等离子切割高性能电源系统的研究
|
摘要
电源是等离子切割的动力来源,电源变换技术是现代等离子切割设备中的核心技术之一,研究高效高可靠性的等离子切割电源对于提高切割效率和质量具有重要意义。
本文设计了一种以两相并联带无源低损缓冲电路的Buck变换器为主电路的等离子切割电源,尤其对无源低损缓冲电路的参数设计作了细致、深入的研究。在分析无源低损缓冲电路的基础上,还对一种适用于大功率场合的耦合电感式无源无损缓冲电路进行了研究。详细分析了该缓冲电路的各个工作模态,并对谐振元件参数作了优化设计。通过一台原理样机验证了理论分析和设计方法的正确性。
等离子切割电源工作中的引弧是产生等离子弧的重要环节,本文详细分析了引弧电路的工作原理和数学模型,讨论了产生高频振荡的条件,对引弧用高频振荡器进行了仿真建模,并给出了引弧电路关键参数的设计原则。
针对等离子切割电源陡降外特性的特点,通过建立等离子切割电源主电路的小信号模型,设计了满足其外特性要求的电流闭环控制系统,给出了控制参数的设计原则,并完成了单片机控制系统、PWM控制电路及驱动电路的设计。
结合主电路和电流闭环控制系统的设计参数,对其进行了仿真研究。在理论分析和仿真研究的基础上,完成了一台30kW的等离子切割电源工程样机的研制,并进行了静态满负载烤机实验和现场切割实验,测试了相关性能指标参数。实验结果表明,所研制的等离子切割电源效率高、可靠性好,符合陡降外特性的要求。
Power supply is the power source of plasma cutting, power conversion technology is one of the core technologies of modern plasma cutting equipments, reseaching the plasma cutting power supply has important significance for improving the cutting efficiency and quality.
A plasma cutting power supply based on two parallel Buck converter with passive low lossy snubber is designed in this paper, especially the parameter design of the passive low lossy snubber is researched in detail and deeply. Based on the analysis of the passive low lossy snubber, this paper also researchs a passive lossless snubber with coupled-inductor applicable to high-power situation. The operation process of the snubber and the optimization of the resonance parameters are analyzed in detail. A prototype is built to verify the correctness of the theory analysis and design methodology.
Arc ignition is an important step to form the plasma arc when the plasma cutting power supply is working, this paper analyzes the working principle and mathematic modle of the arc ignition circuit, discusses the realize conditions of the high frequency oscillator. Also the simulation modle of the high frequency oscillator for arc ignition is built, and the design principle of key parameters is analyzed.
For the dramatic decreasing external characteristics of the plasma cutting power supply, the current closed-loop control system is designed through small signal model of the plasma cutting power supply, which is in accordance with the external characteristics. The design of control parameters, microprocessor control system, PWM control circuit, and drive circuit are respectively analyzed.
Combined with designed parameters, the simulation model of the plasma cutting power supply system is built. Based on the theory analysis and simulation, a 30kW plasma cutting power supply prototype is built. The static full-load and cutting experiments are finished, and the relevant performance parameters are tested. The experimental results show that the built prototype possesses high efficiency, high reliability and meets the requirements of dramatic decreasing external characteristics.
本文设计了一种以两相并联带无源低损缓冲电路的Buck变换器为主电路的等离子切割电源,尤其对无源低损缓冲电路的参数设计作了细致、深入的研究。在分析无源低损缓冲电路的基础上,还对一种适用于大功率场合的耦合电感式无源无损缓冲电路进行了研究。详细分析了该缓冲电路的各个工作模态,并对谐振元件参数作了优化设计。通过一台原理样机验证了理论分析和设计方法的正确性。
等离子切割电源工作中的引弧是产生等离子弧的重要环节,本文详细分析了引弧电路的工作原理和数学模型,讨论了产生高频振荡的条件,对引弧用高频振荡器进行了仿真建模,并给出了引弧电路关键参数的设计原则。
针对等离子切割电源陡降外特性的特点,通过建立等离子切割电源主电路的小信号模型,设计了满足其外特性要求的电流闭环控制系统,给出了控制参数的设计原则,并完成了单片机控制系统、PWM控制电路及驱动电路的设计。
结合主电路和电流闭环控制系统的设计参数,对其进行了仿真研究。在理论分析和仿真研究的基础上,完成了一台30kW的等离子切割电源工程样机的研制,并进行了静态满负载烤机实验和现场切割实验,测试了相关性能指标参数。实验结果表明,所研制的等离子切割电源效率高、可靠性好,符合陡降外特性的要求。
Power supply is the power source of plasma cutting, power conversion technology is one of the core technologies of modern plasma cutting equipments, reseaching the plasma cutting power supply has important significance for improving the cutting efficiency and quality.
A plasma cutting power supply based on two parallel Buck converter with passive low lossy snubber is designed in this paper, especially the parameter design of the passive low lossy snubber is researched in detail and deeply. Based on the analysis of the passive low lossy snubber, this paper also researchs a passive lossless snubber with coupled-inductor applicable to high-power situation. The operation process of the snubber and the optimization of the resonance parameters are analyzed in detail. A prototype is built to verify the correctness of the theory analysis and design methodology.
Arc ignition is an important step to form the plasma arc when the plasma cutting power supply is working, this paper analyzes the working principle and mathematic modle of the arc ignition circuit, discusses the realize conditions of the high frequency oscillator. Also the simulation modle of the high frequency oscillator for arc ignition is built, and the design principle of key parameters is analyzed.
For the dramatic decreasing external characteristics of the plasma cutting power supply, the current closed-loop control system is designed through small signal model of the plasma cutting power supply, which is in accordance with the external characteristics. The design of control parameters, microprocessor control system, PWM control circuit, and drive circuit are respectively analyzed.
Combined with designed parameters, the simulation model of the plasma cutting power supply system is built. Based on the theory analysis and simulation, a 30kW plasma cutting power supply prototype is built. The static full-load and cutting experiments are finished, and the relevant performance parameters are tested. The experimental results show that the built prototype possesses high efficiency, high reliability and meets the requirements of dramatic decreasing external characteristics.
引文
[1]陈苗荪.中国等离子弧切割机的现状及其分析.焊接,2006,(9):23-25.
[2]聂所林,郭邦华.数控空气等离子弧切割技术及应用.电力机车与城轨车辆,2004,27(2):39-40.
[3]高宏武.数控火焰与等离子切割技术在电力变压器制造领域的应用.变压器,2003,40(11): 21-26.
[4]聂素华,麻胜荣,李桓.数控等离子切割机切割质量的控制.焊接,2006,35(15):76-77.
[5]梁桂芳.切割技术手册.北京:机械工业出版社,1997:338~341.
[6]赵家瑞等.空气等离子弧切割机的原理和设计.北京:机械工业出版社,1997.
[7]李金煜,李红,娄晓焕.大功率等离子切割电源的研制.新技术新工艺,2001(8):28~29.
[8]王兆安,黄俊.电力电子技术.北京:机械工业出版社,2000:21~31.
[9] Girish R Kamath.A passive coupled-inductor flying-capacitor lossless snubber circuit for plasma cutting power supply.Applied Power Electronics Conference and Exposition,2005,(1):237~243.
[10]李明武,张伟光.晶体管式空气等离子切割电源.天津大学学报,1995,28(5):709~714.
[11]李继文,唐耀庚,高金生.逆变式空气等离子切割电源的研究.南华大学学报,2004,18(3):102~104.
[12]贾德利,尤波等.基于DSP逆变式等离子切割电源的研制.电力电子技术,2007(11):71~74.
[13]崔海现,陈思跃,吴杰峰.高性能逆变等离子切割机电源的研制.电气传动,2006,26(3):33~36.
[14] Deli Jia,Jinsong He,Changjiang Zhao.Fuzzy Control and Simulation for Inverted Plasma Cutting Power Supply.ICEMI,2009:3523~3527.
[15] Lim J W,Mimura K,Isshiki M.Removal of Metallic Impurities from Zirconium by Hydrogen Plasma Arc Melting.Journal of Materials Science,2005,(40):4109~4111.
[16] Fanara C,Vilarinho L.Electrical Characterization of Atmospheric Pressure Arc Plasmas.The European Physical Journal D,2004,(28):241~251.
[17]杨瑾,朱国荣,刘钊等.软开关型空气等离子切割电源的研制.电力电子,2007(5):31~34.
[18]林周布.一种具有最简拓扑的无源软开关新技术.电工技术学报,2002,17(2):65~70.
[19] Lago V,Graaf M D,Dudeck M.Arc Voltage Fluctuations in a Nitrogen Plasma Torch High Temp.Material Processes,1997,(12):179~190.
[20]尹克宁.变压器设计原理.北京:中国电力出版社,2003.
[21]方大千.电工速算手册.福建:福建科学技术出版社,2003.
[22]沈阳变压器研究所.变压器线圈制造.北京:机械工业出版社,1983.
[23]赵修科.也谈工频整流电容滤波电路中电容器选择.开关电源工程设计,2008:49~50.
[24]盛祖全,张立.IGBT模块驱动及保护技术.电焊机,2000(11):6~13.
[25]杨旭,裴云庆,王兆安.开关电源技术.机械工业出版社,2002.
[26]丁道宏.电力电子技术.北京:航空工业出版社,1995.
[27]杨丹萍.开关稳压电源中输出滤波电容器的选用方法.机电工程,1999(4):44~54.
[28] Sato Y,Kataoka T.An analysis of voltage spike clamping circuits for current type PWM power converters.IEEE PESC,1988:813~819.
[29]纪圣儒等.用于电弧超声激励的Buck变换器电压电流尖峰抑制.电焊机,2007(37):7~11.
[30] Ned Mohan,Tore Undeland,William P Robbins.Power Electronics:Converters,Applications and Design.Wiley,1989:669~692.
[31] McMurray,W.Selection of snubber and clamps to optimize the design of transistor switching converters.IEEE Trans.on Industry Application,1980,IA-16(4):513-523.
[32] IGBT模块使用指南.三菱公司,2006.
[33] Tseng C J, Chen C L.A passive lossless snubber cell for nonisolated PWM DC/DC converter.IEEE Trans.on Industrial Electronics,1998,45(4):593-601.
[34] Mitsubishi IGBT Module CM200DY-12NF Datasheet,2004.
[35] Undeland T M,Petterteig A,Hauknes G,Adnanes A K,Garberg S.Diode and thyristor turn-off snubbers simulation by KREAN and an easy to use design algorithm.Industry Application Society Auuual Meeting,1988:647~654.
[36] McMurray , W.Optimum snubbers for Power semiconductors.IEEE Trans.on Industry Application,1972,8(5):593~600.
[37] K.Mark Smith Jr , Keyue Ma Smedley.Properties and Synthesis of Passive Lossless Soft-Switching PWM Converters.IEEE Trans.on Power Electronics,1999,14(5):890~899.
[38] K.Mark Smith Jr,Keyue Ma Smedley.Engineering design of lossless passive soft Switching methods for PWM converters-part I:with minimum voltage stress Circuit cells.IEEE Trans.on Power Electronics,2001,16(3):336~344.
[39] Tseng C J,Chen C L.Passive lossless snubbers for DC/DC converters.IEEE APEC,1998(2):1049~1054.
[40]屈旭广.一种最小电压应力的无源无损软开关技术研究.[硕士学位论文].北京:中科院电工研究所,2004.
[41] K.Mark Smith Jr,Keyue Ma Smedley.Engineering design of lossless passive soft switching methods for PWM converters II.With non-Minimum voltage stress circuit cells. IEEE Trans.on Power Electronics,2002,17 (6):864~873.
[42] Kevin Mark Smith Jr.The art of soft switching and control of power converters,[A dissertation for Doctor of philosophy].Irvine:University of California,1999.
[43]赵国林,戴志平.NMVS无源无损软开关在PWM变换器中的应用.电力电子技术,2002,36(4):51~53.
[44] Levy H,Zafrany I,Ivensky G,et al.Analysis and evaluation of a lossless turn-on snubber.IEEE APEC,1997(2):757-763.
[45] Ben-Yaakov S,Ivensky G.Passive lossless snubber for high frequency PWM converters.IEEE Conf.of PESC,1997.
[46]黄晨,杨震.一种新型高压脉冲引弧器.上海工程技术大学学报,2000,14(1):34~37.
[47]魏继昆,谭蓉.用于逆变焊机的几种高频引弧器设计.电焊机,2004,34(12):35~37.
[48]中国机械工程学会焊接学会.焊接手册(第1卷焊接方法及设备).北京:机械工业出版社,1992.
[49]胡特生.电弧焊.北京:机械工业出版社,1996.
[50]邱关源.电路(第四版).北京:高等教育出版社,1999.
[51]赵修科.实用电源技术手册-磁性元件器件分册.沈阳:辽宁科学技术出版社,2005.
[52]电子变压器专业委员会.电子变压器手册.辽宁:辽宁科技出版社,1998.
[53]黄石生,郑宜庭.弧焊电源.第3版.北京:机械工业出版社,2004.
[54]崔信昌.等离子弧焊接和切割.北京:国防工业出版社,1980.
[55] Chae Y M,Jang Y,Jovanovic M M,et al.A novel mixed current and voltage control scheme for inverter arc welding machines.IEEE APEC,2001.
[56] Zhu Guorong,Liu Zhao,Li Xun,et al.The multi-functional arc welding/cutting inverter based on PS-FB-ZVZCS.IEEE ICIEA,2007.
[57]刘钊,朱国荣,李勋等.软开关弧焊逆变电源数字控制系统的设计.电力电子技术,2007,41(8):63~65.
[58]朱国荣.特种数字化弧焊电源关键技术研究. [博士学位论文] .武汉:华中科技大学,2009.
[59]张卫平.开关变换器的建模与控制.北京.中国电力出版社,2005.
[60]张明峰.PIC单片机入门与实战.北京:北京航空航天大学出版社,2004:47~218.
[2]聂所林,郭邦华.数控空气等离子弧切割技术及应用.电力机车与城轨车辆,2004,27(2):39-40.
[3]高宏武.数控火焰与等离子切割技术在电力变压器制造领域的应用.变压器,2003,40(11): 21-26.
[4]聂素华,麻胜荣,李桓.数控等离子切割机切割质量的控制.焊接,2006,35(15):76-77.
[5]梁桂芳.切割技术手册.北京:机械工业出版社,1997:338~341.
[6]赵家瑞等.空气等离子弧切割机的原理和设计.北京:机械工业出版社,1997.
[7]李金煜,李红,娄晓焕.大功率等离子切割电源的研制.新技术新工艺,2001(8):28~29.
[8]王兆安,黄俊.电力电子技术.北京:机械工业出版社,2000:21~31.
[9] Girish R Kamath.A passive coupled-inductor flying-capacitor lossless snubber circuit for plasma cutting power supply.Applied Power Electronics Conference and Exposition,2005,(1):237~243.
[10]李明武,张伟光.晶体管式空气等离子切割电源.天津大学学报,1995,28(5):709~714.
[11]李继文,唐耀庚,高金生.逆变式空气等离子切割电源的研究.南华大学学报,2004,18(3):102~104.
[12]贾德利,尤波等.基于DSP逆变式等离子切割电源的研制.电力电子技术,2007(11):71~74.
[13]崔海现,陈思跃,吴杰峰.高性能逆变等离子切割机电源的研制.电气传动,2006,26(3):33~36.
[14] Deli Jia,Jinsong He,Changjiang Zhao.Fuzzy Control and Simulation for Inverted Plasma Cutting Power Supply.ICEMI,2009:3523~3527.
[15] Lim J W,Mimura K,Isshiki M.Removal of Metallic Impurities from Zirconium by Hydrogen Plasma Arc Melting.Journal of Materials Science,2005,(40):4109~4111.
[16] Fanara C,Vilarinho L.Electrical Characterization of Atmospheric Pressure Arc Plasmas.The European Physical Journal D,2004,(28):241~251.
[17]杨瑾,朱国荣,刘钊等.软开关型空气等离子切割电源的研制.电力电子,2007(5):31~34.
[18]林周布.一种具有最简拓扑的无源软开关新技术.电工技术学报,2002,17(2):65~70.
[19] Lago V,Graaf M D,Dudeck M.Arc Voltage Fluctuations in a Nitrogen Plasma Torch High Temp.Material Processes,1997,(12):179~190.
[20]尹克宁.变压器设计原理.北京:中国电力出版社,2003.
[21]方大千.电工速算手册.福建:福建科学技术出版社,2003.
[22]沈阳变压器研究所.变压器线圈制造.北京:机械工业出版社,1983.
[23]赵修科.也谈工频整流电容滤波电路中电容器选择.开关电源工程设计,2008:49~50.
[24]盛祖全,张立.IGBT模块驱动及保护技术.电焊机,2000(11):6~13.
[25]杨旭,裴云庆,王兆安.开关电源技术.机械工业出版社,2002.
[26]丁道宏.电力电子技术.北京:航空工业出版社,1995.
[27]杨丹萍.开关稳压电源中输出滤波电容器的选用方法.机电工程,1999(4):44~54.
[28] Sato Y,Kataoka T.An analysis of voltage spike clamping circuits for current type PWM power converters.IEEE PESC,1988:813~819.
[29]纪圣儒等.用于电弧超声激励的Buck变换器电压电流尖峰抑制.电焊机,2007(37):7~11.
[30] Ned Mohan,Tore Undeland,William P Robbins.Power Electronics:Converters,Applications and Design.Wiley,1989:669~692.
[31] McMurray,W.Selection of snubber and clamps to optimize the design of transistor switching converters.IEEE Trans.on Industry Application,1980,IA-16(4):513-523.
[32] IGBT模块使用指南.三菱公司,2006.
[33] Tseng C J, Chen C L.A passive lossless snubber cell for nonisolated PWM DC/DC converter.IEEE Trans.on Industrial Electronics,1998,45(4):593-601.
[34] Mitsubishi IGBT Module CM200DY-12NF Datasheet,2004.
[35] Undeland T M,Petterteig A,Hauknes G,Adnanes A K,Garberg S.Diode and thyristor turn-off snubbers simulation by KREAN and an easy to use design algorithm.Industry Application Society Auuual Meeting,1988:647~654.
[36] McMurray , W.Optimum snubbers for Power semiconductors.IEEE Trans.on Industry Application,1972,8(5):593~600.
[37] K.Mark Smith Jr , Keyue Ma Smedley.Properties and Synthesis of Passive Lossless Soft-Switching PWM Converters.IEEE Trans.on Power Electronics,1999,14(5):890~899.
[38] K.Mark Smith Jr,Keyue Ma Smedley.Engineering design of lossless passive soft Switching methods for PWM converters-part I:with minimum voltage stress Circuit cells.IEEE Trans.on Power Electronics,2001,16(3):336~344.
[39] Tseng C J,Chen C L.Passive lossless snubbers for DC/DC converters.IEEE APEC,1998(2):1049~1054.
[40]屈旭广.一种最小电压应力的无源无损软开关技术研究.[硕士学位论文].北京:中科院电工研究所,2004.
[41] K.Mark Smith Jr,Keyue Ma Smedley.Engineering design of lossless passive soft switching methods for PWM converters II.With non-Minimum voltage stress circuit cells. IEEE Trans.on Power Electronics,2002,17 (6):864~873.
[42] Kevin Mark Smith Jr.The art of soft switching and control of power converters,[A dissertation for Doctor of philosophy].Irvine:University of California,1999.
[43]赵国林,戴志平.NMVS无源无损软开关在PWM变换器中的应用.电力电子技术,2002,36(4):51~53.
[44] Levy H,Zafrany I,Ivensky G,et al.Analysis and evaluation of a lossless turn-on snubber.IEEE APEC,1997(2):757-763.
[45] Ben-Yaakov S,Ivensky G.Passive lossless snubber for high frequency PWM converters.IEEE Conf.of PESC,1997.
[46]黄晨,杨震.一种新型高压脉冲引弧器.上海工程技术大学学报,2000,14(1):34~37.
[47]魏继昆,谭蓉.用于逆变焊机的几种高频引弧器设计.电焊机,2004,34(12):35~37.
[48]中国机械工程学会焊接学会.焊接手册(第1卷焊接方法及设备).北京:机械工业出版社,1992.
[49]胡特生.电弧焊.北京:机械工业出版社,1996.
[50]邱关源.电路(第四版).北京:高等教育出版社,1999.
[51]赵修科.实用电源技术手册-磁性元件器件分册.沈阳:辽宁科学技术出版社,2005.
[52]电子变压器专业委员会.电子变压器手册.辽宁:辽宁科技出版社,1998.
[53]黄石生,郑宜庭.弧焊电源.第3版.北京:机械工业出版社,2004.
[54]崔信昌.等离子弧焊接和切割.北京:国防工业出版社,1980.
[55] Chae Y M,Jang Y,Jovanovic M M,et al.A novel mixed current and voltage control scheme for inverter arc welding machines.IEEE APEC,2001.
[56] Zhu Guorong,Liu Zhao,Li Xun,et al.The multi-functional arc welding/cutting inverter based on PS-FB-ZVZCS.IEEE ICIEA,2007.
[57]刘钊,朱国荣,李勋等.软开关弧焊逆变电源数字控制系统的设计.电力电子技术,2007,41(8):63~65.
[58]朱国荣.特种数字化弧焊电源关键技术研究. [博士学位论文] .武汉:华中科技大学,2009.
[59]张卫平.开关变换器的建模与控制.北京.中国电力出版社,2005.
[60]张明峰.PIC单片机入门与实战.北京:北京航空航天大学出版社,2004:47~218.