Electric welding machine uses positive and negative polesshort circuitHigh temperature generated duringelectric arcTo meltwelding rodOnsolderThe purpose of combining with the material to be welded and the object to be contacted.Its structure is very simple, which is a high-powertransformer。
Electric welding machines are generally divided into two types according to the type of output power supply, one is AC power supply, the other isDC。They use the principle of inductance, which will produce hugeVoltage variationThe high voltage arc generated when the positive and negative poles are short circuited instantaneously is used to melt the solder on the electrode, so that they can achieve the purpose of atomic bonding.
1、 Advantages of electric welding machine: electric welding machine uses electric energy to convert electric energy into heat energy instantly. Electricity is very common. Electric welding machine is suitable for working in a dry environment without too many requirements. It is widely used in various fields due to its small size, simple operation, convenient use, fast speed, solid weld after welding and other advantages, especially for products with high strength requirements,The same metal materials (or different metals, but with different welding methods) can be permanently connected in an instant. After heat treatment, the weld joint has the same strength as the base metal and is well sealed, which solves the problem of sealing and strength for the manufacture of gas and liquid storage containers.As shown in Figure 1.
2、 Disadvantages of electric welding machine: during the use of electric welding machine, there will be some problems around the welding machinemagnetic fieldWhen the arc burns, it will radiate to the surroundings. There are infrared ray, ultraviolet ray and other light species in the arc light, as well as harmful substances such as metal vapor and smoke, so adequate protective measures must be taken during operation.Welding is not suitable for welding of high carbon steel. Due to the process of crystallization, segregation and oxidation of weld metalWelding performancePoor, easy to crack after welding, resulting in hot and cold cracks.Mild steel has good welding performance, but the process should also be operated properly. Rust removal and cleaning are tedious, sometimesweld lineSlag inclusion, crack, pore undercut and other defects may occur, but proper operation will reduce the occurrence of defects.
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Electric welding machine
It uses the high temperature arc generated by the positive and negative poles in the instant short circuit to melt the solder and the material to be welded on the welding electrode, so as to achieve the purpose of combining them.The structure of the electric welding machine is very simple. It is a high-power transformer, which converts 220/380V AC power into a low voltage, high current power supplydirectIt can also be communication.Welding transformerIt has its own characteristics, that is, the voltage drops sharply.The voltage drops after the ignition of the welding rod, and the adjustment of the working voltage of the electric welding machine is not only the primary 220/380V voltage conversion, but also the secondarycoilThere are also taps to change the voltage. At the same time, the iron core is also used to adjust. The adjustable iron core electric welding machine is generally a largePowerThe transformer is made according to the principle of inductance. When the inductance is turned on and off, it will produce huge voltage changes. The high voltage arc generated when the positive and negative poles are short circuited instantaneously is used to melt the solder on the welding electrode to achieve the purpose of combining them.Apply voltage between the welding rod and the workpiece, and ignite the arc by scratching or contactingelectric arcThe energy of melting electrode and heating base metal.As shown in the figure Electric Welding Machine
The main difference between AC welding machine and DC welding machine is that AC welding machine is generally used in steel structure manufacturing units orGeneral machineryOr agricultural machinery manufacturing unit.DC is mainly used to manufacture pressure vessel boilers, pipes, or welding machines for important structural manufacturing units.
Electric welding machine
⑴Inverter welderIts main application fields are the same, but the welding machine is more energy-saving and portable.
⑵ Main application fields of submerged arc welding machine Large steel structure manufacturer, pressure vesselBoiler manufacturingCompany.
⑶ The main application fields of the gas shielded welding machine are large-scale steel structure manufacturers or general machinery agricultural machinery, automobile manufacturers, anti-theft door processing plants, and pressure vessel boilers. Now, the gas shielded welding machine is also widely used.
⑷ Argon arc welding machine is mainly used for pipes, pressure vessel boilers,Stainless steel processingEnterprise.
(5) AC argon arc welding machine is mainly used by aluminum welding manufacturer and aluminum container manufacturer.AluminiumradiatorWelding.
2. There are two kinds of DC welding machines: one isalternating current dynamoRectifying elements are added on the basis ofDC generator。DC welder mainly welds nonferrous metals and pig iron.AC welder mainly welds steel plate.
3. Argon arc welding machine, carbon dioxide protection welding machine, high-frequency welding machine, flash butt welding machine.Argon arc welding machineCO2 gas shielded welding machineIt can mainly weld thin plates and nonferrous gold layers below 2MM.The flash butt welding machine is mainly used to butt copper aluminum joints and other objects, and the high-frequency butt welding machine is mainly used to weld steel pipes in the pipe factory.
4、Submerged arc weldingIt is mainly used to weld steel structural parts, bridge H steel, I-beam and other thick steel structural materials.
5. Gas shielded welding machine: argon arc weldingCO2 shielded weldingUnder the protection of gas, the welding machine will not be oxidized, the solution welding is firm, and the non-ferrous gold layer and thin materials can be welded.
6. Laser welding machine: can weld the inner part of transistorLeader。
7. Butt welding machine: the cable chain factory mainly welds the iron rope and other objects on the anchor.It can be connected to steel, etc.
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Figure 2
Serial number, standard number, standard name and international standard are shown in Figure 2
1 GB/T2900.22-2005 Electrotechnical terminology Electric welding machine
37 JB/T7824-1995 Technical Conditions of Inverter Arc Welding Rectifier
38 JB/T7834-1995 Arc Welding Transformer
39 JB/T7835-1995 Arc welding rectifier
40 JB/T8086-1999 Friction Welding Machine
41 JB/T8323-1996 Screw injection welding machine
42 JB/T8442.1-1996 Water cooled secondary connecting cable for resistance welding Part 1: Specification and technical requirements for dual core connecting cable
JB/T8442.2-1996 Water cooled secondary connecting cables for resistance welding Part 2: Specifications and technical requirements for single core connecting cables
44 JB/T8442.3-1996 Water cooled Secondary Connecting Cable for Resistance Welding Part 3: Test Requirements
45 JB/T8442.3-1996 Safety Requirements for Cooling Fans for Electric Welding Machines
46 JB/T8588-1997 Technical Conditions for Steel Bar Electroslag Pressure Welders
47 JB/T8597-1997 Technical Conditions for Manual Tungsten Inert Gas Arc Welding Machines (TIG welding machines)
48 JB/T8748-1998 MIG/MAG Arc Welder
49 JB/T8805-1998 Technical Conditions of Pressure Reducers for Gas Protection
50 JB/T8806-1998 Technical Conditions of Mixed Gas Proportioner for Gas Protection
51 JB/T9527-1999 Cone Plug Gauge and Cone Ring Gauge for Spot Welding Equipment
52 JB/T9528-1999 Prime mover arc welding generator set
53 JB/T9529-1999 General Technical Conditions for Transformers of Resistance Welding Machines
54 JB/T9530-1999 Insulating Cap and Insulating Bushing for Resistance Welding Equipment
55 JB/T9531-1999 Spot welding electrode block and clamp block
56 JB/T9534-1999 Technical Conditions of Arc striking Device
57 JB/T9959-1999 Electrode joint with internal taper of 1:10 for resistance welding
58 JB/T9960-1999 Resistance Spot Welding Male Electrode Cap
60 JB/T1010-1999 General Technical Conditions for Resistance Welding Machine Controllers
61 JB/T10113-2002 Dimensions and Characteristics of Secondary Connecting Cables Connected to Water Cooling Connecting Blocks at Both Ends of Resistance Welding Equipment
67 JB/T10258-2001 Bumps for Resistance Projection Welding
68 JB/T10498-2005 Special change-over switch for electric welding machine
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Electric welding machines are widely used.Electric welding machines are indispensable tools for large shipbuilding enterprises, industrial and mining enterprises and various construction enterprises.Electric welding machines are used for welding materials, which are electrified when used. In particular, some small construction units purchase cheap electric welding machines to save costs. When used in the harsh environment of the construction site, it is easy to cause electric shock, fire and desoldering, which will endanger personal safety and property safety.Poor welding quality will also lead to "tofu dregs" project.
Several requirements to be noted when purchasing electric welding machines:
1、 When selecting and purchasing electric welding machine products, you should go to the regular production enterprises or large shopping malls to select and purchase famous brand products with high market share.Never go to a small shop to buy cheap, because the quality of electric welding machines there cannot be guaranteed.
2、 When purchasing, check whether the nameplate on the product contains the name of the manufacturer, production address, specifications, welding current adjustment range, load duration, input voltage and current, etc. Then determine the welding machine you want to purchase according to the work needs.
3、 At the time of purchase, the dealer can be required to provide product quality inspection report or certificate.Since the electric welding machine is a product with national compulsory certification, you must confirm whether the product has passed the "3C" certification when you buy it.You can also check online.
4、 When purchasing, be sure to check whether the product has grounding screws, and the connection of grounding screws should be well grounded without paint.Check whether the movement is clean and the insulation is damaged to ensure safe use. If necessary, check it.
5、 Before purchase, power can be used to check the operation, conversion and installation of the switch on the lower panel, whether the power indicator is on or off, whether the fan is normal, whether the power part has abnormal vibration and beep, whether there is abnormal smell, whether there is discoloration and other heating phenomena on the appearance, so as to ensure the quality of the welding machine and give full play to the performance of the welding machine.
6、 If the gas shielded welding machine is to be purchased, check whether the accessories are complete, whether the wire feeder is contaminated with oil, whether the rotation is stable, whether the connecting cable matches the external insulation and whether there is damage before purchasing, so as to ensure the stability of the arc.
Flash welder
Welding transformer has its own characteristics, that is, it has the characteristics of a sharp drop in voltage.
Flash welderThe harm of light to human body and its prevention
Welding arc light harmful to human body will be generated during welding operation.Welding arc light mainly includesinfrared, visible light and ultraviolet light.These belong to the hot wire spectrum.When the welding arc temperature is 3000 ℃, its radiation wavelength is less than 290m μ m;When the temperature is 3200 ℃, the radiation wavelength is less than 230 m μ m.When light radiation acts on the human body, the tissues in the body will absorb it, causing tissue heatphotochemical action Or ionization, causing acute or chronic damage to human tissues.
The harm of infrared ray to human body is mainly caused by the thermal effect of tissues.During welding, the eyes are exposed to intense infrared radiation, and will immediately feel intense burns and burning pain, resulting in flash illusion.Long term exposure may cause infrared cataract, vision loss, and even blindness in severe cases.
The luminosity of visible light is about 10000 times greater than that normally borne by the naked eye. When visible light radiates people's eyes, it will cause pain, and they can't see clearly, which is usually called "dazzling". They will lose their ability to work in a short time.
The harm of ultraviolet radiation to human body is mainly photochemical action, which causes damage to human skin and eyes.When the skin is exposed to intense ultraviolet radiation, it can cause dermatitis, diffuse erythema, sometimes small blisters, exudates, burning and itching;When the effect is strong, it is accompanied by systemic symptoms: headache, dizziness, fatigue, nervous excitement, fever, insomnia, etc.Ultraviolet rays over irradiating people's eyes can cause acute corneal and conjunctivitis, that is, electric ophthalmia.Most of them come on 4-12 days after irradiation, and the symptoms are high shyness, tears, foreign body sensation, tingling, eyelid redness, spasm, and headache andBlurred vision。
In order to prevent the harm of electric welding arc to human body, the welding workers must wear work clothes with flat surface and large reflection coefficient, gloves and shoe covers. Welders are not allowed to roll up their sleeves or wear short sleeved clothes or open their collars for welding.After wearing work pants, ensure that they are long enough when squatting to avoid being burned by arc light due to exposed ankles.The mask with special filter lenses must be used. The filter lenses must be qualified products produced by the national designated factory. Ordinary dark light lenses cannot be used at will.In order to protect the eyes of other workers in the welding area from injury, a barrier should be set up at the welding site. In the area of the barrier, the welding workers should always remind other workers to avoid. If conditions permit, other workers in the welding area can be equipped withProtective glassesTo avoid eye injury caused by arc light.
In order to ensure smooth welding, this transformer power supply can have the following characteristics according to the needs of the welding process:
The AC welding machine has the characteristics of steep voltage drop
General electrical equipment requires that the voltage of the power supply does not followloadThe voltage is constant, such as 380V (single phase) or 220V.Although the voltage connected to the welding transformer is certain, such as 380V or220VHowever, the output voltage after passing through this transformer can change with the change of output current (load), and the voltage decreases rapidly with the increase of load, which is called steep drop characteristic or drop characteristic.This adapts to various voltage requirements required for welding:
(1) Primary voltage: refers to the external voltage connected to the welding machine.
Since the voltage required at both ends of the primary coil of the arc welding transformer is single380VTherefore, the voltage of AC welding machine connected to the power grid is 380V.
(2) Zero voltage: in order to ensure frequent short circuit during welding (contact between welding rod and weldment), the voltage is required to be automatically reduced to zero, so as to limit the short circuit current from unlimited increase and burning the power supply.
(3)No load voltage: In order to meet the needs of arc striking and safety, the no-load voltage is required to be about 60~80V during no-load (welding), which can not only start the arc smoothly, but also be safe for people.
(4)working voltage : After welding and arc starting, the voltage is required to automatically drop to the voltage required for normal operation of the arc, that is, the working voltage, about 20~40 V, which is also a safe voltage.
(5)arc voltage : the voltage at both ends of the arc, which is within the working voltage range.When welding, the length of the arc will change: the arc length is long, and the arc voltage should be higher;If the arc length is short, the arc voltage should be lower.Therefore, the arc welding transformer shall adapt to the change of arc length to ensure the stability of the arc.
Current and voltage through three phasesmain transformerVoltage reduction is performed by silicon controlled elementsrectification, and leverage changeSilicon controlled rectifierThe trigger angle phase controls the output current.The current signal is taken from the shunt at the DC output end of the rectifier as the current negative feedback signal. As the DC output current increases, the negative feedback also increases, the thyristor conduction angle decreases, and the output current voltage decreases, so as to obtain the declining external characteristics.When the output voltage of the thrust circuit is lower than 15V, the output current will increase. Especially in the case of short circuit, the external characteristic of external drag will be formed, making the welding rod difficult to stick.The arc starting circuit is to increase the given voltage for a short time each time the arc is started, so that the arc starting current is large and easy to start.
It can be seen from the above description that,Electric weldingWhen arcing, the circuit is in a short circuit state, the voltage drops sharply, and the current needs a lot;After the arc is started, the arc should be stabilized. At this time, the solution of the electrode and the tank is still in the short circuit transition state, the voltage still drops, and the current is still high;After the completion of the transition, it is in the normal welding state, the voltage rises and the current drops.The AC welding machine should be correctly wired when using, that is, the shell and the secondary side of the welding machine should be reliably protected from neutral or grounding to prevent the dew point of the shell or the high voltage from flowing into the low voltage, which may cause electric shock to the human body, as shown in the figure below, but its welding clamp end cannot be protected from neutral or grounding, the power line of the welding machine should be a three core rubber cord, and the damaged parts should be repaired or replaced,Check whether the insulation of wires and cables is damaged, so that the equipment is in good technical condition.
Adjustable welding current of AC welding machine
In order to meet the welding requirements of different materials and plate thicknesses, the welding current can be adjusted from tens of amperes to hundreds of amperes, and the required current value can be adjusted arbitrarily according to the thickness of the workpiece and the diameter of the electrode used.The current adjustment is generally divided into two levels: the first level is coarse adjustment. The connection method of the output wire (I position connection or II position connection) is often changed, so as to change the number of turns of the internal coil to achieve a wide range of current adjustment. The coarse adjustment should be carried out when the power supply is cut off to prevent electric shock injury;The other level is fine adjustment. The position of the "movable core" (movable core type) or "movable coil" (movable coil type) in the welding machine is often changed to reach the required current value. The operation of fine adjustment is achieved by rotating the handle. When the handle rotates counterclockwise, the current value increases, and when the handle rotates clockwise, the current decreases. Fine adjustment should be carried out under no-load condition.For the range of coarse adjustment and fine adjustment of various types of electric welding machines, refer to the description on the label
Troubleshooting
Transformer overheating 1. Overload 2. Transformer winding short circuit 1. Reduce welding current 2. Eliminate short circuit fault
The welding current is too small 1. The secondary power line is too long and too thin (the voltage drop of the wire is too large) 2. The secondary power line is coiled in a circle (the inductance is too large) 3. The secondary power line has poor contact (the contact resistance at the connection is too large or poor contact with the overproduction) 1. Reduce the length or amplification area 2. Eliminate the circle 3. Reconnect to reduce the contact resistance.
welding current Too large or too small 1. Insulation damage that plays an inductive role in the circuit (causing excessive current) 2. Eddy current generated in the magnetic circuit (causing current reduction) 1. Repair the insulation damage 2. Adjust the core gap
The welding power line is overheated 1. The whole wire is overheated: the cross-sectional area of the wire is too small 2. The connection is overheated: the contact resistance at the connection is too large 1. Replace the wire with a larger area 2. Reconnect to reduce the contact resistance
The welding current varies from high to low. The position of the moving iron core is unstable during welding. Fix the adjusting handle or the moving iron core
When welding, there is a "buzz" noise. The brake screw or spring of the iron core is too loose. Tighten the brake screw or adjust the spring pressure
Safety Operation Procedures for AC Welding Machines
(1) Welding operators and cooperation personnel must wear as requiredLabor protection articles。Safety measures must be taken to prevent accidents such as electric shock, falling from height, gas poisoning and fire.
(2) The electric welding machine used on site shall be equipped with a shed that is rain proof, moisture-proof and sun proof, and shall be equipped with corresponding fire-fighting equipment.
(3) Flammable and explosive materials such as oil, wood, oxygen cylinder and acetylene generator shall not be stacked within 10m of the welding site.
(4) Before use, check and confirm that the primary and secondary lines are correctly wired, and the input voltage complies with the regulations on the nameplate of the electric welding machine. After the power is connected, it is strictly prohibited to contact the live part of the primary line.The primary and secondary wiring must be equipped with protective covers.
(5) The secondary tap connection copper plate shall be compacted, and the terminal shall be provided with gasket.Before switching on, check the wiring nuts, bolts and other parts in detail and confirm that they are intact, free from looseness or damage.There is a protective cover at the terminal.
(6) When multiple electric welding machines are used together, they should be connected toThree phase power supplyOn the network, makeThree phase load balance。The grounding devices of multiple welding machines shall be led from the grounding electrode, and shall not be connected in series.
(7) When moving the welding machine, the power supply shall be cut off, and the welding machine shall not be moved by dragging the cable.In case of sudden power failure during welding, the power supply shall be cut off immediately.
(8) It is strictly prohibited to weld on the pressure pipes, containers with flammable and explosive materials and stressed components in operation.
(9) Welding copper, aluminum, zinctin, lead and other non-ferrous metals must be carried out in a well ventilated place, and welding personnel should wear gas masks or respiratory filters.
(10) When welding in the container, the following measures must be taken: there must be air inlets and outlets on the container, and ventilation equipment must be set;The lighting voltage in the container shall not exceed 12V, and someone must be present for monitoring during welding.It is strictly prohibited to weld in containers that have been sprayed with paint or glue.(11) When welding the preheated parts, baffle shall be set to isolate the radiant heat from the preheated weldments.
(12) When welding at height, the safety belt must be hung. Fire prevention measures shall be taken around and below the weldment and special personnel shall be assigned for supervision.
(13) When the welding line passes through the road, it must be elevated or embedded in the protective pipe. If it passes through the track, it must pass under the track.
(14) The grounding wire and handlebar wire shall not be laid on flammable, explosive and heat source materials. The grounding wire shall not be laid on pipes, machine tools, equipment and building metal frames or rails. The insulation shall be good, and the grounding resistance of the housing shall not be greater than 4 Ω.
(15) Open air electric welding is not allowed in rainy days.When working in wet areas, the operator should stand at the place covered with insulating materials and wear insulating shoes.
(16) The insulation resistance of the electric welding machine used for long-term power failure must be checked with a megger to ensure that it is not less than 0.5M Ω, and the wiring part must be free of corrosion and moisture.
(17) The welding tongs shall have good insulation and heat insulation capacity.The handle of the welding tongs must be well insulated. The handle and the wire should be firmly connected with good contact. The connection should be wrapped with insulating cloth and should not be exposed.Operators shall not hold welding tongs with their arms.
(18) When removing weld slag, wear protective glasses and keep the head away from the splashing direction of striking weld slag.
(19) During the load operation, the welding personnel shall frequently check the temperature rise of the electric welding machine. If the temperature exceeds 60 ℃ for Grade A and 80 ℃ for Grade B, the welding machine must be stopped and cooled down.
(20) After the operation is completed, clean the site, extinguish the fire, cut off the power supply and lock the gate box after the waste heat of the fire weldment.
·Rated power 5.0KVA, applicable electrode diameter: 2.0-6.0 (mm)
·One machine for dual use
·Power generation&;Electric welding technology, in the true sense of power generation+electric welding.One machine for dual use, usage
·It can achieve the ideal cost performance ratio, allowing you to enjoy more economic benefits
·Synchronous use
·Good load performance, power can be supplied at the same time during electric welding, and electric welding operation will not affect the voltage and wave type of power generation, thus improving work efficiency and facilitating use
·Excellent welding
·AdoptIGBTChopping, pulse width modulation and reactor smoothing technology make the welding voltage waveform more stable
·When welding, the current is not zero, the current fluctuation is small, and the weld quality is high
·High quality power
·NewAVRThe application of technology and damping coil enables the machine to achieve perfect waveform of welding voltage
·No floating welding current means high-quality welding operation
·Ease of operation
·The lightweight and simple design improves the field operability of the machine and saves a lot of storage space
·At the same time, four durablewheelMore convenient for transportation
·Widely used
·Easy arc striking, stable arc, convenient welding current adjustment, large adjustment range
·It can be used in different electrode diameters and welding environments, making the welding operation more convenient
Maintenance
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The electric welding machine uses the high temperature arc generated by the positive and negative poles in the instant short circuit to melt the solder and the material to be welded on the welding electrode, so as to achieve the purpose of combining them.The structure is very simple. It is a high-power transformer. Electric welding machines can be divided into two types according to the type of output power supply. One is AC power supply;One is direct current.During the use of electric welding machine, maintenance and care shall not be overlooked.
Routine maintenance of electric welding machine
1. Check that the output wiring of the welding machine is standard and firm, and the outgoing direction is downward and nearly vertical, and the included angle with the horizontal must be greater than 70 °.
2. Check the fastening of the screw at the cable connection. The screw specification isHexagon boltM10 × 30, flat washer and spring washer are complete, without rust, oxidation and other undesirable phenomena.
3. Check that the exposed length of cable at the wiring is less than 10mm.
4. Check that the welding machine shell is firmly grounded.
5. Check that the welding machine power supply and base metal grounding are in good condition and standard.
6. Check that the cable connection is reliably insulated and wrapped with tape.
7. Whether the shield at the connection of power line, welding cable and electric welding machine is intact.
8. Check whether the cooling fan of welding machine rotates flexibly and normally.
9. Whether the power switch, power indicator and adjusting handle knob are kept in good condition, whether the ammeter and voltmeter pointers are flexible and accurate, and the surface is clear without cracks.The meter cover is intact and can be opened and closed freely.
11 Check whether the welding machine is in good appearance without serious deformation.
12 Check whether the hexagonal socket screws at the connection between the CO2 welding gun and the CO2 wire feeding device are tightened and whether the CO2 welding gun is loose.
13 Check whether the cable and gas pipe of CO2 wire feeding device are wrapped and fixed properly.
14 Check the correction wheel and wire feeding wheel of CO2 wire feeding device for wear and replace them in time.
15 Check whether the motor fixing and insulating coil are in good condition.
16 Check that the remote control box on the CO2 wire feeding device is loose.
17 When checking and installing the CO2 welding gun, tighten the switch plug of the welding gun and insert it into the guide groove. After the welding gun is installed, tighten the fastening screw.
18 Whether the welding tongs are damaged, whether the upper and lower casings are loose, whether the insulation is affected, whether the fastening screws of the casings are loose, and whether the connection with the cables is firm and conductive
19 Check whether the welding machine wheels are complete and flexible.
20 Clean the oil stain on the equipment surface thoroughly once a week.
21 Clean the dust inside the electric welding machine with compressed air (without moisture) every half a year (the power must be cut off before cleaning).When removing dust, take down the upper and both sides of the plate, and blow from top to bottom in order, and wipe off the grease with cloth.
22 Maintenance items shall be undertaken by the operator.
Technical maintenance
Carry out according to the "routine maintenance" item, and add the following work.
1 Check whether all lines and accessories are in good condition.
3 Check whether the fuse meets the requirements. If it is oxidized, seriously overheated or discolored, replace the fuse.
4 The current regulating device shall meet the requirements of the regulating range.
5 Check the lubrication of all parts of the equipment.
matters needing attention
1. The insulation resistance between windings and between windings and casings of new or unused electric welding machines is often greatly reduced due to moisture, which is prone to short circuit and grounding at the beginning of use, resulting in equipment and personal accidents.Therefore, megger shall be used to check whether the insulation resistance is qualified before use.
2. Before starting a new electric welding machine, check whether the contactor part of the electrical system is in good condition. If it is considered normal, start the test run under no load.Only when it is proved that there is no potential electrical hazard can the test run be carried out under load, and then the normal operation can be put into operation.
3. The DC welding machine shall rotate in the specified direction. For the machine with ventilator, pay attention to whether the rotation direction of the fan is correct. The machine shall be blown out from above.In order to cool the welding machine.[1]
Operating Procedures
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1、 Preparation before welding
1. The electric welding machine should be placed in a ventilated and dry place and placed stably.
2. Check the welding mask for light leakage and damage.Welding personnel and auxiliary personnel shall wear labor protection appliances.
3. Welding tongs, power lines and joints of electric welding machine shall be reliably connected and well insulated.Overheating is not allowed at the wiring, and the power terminal shall not be exposed. It shall be wrapped with electrical adhesive cloth.
4. The length of the wire between the welding machine and the welding clamp shall not exceed 30 meters, and in special cases shall not exceed 50 meters. The wire shall be replaced immediately in case of moisture and broken strands.
5. When the welding line passes through the road, it must be elevated or buried in the protective pipe. If it passes through the track, it must pass under the track.
6. The primary and secondary wiring of AC welding machine shall be accurate, and the input current shall meet the equipment requirements.It is forbidden to touch the live part of the primary line.
7. The secondary tap connection copper plate must be pressed tightly, and the terminal should have coils.Check the contact bolts and other elements carefully before closing to ensure that they are not loose or damaged.
2、 Precautions during welding
1. Reasonable welding process shall be selected according to the technical conditions of work. Overload use is not allowed, heavy current welding is not allowed, and electric welding machine is not allowed to be used for metal cutting.
2. During load welding, the temperature rise of the welding machine should not exceed 60 degrees for Grade A and 80 degrees for Grade B. Otherwise, the machine should be shut down for cooling before welding.
3. The working place of electric welding machine shall be dry and well ventilated.When moving the welding machine, the power supply shall be cut off, and it is not allowed to move the welding machine by dragging the power supply.In case of sudden power failure during welding, the power supply shall be cut off.
4. It is not allowed to adjust the current during welding.The adjustment handle must be used when stopping welding. It must not be too fast or too violent to avoid damaging the regulator.
5. It is forbidden to do welding under the workpiece of the crane.
6. If welding is carried out in the area with crane wire rope, attention shall be paid not to make the ground wire of the welder touch the lifted wire rope by mistake to avoid accidents caused by sparks.
7. When the construction must be carried out in the wet area, the welder must stand on the insulated board to work. It is not allowed to touch the welding wire, and it is not allowed to clamp the live welding tongs with arms.
3、 Precautions after welding
1. After the welding operation is completed, the power supply shall be cut off immediately, the welding machine switch shall be turned off, and the power supply and ground wire of the welding tongs shall be cleaned and consolidated respectively to avoid short circuit caused by switching on.
2. If the automatic stop device is found to be invalid during welding, it shall be shut down immediately for maintenance.
3. Wear glasses when removing weld slag.The head shall be kept away from the direction of welding slag splash to avoid injury.Do not knock welding slag on the site.
4. After outdoor operation, the welding machine shall be covered to avoid rain.
5. When welding is not carried out (moving, repairing, adjusting, working intermission and rest), the power supply shall be cut off to avoid accidents.
6. Check whether the welding machine is reliably grounded once a month.
The auxiliary equipment of the electric welding machine includes the ultraviolet, infrared or other devices to prevent the operator from being generated by the welding arc or other welding energyradialEye injuriousGas welding glasses, protection during arc weldingWelderMasks for eyes, face and neck, white overallsWelder's GlovesAnd foot protection, etc.
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1、 High efficiency and energy saving
The energy saving of electric welding machine is embodied in two aspects: energy saving during no-load and load.The welding machine can connect the main circuitFanWhen all are in the stop state, the no-load power consumption is only a few watts;The efficiency of electric welding machine under load is higher than that of thyristor rectifier welding machine.According to the statistics of relevant parameters, the demand for DC welding machines in the national welding industry in 2008 was 890000. If all DC welding machines were used, 43000 tons of copper, 64000 tons of steel and 680 million KW of electricity could be saved directlyH，Indirect saving of 566500 tons of coal, 10.34 million tons of water and 1.1445 million tons of CO2 emissions.It can be seen that the promotion of DC welding machine has great economic and social benefits.
2、 Stable welding performance
Since the working frequency of electric welding machine is above 20KHZresponse speedThe droplet transfer can be subdivided into multiple stages for control.For CO2 gas shielded welding, spatter can be greatly reducedMIG/MAG weldingIt can effectively control the stability of jet transfer, and can also combine the droplet transfer with the movement of wire feeding mechanism to further control the droplet transfer process, so as to obtain good weld formation and stable welding performance.These are all things that the traditional rectifier welder cannot do.
3、 Realize centralized control
Digital controllers such as MCU, DSP and FPGA are widely used for electric welding machinesEthernetFieldbus is used to realize the network communication between multiple welding machines or upper computers and welding machines.It not only solves the problem of multiple welding machines working together, facilitates centralized control in the welding process, but also realizes the setting or monitoring of remote welding machine parameters, making it possible for remote fault diagnosis and maintenance of electric welding machines.
The electric welding machine industry is a small industry, but its products involve many disciplines and marginal disciplines, and closely cross with many disciplines such as machinery, electronics, mechanics, control, metallurgy, materials, computer, and to a large extent, they also rely on the maturity and progress of other industries, such asInsulating material, electromagnetic materialsPower electronic devices, computer technology, etc.Limited by many factors such as technical foundation and capital, it is very difficult for the welding machine industry in China to achieve sustainable and leapfrog development by relying solely on its own capital and strength, or relying only on imported materials and devices to achieve product renewal and rapid development.This phenomenon actually reflects that the development of the electric welding machine industry is bound to be limited by China's overall scientific and technological strength, and the development of the applied industry cannot be separated from the progress of the national basic industry.
China has become a major manufacturer of electric welding machines in the world. The market capacity of electric welding machines has ended the rapid development stage and entered a relatively stable development cycle. According to relevant data, from January to May 2012, the national output of electric welding machines reached 1.566 million, with a year-on-year increase of 5.52%.In May, China produced 344000 electric welding machines, up 0.65% year on year.
From the output of provinces and cities, Zhejiang Province, Guangdong Province and Shanghai City were the top three provinces and cities in the production of electric welding machines in China from January to May 2012, accounting for 36.90%, 27.49% and 19.38% of the total output respectively.
1. Reasonable design and free adjustment.Different discharge frequencies can be selected according to different metal materials to achieve the best repair effect.
2. The heat affected area is small.There is no heat input in the instantaneous process of stacking, so there is no deformation, undercut and residual stress.No local annealing will occur, and no re heat treatment is required after repair.
3. Minimal welding repair impact. This welder overcomes the impact of ordinary argon arc welding on the surrounding of the workpiece during welding repair.The machined surface of the workpiece without allowance can also be repaired with confidence.
4. High repair precision: surfacing thickness ranges from several microns to several millimeters, and only grinding and polishing are required.
5. High welding strength: due to full penetration into the surface material of the workpiece, extremely strong bonding force is generated.
