全数字控制高频感应加热电源的研究
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摘要
感应加热电源以其节能、高效、无污染等优点在工业生产中得到了广泛的应用。本文以感应加热电源为研究对象,对感应加热电源常用的谐振槽路和拓扑结构进行了分析,选择了更适合高频感应加热电源的串联型逆变器;并分析了感应加热电源的各种调功方式,在对比几种功率调节方式的基础上,得出了整流侧调功有利于高频感应加热电源频率和功率提高的结论,选择了不控整流加斩波器的功率调节方式。
感应加热电源的频率跟踪电路大都采用基于CD4046的模拟锁相环,但传统模拟锁相环存在着频率跟踪范围较窄、动态响应较慢、可靠性差,死区时间需要用辅助电路实现等一些缺点。本文对锁相环原理进行了分析,根据其数学模型,针对传统锁相环的缺点提出了一种基于数字信号处理器(DSP)的软件锁相环(SPLL)的实现方法。文中对这种软件锁相环(SPLL)的算法及软硬件设计进行了详细的阐述。本文同时设计了感应加热电源的功率闭环控制系统,将功率控制问题转化为Buck斩波器的电压控制问题。根据感应加热电源功率控制的特点,设计了基于模糊PI控制的功率闭环控制系统,并详细阐述了其基于DSP的软硬件实现方法。
在理论分析的基础上,本文设计了一台10kW的基于DSP的高频感应加热电源实验样机,其中斩波器频率为20kHz,逆变器工作频率为100kHz,控制核心采用TI公司的TMS320LF2407A DSP控制芯片,简化了系统结构的同时提高了系统性能。最后,本文还给出了软硬件设计方案和实验结果。
Induction heating power supply has been widely applied into industry because of its energy saving, high efficiency and no pollution. This paper briefly introduced the basic principle and the development trend of induction heating technology. analyzed power regulating methods of induction heating power supply. It can be concluded that power regulation in the commutate side in favor of enhancing the frequency and power level of high-frequency induction heating power supply. Uncontrolled rectifying circuit and Buck choppering power regulation method have been chosed as the subject investigated.
The traditional analog phase-locked loop based on the CD4046 is mostly used in the induction heating power supply frequency tracking channel, but the traditional analog phase-locked loop has some shortcomings, such as narrow frequency track scope, slow dynamic response, bad reliability, need of using auxiliary circuit to realize dead time and so on. A method of implementing Software Phase-Locked Loop (SPLL) based on DSP was puted forward in this paper puts forward, according to the mathematics model of Phase-Locked Loop (PLL).The algorithm of the software phase-locked loop (SPLL) and the design of software and hardware have carried on the detailed elaboration in the paper. The power closed-loop control system has been designed, then the power control the induction heating power supply transforma to the Buck chopper voltage control. According to the characteristic of the power control of the induction heating power supply, closed-loop control system based on the fuzzy PI control has been designed, And the realization method based on the DSP software and hardware was elaborated in detail.
In theoretical analysis foundation , an induction heating power supply is designed and turned out, the power of which are 10kW with the frequency 20 kHz for the chopper and 100 kHz for the inverter. The special DSP chip of TMS320LF2407A that produced by TI Company is used as main controller of the power to simplided the system. In addition, the software and hardware design proposal and the experimental result is presented in this paper.
感应加热电源的频率跟踪电路大都采用基于CD4046的模拟锁相环,但传统模拟锁相环存在着频率跟踪范围较窄、动态响应较慢、可靠性差,死区时间需要用辅助电路实现等一些缺点。本文对锁相环原理进行了分析,根据其数学模型,针对传统锁相环的缺点提出了一种基于数字信号处理器(DSP)的软件锁相环(SPLL)的实现方法。文中对这种软件锁相环(SPLL)的算法及软硬件设计进行了详细的阐述。本文同时设计了感应加热电源的功率闭环控制系统,将功率控制问题转化为Buck斩波器的电压控制问题。根据感应加热电源功率控制的特点,设计了基于模糊PI控制的功率闭环控制系统,并详细阐述了其基于DSP的软硬件实现方法。
在理论分析的基础上,本文设计了一台10kW的基于DSP的高频感应加热电源实验样机,其中斩波器频率为20kHz,逆变器工作频率为100kHz,控制核心采用TI公司的TMS320LF2407A DSP控制芯片,简化了系统结构的同时提高了系统性能。最后,本文还给出了软硬件设计方案和实验结果。
Induction heating power supply has been widely applied into industry because of its energy saving, high efficiency and no pollution. This paper briefly introduced the basic principle and the development trend of induction heating technology. analyzed power regulating methods of induction heating power supply. It can be concluded that power regulation in the commutate side in favor of enhancing the frequency and power level of high-frequency induction heating power supply. Uncontrolled rectifying circuit and Buck choppering power regulation method have been chosed as the subject investigated.
The traditional analog phase-locked loop based on the CD4046 is mostly used in the induction heating power supply frequency tracking channel, but the traditional analog phase-locked loop has some shortcomings, such as narrow frequency track scope, slow dynamic response, bad reliability, need of using auxiliary circuit to realize dead time and so on. A method of implementing Software Phase-Locked Loop (SPLL) based on DSP was puted forward in this paper puts forward, according to the mathematics model of Phase-Locked Loop (PLL).The algorithm of the software phase-locked loop (SPLL) and the design of software and hardware have carried on the detailed elaboration in the paper. The power closed-loop control system has been designed, then the power control the induction heating power supply transforma to the Buck chopper voltage control. According to the characteristic of the power control of the induction heating power supply, closed-loop control system based on the fuzzy PI control has been designed, And the realization method based on the DSP software and hardware was elaborated in detail.
In theoretical analysis foundation , an induction heating power supply is designed and turned out, the power of which are 10kW with the frequency 20 kHz for the chopper and 100 kHz for the inverter. The special DSP chip of TMS320LF2407A that produced by TI Company is used as main controller of the power to simplided the system. In addition, the software and hardware design proposal and the experimental result is presented in this paper.
引文
1.约翰·戴维斯等.感应加热手册[M].北京:国防工业出版社,1985.5-20.
2.李爱文,张承慧.现代逆变技术及其应用[M].北京:科学出版社,2000.
3. Tentim. Medium Frequency GTO Inverter for Induction Heating Application. Proc.of E.P.E. ,1987: 271—276.
4. Mauch. Transistor inverter for Medium Power Induction Heating Application. Canada AC Statpower Inc.,1987.
5. N.S.Bayindu,O.Kukrer and M.Yakup,DSP-based PLL-Controlled 50-100kHz 20kW high-frequeccy induction heation system for surface hardening and welding application[J]. IEEE Proc-Electr, Power Appl, May 2003, 150(3): 365-371.
6.王华民.串联谐振式感应加热电源系统的建模与研究[J].电力电子技术,2000,34(5):45—47.
7.熊腊森,全亚杰.高频感应加热电源的研究[J].电焊机,1999,VOL.29 No.12:18—20.
8. Dede E J, Gonzalez J V, Esteve V, et al. Transistorized Inverters for Induction Heating Application State-of-the-art and Future Trends[C]. IPEMC’97.Hangzhou (China), 1997. 746—751.
9.孙立萌.基于DSP的超音频感应加热电源数字化控制的研究[D]: [硕士学位论文].西安:西安理工大学, 2004.
10. P.Jain,S.B.Dewan.Starting Problems Associated with a Transformer Coupled Load in a Series Inverter [C].IEEE Trans.Magn. Vol.24. NOV.1988. 2895—2897.
11.戚宗刚,柳鹏,陈辉明.感应加热调功方式的探讨[J].金属热处理,2003 ,28 (7): 54—57.
12.刘红艳.中频感应加热负载分析[J].工业加热,1995(5):35—41.
13.潘天明.现代感应加热装置[M].北京:冶金工业出版社,1996.12.
14.季翼鹏.基于DSP的软斩波功率调节并联谐振感应加热电源的研究[D]:[硕士学位论文].无锡:江南大学通信与控制工程学院, 2004.
15. Angel de Castro, Pabol Zumel. Concurrent and Simple Digital Controller of an AC/DC Converter With Power Factor Correction Based on an FPGA[J]. IEEE TRANSACTI- ONS ON POWER ELECTRONICS, VOL. 18, No. 1,JANNUARY 2003:334—343.
16. Yang Ye, Mehrhad Kazerani. Modeling, Control and Implementation of Three Phase PWM Converters[J].IEEE TRANSAONS ON POWER ELECTRONICS VOL. 18, N0. 3,MAY 2003:857—864.
17.吴雷,惠晶.基于DSP大功率中频感应焊机的研制[J].电力电子技术,2003,37(4): 62-64.
18.沈锦飞,颜文旭等.钢丝热处理用高频感应电源的研制[J].电力电子技术,2003, 37(6):56—58.
19. Tsai-Fu Wu, Shih-An Liang. A Structural Approach to Synthesizing SoftSwitching PWM Converters[J].IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL.18N0. 1,.JANUARY 2003:857—864.
20. Hideaki Fujita,Hirofumi Akagi.Pulse-Density-Modulated Power Control of a 4 kW,450kHz Voltage-Source Inverter for Induction Melting Application [J].IEEE Transactions on Industry Applications,VOL.32,NO.2,March/April,1996:276—286
21.颜文旭,沈锦飞,惠晶,吴雷.脉冲均匀调制功率控制串联谐振式逆变器[J],电力电子技术,2004,38(4):43-45.
22. Chris Iannello, Shiguo Luo, and Issa Batarseh. Small-Signal and Transient Analysis of a Full-Bridge, Zero-Current-Switched PWM Converter Using an Average Model. IEEE Trans.Power Electron. 2003(18):793—801.
23.吴雷,付涣森,韦凯.基于模糊神经网络的感应加热电源机组研究[J].电力电子技术,2007,41(12): 93—96.
24. DAWSON,F.P.,and JAIN,P.,A Comparison of Load Commuted Inverter Systems for Induction Heating and Melting Applications[J].IEEE Trans.Power Electron, 1991.6(3):430-441.
25.沈锦飞,颜文旭等.串联谐振式高频感应焊接逆变电源[J].焊接学报.2003(5) 77-80.
26.王华民,李朝阳.锁相技术在感应加热电源中的应用[J].西安理工大学学报,1999:52—55.
27.李金刚,等.基于DSP的感应加热电源频率跟踪控制的实现[J].电力电子技术,2003:31—33.
28.郑继禹,万心平等.锁相环路原理与应用[M].北京:人民邮电出版社,1984. 43—55.
29. Mu-Ping Chen, Jan-Ku Chen and Shih-Hsin Chen.The Surge Analysis of In-duction Heating Power Supply with PLL. IEEE 1999 International Conference Power Electronics and Drive Systems,PEDS’99,July 1999,Hong Kong.
30.孙立萌.基于DSP的超音频感应加热电源数字化控制的研究[D]:[硕士学位论文].西安:西安理工大学,2005.3.
31.赵为.太阳能光伏并网发电系统的研究[D]:[博士学位论文].合肥:合肥工业大学,2003.4.
32.刘和平,王维俊,江渝等. TMS320LF240x DSP C语言开发应用[M].北京:北京航空航天大学出版社,2003.5-8.
33.陈坚.电力电子学-电力电子变换和控制技术[M].北京:高等教育出版社,2002.100-105.
34.陈维,黄辉先.一类感应加热电源输出功率的最优PI控制[J].电工技术杂志,2002(7): 35-38.
35.张素荣.基于DSP的高频感应加热电源控制系统的研究[D]:[硕士学位论文].西安:西安理工大学2004.3.
36.刑岩,蔡宣三.高频功率开关变换技术[M].北京:机械工业出版社,2005.204—212.
37.朱刚,李纯喜,等.中频感应加热温度智能控制研究与实现[J].电力电子技术,1998.32(4):45-48.
38.蒋峰,吴雷,惠晶等.基于DSP的智能数字三相交流调压调功器的研制[J].电力电子技术,2007.41(11):58-61.
39.颜文旭.基于DSP的高频感应加热电源的研究[D]:[硕士学位论文].无锡:江南大学通信与控制工程学院,2003.
40.章卫国,扬向忠.模糊控制理论与应用[M].西安:西北工业大学出版社,2001.
41.陶永华.新型PID控制及其应用[M].北京:机械工业出版社,2001.
42.沈锦飞,颜文旭等.串联谐振式高频感应焊接逆变电源[J].焊接学报.2003(5): 77-80.
43.彭迎,阮江军,杜志叶. EXB841在驱动中频IGBT半桥电路中的应用[J].电子技术, 2004(8): 46-47.
44.崔冬明.新型ZCT-PWM软斩波调功的感应加热电源研究[D]:[硕士学位论文].无锡:江南大学通信与控制工程学院,2007.
45.惠晶,蔡爱军.新型ZCS-PLL控制的大功率逆变电源的研究[J].电力电子技术,2004,34(6):89-91.
2.李爱文,张承慧.现代逆变技术及其应用[M].北京:科学出版社,2000.
3. Tentim. Medium Frequency GTO Inverter for Induction Heating Application. Proc.of E.P.E. ,1987: 271—276.
4. Mauch. Transistor inverter for Medium Power Induction Heating Application. Canada AC Statpower Inc.,1987.
5. N.S.Bayindu,O.Kukrer and M.Yakup,DSP-based PLL-Controlled 50-100kHz 20kW high-frequeccy induction heation system for surface hardening and welding application[J]. IEEE Proc-Electr, Power Appl, May 2003, 150(3): 365-371.
6.王华民.串联谐振式感应加热电源系统的建模与研究[J].电力电子技术,2000,34(5):45—47.
7.熊腊森,全亚杰.高频感应加热电源的研究[J].电焊机,1999,VOL.29 No.12:18—20.
8. Dede E J, Gonzalez J V, Esteve V, et al. Transistorized Inverters for Induction Heating Application State-of-the-art and Future Trends[C]. IPEMC’97.Hangzhou (China), 1997. 746—751.
9.孙立萌.基于DSP的超音频感应加热电源数字化控制的研究[D]: [硕士学位论文].西安:西安理工大学, 2004.
10. P.Jain,S.B.Dewan.Starting Problems Associated with a Transformer Coupled Load in a Series Inverter [C].IEEE Trans.Magn. Vol.24. NOV.1988. 2895—2897.
11.戚宗刚,柳鹏,陈辉明.感应加热调功方式的探讨[J].金属热处理,2003 ,28 (7): 54—57.
12.刘红艳.中频感应加热负载分析[J].工业加热,1995(5):35—41.
13.潘天明.现代感应加热装置[M].北京:冶金工业出版社,1996.12.
14.季翼鹏.基于DSP的软斩波功率调节并联谐振感应加热电源的研究[D]:[硕士学位论文].无锡:江南大学通信与控制工程学院, 2004.
15. Angel de Castro, Pabol Zumel. Concurrent and Simple Digital Controller of an AC/DC Converter With Power Factor Correction Based on an FPGA[J]. IEEE TRANSACTI- ONS ON POWER ELECTRONICS, VOL. 18, No. 1,JANNUARY 2003:334—343.
16. Yang Ye, Mehrhad Kazerani. Modeling, Control and Implementation of Three Phase PWM Converters[J].IEEE TRANSAONS ON POWER ELECTRONICS VOL. 18, N0. 3,MAY 2003:857—864.
17.吴雷,惠晶.基于DSP大功率中频感应焊机的研制[J].电力电子技术,2003,37(4): 62-64.
18.沈锦飞,颜文旭等.钢丝热处理用高频感应电源的研制[J].电力电子技术,2003, 37(6):56—58.
19. Tsai-Fu Wu, Shih-An Liang. A Structural Approach to Synthesizing SoftSwitching PWM Converters[J].IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL.18N0. 1,.JANUARY 2003:857—864.
20. Hideaki Fujita,Hirofumi Akagi.Pulse-Density-Modulated Power Control of a 4 kW,450kHz Voltage-Source Inverter for Induction Melting Application [J].IEEE Transactions on Industry Applications,VOL.32,NO.2,March/April,1996:276—286
21.颜文旭,沈锦飞,惠晶,吴雷.脉冲均匀调制功率控制串联谐振式逆变器[J],电力电子技术,2004,38(4):43-45.
22. Chris Iannello, Shiguo Luo, and Issa Batarseh. Small-Signal and Transient Analysis of a Full-Bridge, Zero-Current-Switched PWM Converter Using an Average Model. IEEE Trans.Power Electron. 2003(18):793—801.
23.吴雷,付涣森,韦凯.基于模糊神经网络的感应加热电源机组研究[J].电力电子技术,2007,41(12): 93—96.
24. DAWSON,F.P.,and JAIN,P.,A Comparison of Load Commuted Inverter Systems for Induction Heating and Melting Applications[J].IEEE Trans.Power Electron, 1991.6(3):430-441.
25.沈锦飞,颜文旭等.串联谐振式高频感应焊接逆变电源[J].焊接学报.2003(5) 77-80.
26.王华民,李朝阳.锁相技术在感应加热电源中的应用[J].西安理工大学学报,1999:52—55.
27.李金刚,等.基于DSP的感应加热电源频率跟踪控制的实现[J].电力电子技术,2003:31—33.
28.郑继禹,万心平等.锁相环路原理与应用[M].北京:人民邮电出版社,1984. 43—55.
29. Mu-Ping Chen, Jan-Ku Chen and Shih-Hsin Chen.The Surge Analysis of In-duction Heating Power Supply with PLL. IEEE 1999 International Conference Power Electronics and Drive Systems,PEDS’99,July 1999,Hong Kong.
30.孙立萌.基于DSP的超音频感应加热电源数字化控制的研究[D]:[硕士学位论文].西安:西安理工大学,2005.3.
31.赵为.太阳能光伏并网发电系统的研究[D]:[博士学位论文].合肥:合肥工业大学,2003.4.
32.刘和平,王维俊,江渝等. TMS320LF240x DSP C语言开发应用[M].北京:北京航空航天大学出版社,2003.5-8.
33.陈坚.电力电子学-电力电子变换和控制技术[M].北京:高等教育出版社,2002.100-105.
34.陈维,黄辉先.一类感应加热电源输出功率的最优PI控制[J].电工技术杂志,2002(7): 35-38.
35.张素荣.基于DSP的高频感应加热电源控制系统的研究[D]:[硕士学位论文].西安:西安理工大学2004.3.
36.刑岩,蔡宣三.高频功率开关变换技术[M].北京:机械工业出版社,2005.204—212.
37.朱刚,李纯喜,等.中频感应加热温度智能控制研究与实现[J].电力电子技术,1998.32(4):45-48.
38.蒋峰,吴雷,惠晶等.基于DSP的智能数字三相交流调压调功器的研制[J].电力电子技术,2007.41(11):58-61.
39.颜文旭.基于DSP的高频感应加热电源的研究[D]:[硕士学位论文].无锡:江南大学通信与控制工程学院,2003.
40.章卫国,扬向忠.模糊控制理论与应用[M].西安:西北工业大学出版社,2001.
41.陶永华.新型PID控制及其应用[M].北京:机械工业出版社,2001.
42.沈锦飞,颜文旭等.串联谐振式高频感应焊接逆变电源[J].焊接学报.2003(5): 77-80.
43.彭迎,阮江军,杜志叶. EXB841在驱动中频IGBT半桥电路中的应用[J].电子技术, 2004(8): 46-47.
44.崔冬明.新型ZCT-PWM软斩波调功的感应加热电源研究[D]:[硕士学位论文].无锡:江南大学通信与控制工程学院,2007.
45.惠晶,蔡爱军.新型ZCS-PLL控制的大功率逆变电源的研究[J].电力电子技术,2004,34(6):89-91.