基于DSP+MCU数字化焊接电源研究与设计
摘要
新型工业化的浪潮推动了先进制造业的飞速发展,对焊接技术提出了更高的要求。而高质量、高效率的焊接则离不开高性能的焊接电源。随着信息化、智能化技术的发展,焊接电源的数字控制技术已经成为该领域科学研究与应用的前沿与热门课题,数字化焊接电源代表了今后焊接电源发展的方向。
本研究从完善数字化焊接电源系统以及更充分发挥数字化电源优势的角度出发,通过分析比较数字化焊接电源的控制器结构及功能特点,设计出了一套基于DSP+ MCU双处理器的控制架构,可灵活应用于多种焊接方法的数字化焊接电源控制系统。该架构整合DSP的强大数字信号运算处理能力和MCU多任务管理和流程控制的优势,给DSP和MCU双控制器分配了不同的任务。DSP通常执行波形控制等要求数字信号高速处理,计算密集的任务,而MCU则负责焊接控制系统中人机交互界面、网络通讯等调度控制工作。
本文完成了包括基于IGBT的逆变电源主电路、DSP(TMS320LF2407A)和MCU(80C196KC)最小系统和外围电路、送丝电路等硬件电路的设计;数字PID控制算法、人机交互系统、接口通讯等软件设计;并进行了一系列抗干扰设计。为了提高控制系统可靠性,本课题中DSP和MCU之间采用双端口RAM(随机存取存储器)通讯方式;为了方便软件升级和控制,在数字化控制系统和上位机通讯网络建立方面,在MCU与上位机之间采用RS232串行通信。
本课题对数字化焊接电源的扩展功能做了相关研究。针对当前焊接电源联网能力弱的实际,为满足信息化制造的需求,本课题开发设计了基于以太网控制器芯片RTL8019AS数字化焊接电源的嵌入式网络接口,可以直接联入局域网和Internet。针对当前数字化焊接电源对外部设备相关控制接口少的现状,为适应自动化生产的需要,开发了基于模数转换器TLC5615的外部通用设备控制接口。
对控制系统的仿真实验研究表明,该数字化控制系统可以对焊接电源实现实时、快速、准确的控制。该控制器为今后焊接电源数字化控制的研究提供了一个研究平台。
The new industrialization wave promotes the rapid development of advanced manufacturing and requires a higher welding technology. High quality and efficiency welding needs high level of welding power source.With the development of information and intelligence, digital controlled welding power technology has become a frontier and hot topic in the field of scientific research.Digital welding power source represent the development of welding power in the future.
One of important points of this research is to perfect the digital welding power system and make full use of its advantage. By comparing the structure and function of control unit, a digital welding power source system with two control core, which can be used for several welding methods, is developed. It takes the advantage of the strong calculation signal procession ability of DSP and the perfect multitask management and process control of MCU. The former is in charge of sampling and analyzing the high frequency signal, and also the real-time control; the main assignment of the latter is man-machine interactive system, peripheral communication and the sequence control.
This paper include not only the completion of the IGBT inverter main circuit, DSP (TMS320LF2407A) and MCU (80C196KC) minimum system and the external circuit, wire feeder circuit, and other hardware circuit design, but also the software design of a number of PID control algorithms, HCI Systems, communications interface. In order to improve the accuracy and stability of power supply, a series of hardware and software design are still in the paper as anti-jamming method. In order to enhance the reliability of control system, it takes dual-port RAM (random access memory) as communication way between the DSP and MCU in this subject. In order to facilitate software upgrading, it takes RS232 serial communication between MCU and PC.
The issue also did a more in-depth study in digital extension functions of digital welding power. In the view of that the current welding power can’t do network, can’t satisfy the information requirements of the current manufacturing, this dissertation complete innovative design. The embedded network interface for digital welding power based on the Ethernet controller chip RTL8019AS can be directly linked into the LAN and the Internet. In view of the external equipment control of the current welding power source is poor and less related interfaces could be used, which can’t satisfiecd automated production,a common external equipment control interface based on the A/D chip TLC5615 is developed.
The simulation experiment studies of control system show that the digital control system for welding power can achieve real-time, rapid and accurate control. This digital welding power controller could provide a platform for the future research.
本研究从完善数字化焊接电源系统以及更充分发挥数字化电源优势的角度出发,通过分析比较数字化焊接电源的控制器结构及功能特点,设计出了一套基于DSP+ MCU双处理器的控制架构,可灵活应用于多种焊接方法的数字化焊接电源控制系统。该架构整合DSP的强大数字信号运算处理能力和MCU多任务管理和流程控制的优势,给DSP和MCU双控制器分配了不同的任务。DSP通常执行波形控制等要求数字信号高速处理,计算密集的任务,而MCU则负责焊接控制系统中人机交互界面、网络通讯等调度控制工作。
本文完成了包括基于IGBT的逆变电源主电路、DSP(TMS320LF2407A)和MCU(80C196KC)最小系统和外围电路、送丝电路等硬件电路的设计;数字PID控制算法、人机交互系统、接口通讯等软件设计;并进行了一系列抗干扰设计。为了提高控制系统可靠性,本课题中DSP和MCU之间采用双端口RAM(随机存取存储器)通讯方式;为了方便软件升级和控制,在数字化控制系统和上位机通讯网络建立方面,在MCU与上位机之间采用RS232串行通信。
本课题对数字化焊接电源的扩展功能做了相关研究。针对当前焊接电源联网能力弱的实际,为满足信息化制造的需求,本课题开发设计了基于以太网控制器芯片RTL8019AS数字化焊接电源的嵌入式网络接口,可以直接联入局域网和Internet。针对当前数字化焊接电源对外部设备相关控制接口少的现状,为适应自动化生产的需要,开发了基于模数转换器TLC5615的外部通用设备控制接口。
对控制系统的仿真实验研究表明,该数字化控制系统可以对焊接电源实现实时、快速、准确的控制。该控制器为今后焊接电源数字化控制的研究提供了一个研究平台。
The new industrialization wave promotes the rapid development of advanced manufacturing and requires a higher welding technology. High quality and efficiency welding needs high level of welding power source.With the development of information and intelligence, digital controlled welding power technology has become a frontier and hot topic in the field of scientific research.Digital welding power source represent the development of welding power in the future.
One of important points of this research is to perfect the digital welding power system and make full use of its advantage. By comparing the structure and function of control unit, a digital welding power source system with two control core, which can be used for several welding methods, is developed. It takes the advantage of the strong calculation signal procession ability of DSP and the perfect multitask management and process control of MCU. The former is in charge of sampling and analyzing the high frequency signal, and also the real-time control; the main assignment of the latter is man-machine interactive system, peripheral communication and the sequence control.
This paper include not only the completion of the IGBT inverter main circuit, DSP (TMS320LF2407A) and MCU (80C196KC) minimum system and the external circuit, wire feeder circuit, and other hardware circuit design, but also the software design of a number of PID control algorithms, HCI Systems, communications interface. In order to improve the accuracy and stability of power supply, a series of hardware and software design are still in the paper as anti-jamming method. In order to enhance the reliability of control system, it takes dual-port RAM (random access memory) as communication way between the DSP and MCU in this subject. In order to facilitate software upgrading, it takes RS232 serial communication between MCU and PC.
The issue also did a more in-depth study in digital extension functions of digital welding power. In the view of that the current welding power can’t do network, can’t satisfy the information requirements of the current manufacturing, this dissertation complete innovative design. The embedded network interface for digital welding power based on the Ethernet controller chip RTL8019AS can be directly linked into the LAN and the Internet. In view of the external equipment control of the current welding power source is poor and less related interfaces could be used, which can’t satisfiecd automated production,a common external equipment control interface based on the A/D chip TLC5615 is developed.
The simulation experiment studies of control system show that the digital control system for welding power can achieve real-time, rapid and accurate control. This digital welding power controller could provide a platform for the future research.
引文
[1]郑宜庭,黄石生.弧焊电源[M].第三版.北京:机械工业出版社,1999.
[2] K.Weman.New Potential with Modern Welding Power Source[J]. Welding Review International, 1995,14(2):18~20.
[3]黄石生.弧焊电源及其数字化控制[M].北京:机械工业出版社2007.1
[4]陈善本等.焊接过程现代控制技术[M].哈尔滨:哈尔滨工业大学出版社,2001.5.
[5]殷树言,刘嘉,丁京柱,董宝华,陈树君.21世纪的焊接之星-数字化弧焊逆变电源[J].机械工人(热加工)2001.(5):6~8.
[6]吴开源,黄石生,李阳,陆沛涛.弧焊电源的数字化控制技术[J].半导体技术,2005.30(1):72~75.
[7] Dilthey U, Heidirch J. On-line quality in gas-shielded Metal Arc Welding Using Artificial Neural networks [J], Welding and Cutting,1997(2):E22~E24
[8] http://enterprise.tede.cn/2006/08/0R912SH006.html[z]
[9] Murakami,Tajemoto F,Hayashi K. Weld-line Tracking Control of Arc Welding Robot Using Fuzzy logic controller [J]. Fuzzy Sets and Systems,1997.32(2):221~237
[10]鹤岐,吴荣,路广.单片机控制IGBT逆变埋弧焊机设计[J].电焊机,2004.34(10):1~4.
[11] http://www.gongkong.com/exhibit/lunwen/paper_detail.asp?id=8430[z]
[12] http://21ew.caac.net/mcu/mcujj.html[z]
[13] http://zhidao.baidu.com/question/18851687.html?si=1[z]
[14] Texas Instruments. DSP Solution for AC Induction Motor. l996[z].
[15] http://www.dianyuan.com/bbs/d/35/59848.html[z]
[16]李鹤岐,李春旭,高忠林,王睿.基于DSP-MCU实现焊接电源系统数字化控制的设计[J].焊接学报,2005.26(3):17~24.
[17] 80C196KC USER’S GUIDE[z].http://www.intel. com
[18]孙涵方.Intel 16位单片机[M].北京:北京航空航天大学出版社,1995.
[19]李虹,李春旭,路广,陈克选.一种可应用于数字化焊接电源的DSP芯片- TMS320F240[J].兰州理工大学学报,2006.32(4):5~8
[20] TEXAS INSTRUMENTS.TMS320F/C240 DSP Controllers Reference Guide Peripheral Library and Specific Devices [M].Literature Number :SPRU161 C .June 1999.
[21]高志国,弧焊逆变电源单片机控制系统的稳定性研究[D].硕士学位论文.北京:北京工业大学2004年5月.
[22]周志军.单片机控制PMIG逆变焊机的研制[D].硕士学位论文.北京:北京工业大学2002年5月.
[23]李微,郭强.液晶显示应用技术[M].北京:电子下业出版社.2000.
[24]刘建.80C196KC与LCD模块接口设计及其编程实现[J].微处理机,2004.3(6):61~64.
[25]王奇,陈柏超.电力电子装置控制系统的DSP设计方案[J].单片机与嵌入式系统应用,2005.8:33~36.
[26] Tms320f/24x DSP Controllers[z].CPU and Instruction Set. Texas Instruments,1999.
[27] Tms320f/24x DSP Controllers[z].System and peripherals. Texas Instruments,1999
[28]王金柱,基于DSP的脉冲MIG焊全数字化控制.硕士学位论文.北京:北京工业大学2007年4月.
[29] Y. Inui,M. Ishikawa.Power inversion and control of closed cycledisk MHD generator using current source PWM inverter[J].Energy Conversion and Management.2002,43(5):721~732.
[30] Trzynadlowski. A. M, Bech. M. M, Blaabjerg F, et al. An Integral Space-Vector PWM Technique for DSP-Controlled Voltage-Sources Inverters[c]. The IEEE Industry Applications Conferences, Thirty-Third IAS Annual Meeting, 1998
[31] Pinheiro J Renes, Baibi Ivo. The three-level ZVS PWM converter a new concepe in high-voltage dc-to-dc conversion[c]. IEEE IECON,1992, pp: 173~178.
[32]卢亚静.基于DSP的脉冲MIG焊数字控制系统的研究[D].硕士学位论文.天津:天津大学2005年2月.
[33] Moon, Myung S. et al. DSP Control of UPS Inverter Over-current Limit Using Droop Methord[c]. IEEE Annual Power Electronics Specialists Conference. SC, USA, 1999: 552~557.
[34] Chickamenahalli. S A, Jun. Liu. A DSP Controlled Variable-Frequency Resonant-Commutated Converter[c]. Power Electronics, IEEE Transactions , 2000, 15(31):447~455
[35] Pinheiro J Renes, Baibi Ivo. Wide load range the three-level ZVS PWM dc-to-dc converter[c]. IEEE PESC,1993, pp: 171～177.
[36]荣晓飞.脉冲焊机MIG的数字化研究[D].硕士学位论文.山东:山东大学2006年11月.
[37]贾颖巍.基于的可编程交流电源的研究与设计[D].硕士学位论文.河北:河北工业大学2006年12月.
[38]陈国呈.PWM变频调速及软开关电力变换技术[M].北京:机械工业出版社,2001.
[39]郭院波. DSP控制数字化CO2弧焊电源的研制[D].硕士学位论文.天津:天津大学2004年2月.
[40]董雅倩.基于DSP的晶闸管弧焊电源控制系统研究[D].硕士学位论文.青岛:青岛大学, 2006年2月。
[41]李明青.PC机及单片机数据通信技术[M].北京:北京航空航天大学出版社,2000.
[42]毛东方.PC机和80C196KC单片机串行通信设计[J].机械制造与自动化,2007,36(1).
[43] Jan Axeison. Serial Port Complete: Programming and Circuits for RS-232 and RS-485 Links and Networks[M]. Independent Publishers Group. 2001 (1):115～123.
[44]姬轩.双处理器数字化焊接电源控制系统的研究[D].硕士学位论文.天津:天津大学2005年12月.
[45]康静秋.嵌入式互联网络接口的设计与开发[J].计算机工程,2003.29(1):228~230.
[46] RTL8019AS datasheet http://www.realtek.com.cn[Z]
[47] Texas Instruments.Data Aequisition Cireuits Databook [M]. 1995
[48]朱更军,彭永供,项安,胡凯.串行10位D/A转换器TLC5615原理及与DSP的接口[J].电子质量,2003.10:12~13.
[49]吴开源,黄石生.弧焊电源的数字化控制技术[J].半导体技术,2005.2(4):72~75.
[50]黄石生,薛家祥.新型弧焊电源及其智能控制[J],中国工程科学,2000.12(4):70~74.
[51] Shu hualin,Pi Youguo. PID neural networks for time-delay system [J]. Computers and Chemical Engineering, 2000(24):859-861.
[52]舒怀林.PID神经网络控制算法应用[M].北京:国防工业出胶社,2006.
[53] SCOCTGM, SHAVLIK JW, RAGW H. Refining PID controllers using neural networks[M]. Neural Computation, 1992.4(5): 746-757.
[54] AKHYAR S,OMATU S. Neuromorphic self-tuning PID controller[C].IEEE International Conference on Neural Networks, San Fran-cisco, CA, USA: IEEE, 1993: 552-557.
[55]何宽芳,黄石生.基于PID神经网络的弧焊电源控制器的研究[J],电焊机2007.37(7):58~60.
[2] K.Weman.New Potential with Modern Welding Power Source[J]. Welding Review International, 1995,14(2):18~20.
[3]黄石生.弧焊电源及其数字化控制[M].北京:机械工业出版社2007.1
[4]陈善本等.焊接过程现代控制技术[M].哈尔滨:哈尔滨工业大学出版社,2001.5.
[5]殷树言,刘嘉,丁京柱,董宝华,陈树君.21世纪的焊接之星-数字化弧焊逆变电源[J].机械工人(热加工)2001.(5):6~8.
[6]吴开源,黄石生,李阳,陆沛涛.弧焊电源的数字化控制技术[J].半导体技术,2005.30(1):72~75.
[7] Dilthey U, Heidirch J. On-line quality in gas-shielded Metal Arc Welding Using Artificial Neural networks [J], Welding and Cutting,1997(2):E22~E24
[8] http://enterprise.tede.cn/2006/08/0R912SH006.html[z]
[9] Murakami,Tajemoto F,Hayashi K. Weld-line Tracking Control of Arc Welding Robot Using Fuzzy logic controller [J]. Fuzzy Sets and Systems,1997.32(2):221~237
[10]鹤岐,吴荣,路广.单片机控制IGBT逆变埋弧焊机设计[J].电焊机,2004.34(10):1~4.
[11] http://www.gongkong.com/exhibit/lunwen/paper_detail.asp?id=8430[z]
[12] http://21ew.caac.net/mcu/mcujj.html[z]
[13] http://zhidao.baidu.com/question/18851687.html?si=1[z]
[14] Texas Instruments. DSP Solution for AC Induction Motor. l996[z].
[15] http://www.dianyuan.com/bbs/d/35/59848.html[z]
[16]李鹤岐,李春旭,高忠林,王睿.基于DSP-MCU实现焊接电源系统数字化控制的设计[J].焊接学报,2005.26(3):17~24.
[17] 80C196KC USER’S GUIDE[z].http://www.intel. com
[18]孙涵方.Intel 16位单片机[M].北京:北京航空航天大学出版社,1995.
[19]李虹,李春旭,路广,陈克选.一种可应用于数字化焊接电源的DSP芯片- TMS320F240[J].兰州理工大学学报,2006.32(4):5~8
[20] TEXAS INSTRUMENTS.TMS320F/C240 DSP Controllers Reference Guide Peripheral Library and Specific Devices [M].Literature Number :SPRU161 C .June 1999.
[21]高志国,弧焊逆变电源单片机控制系统的稳定性研究[D].硕士学位论文.北京:北京工业大学2004年5月.
[22]周志军.单片机控制PMIG逆变焊机的研制[D].硕士学位论文.北京:北京工业大学2002年5月.
[23]李微,郭强.液晶显示应用技术[M].北京:电子下业出版社.2000.
[24]刘建.80C196KC与LCD模块接口设计及其编程实现[J].微处理机,2004.3(6):61~64.
[25]王奇,陈柏超.电力电子装置控制系统的DSP设计方案[J].单片机与嵌入式系统应用,2005.8:33~36.
[26] Tms320f/24x DSP Controllers[z].CPU and Instruction Set. Texas Instruments,1999.
[27] Tms320f/24x DSP Controllers[z].System and peripherals. Texas Instruments,1999
[28]王金柱,基于DSP的脉冲MIG焊全数字化控制.硕士学位论文.北京:北京工业大学2007年4月.
[29] Y. Inui,M. Ishikawa.Power inversion and control of closed cycledisk MHD generator using current source PWM inverter[J].Energy Conversion and Management.2002,43(5):721~732.
[30] Trzynadlowski. A. M, Bech. M. M, Blaabjerg F, et al. An Integral Space-Vector PWM Technique for DSP-Controlled Voltage-Sources Inverters[c]. The IEEE Industry Applications Conferences, Thirty-Third IAS Annual Meeting, 1998
[31] Pinheiro J Renes, Baibi Ivo. The three-level ZVS PWM converter a new concepe in high-voltage dc-to-dc conversion[c]. IEEE IECON,1992, pp: 173~178.
[32]卢亚静.基于DSP的脉冲MIG焊数字控制系统的研究[D].硕士学位论文.天津:天津大学2005年2月.
[33] Moon, Myung S. et al. DSP Control of UPS Inverter Over-current Limit Using Droop Methord[c]. IEEE Annual Power Electronics Specialists Conference. SC, USA, 1999: 552~557.
[34] Chickamenahalli. S A, Jun. Liu. A DSP Controlled Variable-Frequency Resonant-Commutated Converter[c]. Power Electronics, IEEE Transactions , 2000, 15(31):447~455
[35] Pinheiro J Renes, Baibi Ivo. Wide load range the three-level ZVS PWM dc-to-dc converter[c]. IEEE PESC,1993, pp: 171～177.
[36]荣晓飞.脉冲焊机MIG的数字化研究[D].硕士学位论文.山东:山东大学2006年11月.
[37]贾颖巍.基于的可编程交流电源的研究与设计[D].硕士学位论文.河北:河北工业大学2006年12月.
[38]陈国呈.PWM变频调速及软开关电力变换技术[M].北京:机械工业出版社,2001.
[39]郭院波. DSP控制数字化CO2弧焊电源的研制[D].硕士学位论文.天津:天津大学2004年2月.
[40]董雅倩.基于DSP的晶闸管弧焊电源控制系统研究[D].硕士学位论文.青岛:青岛大学, 2006年2月。
[41]李明青.PC机及单片机数据通信技术[M].北京:北京航空航天大学出版社,2000.
[42]毛东方.PC机和80C196KC单片机串行通信设计[J].机械制造与自动化,2007,36(1).
[43] Jan Axeison. Serial Port Complete: Programming and Circuits for RS-232 and RS-485 Links and Networks[M]. Independent Publishers Group. 2001 (1):115～123.
[44]姬轩.双处理器数字化焊接电源控制系统的研究[D].硕士学位论文.天津:天津大学2005年12月.
[45]康静秋.嵌入式互联网络接口的设计与开发[J].计算机工程,2003.29(1):228~230.
[46] RTL8019AS datasheet http://www.realtek.com.cn[Z]
[47] Texas Instruments.Data Aequisition Cireuits Databook [M]. 1995
[48]朱更军,彭永供,项安,胡凯.串行10位D/A转换器TLC5615原理及与DSP的接口[J].电子质量,2003.10:12~13.
[49]吴开源,黄石生.弧焊电源的数字化控制技术[J].半导体技术,2005.2(4):72~75.
[50]黄石生,薛家祥.新型弧焊电源及其智能控制[J],中国工程科学,2000.12(4):70~74.
[51] Shu hualin,Pi Youguo. PID neural networks for time-delay system [J]. Computers and Chemical Engineering, 2000(24):859-861.
[52]舒怀林.PID神经网络控制算法应用[M].北京:国防工业出胶社,2006.
[53] SCOCTGM, SHAVLIK JW, RAGW H. Refining PID controllers using neural networks[M]. Neural Computation, 1992.4(5): 746-757.
[54] AKHYAR S,OMATU S. Neuromorphic self-tuning PID controller[C].IEEE International Conference on Neural Networks, San Fran-cisco, CA, USA: IEEE, 1993: 552-557.
[55]何宽芳,黄石生.基于PID神经网络的弧焊电源控制器的研究[J],电焊机2007.37(7):58~60.