专利摘要:
The invention relates to a method for controlling a battery-powered welding device (1) and a battery-powered welding device (1) with a rechargeable battery (2) having a rechargeable battery voltage (Uin) and a rechargeable battery current (Iin) and having a boost converter (4) having at least one switch (5) and a downsetting actuator (6) with at least one switch (7) containing welding control (3) for controlling a / to a welding torch (11) supplied welding current (Iout) and welding voltage (Uout). To achieve high efficiency and dynamics and optimum welding properties, a switch (8) for bridging the boost converter (4) is provided, which switch (8) is connected to a switch control (9), which switch control (9) is designed to switch (8) to close when the DC link voltage (Uzw) between boost converter (4) and buck converter (6) is less than or equal to the Akkumulatorspan- (Uin), and the switch (8) to open when the step-up (4 ) is activated.
公开号:AT514357A1
申请号:T50352/2013
申请日:2013-05-23
公开日:2014-12-15
发明作者:Andreas Starzengruber;Alexander Speigner
申请人:Fronius Int Gmbh;
IPC主号:
专利说明:

1
The invention relates to a method for controlling a battery-powered welding apparatus, wherein the battery voltage provided by an accumulator and the accumulator current with the aid of a welding control comprising at least one switch and a step-down converter with at least one switch to a welding current supplied to a welding torch and welding voltage are regulated.
Furthermore, the invention relates to a battery-operated welding machine with a rechargeable battery with a rechargeable battery and a rechargeable battery and with a Hochsetzsteller with at least one switch and a buck converter with at least one switch containing welding control for controlling a / delivered to a welding torch welding and welding voltage. For particularly hard-to-reach places where a weld is to be made, e.g. on a scaffolding or even for welds where direct supply of electrical energy is not permitted, such as In a boiler, the use of portable battery operated welding equipment is particularly advantageous or essential. Most of the prior art battery-powered welding machines have limitations in terms of welding quality that can be achieved because the achievable welding performance and the achievable dynamics compared to mains-powered welding equipment is lower.
EP 1 535 691 B1 describes a portable welding machine with replaceable accumulator which includes a combination of a boost converter and buck converter in order to be able to achieve a higher welding current and a higher welding voltage. Since during normal welding operation mainly the step-down converter is active, however, the intended step-up converter causes an increase in the total losses of the battery-operated welding device and thus a reduction of the efficiency.
The object of the present invention is to provide an above-mentioned method and a battery-operated welding apparatus mentioned above which effect the highest possible efficiency and dynamics and with which optimum welding properties can be achieved. Disadvantages of known battery-operated welding devices should be avoided or at least reduced.
The object of the invention is achieved in procedural respects by the fact that the boost converter is bridged by means of a switch controlled by a switch control when the DC link voltage between the boost converter and the step-down is less than or equal to the battery voltage, and the switch is opened to bridge the boost converter, when the boost converter is activated. By bridging the boost converter according to the invention under certain conditions, the losses of the boost converter circuit can be reduced to a minimum when the boost converter is not needed. For the efficiency of the overall system then only the Leitendverluste the switch to bridge the boost converter are to be considered. In accordance with the specified switch-on and switch-off condition for the bypass switch, the boost converter is then bypassed when the intermediate circuit voltage between the boost converter and the step-down divider is less than or equal to the battery voltage. From this limit, a voltage increase is no longer necessary, which is why the boost converter can be disabled and bridged. The switch-off condition for the switch for bridging the boost converter is given when the boost converter is activated, that is, to increase the battery voltage is required. The present control method is characterized by particular simplicity and causes an increase in efficiency of the battery-operated welding machine.
According to a further feature of the invention, the opening of the switch for bridging the boost converter is provided when the welding current is smaller than the maximum current through the boost converter and the step-down is disabled. This switch-off condition for the bypass switch then starts when the maximum current which the boost converter can deliver is undershot, and the step-down divider is deactivated, that is to say that at least one switch of the step-down converter is switched through. 3/20 3
To increase the dynamics of the method for controlling a battery-operated welding device is provided that the boost converter is disabled when the welding voltage is less than the battery voltage minus a certain voltage, in particular 2 volts. This control condition for the boost converter allows the deactivation of the boost converter, even if the intermediate circuit voltage is above the battery voltage, and the bypass switch is still turned on. It is advantageous, furthermore, if the boost converter is deactivated by the abovementioned control condition only after expiry of a certain switch-on time. By this Mindesteinschaltzeit, which may be, for example, 10 periods of the clock frequency used, vibrations can be avoided and capacitors are charged.
Advantageously, the step-up converter is regulated by means of a regulation in which the intermediate circuit voltage is compared with a desired welding voltage, and this comparison value and the current through the step-up converter are compared with a comparator and fed to the controller. By comparing the control output (from comparison of the intermediate circuit voltage with the set desired welding voltage) with the boost converter current using an analog comparator, the required speed for the required dynamics can be achieved, which is not possible with a digital processing by analog-to-digital converter and appropriate software processing would.
Preferably, the at least one switch of the boost converter and the at least one switch of the buck converter, which are usually formed by corresponding field effect transistors, with the same clock frequency, preferably 40 to 50 kHz operated. For the dynamics of the method or the circuit, it is advantageous if the intermediate circuit voltage is measured only during part of each period of the clock frequency and is evaluated during the remainder of each period. During the measuring phase, the intermediate circuit voltage is measured and averaged several times, for example, and the calculated mean value is then evaluated during the evaluation phase, and the control is carried out accordingly.
The boost converter is preferably operated as a voltage regulator, whereas the step-down divider is preferably operated as a current regulator.
In a normal welding operation, only the buck converter is activated and the boost converter is bridged by the switch. In this case, the welding voltage or arc voltage is lower than the accumulator voltage, which is why an increase in the battery voltage is not required. Normally, a welding voltage of about 30 V is sufficient in normal welding operation, so that at an accumulator voltage in the range of 50 to 60 V, a lowering of the accumulator voltage to this 30 V can occur. Since output voltages of 70 to 90 V are required for optimum ignition of the welding process, which are thus higher than said rechargeable battery voltage of 50 to 60 V, the rechargeable battery voltage must be increased to the corresponding higher value. Battery voltages of less than 60 V have the advantage that many safety precautions are not required.
For example, for the ignition method, both the boost converter and the buck converter are activated, which is regulated by the condition when the desired welding current is smaller than the maximum current through the boost converter. That is, both the boost converter and the buck converter operate in those load ranges in which the desired welding current is below the maximum current that the boost converter can deliver.
If the combination of boost converter and buck converter is operated in the reverse direction, charging of the battery via the output path can be carried out with little effort.
The object according to the invention is also achieved by an above-mentioned battery-operated welding device, in which a switch is provided for bridging the boost converter, which switching device is connected to a switch control, which switch control is designed to close the switch, if the DC link voltage between boost converter and buck converter is less than or equal to the battery voltage, and to open the switch when the boost converter is activated. For the achievable advantages, reference is made to the above description of the control method. The corresponding additional charge circuit of the battery-powered welding device can be produced relatively easily and inexpensively. The switch for bridging the boost converter preferably consists of a field effect transistor.
The switch control is preferably also designed to open the switch for bridging the boost converter, when the welding current is smaller than the maximum current through the boost converter, and the step-down divider is deactivated.
Preferably, a control is provided for the step-up converter, which is designed to deactivate the boost converter, when the welding voltage is smaller than the
Accumulator voltage minus a predetermined voltage, in particular 2 V is. As a result of this control condition, the boost converter can be deactivated, whereby a minimum turn-on time for avoiding oscillations for the deactivation can also be provided.
If a comparator is provided for comparing a comparison value of the intermediate circuit voltage with a desired welding voltage and the current through the step-up converter, which comparator is connected to the regulation for controlling the boost converter, an optimization with regard to the dynamics can be achieved.
It is advantageous if an accumulator with a rechargeable battery voltage equal to or less than 60 V is provided. By falling below this safety extra-low voltage many safety precautions or measures can be omitted.
If a capacitor is arranged between the boost converter and the step-down divider, the voltage increase can be limited to 6/20. The capacitor is dimensioned such that a minimum capacity is given, by which a not very high ripple current or a not too high voltage rise per period is prevented. This is particularly relevant when switching off the boost converter. Furthermore, too high a capacity is unfavorable to achieve a fast response / dynamics.
The switch for bridging the boost converter is preferably formed by a field effect transistor. As a result, the Leitendverluste can be kept particularly low when switching the switch.
The accumulator is preferably formed by a lithium iron phosphate accumulator, which has a particularly high power density with high security and is therefore particularly suitable for use in a portable welding machine.
As already mentioned above, it is advantageous if the step-down converter can be used in the opposite direction as a step-up converter for charging the accumulator.
The present invention will be explained in more detail with reference to the accompanying drawings. Show:
Fig. 1 is a block diagram of a battery-operated welding apparatus according to the present invention;
Fig. 2 is an expanded block diagram of a welding control for a battery-operated welding machine of the subject type;
3 is a block diagram of an embodiment of a control of a boost converter;
4 is a block diagram of an embodiment of a regulation of the buck converter;
5 shows a time diagram for illustrating the method of determining the intermediate circuit voltage as an input variable for the control of the switch for bridging the boost converter; and 7/20 7
6 is a diagram illustrating the various operating states of the battery-operated welding machine with the combination of a boost converter and a buck converter.
1 shows a block diagram of a battery-operated welding apparatus 1 with an accumulator 2, which may be formed, for example, by a lithium iron phosphate accumulator having a particularly high power density. Optionally, the accumulator 2 may also be formed interchangeable. The accumulator 2 supplies a rechargeable battery voltage Uln and a rechargeable battery current Iin. In a welding controller 3, the accumulator voltage Uln provided by the accumulator 2 and the accumulator current Iin are regulated to a corresponding welding current Iout supplied to a welding torch 11 and a welding voltage Uout supplied to the welding torch 11. The outputs of the welding controller 3 are connected to the welding torch 11 and the workpiece 17 to be welded. The desired welding current Iset and the desired welding voltage Uset are set, for example, via an input device 16 and transmitted to the control device 15. The control device 15 supplies the corresponding control signals for the components contained in the welding control, the step-up converter 4 with at least one switch 5 and the step-down divider 6 with at least one switch 7. The control device 15 can further be connected to a display 13 for displaying the most important operating parameters or the like be. If necessary, the battery voltage Uin supplied by the accumulator 2 is changed via the boost converter 4 to a corresponding higher value Uout, in normal welding operation usually only the buck converter 6 is active, which changes the battery voltage Uin to a correspondingly lower value of the welding voltage Uout. In order to reduce the losses during the normal welding operation in which only the buck converter 6 of the welding control 3 is active, a switch 8 is provided, by means of which the boost converter 4 can be bridged. The switch-on condition for the switches 8 is given when the intermediate circuit voltage Uzw between the boost converter 4 and the buck converter 6 is less than or equal to the battery voltage Uin. The switch-off condition for the switch 8 is given when the step-up 8/20 8 ler 4 is activated by the control device 15. Thus, if the accumulator voltage Uin is sufficient for the welding operation and the boost converter 4 is not required, it is bridged by the switch control 9 through the switch 8. Thus, only the Leitendverluste the switch 8 are taken into account in normal welding operation. With appropriate choice of the switch 8, in particular by a Mosfet, these losses are particularly low. For the basic condition of the control of the switch 8, the measurement of the intermediate circuit voltage U2W and the battery voltage Uin is required. In addition, the output voltages Uout can also be included in the switch control 9. Usually, the necessary quantities are digitized with analog-to-digital converters and processed by a microprocessor contained in the switch control 9. Between the boost converter 4 and the buck converter 6, a capacitor 12 is usually provided.
According to a further switch-off condition of the switch 8 for bridging the boost converter 4, the welding current Iout is compared with the maximum current Ib; max by the boost converter 4 and the switch 8 is then opened when the welding current Iout is less than the maximum current Ib; max through the step-up converter 4 and the step-down divider 6 is deactivated.
The boost converter 4 is deactivated when the welding voltage Uout is less than the battery voltage Uln minus a predetermined voltage, for example 2V. In this case, therefore, the welding voltage Uout or the arc voltage is lower than the battery voltage Uln minus the predetermined voltage value, which is why only the buck converter operates.
The switches 5 and 7 of the boost converter 4 or step-down converter 6 are preferably formed by MOSFET effect transistors and are operated at the same switching frequency of preferably 40 to 50 kHz. The boost converter 4 is operated under voltage control, whereas the step-down converter 6 is operated current-controlled.
When the buck converter 6 is used in the opposite direction as the boost converter 9/20 9 4, the battery 2 can be charged via the terminals for the welding torch 11 and the workpiece 17.
FIG. 2 shows a more detailed block diagram of the welding control 3 of the battery-operated welding apparatus 1, wherein the control device 15 determines the corresponding input variables
Uin accumulator voltage
Ib current through the boost converter 4
Uzw DC link voltage
Uout welding voltage
Iout welding current
Uset set or desired welding voltage Iset set or desired welding current
The corresponding data are hardware-technically determined for the control of the boost converter 4 in order to achieve the required speed for a highly dynamic control can.
Fig. 3 shows a block diagram of an embodiment of a control of the boost converter 4, wherein the intermediate circuit voltage Uzw and the set desired welding voltage Uset is compared in a control circuit 18 and converted in a digital-to-analog converter into an analog reference value. In a comparator 10 of this control output and the current flowing through the boost converter 4 current Ib is compared and fed to the control 14 of the boost converter 4. The intermediate circuit voltage Uzw and the current Ib through the boost converter 4 can be filtered by corresponding filter circuits 20, 21.
4 shows a block diagram of an embodiment of a regulation of the buck converter 6, wherein the input variables of the welding current Iout and of the desired set welding current Iset are fed to a regulator 22, which is preferably formed by a PID regulator. An additionally generated signal, which is responsible for the maximum permissible welding current Iout, is supplied to a digital-to-analog converter 23 and then compared analogously in a comparator 24 with the welding current Iout and fed to the control 14. Again, filter 10/20 10 25, 26 can be used again.
Fig. 5 shows a timing diagram of the intermediate circuit voltage Uzw over time, wherein only in a part of the period of the clock frequency ft, the intermediate circuit voltage Uzw is measured. In the example shown, the intermediate circuit voltage Uzw per period Tt is measured four times and the mean value is formed. On the basis of this mean value of the intermediate circuit voltage Uzw, it is decided after comparison with the accumulator voltage Uln whether the switch 8 is switched through for bridging the boost converter 4 or not. The remainder of the period Tt during which the intermediate circuit voltage Uzw is not measured remains for the evaluation. This allows a fast control and sampling, which has been found to be important for a welding process with optimum welding quality.
Finally, FIG. 6 shows a diagram of the welding voltage Uout above the welding current Iout, where both the step-up converter 4 and the step-down actuator 6 operate in the area shown hatched. In area II, only the step-down divider 6 works. This corresponds to the normal state of welding. The envelope according to FIG. 6 represents the maximum values or maximum power statically or dynamically. 11/20
权利要求:
Claims (20)
[1]
1. A method for controlling a battery-powered welding device (1) wherein the accumulator voltage (Uin) and the accumulator current (Iln) provided by an accumulator (2) are converted by means of a boost converter (4) having at least one switch (5). and a step-down divider (6) with at least one switch (7) containing welding control (3) on a / to a welding torch (11) supplied welding current (Iout) and welding voltage (Uout) are regulated, characterized in that the boost converter (4) is bridged with the aid of a switch (8) controlled by a switch control (9) if the intermediate circuit voltage (Uzw) between the boost converter (4) and the step-down divider (6) is less than or equal to the battery voltage (Uin), and the switch (8 ) is opened for bridging the boost converter (4) when the boost converter (4) is activated.
[2]
2. The method according to claim 1, characterized in that the switch (8) for bridging the boost converter (4) is opened when the welding current (Iout) is smaller than the maximum current (Ib, max) through the boost converter (4), and the low setting divider (6) is deactivated.
[3]
3. The method according to claim 1 or 2, characterized in that the boost converter (4) is deactivated when the welding voltage (Uout) is less than the battery voltage (Uin) minus a predetermined voltage, in particular 2V.
[4]
4. The method according to any one of claims 1 to 3, characterized in that the boost converter (4) by means of a control (14) is regulated by the DC link voltage (Uzw) with a desired welding voltage (Uset) is compared and this comparison value and the Current (Ib) by the boost converter (4) with a comparator (10) are compared and the control (14) is supplied.
[5]
5. The method according to any one of claims 1 to 4, characterized in that the at least one switch (5) of the boost converter (4) and the at least one switch (7) of the 12/20 12 buck converter (6) with the same clock frequency (ft ), preferably 40 to 50 kHz.
[6]
6. The method according to claim 5, characterized in that the intermediate circuit voltage (Uzw) is measured only during a portion of each period (Tt) of the clock frequency (ft) and during the remainder of each period (Tt) is evaluated.
[7]
7. The method according to any one of claims 1 to 6, characterized in that the boost converter (4) is operated as a voltage regulator.
[8]
8. The method according to any one of claims 1 to 7, characterized in that the buck converter (6) is operated as a current regulator.
[9]
9. The method according to any one of claims 1 to 8, characterized in that in a normal welding operation only the buck converter (6) is activated.
[10]
10. The method according to any one of claims 1 to 9, characterized in that both the boost converter (4) and the Tief-setter (6) are activated when the desired welding current (Iset) is less than the maximum current (Ib, max) through the boost converter (4).
[11]
11. The method according to any one of claims 1 to 10, characterized in that the accumulator (2) via the reverse step used as step-up converter Tiefsetzsteiler (6) is loaded.
[12]
12. Battery operated welding device (1) with an accumulator (2) with a battery voltage (Uln) and a battery current (Iin) and with a boost converter (4) with at least one switch (5) and a buck converter (6) with at least one switch (7) for controlling a welding current supplied to a welding torch (11) and welding voltage (Uout), characterized in that a switch (8) is provided for bridging the boost converter (4) Switch (8) is connected to a switch control (9), which switch control (9) is designed to close the switch (8) when the intermediate circuit voltage (Uzw) between boost converter (4) and low setting divider (6 ) is less than or equal to the accumulator voltage (Uin), and to open the switch (8) when the boost converter (4) is activated.
[13]
13. Battery operated welding device (1) according to claim 12, characterized in that the switch control (9) is adapted to open the switch (8) for bridging the boost converter (4) when the welding current (Iout) is less than the maximum current (Ib, max) through the boost converter (4) and the buck converter (6) is deactivated.
[14]
14. Battery operated welding device (1) according to claim 12 or 13, characterized in that a control (14) for the step-up converter (4) is provided, which is designed to deactivate the boost converter (4) when the welding voltage (Uout) smaller than the accumulator voltage (Uln) minus a predetermined voltage, in particular 2V.
[15]
15. Battery-powered welding apparatus (1) according to claim 14, characterized in that a comparator (10) for comparing a comparison value of the intermediate circuit voltage (Uzw) with a desired welding voltage (Uset) and the current (Ib) by the step-up converter (4) is provided , which comparator (10) is connected to the controller (14) for controlling the boost converter (4).
[16]
16. Battery operated welding device (1) according to any one of claims 12 to 15, characterized in that an accumulator (2) with a rechargeable battery voltage (Uin) is less than or equal to 60 volts.
[17]
17. Battery operated welding device (1) according to one of claims 12 to 16, characterized in that between the boost converter (4) and step-down converter (6), a capacitor (12) is arranged.
[18]
18. Battery operated welding device (1) according to any one of claims 12 to 17, characterized in that the switch (8) for bridging the boost converter (4) is formed by a field effect transistor. 14/20 14
[19]
19. Battery operated welding device (1) according to any one of claims 12 to 18, characterized in that the accumulator (2) is formed by a lithium iron phosphate accumulator.
[20]
20. Battery-powered welding device (1) according to one of claims 12 to 19, characterized in that the buck converter (6) operated in the opposite direction as a charging circuit for charging the battery (2) is usable. 15/20
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法律状态:
优先权:
申请号 | 申请日 | 专利标题
ATA50352/2013A|AT514357B1|2013-05-23|2013-05-23|A method of controlling a battery powered welder|ATA50352/2013A| AT514357B1|2013-05-23|2013-05-23|A method of controlling a battery powered welder|
US14/649,249| US9919376B2|2013-05-23|2014-05-21|Method for controlling a battery-powered welding device, and battery-powered welding device|
JP2015556339A| JP6043440B2|2013-05-23|2014-05-21|Battery-driven welding apparatus control method and battery-driven welding apparatus|
PCT/AT2014/050121| WO2014186815A2|2013-05-23|2014-05-21|Method for controlling a battery-powered welding device, and battery-powered welding device|
CN201480004510.4A| CN104919691B|2013-05-23|2014-05-21|For the method for controlling battery powered welder and battery powered welder|
EP14732813.2A| EP2915240B1|2013-05-23|2014-05-21|Method for controlling a battery-powered welding device, and battery-powered welding device|
DE102014209849.1A| DE102014209849A1|2013-05-23|2014-05-23|A method of controlling a battery powered welder and a battery powered welder|
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