基于XC164CS单片机MIG焊机控制系统的研究
摘要
当前,新材料的应用,薄板焊接的增多,为满足更高焊接质量要求而产生的新工艺等都对焊接设备提出了更高的要求。从全数字控制的角度对脉冲焊进行研究以提高逆变焊机控制性能,进而进一步提高焊接工艺性能是焊接领域中的重要任务之一。
弧长控制是焊接过程稳定的核心问题。对薄板铝焊而言,脉冲电流波形的精确控制,弧长的及时调整及有效控制;防止自动焊回烧、短路等现象的发生,是获得稳定的焊接过程的关键。本文提出一种新的电弧控制思路,在脉冲电流后期,即熔滴过渡前的瞬间采样电弧电压,然后提供一个表明弧长的信号,采用一定的弧长控制算法使在弧长发生变化的当前脉冲周期就得到有效的控制,如果弧长变短,脉冲频率增加,期间脉冲宽度保持不变,只减小基值电流宽度。实现了全电流范围内对弧长的快速稳定调节,取得了良好的工艺效果。焊接电流和电弧电压是保证焊接质量的重要因素,而焊接电流的大小又取决于送丝速度,所以送丝速度的稳定性是十分重要的,近年来,数字化焊接发展很快,除了焊接电流的数字控制外,还要求送丝机的数字化,以便获得数字化控制系统和良好的控制效果。随着数字化脉冲MIG焊研究的深入,送丝速度对焊接工艺的影响得到了越来越多的关注。本文设计了基于速度负反馈的送丝调速系统,实验证明该系统的性能较一般系统有了明显的提高,在送丝阻力变化、电网波动或电机性能存在一定差异的情况下,该系统均可以稳定输出,为进一步提高脉冲MIG焊接工艺质量打下了基础。
实验证明,本文以英飞凌公司的XC164CS单片机为控制核心,设计开发的一套脉冲MIG焊过程控制系统,不仅实现了焊接参数调节显示、焊接顺序控制、焊接过程中等速送丝配合恒流特性的电源控制等,而且良好的弧长控制作用防止了飞溅的发生,获得了稳定的焊接过程,无回烧、顶丝现象发生(目前铝自动焊中常发生的现象)。
It is important to further improve PMIG/PMAG welding control performance and corresponding process performance by full digital control design in welding machine research. The full digital controlled PMIG welding inverter (based on MCU) is studied and a new sheet metal aluminum welding process-Double PMIG is tried in this paper.
Arc-length control is the core of welding process stability. A new arc-length synchronization pulse control method is presented and the higher arc-length adjustment performance is achieved within a wide range. For sheet metal aluminum welding, timely adjustment and effective control of arc-length is very important in order to avoid melt back events in the GMAW mass production in an automated production line. This paper found an interesting solution to the problem, enabling both self correction and control of the pulse parameters to be used together. This involves a characteristic which constant current during both the pulse and the background current period between pulses. The arc voltage is measured at the end of the current pulse, thus providing a signal to indicate the arc length. If the arc is too short, the pulse frequency is increased, which is done in practice by maintaining the pulse width but reducing the background current duration. The control performance and corresponding process results improved greatly.
The welding current and arc voltage are the important factors of welding quality controlling, the number of welding current is determined by the speed of wire-feed, so the stabilization of wire-feed speed is very important for welding quality. In recent years, the development of digital welding machine is very fast, beside the digital controlling of welding current of the welding machine, it also acquires the wire-feed machine to be digital in order to obtain the digital control system and the better result. With the depth development of the digital pulse MIG welding, the impact of welding technology by the wire-feed speed has been paid more and more attentions. The wire-feed speed control system based on negative feedback of speed is designed. The test proves that the performance of this system has been noticeably improved than the common systems. The system can be output steadily under the factors of wire-feed resistance changing or certain different performance of motors, and this system is the base for the further improving of the quality of the pulse MIG welding. The experimental results validated that the desirable control performance is achieved with the repeatable pulse current waveform, high-speed and stable arc-voltage adjustment. Even if arc length varies with higher frequency and large amplitude in the welding process is very stable. Spatter can be avoided with new arc length control design and suitable process parameters. In addition, arc ignition program is designed and the stable arc ignition process is achieved.
弧长控制是焊接过程稳定的核心问题。对薄板铝焊而言,脉冲电流波形的精确控制,弧长的及时调整及有效控制;防止自动焊回烧、短路等现象的发生,是获得稳定的焊接过程的关键。本文提出一种新的电弧控制思路,在脉冲电流后期,即熔滴过渡前的瞬间采样电弧电压,然后提供一个表明弧长的信号,采用一定的弧长控制算法使在弧长发生变化的当前脉冲周期就得到有效的控制,如果弧长变短,脉冲频率增加,期间脉冲宽度保持不变,只减小基值电流宽度。实现了全电流范围内对弧长的快速稳定调节,取得了良好的工艺效果。焊接电流和电弧电压是保证焊接质量的重要因素,而焊接电流的大小又取决于送丝速度,所以送丝速度的稳定性是十分重要的,近年来,数字化焊接发展很快,除了焊接电流的数字控制外,还要求送丝机的数字化,以便获得数字化控制系统和良好的控制效果。随着数字化脉冲MIG焊研究的深入,送丝速度对焊接工艺的影响得到了越来越多的关注。本文设计了基于速度负反馈的送丝调速系统,实验证明该系统的性能较一般系统有了明显的提高,在送丝阻力变化、电网波动或电机性能存在一定差异的情况下,该系统均可以稳定输出,为进一步提高脉冲MIG焊接工艺质量打下了基础。
实验证明,本文以英飞凌公司的XC164CS单片机为控制核心,设计开发的一套脉冲MIG焊过程控制系统,不仅实现了焊接参数调节显示、焊接顺序控制、焊接过程中等速送丝配合恒流特性的电源控制等,而且良好的弧长控制作用防止了飞溅的发生,获得了稳定的焊接过程,无回烧、顶丝现象发生(目前铝自动焊中常发生的现象)。
It is important to further improve PMIG/PMAG welding control performance and corresponding process performance by full digital control design in welding machine research. The full digital controlled PMIG welding inverter (based on MCU) is studied and a new sheet metal aluminum welding process-Double PMIG is tried in this paper.
Arc-length control is the core of welding process stability. A new arc-length synchronization pulse control method is presented and the higher arc-length adjustment performance is achieved within a wide range. For sheet metal aluminum welding, timely adjustment and effective control of arc-length is very important in order to avoid melt back events in the GMAW mass production in an automated production line. This paper found an interesting solution to the problem, enabling both self correction and control of the pulse parameters to be used together. This involves a characteristic which constant current during both the pulse and the background current period between pulses. The arc voltage is measured at the end of the current pulse, thus providing a signal to indicate the arc length. If the arc is too short, the pulse frequency is increased, which is done in practice by maintaining the pulse width but reducing the background current duration. The control performance and corresponding process results improved greatly.
The welding current and arc voltage are the important factors of welding quality controlling, the number of welding current is determined by the speed of wire-feed, so the stabilization of wire-feed speed is very important for welding quality. In recent years, the development of digital welding machine is very fast, beside the digital controlling of welding current of the welding machine, it also acquires the wire-feed machine to be digital in order to obtain the digital control system and the better result. With the depth development of the digital pulse MIG welding, the impact of welding technology by the wire-feed speed has been paid more and more attentions. The wire-feed speed control system based on negative feedback of speed is designed. The test proves that the performance of this system has been noticeably improved than the common systems. The system can be output steadily under the factors of wire-feed resistance changing or certain different performance of motors, and this system is the base for the further improving of the quality of the pulse MIG welding. The experimental results validated that the desirable control performance is achieved with the repeatable pulse current waveform, high-speed and stable arc-voltage adjustment. Even if arc length varies with higher frequency and large amplitude in the welding process is very stable. Spatter can be avoided with new arc length control design and suitable process parameters. In addition, arc ignition program is designed and the stable arc ignition process is achieved.
引文
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12 S. B. Zhang and Y. M. Zhang. A power source prototype provides multiple functions. Welding Journal. 1998,(9):45-48 .
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23 Mohamed AbdelRahman. Feedback lineatization control of current and arc length in GMAW systems. Proeedings of 1998 American Control Conferrence,(Philadelphia), June 1998:1757-1761
24 Shepard, M.E., Modeling of self-Regulation in Gas Metal Arc Welding, Ph.D.Dissertation, 1991.
25 柯利涛等.基于 ARM 和 uC/OS-Ⅱ的数字控制送丝系统的研究.焊接设备与材料.2007.
26 J.S Gho, Y.M Chae, K.S Kim, C.Y Won, H.S Mok, G.H Choe. A Study on the Effect of Wire Feeding Speed Controller in Inverter Arc Welding Machine.IEEE 1999 InternationalConference on Power Electronic and Drive Systems.1999,(6):394~398.
27 Klas Weman.Equipment for aluminium welding[J].Svetsaren.2000.54(2):12.
28 Amin M.Synergic pulse MIG welding[J].Metal Construction,1981,6.
29 P.Drews.Schulle,United States patent,4,427,875 Jan.24,1980
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32 王伟明.逆变式GMA单脉冲和双脉冲焊机数字控制系统研究[D].北京工业大学工学博士学位论文,2004,4.
33 Johnson.J A,Smartt H.B.,Harmer T.,et al.Derivation and calibration of a gas Metal arc welding(GMAW)dynamic droplet model[C].In Trends in Welding Research.Proc. of the 4th International Conference,1995,377~384.
34 Naidu D.S.,Moore K. L.,Abdelrahman M. A. Gas metal arc welding control:Part2-control atrategy[J].Nonlinear Analysis,1999(35):85~93.
35 沈勇,庞宝刚,宋吉伟.动力系统嵌入式 ECU 开发平台的实现.柴油机.第 27 卷(2005)第 2 期.
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37 沈俊,宋健,黄全安,于良耀.基于 XC164 的六通道 ABS 开发板设计.电子应用世界.2006.02.
38 Infineon Technologies AG. XC164CS datasheet.
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40 Infineon,xc164-16 16-Bit single-chip microcontroller with C166SV2 core user’s manual[D].2004.
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2 侯显智,对几种铝合金焊接工艺的研究。科技信息.
3 国旭明,杨成刚,钱百年,常云龙,张洪延.高强 Al-Cu 合金脉冲 MIG 焊工艺.焊接学报.第 25 卷.第 4 期.2004 年 8 月.
4 李妙珍.关于铝及铝合金的焊接工艺浅析.轻金属.2007 年第 9 期.
5 李德全等.国内焊接技术应用现状与发展趋势.现代焊接.2008 年第 1 期总第 61 期 J-9.
6 左敦桂等.铝合金焊接新技术在汽车制造中的应用电焊机.2007 年 7 月,第 37 卷第 7 期.
7 黄石生.GMAW-P 焊熔滴过渡及其控制的研究现状[J].电焊机,2000(1):1~5.
8 陈涛.铝及铝合金管的焊接工艺分析.现代焊接.2007 年第 10 期,总第 58 期.
9 杨宗辉,孙孝纯.现代铝合金焊接技术.铝加工.2003,No.6 总第 153 期.
10 吴 芸,张其林.纵向焊接铝合金构件的试验和设计研究.建筑钢结构进展.2008 年 2 月第 10 卷第 1 期.
11 廖平等.变极性脉冲 MIG 焊控制系统.焊接学报.2006 年 3 月第 27 卷第 3 期.
12 S. B. Zhang and Y. M. Zhang. A power source prototype provides multiple functions. Welding Journal. 1998,(9):45-48 .
13 王克鸿,徐越兰等.微机 PMIG 焊机动态调节过程试验研究.南京理工大学报.Vol.21,No.3 Jun.1997: 213~216.
14 仝红军,上山智之.低频调制型脉冲 MIG 焊接方法的工艺特点.焊接.2001.
15 王显明等.铝合金板焊缝表面缺陷原因分析.轻合金加工技术.2007,Vol.35.No.7
16 孟宪福,高栋.铝合金工件的焊接变形及控制措施,铁道机车车辆工人.第 2 期,2007 年
2 月.文章编号 1007-6042(2007)02-0024-03.
17 杭争翔,李利,甘洪岩.变极性脉冲 MIG 焊接工艺.现代焊接.2006 年第 1 期,总第 37期.
18 黄石生.新型弧焊电源及其智能控制[M].北京:机械工业出版社,2000.
19 张九海.MIG(MAG)脉冲焊的熔滴过渡行为[J].焊接学报,1994(3):26~29.
20 Larsson,L.,Palmquist,N., and Larsson,J.K.2000.High-quality aluminum welding-a key factor in futor car body production. Svetsaren54 (2):17-24
21 潘际銮.现代弧焊控制[M].北京:机械工业出版社.2000.
22 吴开源等.脉冲 MIG 焊控制的研究现状与展望.电焊机.2003 年 2 月,第 33 卷第 2 期.
23 Mohamed AbdelRahman. Feedback lineatization control of current and arc length in GMAW systems. Proeedings of 1998 American Control Conferrence,(Philadelphia), June 1998:1757-1761
24 Shepard, M.E., Modeling of self-Regulation in Gas Metal Arc Welding, Ph.D.Dissertation, 1991.
25 柯利涛等.基于 ARM 和 uC/OS-Ⅱ的数字控制送丝系统的研究.焊接设备与材料.2007.
26 J.S Gho, Y.M Chae, K.S Kim, C.Y Won, H.S Mok, G.H Choe. A Study on the Effect of Wire Feeding Speed Controller in Inverter Arc Welding Machine.IEEE 1999 InternationalConference on Power Electronic and Drive Systems.1999,(6):394~398.
27 Klas Weman.Equipment for aluminium welding[J].Svetsaren.2000.54(2):12.
28 Amin M.Synergic pulse MIG welding[J].Metal Construction,1981,6.
29 P.Drews.Schulle,United States patent,4,427,875 Jan.24,1980
30 Ohshima K,Abe M,Kubota T.Effect of power source characteristic on stability of pulsed current transfer-sampled-data control pulsed arc[A].JWS-I-3.
31 左敦桂.基于DSP的数字化脉冲MIG焊接电源的弧长控制及仿真研究.上海交通大学硕士学位论文.2007.01.
32 王伟明.逆变式GMA单脉冲和双脉冲焊机数字控制系统研究[D].北京工业大学工学博士学位论文,2004,4.
33 Johnson.J A,Smartt H.B.,Harmer T.,et al.Derivation and calibration of a gas Metal arc welding(GMAW)dynamic droplet model[C].In Trends in Welding Research.Proc. of the 4th International Conference,1995,377~384.
34 Naidu D.S.,Moore K. L.,Abdelrahman M. A. Gas metal arc welding control:Part2-control atrategy[J].Nonlinear Analysis,1999(35):85~93.
35 沈勇,庞宝刚,宋吉伟.动力系统嵌入式 ECU 开发平台的实现.柴油机.第 27 卷(2005)第 2 期.
36 XC164CS User's manual,v2.0,Dec.2003.
37 沈俊,宋健,黄全安,于良耀.基于 XC164 的六通道 ABS 开发板设计.电子应用世界.2006.02.
38 Infineon Technologies AG. XC164CS datasheet.
39 韩玉,李欣,林平,胡长生.基于 XC164CS 的数字式光伏阵列模拟器研制.电气应用.2007年第 26 卷第 12 期.
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