高频脉冲电解开关电源研制及工艺试验
摘要
电解加工(Electrochemical Machining ECM)技术在加工各种难切削金属材料时,具有传统加工方法无法比拟的优点。这些优点使其广泛应用于国防、航空航天和各个民用领域,成为了机械制造业中不可缺少的组成部分。但电解加工精度还不够高,逐渐难以满足高科技产品对其精度越来越高的要求。科技的发展也推动了电解加工技术的进步,研究实践表明,用高频脉冲电源电解加工能有效地提高加工精度和表面质量。而且频率越高,脉宽越窄,其加工效果就越好。该技术有望促使电解加工进入微精加工领域,而高频脉冲电解电源的研究是推动电解加工技术向前发展的关键之一。
本文针对相关项目的内容,研制了频率更高的高频脉冲电源样机。结合电解加工的需要,并综合考虑了电源效率、体积重量等问题,本电源样机采用全桥变换器加斩波脉冲输出方案。变换器调压方案省略了铜、铁损耗大的工频变压器,提高了电源的效率,减小了电源的体积和重量,而且调压精度较高。斩波输出方案又使电路简单,降低了电源的成本。
电源的变换器部分,用脉宽调制法对电压进行闭环控制,能够为斩波部分提供一个稳定可调的直流电压。变换器部分主要解决了高频磁芯变压器的波形畸变问题,成功设计制造出输出波形良好,工作稳定的高频功率变压器。
电源的斩波部分针对高频较大电流的脉冲输出,较好地解决了驱动电路快速性问题,功率场效应管的并联均流问题,和脉冲关断瞬间的电压过冲问题。并针对电解加工的特点设计了快速保护电路。
结合相关项目的内容,用电源样机进行了电解机械复合抛光的工艺试验,试验结果验证了高频脉冲电源有利于提高加工的表面质量。用电源样机进行微细孔电解加工试验,结果也验证了脉冲频率的提高,脉宽的缩小有利于提高加工精度。
Electrochemical Machining (ECM) has many excellences than conventional machining in machining hard cutting material. These bring its broad application to national defense, aviation, and many civil fields. And ECM has become an indispensable part in machine manufacturing. But its machining precision is not so high enough to reach the higher and higher requirement of the high-tech products. The development of science and technology also improve the ECM technique. Many research and applications show that, by using pulse power supply the ECM precision and surface quality can be improved effectively. And the effect will be better with higher frequency and shorter pulses. This technique is expectant to lead ECM into the micro and precision machining fields. And the key is high frequency pulse power supply.According to relative project, this dissertation developed an ECM pulse power supply with relatively higher frequency. The power supply model adopts the scheme of converter-plus-chopper. This scheme can reduce the bulk and weight of the power supply, and can improve its efficiency. Moreover the voltage regulation is more precise.The converter applies PWM (Pulse Width Modulation) technique to regulate the voltage. A tailor-made transformer and snubber circuit have been design to reduce the distortion of output waveform.In the part of chopper, a fast drive circuit, a snubber of over-voltage-protection and a fast over-current-protection circuit have been design. And the parallel operation of MOSFET was achieved effectively.An electrochemical mechanical polishing test and a micro-holes' machining test was carried out. The test result validate that high frequency pulse power supply can improve the surface quality precision of the workpiece.
本文针对相关项目的内容,研制了频率更高的高频脉冲电源样机。结合电解加工的需要,并综合考虑了电源效率、体积重量等问题,本电源样机采用全桥变换器加斩波脉冲输出方案。变换器调压方案省略了铜、铁损耗大的工频变压器,提高了电源的效率,减小了电源的体积和重量,而且调压精度较高。斩波输出方案又使电路简单,降低了电源的成本。
电源的变换器部分,用脉宽调制法对电压进行闭环控制,能够为斩波部分提供一个稳定可调的直流电压。变换器部分主要解决了高频磁芯变压器的波形畸变问题,成功设计制造出输出波形良好,工作稳定的高频功率变压器。
电源的斩波部分针对高频较大电流的脉冲输出,较好地解决了驱动电路快速性问题,功率场效应管的并联均流问题,和脉冲关断瞬间的电压过冲问题。并针对电解加工的特点设计了快速保护电路。
结合相关项目的内容,用电源样机进行了电解机械复合抛光的工艺试验,试验结果验证了高频脉冲电源有利于提高加工的表面质量。用电源样机进行微细孔电解加工试验,结果也验证了脉冲频率的提高,脉宽的缩小有利于提高加工精度。
Electrochemical Machining (ECM) has many excellences than conventional machining in machining hard cutting material. These bring its broad application to national defense, aviation, and many civil fields. And ECM has become an indispensable part in machine manufacturing. But its machining precision is not so high enough to reach the higher and higher requirement of the high-tech products. The development of science and technology also improve the ECM technique. Many research and applications show that, by using pulse power supply the ECM precision and surface quality can be improved effectively. And the effect will be better with higher frequency and shorter pulses. This technique is expectant to lead ECM into the micro and precision machining fields. And the key is high frequency pulse power supply.According to relative project, this dissertation developed an ECM pulse power supply with relatively higher frequency. The power supply model adopts the scheme of converter-plus-chopper. This scheme can reduce the bulk and weight of the power supply, and can improve its efficiency. Moreover the voltage regulation is more precise.The converter applies PWM (Pulse Width Modulation) technique to regulate the voltage. A tailor-made transformer and snubber circuit have been design to reduce the distortion of output waveform.In the part of chopper, a fast drive circuit, a snubber of over-voltage-protection and a fast over-current-protection circuit have been design. And the parallel operation of MOSFET was achieved effectively.An electrochemical mechanical polishing test and a micro-holes' machining test was carried out. The test result validate that high frequency pulse power supply can improve the surface quality precision of the workpiece.
引文
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3. http://www.sitec-chemnitz.de/content-eng/ecm/ecm.html
4. http://www.unl.edu/nmrc/ecm 1/ecm 1.htm
5. http://www.memagazine.org/backissues/nov01/features/makcut/makcut.html
6.徐家文,王建业,田继安.21世纪初电解加工的发展和应用[J].电加工与模具, 2001,6:1～5
7.余艳青.电解加工高频窄脉冲电流源特性试验研究及工程化样机研制[D]. 广州:华南理工大学,2003年
8.M. Kock, V. Kirchner, R. Schuster. Electrochemical micromachining with ultrashort voltagepulses-a versatile method with lithographical precision[J]. Electrochimica Acta, 2003, 48:3213-3219
9.A. L. Trimmer, J. L. Hudson, M. Kock, R. Schuster. Single-step electrochemical machining of complex nanostructures with ultrashort voltage pulses[J]. APPLIED PHYSICS LETTERS, 2003, 82(19):3327～3329
10.余艳青,王建业,韩冠军.MOSFET高频窄脉冲电解加工工程化电源研制[J].电加工与模具,2005,2:59～63
11 .詹兴抡,张之敬,王建平,张利波.一种高频群脉冲电解加工电源的研究和开发[J].电力电子技术,2003,037(005):50～52
12.唐勇,王辉,周锦进,王海峰,董华军.大功率脉冲电化学光整加工电源的研制[J].电加工与模具,2005,S1:62～64
13. http://electrochem.cwru.edu/ed/encycl/art-m03-machining.htm
14.王建业,王晓燕.MOSFET高频、窄脉冲电解加工新型电源试验研究[J].航空制造技术,2001,000(001):27～29,37
15.华伟,周文定编著.现代电力电子器件及应用[M].第一版.北京:北方交通大学出版社,清华大学出版社,2002.3
16.王文焕,张之敬,唐兴伦.电解加工电源的发展及特点[J].现代机械,2004,1:54～57
17. Viola Kirchner, Laurent Cagnon, Rolf Schuster, and Gerhard Ertl. Electrochemical machining of stainless steel microelements with ultrashortvoltage pulses[J]. 2001 American Institute of Physics, 2001, 79(11):1721～1723
18. A. L. Trimmer and J. L. Hudson, M. Kock and R. Schuster. Single-step electrochemical machining of complex nanostructures with ultrashort voltage pulses[J]. 2003 American Institute of Physics, 2003, 82(19): 3327～3329
19. Rosario Casanueva, Francisco J. Azcondo, Salvador Bracho. Series-parallel resonant converter for an EDM power supply[J]. Journal of Materials Processing Technology, 2004, 149:172-177
20.朱荻.国外电解加工的研究进展[J].电加工与模具,2000,1:11～16
21. http://www.maxim-ic.com/appnotes.cfm/appnote_number/848
22.刘胜利编著.现代高频开关电源实用技术[M].第一版.北京:电子工业出版社,2001.9
23.张占松,蔡宣三编著.开关电源的原理与设计[M].第一版.北京:电子工业出版社,1998.7
24.赵修科主编.实用电源技术手册磁性元件分册[M].第一版.辽宁科学技术出版社,2002.8
25.原田耕介主编,耿文学译.开关电源手册[M].第二版.北京:机械工业出版社,2004.8
26.包兴,胡明主编.电子器件导论[M].第一版.北京:北京理工大学出版社,2001.1
27.杨志亮主编.Prote199SE电路原理图设计技术[M].第一版.西安:西北工业大学出版社,2002.2
28.白砮雳著,北大宏博改编.Protel PCB99电路设计快易通[M].第一版.北京:北京大学出版社,2001.2
29.高嵩.史政记.何宁.范植坚.高频脉冲电解加工电源MOSFET并联技术研究[J].电力电子技术,2005,4:97～99
30.高嵩.史政记.倪原.高频脉冲电解加工电源快速短路保护电路设计[J].探测与控制学报,2005,2:58～60,64
31.王建业.提高电解加工模具成型精度的新途径——高频、窄脉冲电流源电解加工(HSPECM)[J].航空制造技术,2002,12:21～24,58
32. A. Zaytsev, I. Agafonov, N. Gimaev, R. Moukhoutdinov, A. Belogorsky. Precise pulse electrochemical machining by bipolar current Aspects of effective technological application [J]. Journal of Materials Processing Technology, 2004, 149:419-425
33.王晓明,李洪友,周锦进,张芝涛.脉冲电化学光整加工电源设计与研究[J].电加工与模具,200l,2:23～25
34.李洪友,王辉,张芝涛,王晓明,周锦进.脉冲电化学齿轮光整加工电源设计与研究[J].大连理工大学学报,2003,4:452～456
35.徐玉春,赵万生,赵家齐,刘晋春.精密脉冲电解磨削的电源和试验研究[J].航空精密制造技术,1999,3:12～14
36.狄士春,吴海波,王贤成,赵万生.电化学加工脉冲电源的研制与实验研究[J].电加工与模具,2005,1:42～44
37.王建业.高频窄脉冲电解加工的机理研究[J].华南理工大学学报:自然科学版,2002,1:6～11
38. Shuo-Jen Lee, Yu-Ming Lee, Ming-Feng Du. The polishing mechanism of electrochemical mechanical polishing technology [J]. Journal of Materials Processing Technology, 2003, 140:280～286
39. Shuo-Jen Lee, Jian-Jang Lai. The effects of electropolishing (EP) process parameters on corrosion resistance of 316L stainless steel [J]. Journal of Materials Processing Technology, 2003, 140:206～210
40. Rolf Schuster, Viola Kirchner, Philippe Allongue, et al. Electrochemical Micromachining [J]. Science, 2000, 289:98～101
41.安军,王晓明,李洪友,倪新元,周锦进.影响脉冲电化学抛光加工质量的因素研究[J].制造技术与机床,2001,5:32～34
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