Foreword
According to statistics, more than half of the world's steel production is made into steel products by welding. The welding process is achieved by means of welding power supplies. Welding is mainly based on arc welding. Arc welding has a history of nearly one hundred years, and batteries were used as power sources in the early days. The power frequency transformer arc welder and DC arc welding generator invented in the early 1920s have been the main arc welding equipment for the next 50 years.
Development and application status of inverter welding machines at home and abroad
The development of modern welding equipment is closely related to the development of power electronics technology and devices. In the late 1950s, power semiconductor diodes began to be used for welding power supplies, and the arc-welded rectifiers formed were significantly better than arc-welded generators. In the early 1970s, the emergence of a controlled rectifier arc welder consisting of a thyristor (SCR) marked the beginning of modern power electronics technology entering the field of welding power equipment. The electrical characteristics and process characteristics of the SCR arc welder are superior to the diode rectifier arc welder, which is an important welding power supply device widely used at that time. In the mid-1970s to the mid-1980s, high-performance self-shutdown power electronic switching devices: power transistors (GTR), power FETs, insulated gate transistors (IGBTs), turn-off thyristors (GTOs), etc. . The thyristor-type inverter arc welder began to appear in the late 1970s and was mainly used in TIG and manual arc welding, and later extended to CO2, MAG and other welding methods and cutting. In 1982, visiting scholars from South China University of Technology first developed the field effect tube arc welding inverter in Germany. Its application fields from TIG to manual arc welding, gas shielded welding and cutting promoted the development of welding equipment. In the late 1980s, IGBT inverter welding machines were introduced, which were mainly used in various arc welding and cutting. A new generation of arc welding inverters with power thyristors, transistors, MOSFETs, IGBTs, etc. as switching devices, using high-frequency PWM switching technology and microelectronic control technology, eliminated the cumbersome power frequency transformer and clumsy electromagnetic control. It not only has the advantages of high efficiency, energy saving, small size, light weight, multi-function, multi-purpose, etc., but also has good dynamic and static characteristics and process characteristics. Therefore, since the advent of the new generation of arc welding inverters, they have received extensive attention and developed rapidly. More than 30 manufacturers at the World Welding and Cutting Expo (Essen Expo) exhibited arc welding inverters. At the Essen conference in 1993, most manufacturers exhibited arc welding inverters and equipment. According to a survey conducted by IIW XIIC in November 1993, inverter welders accounted for 17% of the welders used in Japan, the United States, and Europe, of which more than 30% were in gas shielded welding and TIG welding. In 1996, Hitachi’s IGBT inverter welding machine accounted for 70% of MIG/MAG welding machines, accounting for more than 95% of TIG welding machines, accounting for 100% of cutting machines, and inverters from Panasonic and Osaka Transformers. The welder is over 50%. Arc welding inverters with IGBTs, MOSFETs, etc. as switching devices have broad application prospects and are the mainstream and direction of current international welding power equipment development.
In China, the research work of inverter welding machine began in the early 1980s, closely following the process of international research and development, and the level gap is not large. Three generations of products have been formed. The first generation is an arc welding inverter with SCR as the main switching device, and its inverter frequency is 2000-5000 Hz. The second generation is an arc welding inverter with GTR or MOSFET as the main switching device, and its inverter frequency is 20kHz-50kHz. The third generation is an IGBT arc welding inverter with an inverter frequency of 20 kHz to 30 kHz. By the early 1990s, many specifications of the first, second and third generation of arc welding inverters have been successfully researched in many universities and research institutes, and gradually entered small batch production, but large-scale production and large-area promotion and application of inverter The welder is slower. There are only a handful of mass production manufacturers that started in the mid to late 1990s.
Development direction of inverter welding machine
The general development trend of inverter welding machine is to focus on large capacity, light weight, high efficiency, modularization, intelligent development and improve reliability, performance and widening of use, and it is more and more widely used in various arc welding methods. , resistance welding, cutting and other processes. Efficient and high power density (miniaturization) is one of the main goals pursued by international arc welding inverters. High frequency and reduced power consumption of major devices are the main technical approaches to achieve this goal. At present, in Japan, the United States, Europe and other countries and regions, the arc welding inverter technology of about 20 kHz has matured, the quality of the products is high and the products have been serialized. Arc welding inverter technology is developing in the following directions:
(1) Develop a 50 kHz, 100 kHz class arc welding inverter along the 20 kHz technology route.
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