基于波控技术的CO_2焊电源的研究
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摘要
随着微机技术在焊接领域应用的不断深入，波控技术在弧焊电源中的应用也成为新型焊机研究的一主流方向。本文以波控技术为基本指导思想，应用微机技术，对CO_2焊短路过渡用电源加以研究。根据CO_2焊短路过渡过程的特点对其进行细分成七个阶段。在颈缩形成过程中，提高电流上升速度，促进颈缩形成，而在短路过渡后期降低电流，使液桥低能量爆破，完成较小飞溅的短路过渡。在此过程中，通过电流电压传感器实时采样电流电压值，并送至微机处理，控制输出符合于短路过渡特点的电流电压波形。
本文在分析CO_2焊飞溅产生和焊缝成型机理的基础上，探讨了CO_2焊短路过渡过程的控制策略，采用简单的三相桥式不可控全桥电路的主回路形式。利用IGBT响应速度快且易于控制的特点，在主回路的输出侧直接用单片机控制大功能器件(IGBT)工作于开关状态。IGBT驱动电路采用的是专用驱动模块M57962AL，其特点是能稳定可靠地驱动IGBT，为整个系统的正常工作提供保障。利用定频调宽原理，实时准确地检测CO_2焊短路时刻和熔滴颈缩时刻及各细分阶段的电弧参数值，并通过单片机处理，控制得到符合CO_2焊短路过渡细分各阶段的电源外特性。
单片机控制系统芯片采用的80C196KC。主要用到的资源引脚有HSI高速输入引脚，P1口，P2多功能口和A/D转换接口等。同时系统设有键盘/显示电路和指示报警系统，用于指示过程控制状态和系统故障报警。软件技术，采用了中断服务技术，及时处理各类故障和实时控制，程序结构采用了子程序编程思想，使其清晰明了，便于调试修改，同时采用了软硬件综合抗干扰措施，提高系统稳定性。
系统研究证明了本系统的可行性，同时也是控制CO2焊飞溅问题的有效措施，即降低了成本又使控制简单，易于实现。
With the further application of microcomputer in the welding field, the research of wave controlled technology in new welding machine exploits a mainstream method .In this paper, the new power source for CO2 short circuiting transfer is researched which is based on the technology of microcomputer and wave control. In terms of the character of short circuit transfer of CO2 welding, the process is made into seven subsections. During the neck of metal becoming, rising the current velocity make it coming into being. And at the later of short circuiting transfer, the welding current is detracted, as is make the bridge braking at the low energy and finishes the transfer without splash. During the process, the real time current and voltage values information are obtained and sent to the microcomputer for processing, then the wave of current and voltage is produced by the control of microcomputer at the output end which is suit for the short circuiting transfer
In this paper, basing on analyzing of the reasons for splashing of CO2 welding and weld moulding, the control project of short circuiting transfer is probing. The main circuit is three phase whole bridge which can not be controlled. By using the characters of IGBT, swift responding and easy controlling, at the fan-out of DC, IGBT is made to works in a on-off statue with the controlling of single chip On the output end of the main circuit .The driver circuit for high power devices IGBT adopts the module M57962AL ,which can working reliably .So the hole system working well is possible. To transmit the wave shape of current and voltage which is suitable for each step of the CO2 short circuit subsections , the principle of PWM is used . At the time of short circuit and shrinking neck of melting drop and other subsections, the arc values are exactly checked in real time and sent to be processed by the chip. The out character of the power source that comes up to every subsection of short circuit transfer of co2 we
lding is obtained.
At the same time, the chip used as control is the single chip 80C196KC .Some source ports,such as HSI> PK P2, A/D ect, are used in this
paper.At the same time there are keyboard and display circuit and alarm system ,which is for setting and displaying parameter in advance and alarming the system malfunction .In software technology ,interrputting service technology is used,which can disposal every kind of malfunction in time and real time control. The structure of software adopts the subroutime thinking which is in focus and easy to debug and modify, in order to improve the system stability, hardware and software synthesis measures are adopted for the disturbance problem.
In this paper,the research has born out that the project is workable,at the same time it is the available measure for solving the splashing when welding ,namely,it not only decline the price but also easy for controlling and realizing.
本文在分析CO_2焊飞溅产生和焊缝成型机理的基础上，探讨了CO_2焊短路过渡过程的控制策略，采用简单的三相桥式不可控全桥电路的主回路形式。利用IGBT响应速度快且易于控制的特点，在主回路的输出侧直接用单片机控制大功能器件(IGBT)工作于开关状态。IGBT驱动电路采用的是专用驱动模块M57962AL，其特点是能稳定可靠地驱动IGBT，为整个系统的正常工作提供保障。利用定频调宽原理，实时准确地检测CO_2焊短路时刻和熔滴颈缩时刻及各细分阶段的电弧参数值，并通过单片机处理，控制得到符合CO_2焊短路过渡细分各阶段的电源外特性。
单片机控制系统芯片采用的80C196KC。主要用到的资源引脚有HSI高速输入引脚，P1口，P2多功能口和A/D转换接口等。同时系统设有键盘/显示电路和指示报警系统，用于指示过程控制状态和系统故障报警。软件技术，采用了中断服务技术，及时处理各类故障和实时控制，程序结构采用了子程序编程思想，使其清晰明了，便于调试修改，同时采用了软硬件综合抗干扰措施，提高系统稳定性。
系统研究证明了本系统的可行性，同时也是控制CO2焊飞溅问题的有效措施，即降低了成本又使控制简单，易于实现。
With the further application of microcomputer in the welding field, the research of wave controlled technology in new welding machine exploits a mainstream method .In this paper, the new power source for CO2 short circuiting transfer is researched which is based on the technology of microcomputer and wave control. In terms of the character of short circuit transfer of CO2 welding, the process is made into seven subsections. During the neck of metal becoming, rising the current velocity make it coming into being. And at the later of short circuiting transfer, the welding current is detracted, as is make the bridge braking at the low energy and finishes the transfer without splash. During the process, the real time current and voltage values information are obtained and sent to the microcomputer for processing, then the wave of current and voltage is produced by the control of microcomputer at the output end which is suit for the short circuiting transfer
In this paper, basing on analyzing of the reasons for splashing of CO2 welding and weld moulding, the control project of short circuiting transfer is probing. The main circuit is three phase whole bridge which can not be controlled. By using the characters of IGBT, swift responding and easy controlling, at the fan-out of DC, IGBT is made to works in a on-off statue with the controlling of single chip On the output end of the main circuit .The driver circuit for high power devices IGBT adopts the module M57962AL ,which can working reliably .So the hole system working well is possible. To transmit the wave shape of current and voltage which is suitable for each step of the CO2 short circuit subsections , the principle of PWM is used . At the time of short circuit and shrinking neck of melting drop and other subsections, the arc values are exactly checked in real time and sent to be processed by the chip. The out character of the power source that comes up to every subsection of short circuit transfer of co2 we
lding is obtained.
At the same time, the chip used as control is the single chip 80C196KC .Some source ports,such as HSI> PK P2, A/D ect, are used in this
paper.At the same time there are keyboard and display circuit and alarm system ,which is for setting and displaying parameter in advance and alarming the system malfunction .In software technology ,interrputting service technology is used,which can disposal every kind of malfunction in time and real time control. The structure of software adopts the subroutime thinking which is in focus and easy to debug and modify, in order to improve the system stability, hardware and software synthesis measures are adopted for the disturbance problem.
In this paper,the research has born out that the project is workable,at the same time it is the available measure for solving the splashing when welding ,namely,it not only decline the price but also easy for controlling and realizing.
引文
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[3] 俞建荣，将力培，史耀武．CO_2弧焊熔滴过渡过程焊接电弧的并联式波形控制．电工技术学报，2001／8第16卷第4期
[4] Mita T. Waveform control method in CO2 shielded welding溶接学会论文集，1988，
[5] 王雅生．细丝CO_2自动焊机的单片机智能控制系统[J]．电焊机，2000，30(10)：7-10
[6] JenogⅡK et al. A Modified Genetic Algorithm for Neurocontrollers. Proc. of IEEE International Conference on Evolutionary Computation, 1995
[7] 何方殿．弧焊整流电源及控制．北京：机械工业出版社，1983
[8] 韩赞东，都东，张人豪．CO_2焊接过程熔滴过渡频率的Fuzzy／PID控制．焊接学报，Vol．21 No．1 March 2000
[9] 何立民．单片机应用技术选编，1993／4
[10] 黄石生．新型弧焊电源及其智能控制．北京：机械工业出版社，2000
[11] 王其隆．弧焊过程质量实时传感与控制．北京：机械工业出版社，2000／12
[12] 韩赞东．微机控制逆变电源电弧焊系统的研究：[博士学位论文]．北京：清华大学，1996
[13] 朱志明，张人豪．新型CO_2焊接方法的研究[J]．电焊机，1994，24(6)：12-15
[14] 朱志明，张人豪．恒流CO_2焊接的熔滴过渡形式及其参数的研究[J]．电焊机，1997，27(2)：36-39
[15] 胡小建．单片机实现逆变式CO_2气保焊电源双阶梯恒流外特性系统的研究[J]．电焊机，1999，29(6)：10-12
[16] 韩赞东，都东，张前等．焊接电弧的三维外特性控制研究[J]．清华大学学报(自然科学版)，1999，39(4)：35-37
[17] 郭大勇．CO_2短路过渡过程检测及应用[J]．焊接，1998，(7)：12-15
[18] 郭大勇．短路过渡CO_2焊熔滴过渡过程控制[J]．焊接，1999，(9)：10-14
[19] 张富巨．表面张力过渡的波形分析[J]．武汉水利电力大学学报，1998，31(2)：79-81
[20] 吴文楷等．自适应恒频短路过渡焊接过程的控制系统[J]．焊接学报，1999，20(4)：244-247
[21] 殷树言，新型逆变式焊接电源的设计思想[J]．电焊机，2000，30(7)：3-8
[22] 赵举东等．CO_2逆变弧焊电源短路模糊控制问题的研究[J]．电力电子技术，1997，(3)：14-17
[23] 吴文楷等．自适应恒频短路过渡焊接过程的控制系统[J]．焊接学报，1999，20(4)：244-247
[24] 潘雪峰．IGBT逆变式波形控制CO_2弧焊电源的研究[J] 电焊机，1996，26(6)：16-18
[25] 黄石生．新型智能控制技术在CO_2焊电源系统中的应用[J]．焊接，1999，(12)：4-7
[26] 吴文楷等．弧焊逆变电源动态性能的提高及其对短路过渡焊接过程的影响[J]．焊接学报，1999，20(6)：90-95
[27] 王雅生．可消除网路电压对CO_2焊电弧电压的模糊控制系统研究[J]．电焊机，2000，30(5)：24-26
[28] 齐铂金，毛三可，杜中义．IGBT逆变式弧焊电源及其外特性控制研究．电焊机，1993／6
[29] 丁京柱．双闭环单片机波控逆变CO_2焊机系统[J]．焊接学报，2000，21(9)：48-52
[30] 潘雪峰．IGBT逆变式波形控制CO_2弧焊电源的研究[J]．电焊机，1996，26(6)：16-18
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