基于DSP的数字化超声冲击电源装置研究
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摘要
本教研室研制的采用超声冲击提高焊接接头疲劳性能的技术一经实现就受到了学术界的高度关注,成为研究热点。目前,超声冲击技术由于其执行机构轻巧、噪音小、效率高、成本低且节能等诸多优势,已成为一种理想的焊后改善接头疲劳性能的方法。但目前所使用的模拟电源有着自身无法克服的缺陷。
数字化电源控制灵活、易于实现柔性化,可以达到更高的稳定性和控制精度,接口兼容性良好。为了很好地解决模拟电源实时性较差和不可回调的缺点,本课题以DSP(数字信号处理器)为控制核心研制了一套数字化超声冲击电源。
本文首先设计了系统的硬件电路,包括DSP的最小系统电路、采样预处理电路、输出信号死区形成电路、恒幅控制电路和显示电路。根据DSP的工作主频和控制系统的精度要求,引入倍频器来减小频率调整步长,以实现高精度控制。
在软件编写过程中,根据超声冲击机的工作特点对控制算法进行了改进,确定了最佳扫描区域,同时设置了电流门槛值,从而减轻了频率跟踪的压力。循环跟踪阶段,编写了A/D转换程序、相位差计算程序、PWM生成程序、D/A转换程序和参数显示程序,实现了控制思想。
联机试验表明,本文研制的基于DSP的数字化超声冲击电源可以使系统工作在谐振状态,冲击过程稳定。所设计的软硬件系统基本实现了预期功能。
Once the technique of improving the fatigue performance of welded joints by ultrasonic peening treatment (UPT) has been realized by this research group, it has been paid fully attention to. As for its advantages of handy equipment, little noise, high efficiency, low cost and energy saving, it has been one of the perfect post-weld treatments for improving the fatigue performance of the joints. However, its analog power supply has the shortage that cannot be overcome.
Digital power supply can achieve flexible control, high stability and precision and fine interface compatibility. In order to solve the problem of real-time control and back adjustment of the analog power, in this paper, digital ultrasonic peening power supply whose control system is based on DSP (Digital Signal Processor) has been developed.
At first, hardware circuit of the system has been designed, including minimum system of DSP, sampling pretreatment, dead zone formation, constant amplitude control and display circuit. According to the frequency of DSP and the requirement of control precision, frequency multiplier has been used to reduce to adjusting step size. In the software programming, control algorithm is improved according to the characteristic of ultrasonic peening machine. Optimal scan region is settled as well as the threshold of the current, so that it is easier for frequency track. The program includes A/D conversion, phase difference calculation, PWM formation, D/A conversion and numeral display.
On-line testing shows that, this digital ultrasonic peening power supply based on DSP can make the system work at the resonance state, and the peening process is stable. Both the hardware and software can achieve the expected function.
数字化电源控制灵活、易于实现柔性化,可以达到更高的稳定性和控制精度,接口兼容性良好。为了很好地解决模拟电源实时性较差和不可回调的缺点,本课题以DSP(数字信号处理器)为控制核心研制了一套数字化超声冲击电源。
本文首先设计了系统的硬件电路,包括DSP的最小系统电路、采样预处理电路、输出信号死区形成电路、恒幅控制电路和显示电路。根据DSP的工作主频和控制系统的精度要求,引入倍频器来减小频率调整步长,以实现高精度控制。
在软件编写过程中,根据超声冲击机的工作特点对控制算法进行了改进,确定了最佳扫描区域,同时设置了电流门槛值,从而减轻了频率跟踪的压力。循环跟踪阶段,编写了A/D转换程序、相位差计算程序、PWM生成程序、D/A转换程序和参数显示程序,实现了控制思想。
联机试验表明,本文研制的基于DSP的数字化超声冲击电源可以使系统工作在谐振状态,冲击过程稳定。所设计的软硬件系统基本实现了预期功能。
Once the technique of improving the fatigue performance of welded joints by ultrasonic peening treatment (UPT) has been realized by this research group, it has been paid fully attention to. As for its advantages of handy equipment, little noise, high efficiency, low cost and energy saving, it has been one of the perfect post-weld treatments for improving the fatigue performance of the joints. However, its analog power supply has the shortage that cannot be overcome.
Digital power supply can achieve flexible control, high stability and precision and fine interface compatibility. In order to solve the problem of real-time control and back adjustment of the analog power, in this paper, digital ultrasonic peening power supply whose control system is based on DSP (Digital Signal Processor) has been developed.
At first, hardware circuit of the system has been designed, including minimum system of DSP, sampling pretreatment, dead zone formation, constant amplitude control and display circuit. According to the frequency of DSP and the requirement of control precision, frequency multiplier has been used to reduce to adjusting step size. In the software programming, control algorithm is improved according to the characteristic of ultrasonic peening machine. Optimal scan region is settled as well as the threshold of the current, so that it is easier for frequency track. The program includes A/D conversion, phase difference calculation, PWM formation, D/A conversion and numeral display.
On-line testing shows that, this digital ultrasonic peening power supply based on DSP can make the system work at the resonance state, and the peening process is stable. Both the hardware and software can achieve the expected function.
引文
[1] 刘嘉,卢振洋,等.电焊机的数字化[J].焊接学报,2002,23(1):88~92.
[2] 华学明,吴毅雄,等.数字化焊接电源系统的特征[J].焊接技术,2002,31(2):6~7.
[3] 王东坡,霍立兴,张玉凤,等.提高焊接接头疲劳强度的超声冲击法,焊接学报,1999,20(3):158～163.
[4] 王东坡.改善焊接接头疲劳强度超声冲击方法的研究:[博士学位论文],天津;天津大学,2000.16～43.
[5] 王东坡、张玉凤、霍立兴.超声冲击处理焊接接头焊趾区材料的疲劳性能,天津大学学报,2001,34(1):13～17.
[6] Janosch J J,Koneczny H,Debiez S,et al.Improvement of fatigue strength in welded joints(in HSS and in aluminum alloys)by ultrasonic hammer peening[J].Welding in the World,1996,(37):72～81.
[7] Maddox.Development in Fatigue Design Code and Fitness for-service Assessment Methods[C].IIW 50th Annual Assembly Conference,1997.
[8] 王珩.基于DSP的CO2焊波形数字控制器的研究:[硕士学位论文],天津;天津大学,2004.3～6.
[9] 刘和平.TMS320LF240x DSP 结构原理及应用[M].北京:北京航空航天大学出版社,2002.
[10] 江思敏.TMS320LF240x DSP 硬件开发教程[M].北京:机械工业出版社,2003.
[11] 张雄伟,陈亮,徐光辉.DSP 芯片的原理与开发应用[M].北京:电子工业出版社,2003.
[12] TDS2407EA 用户使用手册[M].闻亭科技发展有限责任公司,2003.18～24.
[13] 解决 3.3V 的几种方案[N]. http://www.211C.com.2004.
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[16] 阎石.数字电子技术基础[M]. 北京:高等教育出版社,1998.62～113.
[17] 丁士圻.模拟滤波器[M].哈尔滨:哈尔滨工程大学出版社,2004.148～170.
[18] 杜锡珏,王文煊,张世演,等.有源滤波器[M].北京:中国铁道出版社,1982.322～327.
[19] 胡寿松.自动控制原理[M].北京:国防工业出版社,1999.
[20] 芦家成,姚永刚,戚新波.IGBT 的保护要求和驱动模块 EXB841 的保护特性研究[J].河南科学,2000,18(2):187～190.
[21] 张贵锋,李永兵,王士元.EXB841 的自身保护及驱动电压的调整[J].电焊机,2002,2:16～18.
[22] 吴良辰.塑料压力管道热熔对接焊机感应加热板的研制:[硕士学位论文],天津;天津大学,2004.33～39.
[23] 张立,赵永健.现代电力电子技术[M].北京:科学出版社,1992.21～40.
[24] 李俊义,陈广来,王收军.多台设备同步控制方法研究[J].制造业自动化,2002,24(8):42~46.
[25] 范世忠.锁相式超声振动系统频率自动跟踪的初步研究[J].应用声学,1991,11(1):28～33.
[26] Kay Soon Low.A DSP-Based Single-Phase AC Power Source[A].IEEE Transactions on Industrial Electronics[C].2001,46(5):936~941.
[27] Moon, Myung S. et al. DSP Control of UPS Inverter Over-current Limit Using Droop Methord[A]. IEEE Annual Power Electronics Specialists Conference[C]. SC, USA, 1999: 552~557.
[28] 朱正超,姬劳,彭卫东. 用 TMS320LF2407 和 FPGA 实现电能质量监测[J]. http://www.211C.com.
[29] 蒋毅凯,李国通,杨根庆. 基于定点 DSP 的软件锁相环的设计和实现[J]. http://www.211C.com.
[30] 张镜澄.超声换能器机械振速的自动稳定[J].应用声学,1992,(10):22~25.
[31] 徐德高.脉宽调制变换器型稳压电源[M].北京:科学出版社,1986.
[32] 沈雷.CMOS 集成电路原理及应用[M]. 北京:光明日报出版社,1986.135～140.
[33] 科林、孙人杰.TTL、高速 CMOS 手册[M]. 北京:电子工业出版社,2004.35～36.
[34] 张小虹.数字信号处理[M].北京:机械工业出版社,2005.
[35] TDS510USB2.0 仿真器使用说明书.闻亭科技发展有限责任公司,2003.
[36] 章云,谢莉萍,熊红艳.DSP 控制器及其应用[M].北京:机械工业出版社,2002.
[37] User'sManual_2407A.TEXAS Instruments,2002.
[38] 姜立东,姜雪松.Protel DXP 原理图与 PCB 设计[M]. 北京:北京邮电大学出版社,2004.236～241.
[39] 李珩,杨彬,欧大生.电路设计与制板—Protel DXP 实用教程[M]. 西安:西安电子科技大学出版社,2004.235～257.
[40] 彭启琮,管庆.DSP 集成开发环境[M].北京:电子工业出版社,2004.
[41] 孟庆昌.标准 C 语言程序设计[M].北京:宇航出版社,1993.
[42] 刘和平.TMS320LF240x DSP C 语言开发应用[M].北京:北京航空航天大学出版社,2003.
[43] 鲁岩.实用 C 语言及其设计[M]. 大连:大连理工大学出版社,1993.34～48.
[44] Michael J.Pont.Embedded C[M].北京:中国电力出版社,2003.
[2] 华学明,吴毅雄,等.数字化焊接电源系统的特征[J].焊接技术,2002,31(2):6~7.
[3] 王东坡,霍立兴,张玉凤,等.提高焊接接头疲劳强度的超声冲击法,焊接学报,1999,20(3):158～163.
[4] 王东坡.改善焊接接头疲劳强度超声冲击方法的研究:[博士学位论文],天津;天津大学,2000.16～43.
[5] 王东坡、张玉凤、霍立兴.超声冲击处理焊接接头焊趾区材料的疲劳性能,天津大学学报,2001,34(1):13～17.
[6] Janosch J J,Koneczny H,Debiez S,et al.Improvement of fatigue strength in welded joints(in HSS and in aluminum alloys)by ultrasonic hammer peening[J].Welding in the World,1996,(37):72～81.
[7] Maddox.Development in Fatigue Design Code and Fitness for-service Assessment Methods[C].IIW 50th Annual Assembly Conference,1997.
[8] 王珩.基于DSP的CO2焊波形数字控制器的研究:[硕士学位论文],天津;天津大学,2004.3～6.
[9] 刘和平.TMS320LF240x DSP 结构原理及应用[M].北京:北京航空航天大学出版社,2002.
[10] 江思敏.TMS320LF240x DSP 硬件开发教程[M].北京:机械工业出版社,2003.
[11] 张雄伟,陈亮,徐光辉.DSP 芯片的原理与开发应用[M].北京:电子工业出版社,2003.
[12] TDS2407EA 用户使用手册[M].闻亭科技发展有限责任公司,2003.18～24.
[13] 解决 3.3V 的几种方案[N]. http://www.211C.com.2004.
[14] 姚海彬.电工技术[M].天津:高等教育出版社,1999.69～73.
[15] 童诗白,华成英.模拟电子技术基础[M]. 北京:高等教育出版社,2001.312～322.
[16] 阎石.数字电子技术基础[M]. 北京:高等教育出版社,1998.62～113.
[17] 丁士圻.模拟滤波器[M].哈尔滨:哈尔滨工程大学出版社,2004.148～170.
[18] 杜锡珏,王文煊,张世演,等.有源滤波器[M].北京:中国铁道出版社,1982.322～327.
[19] 胡寿松.自动控制原理[M].北京:国防工业出版社,1999.
[20] 芦家成,姚永刚,戚新波.IGBT 的保护要求和驱动模块 EXB841 的保护特性研究[J].河南科学,2000,18(2):187～190.
[21] 张贵锋,李永兵,王士元.EXB841 的自身保护及驱动电压的调整[J].电焊机,2002,2:16～18.
[22] 吴良辰.塑料压力管道热熔对接焊机感应加热板的研制:[硕士学位论文],天津;天津大学,2004.33～39.
[23] 张立,赵永健.现代电力电子技术[M].北京:科学出版社,1992.21～40.
[24] 李俊义,陈广来,王收军.多台设备同步控制方法研究[J].制造业自动化,2002,24(8):42~46.
[25] 范世忠.锁相式超声振动系统频率自动跟踪的初步研究[J].应用声学,1991,11(1):28～33.
[26] Kay Soon Low.A DSP-Based Single-Phase AC Power Source[A].IEEE Transactions on Industrial Electronics[C].2001,46(5):936~941.
[27] Moon, Myung S. et al. DSP Control of UPS Inverter Over-current Limit Using Droop Methord[A]. IEEE Annual Power Electronics Specialists Conference[C]. SC, USA, 1999: 552~557.
[28] 朱正超,姬劳,彭卫东. 用 TMS320LF2407 和 FPGA 实现电能质量监测[J]. http://www.211C.com.
[29] 蒋毅凯,李国通,杨根庆. 基于定点 DSP 的软件锁相环的设计和实现[J]. http://www.211C.com.
[30] 张镜澄.超声换能器机械振速的自动稳定[J].应用声学,1992,(10):22~25.
[31] 徐德高.脉宽调制变换器型稳压电源[M].北京:科学出版社,1986.
[32] 沈雷.CMOS 集成电路原理及应用[M]. 北京:光明日报出版社,1986.135～140.
[33] 科林、孙人杰.TTL、高速 CMOS 手册[M]. 北京:电子工业出版社,2004.35～36.
[34] 张小虹.数字信号处理[M].北京:机械工业出版社,2005.
[35] TDS510USB2.0 仿真器使用说明书.闻亭科技发展有限责任公司,2003.
[36] 章云,谢莉萍,熊红艳.DSP 控制器及其应用[M].北京:机械工业出版社,2002.
[37] User'sManual_2407A.TEXAS Instruments,2002.
[38] 姜立东,姜雪松.Protel DXP 原理图与 PCB 设计[M]. 北京:北京邮电大学出版社,2004.236～241.
[39] 李珩,杨彬,欧大生.电路设计与制板—Protel DXP 实用教程[M]. 西安:西安电子科技大学出版社,2004.235～257.
[40] 彭启琮,管庆.DSP 集成开发环境[M].北京:电子工业出版社,2004.
[41] 孟庆昌.标准 C 语言程序设计[M].北京:宇航出版社,1993.
[42] 刘和平.TMS320LF240x DSP C 语言开发应用[M].北京:北京航空航天大学出版社,2003.
[43] 鲁岩.实用 C 语言及其设计[M]. 大连:大连理工大学出版社,1993.34～48.
[44] Michael J.Pont.Embedded C[M].北京:中国电力出版社,2003.