CN117697079B - A welding power source suitable for continuous and uninterrupted welding of ultra-long welds - Google Patents

Abstract

The present application discloses a welding power supply suitable for continuous and uninterrupted welding of ultra-long welds, and relates to the technical field of welding equipment. The power supply includes 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, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT module, a spare dual-channel IGBT module, a power supply output negative electrode, a power supply output positive electrode, and an operation status feedback module. Through the connection relationship and functional collaboration of these modules, the probability value of an arc stop event occurring at the end of the next cycle can be periodically estimated after successful arc starting, and when the probability value is determined to be greater than or equal to a preset threshold, the standby dual-channel drive module and the standby dual-channel IGBT module are switched to start outputting a DC current for maintaining the arc, so that the purpose of continuous and uninterrupted welding can be achieved during the ultra-long weld 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 in particular relates to a welding power source suitable for continuous and uninterrupted welding of ultra-long welds.

Background technique

TIG (Tungsten Inert Gas Welding) welding, also known as non-melting inert gas shielded arc welding, is a mature welding method that is widely used in the welding 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 is shallow, the welding speed is slow, and the efficiency is low. It is generally used for thin plate welding or bottom penetration weld bead root welding of thick-walled important components.

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

Summary of the invention

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

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

In a first aspect, a welding power supply suitable for continuous and uninterrupted welding of ultra-long welds is provided, comprising 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, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT module, a spare dual-channel IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation status feedback module, wherein the power supply output negative electrode is used to connect a welding gun head, and the power supply output positive electrode is used to connect a workpiece to be welded;

The first output end of the welding power supply control module is connected to the controlled end of the control switch module, the second output end of the welding power supply control module is connected to the first input end of the current balancing module, the third output end of the welding power supply control module is respectively connected to 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 to the high-frequency arc starting module, and the output end of the high-frequency arc starting module is connected to the negative electrode of the power supply output;

The first PWM pulse signal output end of the current balancing module is connected to the common end of the first single-pole double-throw switch, the second PWM pulse signal output end of the current balancing module is connected to 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 to the input end of the first current driving unit in the dual-way driving module in use, the output end of the first current driving unit in the dual-way driving module in use is connected to the input end of the first IGBT unit in the dual-way IGBT module in use, the normally open end of the first single-pole double-throw switch is connected to the input end of the first current driving unit in the standby dual-way driving module, the output end of the first current driving unit in the standby dual-way driving module is connected to the input end of the first IGBT unit in the standby dual-way IGBT module, the output end of the first IGBT unit in the dual-way IGBT module in use and the The output end of the first IGBT unit in the standby dual-path IGBT module is respectively connected to the negative output electrode of the power supply, the normally closed end of the second single-pole double-throw switch is connected to the input end of the second current driving unit in the dual-path driving module in use, the output end of the second current driving unit in the dual-path driving module in use is connected to the input end of the second IGBT unit in the dual-path IGBT module in use, the normally open end of the second single-pole double-throw switch is connected to the input end of the second current driving unit in the standby dual-path driving module, the output end of the second current driving unit in the standby dual-path driving module is connected to the input end of the second IGBT unit in the standby dual-path IGBT module, and the output end of the second IGBT unit in the dual-path IGBT module in use and the output end of the second IGBT unit in the standby dual-path IGBT module are respectively connected to the positive output electrode of the power supply;

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

The welding power supply control module is used, on the one hand, to start/stop the high-frequency arc starting module through the control switch module according to the welding control timing data, and output an excitation control signal to the current balancing module, so that the current balancing module outputs two balanced PWM pulse signals through two current fixed-frequency PWM pulse generator circuits connected in a master-slave manner and running in parallel, thereby making the in-use dual-channel drive module and the in-use dual-channel IGBT module output direct current and superimpose it with the high-frequency pulse high-voltage signal generated by the high-frequency arc starting module and input it into the welding gun;

On the other hand, the welding power supply control module is also used to periodically extract and process the real-time operating status data from the operating status feedback module after successful arcing, so as to obtain multi-dimensional operating status features, and then import the multi-dimensional operating status features into a pre-trained arc stopping event prediction model based on a machine learning algorithm, and output a probability value of an arc stopping event occurring at the end of the next cycle, and finally, when it is determined that the probability value is greater than or equal to a preset threshold, control the first single-pole double-throw switch to turn on the corresponding common end and the normally open end and cut off the corresponding common end and the normally closed end, and control the second single-pole double-throw switch to turn on the corresponding common end and the normally open end and cut off the corresponding common end and the normally closed end, so as to enable the standby dual-channel drive module and the standby dual-channel IGBT module to output the DC current.

Based on the above invention content, a new welding power supply scheme that can automatically switch to use an arc maintaining 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, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT module, a spare dual-channel IGBT module, a power supply output negative pole, a power supply output positive pole and an operation status feedback module. Through the connection relationship and functional collaboration of these modules, the probability value of an arc stop event occurring at the end of the next cycle can be periodically estimated after successful arc starting, and when it is determined that the probability value is greater than or equal to a preset threshold, the standby dual-channel drive module and the standby dual-channel IGBT module are switched to start using the standby dual-channel drive module and the standby dual-channel IGBT module to output a DC current for maintaining the arc. In this way, the arc maintaining module currently in use can be deactivated in time before a failure occurs, thereby avoiding accidental triggering of an arc stop event, and thus achieving the purpose of continuous and uninterrupted welding during the welding of ultra-long welds, which is convenient for 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, 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 standby dual-channel drive module, the in-use dual-channel IGBT module, the standby dual-channel IGBT module and the operating status feedback module.

In a possible design, the first electronically controlled switch, the second electronically controlled switch, the first capacitor and the second capacitor are also included, wherein one end of the first electronically controlled switch is connected to the negative electrode of the power supply output, 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 electrode of the power supply output, the other end of the second electronically controlled switch is connected to one end of the second capacitor, and the other end of the second capacitor is grounded;

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

Controlling the first single-pole double-throw switch to turn on the corresponding common end and the normally-open end and to turn off the corresponding common end and the normally-closed end, and controlling the second single-pole double-throw switch to turn on the corresponding common end and the normally-open end and to turn off the corresponding common end and the normally-closed end, comprises:

Controlling the first electronically controlled switch and the second electronically controlled switch to switch from an off state to an on state respectively, and starting a timer;

When the timing of the timer reaches a preset time threshold, the first single-pole double-throw switch is controlled to turn on the corresponding common end and the normally-open end and turn off the corresponding common end and the normally-closed end, and the second single-pole double-throw switch is controlled to turn on the corresponding common end and the normally-open end and turn off the corresponding common end and the normally-closed end, wherein the preset time threshold is shorter than half of the cycle length of the next cycle;

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

In a possible design, the first electrically controlled switch or the second electrically controlled switch is a thyristor or a relay.

In a possible design, the welding power supply control module is further configured to:

When the continuous use time of the in-use dual-channel drive module and the in-use dual-channel IGBT module reaches M cycle time, the first single-pole double-throw switch is controlled to turn on the corresponding common end and the normally open end and turn off the corresponding common end and the normally closed end, and the second single-pole double-throw switch is controlled to turn on the corresponding common end and the normally open end and turn off the corresponding common end and the normally closed end, so as to enable the standby dual-channel drive module and the standby dual-channel IGBT module to output the DC current, wherein M represents a positive integer greater than or equal to 5;

When the continuous use time of the standby dual-channel drive module and the standby dual-channel IGBT module reaches N cycles, the first single-pole double-throw switch is controlled to cut off the corresponding common terminal and the normally-open terminal and to turn on the corresponding common terminal and the normally-closed terminal, and the second single-pole double-throw switch is controlled to cut off the corresponding common terminal and the normally-open terminal and to turn on 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 resume outputting the DC current, wherein N represents a positive integer greater than or equal to 5.

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

In a possible design, the arc-stop event occurrence prediction model is pre-trained in the following manner:

Acquire multiple copies of normal operating status data and multiple copies of previous operating status data corresponding to multiple historical arcing events, wherein the normal operating status data refers to the real-time operating status data collected by the operating status feedback module at the start time of a K-hour historical period without arcing events, 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 time before the corresponding event occurs, and the determined time is equal to the time when the corresponding event occurs minus a cycle length;

For each piece of normal operating status data in the plurality of pieces of normal operating status data, extract a multidimensional operating status feature from the corresponding data as a corresponding model input item, and use a value of 0 as a corresponding model output item, to obtain a corresponding negative sample that includes the model input item and the model output item;

For each of the plurality of pieces of previous running state data, extract a multidimensional running state feature from the corresponding data as a corresponding model input item, and use a value of 1 as a corresponding model output item, to obtain a corresponding positive sample that includes the model input item and the model output item;

Applying multiple negative samples and multiple positive samples, the artificial intelligence model based on the machine learning algorithm is calibrated and verified to obtain the arc failure event prediction model, wherein the confidence of the arc failure event prediction model with an output value of 1 is used as the probability value of the arc failure event occurring at the end of the next cycle.

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

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

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

Beneficial effects of the above scheme:

(1) The present invention creatively provides a novel welding power supply scheme that can automatically switch to use an arc maintenance module, that is, it includes 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, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT module, a spare dual-channel IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation status feedback module. Through the connection relationship and functional collaboration of these modules, after successful arc starting, the probability value of an arc stop event at the end of the next cycle can be periodically estimated, and when it is determined that the probability value is greater than or equal to a preset threshold, the standby dual-channel drive module and the standby dual-channel IGBT module are switched to start using the standby dual-channel drive module and the standby dual-channel IGBT module to output a DC current for maintaining the arc. In this way, the arc maintenance module currently in use can be deactivated in time before a fault occurs, thereby avoiding accidental triggering of an arc stop event, and further achieving the purpose of continuous and uninterrupted welding during the welding of ultra-long welds, which is convenient for practical application and promotion.

(2) The use of UPS uninterruptible power supply can also avoid accidental arc stop accidents caused by unexpected power outages, further ensuring the purpose of continuous and uninterrupted welding during the welding process of ultra-long welds;

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

BRIEF DESCRIPTION OF THE DRAWINGS

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

FIG1 is a schematic diagram of the structure of a welding power supply suitable for continuous and uninterrupted welding of ultra-long welds provided in an embodiment of the present application.

Detailed ways

In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the present invention will be briefly introduced below in combination with the drawings and the description of the embodiments or the prior art. Obviously, the following description of the structure of the drawings is only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. It should be noted 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 and 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 object. For example, a first object can be referred to as a second object, and similarly, a second object can be referred to as a first object without departing from the scope of the exemplary embodiments of the present invention.

It should be understood that the term "and/or" that may appear in this document is merely a description of the association relationship between associated objects, indicating that there may be three relationships. For example, A and/or B can indicate three situations: A exists alone, B exists alone, or A and B exist at the same time. For another example, A, B and/or C can indicate the existence of any one of A, B and C or any combination of them. The term "/and" that may appear in this document describes another type of association object relationship, indicating that there may be two relationships. For example, A/and B can indicate two situations: A exists alone or A and B exist at the same time. In addition, the character "/" that may appear in this document generally indicates that the previous and next associated objects are in 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 balancing module, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT (Insulate-Gate Bipolar Transistor, insulated gate bipolar transistor) module, a spare dual-channel IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation status feedback module, wherein the power supply output negative electrode is used to connect the welding gun head, and the power supply output positive electrode is used to connect the workpiece to be welded.

The first output end of the welding power supply control module is connected to the controlled end of the control switch module, the second output end of the welding power supply control module is connected to the first input end of the current balance module, the third output end of the welding power supply control module is respectively connected to 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 to the high-frequency arc starting module, and the output end of the high-frequency arc starting module is connected to the negative output electrode 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 shielding gas valve switch, a chiller start-stop switch and an arc starting start-stop switch, wherein the welding gun shielding gas valve switch is used to control the opening/closing of the welding gun shielding gas valve, so that the shielding gas continues to flow out of the welding gun nozzle when the valve is opened, and the shielding gas stops flowing out when the valve is closed; the chiller start-stop switch is used to control the start/stop of the chiller, so that the welding gun is cooled when the chiller is started, and in particular, the welding power supply control module can also be controlled by a constant The temperature measuring means monitors the temperature of the welding gun in real time, and when the temperature of the welding gun is higher than a first preset temperature (for example, room temperature plus 10 degrees Celsius, i.e., 35 degrees Celsius), the chiller start-stop switch is triggered to start the chiller; and when the temperature of the welding gun is continuously lower than a second preset temperature (which is lower than the first preset temperature, such as room temperature) within a preset time (for example, within 30 minutes), the chiller start-stop switch is triggered to stop the chiller, so as to realize the intelligent start and stop of the chiller, which is beneficial to saving electricity; the arc starting start-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 end of the current balancing module is connected to the common end of the first single-pole double-throw switch, the second PWM pulse signal output end of the current balancing module is connected to 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 to the input end of the first current driving unit in the dual-way driving module in use (i.e., the current driving unit A in FIG. 1 ), the output end of the first current driving unit in the dual-way driving module in use is connected to the input end of the first IGBT unit in the dual-way IGBT module in use (i.e., the IGBT unit A in FIG. 1 ), the normally open end of the first single-pole double-throw switch is connected to the input end of the first current driving unit in the standby dual-way driving module (i.e., the current driving unit C in FIG. 1 ), the output end of the first current driving unit in the standby dual-way driving module is connected to the input end of the first IGBT unit in the standby dual-way IGBT module (i.e., the IGBT unit C in FIG. 1 ), the output end of the first IGBT unit in the dual-way IGBT module in use and the The output end of the first IGBT unit in the standby dual-path IGBT module is respectively connected to the negative output electrode of the power supply, the normally closed end of the second single-pole double-throw switch is connected to the input end of the second current driving unit in the dual-path driving module in use (i.e., the current driving unit B in FIG. 1), the output end of the second current driving unit in the dual-path driving module in use is connected to the input end of the second IGBT unit in the dual-path IGBT module in use (i.e., the IGBT unit B in FIG. 1), the normally open end of the second single-pole double-throw switch is connected to the input end of the second current driving unit in the standby dual-path driving module (i.e., the current driving unit D in FIG. 1), the output end of the second current driving unit in the standby dual-path driving module is connected to the input end of the second IGBT unit in the standby dual-path IGBT module (i.e., the IGBT unit D in FIG. 1), and the output end of the second IGBT unit in the dual-path IGBT module in use and the output end of the second IGBT unit in the standby dual-path IGBT module are respectively connected to the positive output electrode of the power supply.

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

The welding power supply control module, on the one hand, is used to start/stop the high-frequency arc starting module through the control switch module according to the welding control timing data, and output an excitation control signal to the current balancing module, so that the current balancing module can 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 enabling the in-use dual-channel drive module and the in-use dual-channel IGBT module to output direct current and superimpose it with the high-frequency pulse high-voltage signal generated by the high-frequency arc starting module and input it into the welding gun. The above functions are basic functions of existing welding power supplies and can be conventionally implemented based on existing technologies, specifically including but not limited to: according to precise welding control timing data, the chiller start-stop switch and the welding gun shielding gas valve switch are controlled to be turned on in sequence, so that the welding gun circulates cooling water and the shielding gas is continuously discharged 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-starting excitation current is output to the current balancing module, which generates two balanced PWM (Pulse width modulation) pulse signals to drive the in-use dual-channel driving module and the in-use dual-channel IGBT module to work, thereby forming a stable DC voltage between the tungsten electrode tip of the welding gun and the surface of the workpiece, and then by turning on the arc starting start-stop switch, the high-frequency arc starting module is controlled to output a high-frequency high-voltage signal and load it to the negative electrode of the power supply output to excite the arc, so that the negative electrode of the power supply output and the positive electrode of the power supply output are connected, and finally after the arc is generated, the high-frequency arc starting module is controlled to stop working immediately, and the in-use dual-channel IGBT module outputs a base current (i.e., the DC current) to maintain the arc.

The welding power supply control module, on the other hand, is also used to periodically extract and process the real-time operation status data from the operation status feedback module after successful arcing, obtain multi-dimensional operation status features, and then import the multi-dimensional operation status features into the arc stopping event prediction model based on the machine learning algorithm and pre-trained, and output the probability value of the arc stopping event at the end of the next cycle. Finally, when it is determined that the probability value is greater than or equal to a preset threshold (for example, preset to 62.8%), the first single-pole double-throw switch is controlled to turn on the corresponding common end and the normally open end and cut off the corresponding common end and the normally closed end, and the second single-pole double-throw switch is controlled to turn on the corresponding common end and the normally open end and cut off the corresponding common end and the normally closed end, so as to enable the standby dual-way drive module and the standby dual-way IGBT module to output the DC current. The cycle length of the aforementioned cycle can be, but is not limited to, 1 minute. The specific method of the feature extraction processing is an existing conventional method, for example, the welding current value, welding voltage value, temperature value of the power device, and operating status value of the chiller are extracted as multi-dimensional operation status features. The machine learning algorithm is a core artificial intelligence algorithm that specifically studies how computers 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 the fundamental way to make computers intelligent; specifically, the machine learning algorithm preferably uses a linear regression algorithm based on the Python sklearn library to quickly and accurately find patterns in the data. The arc failure event prediction model can be, but is not limited to, pre-trained according to the following steps S101 to S104.

S101. Acquire multiple sets of normal operating status data and multiple sets of previous operating status data corresponding to multiple historical arcing events, wherein the normal operating status data refers to the real-time operating status data collected by the operating status feedback module at the starting time of a K-hour historical period without an arcing event, 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 time before the corresponding event occurs, and the determined time is equal to the time when the corresponding event occurs minus a cycle length.

In the step S101, for example, if no arcing event occurs within the 4 hours from 8:00 to 12:00 (i.e., K takes a value of 4), the real-time operating status data collected at 8:00 can be used as a copy of the normal operating status data; and if an arcing event occurs at 12:01, the real-time operating status data collected at 12:00 (i.e., the determined time, with a cycle length of 1 minute) can be used as a copy of the previous operating status data.

S102. For each piece of normal operating status data in the multiple pieces of normal operating status data, a multidimensional operating status feature is extracted from the corresponding data as a corresponding model input item, and a value of 0 is used as a corresponding model output item to obtain a corresponding negative sample that includes the model input item and the model output item.

S103. For each of the multiple copies of previous running status data, a multidimensional running status feature is extracted from the corresponding data as a corresponding model input item, and a value 1 is used as a corresponding model output item, to obtain a corresponding positive sample that includes the model input item and the model output item.

S104. Apply multiple negative samples and multiple positive samples to calibrate and verify the artificial intelligence model based on the machine learning algorithm to obtain the arcing event occurrence prediction model, wherein the confidence level of the arcing event occurrence prediction model with an output value of 1 is used as the probability value of the arcing event occurring at the end of the next cycle.

In step S104, the specific process of calibration verification modeling includes the calibration process and verification process of the model, that is, first by comparing the model simulation results with the 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 failure event prediction model can be obtained through the conventional calibration verification modeling method. Preferably, in the calibration verification modeling process of the artificial intelligence model, the model parameters are tuned by a Bayesian optimization algorithm based on a tree structure. In addition, the artificial intelligence model can also be implemented by, but not limited to, machine learning algorithms such as support vector machines, K nearest neighbor methods, stochastic gradient descent methods, multilayer perceptrons, decision trees, back propagation neural networks, or radial basis function networks.

Therefore, 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 an arc maintaining 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, a first single-pole double-throw switch, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT module, a spare dual-channel IGBT module, a power supply output negative pole, a power supply output positive pole and an operation status feedback module. Through the connection relationship and functional collaboration of these modules, the probability value of an arc stop event occurring at the end of the next cycle can be periodically estimated after successful arc starting, and when it is determined that the probability value is greater than or equal to a preset threshold, the standby dual-channel drive module and the standby dual-channel IGBT module are switched to start using the standby dual-channel drive module and the standby dual-channel IGBT module to output a DC current for maintaining the arc. In this way, the arc maintaining module currently in use can be deactivated in time before a failure occurs, thereby avoiding accidental triggering of an arc stop event, thereby achieving the purpose of continuous and uninterrupted welding during the welding of ultra-long welds.

Preferably, a UPS (Uninterruptible Power Supply) is also included, wherein the power supply end of the UPS is respectively but not limited to connected to the welding power control module, the control switch module, the high-frequency arc starting 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 standby dual-channel drive module, the in-use dual-channel IGBT module, the standby dual-channel IGBT module and the operating status feedback module. The UPS is an uninterruptible power supply containing an energy storage device, which can provide uninterruptible power supply to some equipment with high requirements for power supply stability. In this way, by using a UPS uninterruptible power supply, accidental arc stop 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 (i.e., an inverter connected in parallel between the mains and the load and used simply as a backup power supply; for this type of UPS power supply, when the mains is 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), an online interactive UPS power supply (i.e., an inverter connected in parallel between the mains and the load, acting as a backup power supply, and the inverter acts as a charger to charge the battery; through the reversible operation of the inverter, it interacts with the mains, Therefore, it is called interactive type; for this type of UPS power supply, when the mains power is normal, the load is powered by the improved mains power, and the inverter acts as a charger to charge the battery. At this time, the inverter plays the role of AC/DC converter; when the mains power fails, the load is completely powered by the inverter. At this time, the inverter plays the role of DC/AC converter) or double conversion UPS power supply (refers to the inverter connected in series between the AC input and the load, and the power supply continuously supplies power to the load through the inverter; the power supply mode of this 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 battery supplies power to the load through the inverter). In addition, considering that the energy storage of the UPS is limited and the amount of electricity required for welding is large, the UPS cannot provide power for a long time. Preferably, the welding power control module is also used to monitor the working status of the UPS. When it is found according to the monitoring result that the UPS enables the inverter for power supply due to abnormal mains power, the control switch module and/or the current balancing module are controlled to make the welder enter the arc closing process or create a weld that is convenient for the next overlap (the specific control process can be conventionally implemented based on the existing technical means), and after completion, the operation is delayed for a preset time (for example, 10 minutes) before officially shutting down, or after completion, the welding gun temperature is monitored in real time by conventional temperature measurement means, and then the welding gun temperature is restored to a third preset temperature (for example, 10 degrees Celsius plus room temperature, i.e., 35 degrees Celsius) or reaches other preset temperature conditions before officially shutting down, so as to avoid problems such as condensed water caused by a large difference between the welding gun temperature and the room temperature, and effectively protect the welding power supply and welding gun. In this way, through the aforementioned delayed power-off scheme, the welding machine and welding gun can be cooled down first when the mains power is abnormal, effectively protecting the welding power supply and welding gun, thereby effectively ensuring long-term stability of welding and reducing losses.

Preferably, it also includes a first electric-controlled switch K1, a second electric-controlled switch K2, a first capacitor C1 and a second capacitor C2, wherein one end of the first electric-controlled switch K1 is connected to the negative electrode of the power supply output, the other end of the first electric-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 electric-controlled switch K2 is connected to the positive electrode of the power supply output, the other end of the second electric-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 to the controlled ends of the first electric-controlled switch K1 and the second electric-controlled switch K2; the first single-pole double-throw switch is controlled to turn on the corresponding common end and the normally open end and turn off the corresponding common end and the normally closed end, and the second single-pole double-throw The switches turn on the corresponding common terminal and the normally open terminal and turn 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 electrically controlled switch K1 and the second electrically controlled switch K2 to switch from the off state to the on state respectively, and start the timer; S202. When the timing of the timer reaches the preset time threshold, control the first single-pole double-throw switch to turn on the corresponding common terminal and the normally open terminal and turn off the corresponding common terminal and the normally closed terminal, and control the second single-pole double-throw switch to turn on the corresponding common terminal and the normally open terminal and turn off the corresponding common terminal and the normally closed terminal, wherein the preset time threshold is shorter than half of the cycle length of the next cycle; S203. Control the first electrically controlled switch K1 and the second electrically controlled switch K2 to return from the on state to the off state respectively. In this way, before switching to start using the spare dual-way drive module and the spare dual-way IGBT module, the power output negative electrode and the first capacitor C1 and the power output positive electrode and the second capacitor C2 are connected respectively, and 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 single-pole double-throw switch and the second single-pole double-throw switch, so as to maintain the output stability of the DC current, and thus completely avoid the arc stop event during the switching process, further ensuring the purpose of continuous and uninterrupted welding. In addition, since the connection between the power output negative electrode and the first capacitor C1 and the power output positive electrode and the second capacitor C2 will be disconnected after switching to start using the spare dual-way drive module and the spare dual-way IGBT module, it is also possible to avoid the capacitor charge from having an adverse effect on the stability of the DC current. Specifically, the first electric control switch K1 or the second electric control switch K2 can be, but not limited to, a thyristor or a relay.

Preferably, the welding power supply control module is also used for: after successful arc starting: when the continuous use time of the in-use dual-way drive module and the in-use dual-way IGBT module reaches M cycle time, controlling the first single-pole double-throw switch to turn on the corresponding common end and the normally open end and cut off the corresponding common end and the normally closed end, and controlling the second single-pole double-throw switch to turn on the corresponding common end and the normally open end and cut off the corresponding common end and the normally closed end, so as to enable the standby dual-way drive module and the standby dual-way IGBT module to output the DC current, wherein M represents a positive integer greater than or equal to 5; and when the continuous use time of the standby dual-way drive module and the standby dual-way IGBT module reaches N cycle time, controlling the first single-pole double-throw switch to cut off the corresponding common end and the normally open end and turn on the corresponding common end and the normally closed end, and controlling the second single-pole double-throw switch to cut off the corresponding common end and the normally open end and turn on the corresponding common end and the normally closed end, so as to enable the in-use dual-way drive module and the in-use dual-way IGBT module to resume outputting the DC current, wherein N represents a positive integer greater than or equal to 5. The aforementioned M and N can be exemplified as 60, that is, the in-use dual-way drive module and the in-use dual-way IGBT module are activated alternately with the standby dual-way drive module and the standby dual-way IGBT module every 60 minutes. By rotating the dual-way drive module and the dual-way IGBT module, it is also possible to avoid failures due to long-term use, thereby 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) analog switch of model LN3657.

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

(1) This embodiment provides a new type of welding power supply scheme that can automatically switch to use an arc maintenance module, that is, it includes 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, a second single-pole double-throw switch, an in-use dual-channel drive module, a spare dual-channel drive module, an in-use dual-channel IGBT module, a spare dual-channel IGBT module, a power supply output negative electrode, a power supply output positive electrode and an operation status feedback module. Through the connection relationship and functional collaboration of these modules, after successful arc starting, the probability value of an arc stop event at the end of the next cycle can be periodically estimated, and when it is determined that the probability value is greater than or equal to a preset threshold, the standby dual-channel drive module and the standby dual-channel IGBT module are switched to start using the standby dual-channel drive module and the standby dual-channel IGBT module to output a DC current for maintaining the arc. In this way, the arc maintenance module currently in use can be deactivated in time before a fault occurs, thereby avoiding accidental triggering of an arc stop event, and further achieving the purpose of continuous and uninterrupted welding during the welding of an ultra-long weld, which is convenient for practical application and promotion.

(2) The use of UPS uninterruptible power supply can also avoid accidental arc stop accidents caused by unexpected power outages, further ensuring the purpose of continuous and uninterrupted welding during the welding process of ultra-long welds;

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

Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle 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.