current and -voltage, respectively
Fronius –The Pioneer in Inverter Welding Power Source development
福尼斯-逆变焊接电源开发的先驱者
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Christoph Kammerhuber
克里斯多夫卡玛琥珀
Fronius International GmbH
福尼斯国际有限公司
Welding Division Buxbaumstrasse 2 A –4600 Wels
Content
目录
Physical principles of transistorized Power-Source design and digitalised Welding-Power-Sources
晶体管电源和数字化焊接电源的基本原理
Cold Metal Transfer –Process CMT冷金属过渡技术
Conclusion
结论
Different basic designs of transistorisedwelding-power-sources
各种晶体管焊接电源的基本设计原理
zAnalogue transistor power-source
模拟晶体管电源
zSecondary transistor-switched power-source
次级晶体管开关电源
zPrimary transistor-switched power-source (Inverter)
初级晶体管开关电源（逆变）
zFully digitalised primary transistor-switched power-source
全数字化逆变电源
zCMT –power-source CMT电源
Analogue transistorised welding-power- source模拟晶体管电源
zA shunt connected transistor cascade fulfils the function of a resistor
晶体管组在回路中的作用相当于负载的串联电阻
zTransistor cascade generates the welding-
current and -voltage, respectively
提供相应的焊接电流电压
zLow current ripples and good pulsed-arc characteristics can be obtained
电流波纹小，脉冲电弧特性好
zResistance heat must be dissipated by usinga cooling circuit thus poorly efficiency of -and heavy and voluminous power-sourcecan be remarked, and therefore…
产生的电阻热需要冷却回路散热，效率低、重量 大、体积大
zAnalogue power-sources play no more major- role in the field of welding and disappeared bit by bit within industrial applications
因此模拟控制的电源在焊接领域中不再担任主要角 色并且逐渐在工业应用中消失
Fronius –ThePioneer in Inverter Welding Power Source developement 02.05.2008
Different basic designs of transistorisedwelding-power-sources
各种晶体管焊接电源的基本设计原理
zAnalogue transistor power-source
模拟晶体管电源
zSecondary transistor-switched power-source
次级晶体管开关电源
zPrimary transistor-switched power-source(Inverter)
初级晶体管开关电源（逆变）
zFully digitalised primary transistor-switched power-source
全数字化逆变电源
zCMT –power-source CMT电源
Secondary transistor-switched welding-power-source 次级晶体管开关焊接电源
zLarge 50 Hz transformer on the primary –andrectifier on the secondary side, id est...
50Hz的大型工频变压器在初级，整流在次级
zRectified current is being transistor-switched
on the secondary side of the welding-circuit
晶体管开关在焊接回路的次级端对电流整流
zRelatively insensitivity against main voltagepeaks and relatively good electrical efficiencycan be remarked positively, but...
动态响应特性好、效率高
zLarge volume and weight of these machinescan be remarked as disadvantages
但是体积大、重量大
Different basic designs of transistorisedwelding-power-sources
各种晶体管焊接电源的基本设计原理
zAnalogue transistor power-source
模拟晶体管电源
zSecondary transistor-switched power-source
次级晶体管开关电源
zPrimary transistor-switched power-source(Inverter)
初级晶体管开关电源（逆变）
zFully digitalised primary transistor-switched power-source
全数字化逆变电源
zCMT –power-source CMT电源
Primary transistor-switched welding-power-source (Inverter)初级晶体管开关电源（逆变）
zIncreased frequency, e.g. 100 kHz,of the rectified current is being generated on theprimary side of the welding-circuit by use ofMOSFET –semiconductors
在焊接回路的初级端采用场效应管提高逆变
频率，如100KHz zVery low mass and volume of usedtransformers can be realized, thus small size of power-source can be obtained
可以使用非常小的变压器，电源体积小、重量轻
zMinimum current-and voltage ripple can beobtained, thus maximal arc-stability
最小的电流电压波纹，最大的电弧稳定性
zMaximum grade of electrical efficiency of the power-source can be obtained
电源可以得到最高等级的效率
FRONIUS leads the Gas-shielded Metal-Arc-Welding into a new future福尼斯引领GSM熔化极气体保护焊进入一个新的时代
z1981:Development and presentation of the worldwide first primary transistor-switched GMAW-Power-Source with
Pulse Arc in Essen –Germany >>TRANSARC 500<<
1981年，开发出世界上第一台初级晶体管开 关GSM脉冲焊接电源，并在德国埃森展上推 出
Revolution with T.I.M.E. –PROCESS
T.I.M.E高速焊工艺的革命
z1989:Development and presentation of the worldwide first primary transistor-switched GMAW- Power-Source for High Deposition Welding with 1- Wire electrode Wire feed speeds up to 30m/min and deposition rates up to more 20kg/hour >>T.I.M.E. -Synergic<<
1989年，开发并推出世界上第一台单丝高速焊逆变 电源>>T.I.M.E. -Synergic<< 送丝速度达30米/分， 熔敷效率可达20公斤/小时
Revolution with T.I.M.E. –PROCESS
T.I.M.E高速焊工艺的革命
MAG: Bevelangle 坡口角度50° Wire feed speed 11m/min Depositionrate : 5,8kg/h Pass no. 焊道数量65
T.I.M.E.: Bevalangle坡口角度40° Wire feed speed 18m/min Depositionrate: 9,6kg/h Pass no.焊道数量45
Different basic designs of transistorisedwelding-power-sources
各种晶体管焊接电源的基本设计原理
zAnalogue transistor-switched power-source
模拟晶体管开关电源
zSecondary transistor-switched power-source
次级晶体管开关电源
zPrimary transistor-switched power-source(Inverter)
初级晶体管开关电源（逆变）
zFully digitalised primary transistor-switched power-source
全数字化逆变电源
zCMT –power-source CMT电源
Digitalised power-source for GMA-welding 全数字化熔化极气体保护焊电源
Exchange of analogue to digital process-controller(DSP) means: 采用DSP数字信号处理器取代模拟控制意味着：
送丝机
遥控器数据总线传输
zObtaining digital repeatability of weld-properties
得到数字式的重现精度
zObtaining never known arc-stability and 主控系统welding performance
得到前所未有的电弧稳定性和焊接性能Digital 数据处理器 actual Value
zObtaining additional reduction of (实际值的数字信号)
Actual value (U/I)
power-sources‘ weight and volume (实际值)降低电源的重量和体积-轻便灵活
zBasis for the realisation of the CMT-process 实现CMT工艺的前提基础
Gas-Metal-Arc-Welding becomes digitally reproducible 气保焊具有数字化的重复性能
Use of digital power-sources means:
使用数字化电源意味着：
zImproved arc-ignition
提升引弧性能
zOptimised short-circuit-arc characteristics
最优化的短路过渡电弧特性曲线
zVariable and optimized pulse-arc-characteristics
可变的、最优化的脉冲电弧特性曲线
zConstant arc-length-control
恒定的弧长控制
zHighest grade of arc-stability
最高等级的电弧稳定性
zHighest grade of weld-performance repeatability
最高等级的焊接性能重现性
zBasis for power-source advancements, e.g. TIME 5000 digital, TIME
TWIN Tandem welding or CMT-power-source 作为更先进的电源的基础条件，例如TIME5000 Digital 数字化单丝高速焊、TIME Twin 数字化双丝高效焊、CMT电源等
双丝高效焊
z2002: FRONIUS presents the
Tandem welding Power-Source 2002年，福尼斯推出世界上第一套全数字化双丝高效焊电源
>>TIME TWIN 4000 / 5000 / 7200 / 9000 Digital<<
zPresentation on the worlds largest welding fair in Essen/Germany 2001 在2001年德国埃森展上展示
Application Rail Vehicle Construction
机车行业应用
Reference Alstom
阿尔斯通
Workpiece: Extrusion profiles
工件：机车侧板
Seam type:V-seam, fillet weld V型坡口 Base metal:AlMgSi0.7 Filler metal:Al Mg 4.5 Mn0.7 Weld speed:250 cm/min 焊接速度：250cm/min Fusing performance:7 kg/h 熔敷效率：7kg/h Welding position:PA 焊接位置：PA平焊位
Different basic designs of transistorisedwelding-power-sources
各种晶体管焊接电源的基本设计原理
zAnalogue transistor-switched power-source
模拟晶体管电源
zSecondary transistor-switched power-source
次级晶体管开关电源
zPrimary transistor-switched power-source(Inverter)
初级晶体管开关电源（逆变）
zFully digitalised primary transistor-switched power-source
完全数字化逆变电源
zCMT –power-source CMT电源
CMT –a new epoch in Gas-shielded Metal-Arc-Joining beginsCMT-熔化极气体保护焊的一个新纪元的开始
z 2004: A quantum-leap in GMA-Joining becomes reality –FRONIUS develops and presents the C M T -process to the world
2004年，溶化极气体保护焊的 一个巨大突破，福尼斯开发出 C M T冷金属过渡技术
What is CMT?
zCMT stands for Cold Metal Transfer
CMT-Cold Metal Transfer冷金属过渡zShort-circuit-arc based process with an absolutely new principleof droplet detachment
基于短路过渡工艺，采用一种全新的熔滴分离过渡技术
zMetal transfer with relatively low thermal energy-input in comparison to conventional GMA-modes
和常规的GMA工艺相比，金属过渡的热量很低
Striking differences define a new process
For the very first time, the wire movement could be directly integrated into the process-control
第一次将焊丝的运动直接同焊接过程控制相结合
Wire feeder Wire buffer
CMT Welding Seam under CO2纯CO2 CMT焊接
Innovation: high formability steel–aluminumsheet 创新：钢铝焊接板具有很高的可锻性
Conclusion
zFully digitalised Inverters have revolutionized the Gas-Metal-Arc-Welding-processes due to their very sophisticated welding-properties and peripheral advantages, e.g. size and volume and plug & weld characteristic
全数字化电源以其非常成熟完善的焊接特性和诸如尺寸小、重量轻、即
插即用等优点，演绎了GMAW工艺的革命。zThey form also the basis for the CMT-power-source –the actual andfuture standard for Gas-Metal-Arc-joining applications
这也是CMT电源的基础– 现在以至将来GMAW应用的工艺标准zCMT as a completely new process for joining a large range of base materials with an also large spectrum of properties enables the user to enter the future of metal-joining already today
CMT作为一种全新的工艺，特性范围广、适用于多种母材的焊接；让用户现在就可以进入领略未来的焊接技术。
PERFECT WELDING
