逆变电源的优势.ppt

IntroductionofadvantageinSubmergedArcWeldingTechnology埋弧焊技术的优势介绍September2008,TheNextGenerationinSubmergedArcWelding新一代的埋弧焊,The“State-of-the-Art”inInverterTechnology最先进的逆变焊机技术HighestCapacityavailableontheMarket市场上同类产品中最高的容量HighEfficiencyInverter高效率逆变焊机WaveFormControlTechnology波形控制技术GreatestControlovertheWeldingProcess焊接过程的最佳控制SolidStateSwitchingTechnology固态开关技术ACorDCWeldingProcesses交流或直流焊接工艺,TheNextGenerationinSubmergedArcWelding新一代的埋弧焊,Market/CustomerDemands市场/客户需求IncreasedProduction4to5arcs)技术上一般允许在焊接中增加一个电弧（如3弧转为4弧以及4弧转为5弧）。,PWAC/DCPipemillAdvantagesPWAC/DC运用在管道焊时的优势,VoltageandCurrentregulationisexcellent-thisallowsrunningnearthetopendofthevoltagerangeallowedbytheprocedurequalification极佳的电流电压调整可以在评定所允许的极限值上运行Thetoeconditionandreinforcementoftheweldsareveryconsistent均匀的焊脚和焊缝余高ExcellentVisualAppearance极佳的焊缝成形,OverviewRecommendationforFineTuningProcedures推荐微调程序,Step1:步骤1UseDC+LeadArc前导电弧使用DC+Use50%BalancedandSymmetricalACTrailingArcs拖后电弧使用50%平衡且对称AchieveStableOperationandConfirmInstallation确保运行稳定和安装正确Step2:步骤2IncreaseFrequencyonTrailingarcstohighestlevelwithoutdegradingbeadshapeorreducingcurrentduetoinductiveeffects(typicallylessthan90Hz)增加拖后电弧的频率并保持焊道成形，或由于电感的影响而减小电流（一般少于90Hz）,OverviewRecommendationforFineTuningProcedures推荐微调程序,Step3:步骤3IncreaseVoltageandTravelSpeedtogethertomaximizeproductivity增加电压和焊接速度以提高生产率AdjustCurrentonLeadArctoachievepenetrationasrequired调整前导电弧的电流以提高熔深Increasecurrentonthetrailarcstoincreasedepositionasrequired增加拖后电弧的电流以增加熔敷率Step4:步骤4AddasmallamountofDC-imbalancetoACwaveformsandrepeatstep3在交流波形上增加一点DC-分量，然后重复步骤3,Applications-PressureVessel应用-压力容器,DeepGrooveMulti-PassWelding深坡口多道焊TwoArcAC-ACSAWProcess双弧AC-AC埋弧弧工艺165mmThickPlate165mm厚板62Passes62道30%increaseinTravelspeed30%焊接速度的增加23%ReductioninHeatInput23%热输入的减少,SpinCastingApplication旋转铸件的应用Castingmoldsareresurfacedwithsubmergedarc铸模用埋弧焊进行表面堆焊Max.MoldTemp.245Deg.C模具最高温度245C50%increaseinweldingspeed焊接速度增加50%Reducedrebuildtime减少堆焊时间11daysto6-7days11天到6-7天$511,000yearlycostreduction年成本减少$511,000$6millionreductioninMoldStock模具库存量减少$6million,应用:模具修复,RollFormedandWelded管件成型和焊接TrialSystem-April2003试用系统-2003年4月28WeldingStations28个焊接站Estimated30,000Man-hourSavingsbasedonTrialSystem试用系统估计节约人力30,000小时,Application:OffshoreStructural应用:海洋平台结构,TandemSubArc双丝埋弧焊TypicalDC-ACDeposition=15Kg/hr典型的DC-AC熔敷率=15Kg/hrAC-ACwith25%DCPos.=20Kg/hrAC-AC带25%DC正极=20Kg/hr35%increaseinProduction生产率增加35%,Application:OffshoreStructural应用:海洋平台结构,LongitudinalPipeWelding直缝管焊接Conversion3-ArcWeldingto4-ArcWelding将3丝焊改为to4丝焊1.7m/mtravelspeedincreasedto2.3m/m焊接速度从1.7m/m增加到2.3m/mNoChangetoWeldBeadProfileorMechanicalProperties焊缝形状和机械性能无改变35%increaseinProduction生产率增加35%,应用:管道制造,SpiralPipeWelding螺旋管焊接DC-ACtoAC-ACIDWeldDC-AC改为AC-AC内焊1.54m/mto1.90m/mTravelSpeedIncrease焊接速度从1.54m/m增加到1.90m/m23%increaseinProduction生产率增加23%ExcellentIDBeadQuality出色的内焊道质量,Application:PipeMills应用:管道制造,TandemArcPF10AUserInterfaces双丝焊PF10A用户接口ExcellentProductivityGains30%出色的生产率提高30%,Application:PipeMills应用:管道制造,NewWeldingFlux新焊剂DesignedtotakeadvantageofWaveFormControl设计时充分利用波形控制的优点Criticalperformancerequirements重要的应用要求MinimizeundercutonIDweld减少内焊道的咬边Wider,flatterbeadprofile焊道宽且平滑Noslagsticking无粘渣Robustforproceduralvariations参数变化小Maintainmechanicalproperties机械性能一致LowerHeatoperation热输入小,FutureFluxImprovements将来焊剂的改进,PowerWaveAC/DC1000MachineOverview,ThePowerWaveAC/DCmachinecanbebrokendownintotwosub-assemblies(PowersourceandAC-Switch)thatarecombinedtomakethefinalassembly.Thesesub-assembliesarenotsoldseparately.PWAC/DC机器可以分成两部分（电源和AC开关箱），这两部分不单独出售ThePowersourcesub-assemblyisthe“upperportion”andissimilartothePowerWave655.ThepowersourcesmainfunctionistocreateaDCoutput.电源部分就是上半部分，和PW655相似。主要功能是DC输出。TheAC-Switchsub-assemblyisthe“lowerportion”andisresponsibleforconvertingthePowersourcesDCoutputintoanACoutput.TheAC-switchwasdesignedwitharemovable“slideassembly”.Thisslideassemblycontainsalloftheelectricalcomponentsforsimplerserviceability.AC开关箱就是下半部分，主要负责将DC转换成AC输出。该开关箱设计成可移动的“滑动式装配”，包括了所有电气元件，以便于维修。,ACSwitchAC开关箱,PowerWaveAC/DC1000,PWAC/DC1000,PF-10A,PowerFeed10AControllerPowerFeed10A控制箱,PowerFeed10AControllerPowerFeed10A控制箱,MainUserInterfaceforAC/DCSubarcCell焊接单元的主用户界面FunctionalityBasedonNA-5andPF-10功能主要基于NA5和PF10AllWeldParameters,Timers,Motion,ProcedureMemory,Configuration,andDiagnosticsareaccessedatthePF-10AController所有的焊接参数，计时器，程序记忆，配置和故障诊断都需从该控制箱操作CommunicatesusingArcLink使用ArcLink通讯协议VersatileCanInterfacewithCustomControlsandPLCs,IntegratorFriendly,MultipleConfigurations,easySetup,etc通用性可以进行传统控制和PLC控制，教易集成，多重配置，容易安装，等,Layout布局,DualDisplays双重显示ArcIndicator电弧指示DualEncoders双译码器StatusLight状态指示SwitchPanel控制板MemoryPanel存储板ModeSelectPanel4模式选择板4InfraredPort红外接口,RemotePendant遥控器,SeeinstructionsinIMManualforconversion转换详见操作手册,Functions功能,SixProcedureMemoryStorageLocations六个程序存储单元On-The-FlyMulti-ProcedureWelding(sameMode)焊接中多程序转换（相同模式）ALLProceduresettingsareStored所有程序设置将被储存PressMemoryButtontoRestoreParameters按下记忆键重新存储参数HoldMemoryButtonfor2secondstoSave按住记忆键保持2秒，存储操作完成MemoryPanelcanbeusedtoSetLimits存储板可以用作设定极限值,Functions功能,DigitalAlphaNumericDisplaysforTextMessaging文本信息数字化显示SETUPModeforadditionalWeldParameters,Timers,Starting/StoppingConfiguration,Diagnostics,etc“设置”模式是针对额外的焊接参数，计时器，起弧和熄弧设定，诊断等的设置WELDMODEProcedure,WireSize焊接模式程序，焊丝规格ACCONTROLACParameters.AC控制交流参数STARTOPTIONSStrikeandStartParameters开始选项起弧和开焊时参数ENDOPTIONS-CraterandBurnbackParameters结束选项弧坑和回烧参数IRPORTWirelessCommunication红外接口无线通讯,WeldControls焊接控制,ParametermustbesetinSETUPMODE该虚线框内的数据必须在”设置”模式下设定,AC/DCSubmergedArcSystemAC/DC埋弧焊系统,ACWaveControls交流波形的控制Frequency:ThePWAC/DCcanobtainoutputfrequenciesupto200Hz.TheUserInterfacelimitstherangefrom10Hz.To100Hz.频率：该电源可以得到200Hz以下的输出频率。用户界面限定的范围为10100Hz。WaveBalance:ThisvariablereferstotheamountoftimethewaveformspendsintheDC+partofthecycle波形平衡：此变量是指一周期中交流波形的正半周所占时间。DCOffset:ThisreferstotheshiftofthepeakcurrentwithrespecttothezerocrossingDC偏差：是指峰值电流相对于“0”坐标的偏差值。,Security安全,Lockouts停机MustbeenabledwithPCorPalmApplication必须通过PC或Palm来激活。SETUPMenu设置菜单“ViewDiags”“ViewLockouts”,Security安全,Limits限制AccessedonMemoryPanel进入存储器PressandholdanyMemoryButtonuntilLimitsmenucomesup按下并按住存储钮直到限制设定菜单弹出PresstheRightMSP4Buttontoaccessupperandlowerrange,useKnobtosetvalues按下MSP4面板右边按钮进入上下限设定，用旋钮设定PressLeftMSP4Buttontoexitparameter按MSP4面板左边按钮，退出。,PowerFeed10AController控制器,SingleArcConfiguration单电弧配置,ElectrodeSenseLead,ElectrodeCable,TandemArcConfiguration双弧双电源,ElectrodeSenseLead,ElectrodeCables,MultiArcConfiguration多电弧配置,ElectrodeSenseLead,Electrodecables,SubarcSystemSoftware&Communications埋弧焊系统中的软件和通讯,ArcLink,DeviceNet,EthernetProtocols,Overview总揽,SystemsSoftware系统软件SoftwareComponents软件组成PCApplications应用软件Communications通讯Protocols协议SubarcSystem埋弧焊系统,Communications通讯,Analoganddigitalcommunications.模拟和数字通讯Roleofcommunicationsinsubarcsystems.埋弧焊中通讯的作用Advancedfeaturesforprocessmonitoring.先进的焊接过程实时监视,AnalogCalibration模拟校验,Analogcircuitrymayrequirecalibrationtoensurethattheminimumvalue(e.g,0ipm)istruly0voltsandthatthemaximumvalue(e.g,800ipm)istruly10volts.模拟电路需进行校验，以确保最小值（例如:0ipm）是真正的0伏，以及最大值（如：800ipm)是真正的10伏。Calibrationisamaintenanceitemthatmustbedonetoensureoptimumperformance.校验是维修的一项内容，以确保最佳性能Re-calibrationmaybenecessaryifthepowersourceorrobotisreplaced.如果电源被更换后，需重新校验。,CableSize电缆尺寸,Typicallyeachanaloganddiscretesignalrequiresaseparatepairofwiresresultinginlargebulkycables.一般来说，每一模拟和离散信号需要一对单独的电线，从而增加电线的尺寸。,37pinAnalog/DiscreteI/OConnector,LimitedAccess有限的访问,AccesstoinformationovertheAnalog/Discretelinkisrestrictedtothosecircuitsinthecableandislimitedbythecablesize.模拟连接的访问将受电缆尺寸等的限制。Allotheradjustmentandstatusinformationcanonlybeaccessedmanuallyusingthecontrols(knobs/displays)presentonthemachine.所有其他调整和状态信息只能通过手动来调整机器上的旋钮来完成。,DigitalCommunications数字通讯,NoCalibrationisrequired=LowerMaintenance!无需校验节省维修Typicallyonlytwowiresrequiredforcommunications=LessBulkyCables!只需两根线来完成通讯无需大容量电缆Allinformationisaccessible=SupportsAdvancedWeldingProcesses.所有信息都可访问支持更先进的焊接过程Allinformationisaccessible=FeatureUpgradesWithoutNewHardware!所有信息都可访问无需新的硬件就可进行功能升级,SystemInterface,PC,ArcLink,Ethernet,PF10AControlledSystemsPF10A控制系统,PLC,SystemInterface,PC,DeviceNet,Ethernet,PLCControlledSystemsPLC控制系统,ProtocolUsage协议的使用,ArcLink.AllboardsinternaltoapowersourcetalkoverArcLink.Control,feedhead,EthernetgatewayboardsaswellastheSystemsInterfaceandthePF10A.ArcLink：所有的PC板，控制板、送丝板、通讯板以及系统界面和PF10，在内部和电源之间的通讯都是通过它来完成。DeviceNet.OnlyusedinPLCcontrolledsystems.Canconnecteach“Master”powersourceandtheSystemsInterface.Devicenet：只在PLC控制系统中使用。可以连接每一个主电源和系统的界面。Ethernet.Requiredwhenparallelingpowersources.OptionaluseforPCtools.Ethernet：当有并联的电源时才使用。可以采用PC。,ArcLink,ArcLinkistheleadingdigitalcommunicationsprotocolforthearcweldingindustry.ArcLink是焊接领域最领先的数字通讯协议。ArcLinkcommunicatesinapre-definedweldinglanguage.ArcLink通讯采用预定义的焊接语言。TheArcLinkcableincludesenoughpowertosupplytheMIGfeeder.它的通讯线中有电源线，可以提供给MIG送丝机。TheArcLinkcableincludesatorchvoltagesenselead.ArcLink电缆中包括了焊枪上的电压反馈线。,ArcLinkAdvantagesArcLink的优势,Simplercablesystem=EasyInstallation!简单的电缆容易安装IsStandard=LowerCost!标准件低成本Highestperformanceroboticinterface=LowestCycleTime=MorePartsperDay!高性能的机器人界面最短的周期时间每天生产更多的工件Highestfeaturedroboticinterface=GreaterProcessControl!高品质的机器人界面更好的过程控制,Ethernet以太网,Ethernethasbeenanetworkingstandardfordecades.以太网成为网络的标准已有几十年了Ethernetprovidestheabilitytotopulllargeamountsofinformationintomonitoringandsupervisoryapplications.以太网使得传送大量信息作为监视和追踪之用成为可能。Ethernetinterfacecardsandcablesarereadilyavailableandarerelativelyinexpensive.以太网界面卡和电缆线比较容易得到并且相对便宜。,Ethernet/DeviceNetGatewayPCBoard,Ethernet以太网,Anunlimitednumberofpowersourcescanbenetworkedandviewedfromasinglecomputer=TotalProcessManagement!连接电源数不受限制且只需一台电脑全部过程管理,Wirelessnetworkingtechnologiescanmakeinstallationeasierbyeliminatingmuchoftheneedfornetworkwiring=EasyInstallation!无线技术可以减少网络线容易安装,SoftwareUpgrades软件升级,Allsoftwarecomponentscanbeupgradedinthefield.所有的软件可以在现场升级。,PCApplications应用软件,LincolnprovidesanumberofPCapplicationsthatcanbeusedfortheinstallationandoperationoftheequipment.林肯提供相当数量的应用软件，用来设备的安装和运行。NetSet网络设定NetworkCellSetup网络单元的设定CommandCenter指令中心Diagnostics诊断,CommandCenter指令中心,Purpose目的High-levelMonitoring&ControlofMultiple-arcSystems高效的多电弧监控DesignedforEaseofUse&ConvenienceforOperators&Administrators为了使操作者和管理者轻松、方便ComprehensiveMonitoring&LoggingFeatures全面的监控各功能,ArcIndicator电弧指示,MachineStatus机器状态,WorkpointControl工作点控制,TrimControl弧长控制,Cold-inchControl冷送丝,OperatorScreenControls操作者屏幕控制,ControlofEachArcsParameters&DisplaysStatus控制每个电弧的参数和状态显示,StartAllArcs起弧所有电弧,StopAllArcs停止所有电弧,Increase/DecreaseTravelCarriageSpeed（Forlaterreference）增加/减少机头架移动速度,Stopallarcs停止所有电弧VisibleEvenwhenOutsideofOperatorScreen,OperatorScreenControls操作者屏幕控制,ArcStart&TravelCarriageControls起弧和机头架的控制,OperatorScreenCharts操作者屏幕图表,DisplaysgraphsofCurrent,Voltage,WireFeedSpeed,&TravelSpeed显示焊接电流、电压、送丝速度、焊接速度。DatacanbeSavedtoaTextFilefo