Analysis of the current situation and development of arc welding power supply
Abstract: The development history, current situation and future development trend of domestic and foreign arc welding power sources are expounded, and the application prospects of new technologies emerging in recent years in arc welding power supply production are discussed.
Key words: arc welding power source; status quo; development
Arc welding technology is an important part of modern welding technology, and its application range covers almost all welding production areas. As a basic metal treatment method, arc welding has been widely used in various sectors of the national economy. Arc welding power sources for arc welding have made great progress since its birth.
1 arc welding power supply development process
As a physical phenomenon of gas conduction, the arc was discovered in the early 19th century, until the invention of the carbon arc in Russia by Bernardus in 1885 can be regarded as the founding of arc as a heat source application, and the arc is really used in industry. It was discovered after the metal arc in 1892. Submerged arc welding was successfully studied in the 1940s, and argon arc welding occurred with the development of aerospace and atomic energy. In the 1950s, CO2 and various gas shielded weldings were developed and plasma arc welding was studied. By the 70s and 80s, the development of arc welding power sources was a leap: various types of arc welding rectifiers appeared and improved successively. Various types of pulsed arc welding power supplies provide excellent arc welding power for further improving welding quality and adapting to all-position welding automation. In addition, it has successfully developed high efficiency, energy saving, good performance, thyristor, transistor, field effect tube and IGBT arc welding inverter. With the development of new arc welding technology, the arc welding power supply has also made great progress.
Classification, characteristics and application of 2 arc welding power sources
2.1 Classification of arc welding power sources
The classification of arc welding power sources has different classification methods both at home and abroad, so the results are not the same. This paper uses Chen Zhunian's classification method.
2.2 Characteristics and application of various arc welding power sources
An arc welding transformer that converts the alternating current of the network voltage into a low-voltage alternating current suitable for arc welding, consisting of a main transformer and a required regulating portion and indicating means.
The utility model has the advantages of simple structure, easy manufacture, low cost and high efficiency, but the current waveform is a sine wave, the output is an external characteristic of AC drop, the arc stability is poor, the power factor is low, but the magnetic partial blow phenomenon rarely occurs. The utility model has the advantages of small no-load loss, and is generally applied to methods such as hand arc welding, arc welding and tungsten argon arc welding.
Rectangular wave AC arc welding power source, which uses semiconductor control technology to obtain rectangular wave AC current, has good arc stability, many adjustable parameters and high power factor. In addition to the use of AC TIG, it can also be used for submerged arc welding, and can even be used in place of DC arc welding power for alkaline arc welding.
The DC arc welding generator is generally composed of a special DC generator and an adjusting device for obtaining the required external characteristics. Its disadvantages are large no-load loss, obvious magnetic blow-off phenomenon, low efficiency, high noise, high cost, Difficulties in maintenance; the advantages are strong overload capability, small output pulsation, power supply for various arc welding methods, and diesel engine drive for field construction without power supply. The arc welding rectifier is obtained by step-down rectifying the alternating current to obtain direct current. The external characteristic can be flat or descending. It consists of a main transformer, a semiconductor rectifying element, and an adjusting device for obtaining a desired external characteristic. Compared with DC arc welding generator, it has the advantages of convenient manufacturing, low price, low no-load loss, low noise, etc., and most of them can be adjusted remotely, which can automatically compensate the influence of grid voltage fluctuation on output voltage and current, but there are Magnetic partial blow phenomenon. It can be used as a power source for various arc welding methods.
The arc welding inverter converts the single-phase (or three-phase) alternating current into an intermediate frequency alternating current of several hundred to several tens of Hz by the inverter, and outputs alternating current or direct current after being stepped down. The entire process is controlled by electronic circuitry that allows the power supply to have the desired external and dynamic characteristics. It has the advantages of high efficiency, low quality, small size, high power factor, good control performance, fast dynamic response, easy real-time control of the welding process, good welding performance, etc. It can be used in various arc welding methods. The most promising popular arc welding power source. The pulse arc welding power source, the welding current is fed by the low frequency modulation pulse method, generally consists of a common arc welding power source and a pulse generating circuit, and has other structural forms. It has high efficiency, low input line energy, and can control line energy in a wide range. This arc welding power supply has unique advantages for high-alloy material sheets and all-position welding that are sensitive to heat input.
The status quo and development of 3 arc welding power technology
3.1 Current status of arc welding power technology
The traditional arc welding power source, such as the hand arc welding machine which accounts for 90% of the total output of the welding machine, is mainly a moving coil type AC arc welding machine with backward geometry and a large amount of consumables. In China's DC arc welding power supply, under the national three-five application, although the production of rotary DC arc welding generators for electric drive has been gradually reduced, it has not been completely banned. It is also difficult to promote the rectifier arc welding power supply. The performance of the old-fashioned silicon rectifier arc welding power source is difficult to match the rotary DC arc welding power source, and the national key thyristor rectifier power supply ZX5-250 and ZX5-400 Performance is not stable, and users are at a loss. This situation did not change until the mid-1990s.
Digital arc welding technology is an emerging technology. Digital arc welding power source refers to the main control circuit of the welding machine. The digital control technology replaces the traditional analog control technology, and the control signal in the control circuit also transitions from analog signal to 0 / 1 encoded digital signal. Compared with the analog system, the digital system has obvious advantages. The digital system has the characteristics of good system flexibility, high control precision, good stability and product consistency, good interface compatibility and convenient system function upgrade. In 1994, Lahnsteiner.Robert of Fronius abroad pointed out that modern GMAW welding power supply should meet various needs, such as: suitable for short-circuit transition welding, pulse welding, jet transition welding and high deposition rate welding, etc., reasonable The external characteristics of the welding power source can be realized by the inverter power supply working in the switching state on the primary side; a large number of welding specification parameters must be designed by Synergic control (uniform control) to make the welding power supply easy to operate; to meet the new quality control requirements, the welding power source The welding specification parameters and the deviation amount must be recorded in real time. Based on the above ideas, along with the emergence of a new powerful digital information processor DSP, Fronius introduced a fully digital welding power supply, and then Panosonic and other companies also launched their own digital welding power products, and have entered the Chinese market. The digital welding power source realizes flexible control and multi-function integration, and has the advantages of high control precision, good system stability, good product consistency, and convenient function upgrade. For example, Fronius' Transplus synergic 2700 /4000 /5000 series products implement a variety of welding methods such as MIG/MAG, TIG and manual arc welding on a single welder. It can store nearly 80 welding programs and display welding specification parameters in real time. Accurate control of droplet transfer and arc length variation can be achieved by specifying the welding specification parameters and current waveform parameters with a single knob. At the same time, such welding power supplies can also be upgraded through process management and control software.
3.2 Arc welding power supply technology development
Since its birth, arc welding power has experienced more than one hundred years of history, and it has always evolved with the advancement of technology. It is expected that the future arc welding power supply will develop in these aspects:
First, digital arc welding power supply. From the perspective of the hardware circuit, the digital power supply realizes the digitization of the PID controller and the PWM signal generation circuit by means of DSP technology. With the advent of mixed-mode circuits that combine the combination of analog and digital circuits, discrete analog circuits are expected to be gradually replaced by highly integrated digital-mixed circuits in the near future. The design and manufacture of welding power and power modules can also be done digitally as needed. The energy control of the welding power source is completed by a synergistic manner of current, voltage and time, which is embodied by the digitization of the output waveform.
Second, the green arc welding power supply. As early as 2000, the concept of green welding machine was proposed. Green welding was proposed in the context of the increasing shortage of global resources and energy and the increasing awareness of environmental protection among the people. Energy-saving and environmentally-friendly green welding machine must be the development direction of future welding machine arc welding power supply.
4 Conclusion
In recent years, with the increasingly fierce market competition, the productivity of welding production, the quality of products, the automation and intelligentization of welding production have been paid more and more attention by welding manufacturers. The integration of modern high-tech such as artificial intelligence technology, computer vision technology, digital information processing technology and robot technology has also promoted arc welding technology to improve the efficiency of welding process, digitization of welding power supply control, intelligent welding quality control, and welding production process. With the development of robotization, arc welding equipment is also developing towards intelligent development and robotization. The content of this article is only a small part of it, and it is hoped that it can promote communication and improve together.
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