the second electronically controlled switch K2; control the common end corresponding to the first single-pole double-throw switch to be turned on and the normally open end and the normally closed end corresponding to the cutoff, and control the second The single-pole double-throw switch turns on the corresponding common terminal and the normally open terminal and turns off the corresponding common terminal and the normally closed terminal, including but not limited to the following steps S201 to S203: S201. Control the first electronically controlled switch K1 and the third electronically controlled switch K1. The two electronically controlled switches K2 are respectively switched from the off state to the on state, and start the timer; S202. When the timer reaches the preset duration threshold, control the first single-pole double-throw switch to turn on the corresponding common The common terminal and the normally closed terminal corresponding to the normally open and closed terminal, and the common terminal corresponding to the conduction of the second single-pole double throw switch and the common terminal and the normally closed terminal corresponding to the normally open and closed terminal, wherein the predetermined Assume that the duration threshold is shorter than half of the cycle duration of the next cycle; S203. Control the first electronically controlled switch K1 and the second electronically controlled switch K2 to respectively return from the on state to the off state. In this way, before switching to start using the backup dual-channel drive module and the backup dual-channel IGBT module, the negative electrode of the power output and the first capacitor C1 and the positive electrode of the power output and the second capacitor C2 are connected respectively. The first capacitor C1 and the second capacitor C2 can be used to charge first, and then the two capacitors are discharged at the switching moment of the first SPDT switch and the second SPDT switch, so as to maintain the The output of the DC current is stable, which can completely avoid arc stoppage events during the switching process, further ensuring the purpose of continuous and uninterrupted welding. In addition, after switching and starting to use the backup dual-channel drive module and the backup dual-channel IGBT module, the connection between the negative pole of the power output and the first capacitor C1 and the positive pole of the power output and the second capacitor C2 will be disconnected. , therefore it is also possible to prevent the capacitor charge from adversely affecting the stability of the DC current. Specifically, the first electronically controlled switch K1 or the second electronically controlled switch K2 may be, but is not limited to, a thyristor or a relay.

Preferably, the welding power supply control module is also used to control the welding power supply control module when the continuous use time of the in-use dual-channel drive module and the in-use dual-channel IGBT module reaches M cycles after successful arc starting. The common terminal corresponding to the conduction of the first single-pole double throw switch, the common terminal corresponding to the normally open and closed terminal, and the common terminal corresponding to the normally closed terminal are controlled to control the common terminal corresponding to the conduction of the second single-pole double throw switch and the common terminal corresponding to the normally open and closed state. terminal and the normally closed terminal to enable the backup dual-channel drive module and the backup dual-channel IGBT module to output the DC current, where M represents a positive integer greater than or equal to 5; and when the backup dual-channel drive module And when the continuous use time of the backup dual-channel IGBT module reaches N cycles, control the first single-pole double-throw switch to turn off the corresponding common terminal and the normally open terminal and conduct the corresponding common terminal and the normally closed terminal, and control The second single-pole double-throw switch turns off the corresponding common terminal and the normally open terminal and conducts the corresponding common terminal and the normally closed terminal so as to enable the in-use dual-channel drive module and the in-use dual-channel IGBT module to restore the output. Said DC current, where N represents a positive integer greater than or equal to 5. The aforementioned M and N can be respectively, for example, 60, that is, the in-use dual-channel drive module and the in-use dual-channel IGBT module and the backup dual-channel drive module and the backup dual-channel IGBT module are activated every 60 minutes. In this way, by rotating the dual-channel drive module and the dual-channel IGBT module, it can also avoid their failure due to long-term use, further ensuring the purpose of continuous and uninterrupted welding.

Preferably, the first single-pole double-throw switch or the second single-pole double-throw switch may be, but is not limited to, a single-channel single-pole double-throw CMOS (Complementary Metal Oxide Semiconductor, Complementary Metal Oxide Semiconductor) analog switch with model number LN3657.

In summary, the use of the welding power supply provided by this embodiment suitable for continuous and uninterrupted welding of ultra-long welds has the following technical effects:

(1) This embodiment provides a new welding power supply solution that can automatically switch to use an arc maintenance module, which includes a welding power supply control module, a control switch module, a high-frequency arc starting module, a current balance module, a first single-pole dual throw switch, the second single-pole double-throw switch, the dual-channel drive module in use, the spare dual-channel drive module, the dual-channel IGBT module in use, the spare dual-channel IGBT module, the negative pole of the power output, the positive pole of the power output and the operating status feedback module, and Through the connection relationship and functional cooperation of these modules, it is possible to periodically estimate the probability value of an arc stop event at the end of the next cycle after successful arc starting, and when it is determined that the probability value is greater than or equal to the preset threshold, switch to start using the backup dual A circuit drive module and a backup dual-circuit IGBT module are used to output the DC current used to maintain the arc. This way, the arc maintenance module currently in use can be deactivated in time before it fails to avoid accidentally triggering an arc stop event, and thus can be used in ultra-long welding. The purpose of continuous and uninterrupted welding is achieved during the seam welding process, which facilitates practical application and promotion;

(2) UPS uninterruptible power supply can also be used to avoid accidental arc stoppage accidents due to unexpected power outages, and further ensure the purpose of continuous uninterrupted welding during the ultra-long welding seam welding process;

(3) By adopting the delayed power-off solution, the welding machine and welding gun can be cooled down first when the mains power is abnormal, effectively protecting the welding power source and welding gun, thereby effectively ensuring long-term stability of welding and reducing losses.

Finally, it should be noted that the above descriptions are only preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the present invention.

Claims (10)

1. The welding power supply is characterized by comprising a welding power supply control module, a control switch module, a high-frequency arcing module, a current balancing module, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use double-way driving module, a standby double-way driving module, an in-use double-way IGBT module, a standby double-way IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation state feedback module, wherein the power supply output negative electrode is used for being connected with a welding gun head, and the power supply output positive electrode is used for being connected with a workpiece to be welded;

The first output end of the welding power supply control module is connected with the controlled end of the control switch module, the second output end of the welding power supply control module is connected with the first input end of the current balance module, the third output end of the welding power supply control module is respectively connected with the controlled ends of the first single-pole double-throw switch and the second single-pole double-throw switch, the control switch module is connected with the high-frequency arcing module, and the output end of the high-frequency arcing module is connected with the power supply output cathode;

the first PWM pulse signal output end of the current balance module is connected with the common end of the first single-pole double-throw switch, the second PWM pulse signal output end of the current balance module is connected with the common end of the second single-pole double-throw switch, the normally closed end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit in the using double-path driving module, the output end of the first path current driving unit in the using double-path driving module is connected with the input end of the first path IGBT unit in the using double-path IGBT module, the normally open end of the first single-pole double-throw switch is connected with the input end of the first path current driving unit in the standby double-path driving module, the output end of the first path current driving unit in the standby double-path driving module is connected with the input end of the first path IGBT unit in the standby double-path driving module, the output end of the second normally closed end of the second single-pole double-throw switch is connected with the input end of the first path IGBT unit in the standby double-path driving module, the normally open end of the second single-pole double-throw switch is connected with the input end of the first path IGBT unit in the standby double-path driving module, the output end of the second IGBT unit in the in-use double-path IGBT module and the output end of the second IGBT unit in the standby double-path IGBT module are respectively connected with the power supply output anode;

The output end of the running state feedback module is connected with the input end of the welding power supply control module;

the welding power supply control module is used for executing starting/stopping actions on the high-frequency arcing module through the control switch module according to welding control time sequence data, and outputting excitation control signals to the current balance module so as to enable the current balance module to output two paths of balanced PWM pulse signals through two paths of current constant-frequency PWM pulse generator circuits which are connected in a master-slave mode and run in parallel, and further enable the in-use double-path driving module and the in-use double-path IGBT module to output direct current and to be overlapped with high-frequency pulse high-voltage signals generated by the high-frequency arcing module to be input into a welding gun;

and the welding power supply control module is also used for periodically extracting and processing the real-time operation state data from the operation state feedback module to obtain multi-dimensional operation state characteristics after successful arcing, then guiding the multi-dimensional operation state characteristics into an arc stopping event occurrence prediction model which is based on a machine learning algorithm and is trained in advance, outputting a probability value of the arc stopping event when the next period is finished, and finally controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a normally open end and a public end corresponding to the cut-off of the first single-pole double-throw switch and a normally closed end when the probability value is judged to be more than or equal to a preset threshold value, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch so as to enable the standby double-way driving module and the standby double-way IGBT module to output the direct current.

2. The welding power supply of claim 1, further comprising a UPS uninterruptible power supply, wherein a power supply end of the UPS uninterruptible power supply is connected to the welding power supply control module, the control switch module, the high frequency arcing module, the current balancing module, the first single pole double throw switch, the second single pole double throw switch, the on-use two-way drive module, the standby two-way drive module, the on-use two-way IGBT module, the standby two-way IGBT module, and the operational status feedback module, respectively.

3. The welding power supply according to claim 1, further comprising a first electrically controlled switch (K1), a second electrically controlled switch (K2), a first capacitor (C1) and a second capacitor (C2), wherein one end of the first electrically controlled switch (K1) is connected to the power output negative electrode, the other end of the first electrically controlled switch (K1) is connected to one end of the first capacitor (C1), the other end of the first capacitor (C1) is grounded, one end of the second electrically controlled switch (K2) is connected to the power output positive electrode, the other end of the second electrically controlled switch (K2) is connected to one end of the second capacitor (C2), and the other end of the second capacitor (C2) is grounded;

The fourth output end of the welding power supply control module is respectively connected with the controlled ends of the first electric control switch (K1) and the second electric control switch (K2);

controlling the common end corresponding to the first single-pole double-throw switch to be conducted and the common end corresponding to the normally open end to be cut off and the normally closed end, and controlling the common end corresponding to the second single-pole double-throw switch to be conducted and the common end corresponding to the normally open end to be cut off and the normally closed end, comprising:

controlling the first electric control switch (K1) and the second electric control switch (K2) to be respectively switched from an off state to an on state, and starting a timer;

when the timing of the timer reaches a preset duration threshold, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a normally-open end and a public end corresponding to the cut-off of the first single-pole double-throw switch and a normally-closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and a normally-open end and a public end corresponding to the cut-off of the second single-pole double-throw switch and a normally-closed end, wherein the preset duration threshold is shorter than half of the period duration of the next period;

and controlling the first electric control switch (K1) and the second electric control switch (K2) to respectively recover from an on state to an off state.

4. A welding power supply according to claim 3, characterized in that the first electrically controlled switch (K1) or the second electrically controlled switch (K2) employs a thyristor or a relay.

5. The welding power supply of claim 1, wherein the welding power supply control module is further configured to, upon successful arcing:

when the continuous use time of the on-use double-circuit driving module and the on-use double-circuit IGBT module reaches M period time, controlling a public end corresponding to the conduction of the first single-pole double-throw switch and a public end corresponding to the normally open end and the normally closed end, and controlling a public end corresponding to the conduction of the second single-pole double-throw switch and the normally open end and the public end corresponding to the cut-off of the second single-pole double-throw switch and the normally closed end, so as to enable the standby double-circuit driving module and the standby double-circuit IGBT module to output the direct current, wherein M represents a positive integer greater than or equal to 5;

and when the continuous use time of the standby double-circuit driving module and the standby double-circuit IGBT module reaches N period time, controlling the public end and the normally open end corresponding to cut-off of the first single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, and controlling the public end and the normally open end corresponding to cut-off of the second single-pole double-throw switch and the public end and the normally closed end corresponding to conduction, so as to enable the in-use double-circuit driving module and the in-use double-circuit IGBT module to resume outputting the direct current, wherein N represents a positive integer greater than or equal to 5.

6. The welding power supply of claim 1, wherein the machine learning algorithm employs a linear regression algorithm based on a Python sklearn library.

7. The welding power supply of claim 1, wherein the arc-stopping event occurrence prediction model is pre-trained in the following manner:

acquiring a plurality of pieces of normal running state data and a plurality of pieces of previous running state data which are in one-to-one correspondence with a plurality of historical arc stopping events, wherein the normal running state data are real-time running state data acquired by the running state feedback module at the starting moment of a K-hour historical period when no arc stopping event occurs, K represents a positive integer, the previous running state data are real-time running state data acquired by the running state feedback module at the moment when the corresponding event occurs at the moment of determining, and the moment of determining is equal to the moment of the corresponding event occurrence minus one period duration;

extracting multidimensional operation state characteristics from corresponding data as corresponding model input items and taking a value 0 as a corresponding model output item aiming at each piece of normal operation state data in the plurality of pieces of normal operation state data to obtain a corresponding negative sample containing the model input items and the model output items;

Extracting multidimensional operation state characteristics from corresponding data as corresponding model input items aiming at each previous operation state data in the previous operation state data, and taking a numerical value 1 as a corresponding model output item to obtain a corresponding positive sample containing the model input item and the model output item;

and performing calibration verification modeling on the artificial intelligent model based on the machine learning algorithm by applying a plurality of negative samples and a plurality of positive samples to obtain the arc stopping event occurrence prediction model, wherein the confidence coefficient of the arc stopping event occurrence prediction model with the output value of 1 is used as a probability value of the arc stopping event at the end of the next period.

8. The welding power supply of claim 1, wherein the first single pole double throw switch or the second single pole double throw switch is a single pole double throw CMOS analog switch model LN 3657.

9. The welding power supply of claim 1, wherein the operating state feedback module comprises a welding current feedback unit, an arc voltage feedback unit, a temperature signal feedback unit, a chiller operating state feedback unit and a two-way IGBT output feedback unit.

10. The welding power supply of claim 1, wherein the control switch module comprises a gun protection gas valve switch, a chiller start-stop switch, and an arc start-stop switch.