变极性PMIG焊接设备数字化控制系统研制
|
摘要
变极性PMIG(简称VP PMIG)焊是一种交流脉冲熔化极焊接方法,可用于焊接铝合金、低碳钢以及不锈钢,它的优势是可以通过调整EN极性占整个变极性脉冲电流周期的比例(简称EN比率),实现对焊接电弧能量的控制,从而达到对焊缝熔深、送丝速度的控制,非常适合于薄板铝和金焊接,并且可以获得很高的焊接效率。
根据薄板铝合金焊接工艺要求,在基于DSP控制的VP PMIG焊接设备结构的基础上,设计了逆变焊接电源数字化控制系统,完善了该焊接设备,系统工作过程稳定、控制精度高。焊接电源主电路采用IGBT二次逆变技术实现变极性焊接电流的输出,内环电流反馈实现焊接电流的恒流控制,外环电压反馈通过控制电弧电压实现电弧弧长的调节。针对铝合金VP PMIG焊接电流过零后存在电弧再引燃问题,采用单电源供电方式,设计了一种全桥式高压脉冲稳弧电路,可实现小基值电流过零时的双向稳弧,保证了焊接电流过零时电弧燃烧的稳定性。
采用DSP(TMS320F2812)作为控制系统核心,用软件编程实现复杂焊接过程的控制,减少了较多硬件控制电路,使焊接设备向柔性化控制方向发展。对于焊接过程的控制,采用数字化PI算法,实现了闭环的恒流控制。
采用CPLD(EPM7128STC100)作为数字化PWM控制系统核心,完成数字化PWM控制,避开了模拟PWM控制的种种缺陷,使PWM控制更灵活,更可靠,成本更低廉。应用了CPLD灵活的逻辑可编程能力,把保护电路融入其中,达到对PWM输出信号的控制作用。
本文把完成所设计的数字化控制系统应用与焊机主电源上,编写软件实现了电源的恒流控制,并研究了该电源的电流、电压的响应性能。结果表明,所研制的数字化控制系统能实现精确的恒流控制,达到了最初的设定研究目标。
Variable Polarity Pulsed MIG (VP PMIG)is a consumable electrode AC pulse weldingprocess, it can used to weld aluminum alloy, mild steel and stainless steel. The advantages such aswelding arc energy, wire melting rate and penetration of weld can be controlled by regulate theratio of EN time to the period of varied polarity pulse current. VP PMIG is appropriate to weldthin plate of aluminum alloy and efficiency is great.
A digital control system of VP PMIG arc welding power source is developed based on DSP,the topology and the output current waveform designed can meet the requirement of thin platewelding. Waveform of Varied polarity current is realized by using IGBT as switches of secondaryinverter, constant welding current is realized by inside loop of feedback of current, regulate of arclength can be realized by outside loop of feedback of arc voltage. A full bridge high voltage pulsedarc stabilizing circuit which was powered by single power source is designed to avoid ofextinguishing of cross zero welding arc. This circuit can maintain the stable of arc di-directionallywhen small background current cross zero, ensure the stable burning of welding arc when weldingcurrent cross zero.
DSP (TMS320F2812) is the control kernel of VP PMIG power source. Hardware circuit issimplified by using software to control complicated welding process.As to control of weldingprocess,a way of digitital PI arithmetic is used for closed loop of constant-current.
CPLD(EPM7128STC100) is the PWM kernel of digital control system.The digital control ofPWM is developed,without the fault of former ananlog control of PWM,the new control of PWMis much more convenient,dependable and cheaper.With the ability of logic programed as toCPLD,the protect circuit is designed to control the signal of PWM.
The digital controlling system is used in welding power source .we program constant-currentcontrol software and research respectively the current and voltage step response of power source.The experiment proved that the welding inverter can control the constant-current waveformsprecisely and meet the design requirements.
根据薄板铝合金焊接工艺要求,在基于DSP控制的VP PMIG焊接设备结构的基础上,设计了逆变焊接电源数字化控制系统,完善了该焊接设备,系统工作过程稳定、控制精度高。焊接电源主电路采用IGBT二次逆变技术实现变极性焊接电流的输出,内环电流反馈实现焊接电流的恒流控制,外环电压反馈通过控制电弧电压实现电弧弧长的调节。针对铝合金VP PMIG焊接电流过零后存在电弧再引燃问题,采用单电源供电方式,设计了一种全桥式高压脉冲稳弧电路,可实现小基值电流过零时的双向稳弧,保证了焊接电流过零时电弧燃烧的稳定性。
采用DSP(TMS320F2812)作为控制系统核心,用软件编程实现复杂焊接过程的控制,减少了较多硬件控制电路,使焊接设备向柔性化控制方向发展。对于焊接过程的控制,采用数字化PI算法,实现了闭环的恒流控制。
采用CPLD(EPM7128STC100)作为数字化PWM控制系统核心,完成数字化PWM控制,避开了模拟PWM控制的种种缺陷,使PWM控制更灵活,更可靠,成本更低廉。应用了CPLD灵活的逻辑可编程能力,把保护电路融入其中,达到对PWM输出信号的控制作用。
本文把完成所设计的数字化控制系统应用与焊机主电源上,编写软件实现了电源的恒流控制,并研究了该电源的电流、电压的响应性能。结果表明,所研制的数字化控制系统能实现精确的恒流控制,达到了最初的设定研究目标。
Variable Polarity Pulsed MIG (VP PMIG)is a consumable electrode AC pulse weldingprocess, it can used to weld aluminum alloy, mild steel and stainless steel. The advantages such aswelding arc energy, wire melting rate and penetration of weld can be controlled by regulate theratio of EN time to the period of varied polarity pulse current. VP PMIG is appropriate to weldthin plate of aluminum alloy and efficiency is great.
A digital control system of VP PMIG arc welding power source is developed based on DSP,the topology and the output current waveform designed can meet the requirement of thin platewelding. Waveform of Varied polarity current is realized by using IGBT as switches of secondaryinverter, constant welding current is realized by inside loop of feedback of current, regulate of arclength can be realized by outside loop of feedback of arc voltage. A full bridge high voltage pulsedarc stabilizing circuit which was powered by single power source is designed to avoid ofextinguishing of cross zero welding arc. This circuit can maintain the stable of arc di-directionallywhen small background current cross zero, ensure the stable burning of welding arc when weldingcurrent cross zero.
DSP (TMS320F2812) is the control kernel of VP PMIG power source. Hardware circuit issimplified by using software to control complicated welding process.As to control of weldingprocess,a way of digitital PI arithmetic is used for closed loop of constant-current.
CPLD(EPM7128STC100) is the PWM kernel of digital control system.The digital control ofPWM is developed,without the fault of former ananlog control of PWM,the new control of PWMis much more convenient,dependable and cheaper.With the ability of logic programed as toCPLD,the protect circuit is designed to control the signal of PWM.
The digital controlling system is used in welding power source .we program constant-currentcontrol software and research respectively the current and voltage step response of power source.The experiment proved that the welding inverter can control the constant-current waveformsprecisely and meet the design requirements.
引文
1 殷树言,张九海.气体保护焊工艺[M].哈尔滨:哈尔滨工业大学出版社,1989:93-96.
2 潘际銮.现代弧焊控制[M].北京:机械工业出版社,2000.6:3-8.
3 M.Amin.Synergic Pulse MIG Welding[J].Metal Construction,1981,13 (6):349–353.
4 殷树言,刚铁,卜华金.协同式脉冲 MIG 焊的微机控制系统[J].焊接学报,1991,12(1):46-52.
5 廖平. 薄板铝合金 VP PMIG 焊接设备及电弧稳定性研究[D].北京工业大学博士学位论文,2007,
6 王其隆,殷树言,张九海.关于熔化极气体保护焊熔滴自由过渡的分类与名词问题[J].焊接学报,1983,4(3):149-154.
7 Hongjun Tong,Ichizo Yazawa,Tomoyuki Ueyama.High Speed Welding of Aluminum AlloySheets Using Laser Assisted AC Pulsed MIG Process[C].2003 汽车焊接国际论坛论文集.上海,2003:133-142.
8 Y.M.Zhang,P.J.Li.Modified active control of metal transfer and pulsed GMAW oftitanium.Welding Journal, 2001,80(2):54-s-61-s.
9 童诗白, 华成英. 模拟电子技术基础(第三版). 高等教育出版社, 2001: 352~353
10 (美)Donald A. Neamen著, 赵桂钦, 卜艳萍译. 电子电路分析与设计. 电子工业出版社,2003: 742~745
11 Tong,T.Ueyama,M.Tanaka,at al. Observations of the phenomenon of abnormal arc voltageoccurring in pulsed metal inert gas welding of aluminium alloy[J].Science and Technology ofWelding and Joining,2005,10(6):695-700.
12 方臣富.VPTIG 焊接电源与电弧稳定性研究[D].北京工业大学博士学位论文,2005.
13 杭争翔 , 殷树言 , 方臣富 .AC MIG 与 DC MIG 焊接工艺及控制的分析 [J]. 电焊机,2001,31(9):17-21.
14 焦向东,潘际銮,张骅.双凹波形脉冲氩弧焊的焊接电源[J].焊接学报 1996,17(1):56-61.
15 焦 向 东 , 潘 际 銮 , 张 骅 .AC/DCRP 交 替 MIG 焊 接 方 法 的 研 究 [J]. 中 国 机 械 工程,1996,7(2):88-89.
16 焦向东等.新型交流脉冲 MIG 焊接法的研究[J].石油机械,2002,30(9):8-10.
17 Texas Instruments. TMS320C28x DSP CPU and Instruction Set Reference Guide Rev.2004:1～12
18 TMS320F28x Analog to Digital Converter (ADC) Reference Guide. Texas Instruments, 05Nov 2004: 12~21
19 杭 争 翔 , 殷 树 言 , 黄 鹏 飞 . 交 流 脉 冲 MIG 弧 焊 电 源 及 弧 长 控 制 [J]. 焊 接 学报,2003,24(2):83-85,88.
20 杭争翔,殷树言,黄鹏飞,等.逆变弧焊电源输出变极性过程[J].电焊机,2003,33(6):13-15,38.
21 廖日坤,CPLD/FPGA 嵌入式应用开发技术白金手册,中国电力出版社,2005:182～297.
22 [美]Texas Instruments Incorporated 著, 张卫宁编译. TMS320C28X 系列 DSP 的 CPU 与外设(上). 北京:清华大学出版社, 2004: 13~15.
23 杭争翔,汪江,李利,等.变极性脉冲 MIG 焊的控制[J].电焊机,2006,36(2):30-32.
24 杭 争 翔 , 宋 政 . 交 流 脉 冲 MIG 电 弧 稳 定 性 及 其 控 制 [J]. 沈 阳 工 业 大 学 学报,2002,24(5):374-377.
25 杭争翔,宋政,常小芳.AC PMIG 电源动特性[J].沈阳工业大学学报,2004,26(3):254-257.
26 杭争翔 , 殷树言 , 宋政 . 交流脉冲 MIG 焊接铝合金薄板的工艺特性 [J]. 焊接学报,2004,25(2):99-106.
27 都岛贞雄,滕田治男,岩见博志.大电流 AC-MIG 溶接法の开发(第二报)[J].溶接学会论文集,1992,10(1):88-94.
28 都岛贞雄,大北茂.AC-MIG 溶接法にぉける Ti-B 系溶接金属の韧性にぉよぼす酸素の影响[J].溶接学会论文集,1992,10(2):54-63.
29 H.Tong, T.Ueyama, S.Harada, at al.Quality and productivity improvement in aluminium alloythin sheet welding using alternating current pulsed metal inert gas welding system[J]. Scienceand Technology of Welding and Joining,2001,6(4):203-208.
30 Tomoyuki Ueyama,Hongjun Tong,Shoji Harada.Improve Sheet Metal Welding Quality &Productivity with AC Pulsed MIG Welding System[C].IIW DOC.Ⅻ-1629-00.
31 仝红军,上山智之.低频调制型脉冲 MIG 焊接工艺方法的特点[J].焊接,2001(11):33-40.
32 仝红军,上山智之.交流脉冲 MIG 焊接机器人系统的工艺特点[J].焊接,2002(1):20-22.
33 黄石生.逆变理论与弧焊逆变器[M].北京:机械工业出版社,1995:151-168.
34 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,2000:117-129.
35 TMS320C6000 Code Composer Studio Getting Started Guide. Texas Instruments. Aug, 2003:
1～12
36 Texas Instruments. TMS320C28x DSP Event Manager (EV) Reference Guide. Rev.November 2003:4～48
37 TMS320F2810/F2812 Alpha Flash Programming Utilities, Alpha Release 1.0. SpectrumDigital Inc. www.spectrumdigital.com
38 赵家瑞.逆变焊接与切割电源[M].北京:机械工业出版社,1995:200-234.
39 李爱文,张承慧.现代逆变技术及其应用[M].北京:科学出版社,2000:140-154.
40 苏奎峰,吕强,耿庆,等.TMS320F2812 原理与开发[M].北京:电子工业出版社,2005:156-225.
41 彭启琮,管庆.DSP 集成开发环境[M].北京:电子工业出版社,2004:8-175.
42 ( 美 )H.M.Deitel, P.J.Deitel. C 程序设计教程 [M]. 薛万鹏译 . 北京 : 机械工业出版社,2004:41-92.
43 刘和平,王维俊,江渝,等.TMS320LF240x DSP C 语言开发应用[M].北京:北京航空航天大学出版社,2003:236-238.
44 陶永华.新型 PID 控制及其应用[M].北京:机械工业出版社,2003:2-17.
45 李朝青.单片机&DSP 外围数字 IC 技术手册[M].北京:北京航空航天大学出版社,2002:256-260.
46 TMS320 F2812 DEMO Board User's Manual, SEED Nov, 2003:1～20
47 D.D.Hwrwing, J.E.Dierksheide, D.Yapp,at al. Droplet Burnoff Rate Measurements on theVP-GMAW Process[C]. IIW Doc.Ⅻ-1858-05.
48 D.Bohme,W.Rosenfeld,L.Baum,at al.MIG-welding of Very Thin Al-Sheets by AC PulsedArc[C].IIW Doc.Ⅻ-1720-02.
49 Hitoshi Matsui,Shoji Harada,Masao Ushio.Current Topics on Sheet Metal Welding in theJapanese Automobile Industry Pulsed GMA Welding of Hot-dip Galvanized Steel and ACPulsed GMA Welding of Al Alloys[C].IIW Doc.Ⅻ-1674-00.
50 Jan Axeison. Serial Port Complete:Programming and Circuits for RS-232 and RS-485 Linksand Networks. Independent Publishers Group. 2001, (1):115~123
51 +5V-Powered, Multi channel RS-232 Drivers/Receivers. MAXIM, Nov, 1999
52 徐爱钧, 彭秀华.Keil Cx51 V7.0 单片机高级语言编程与μVision2 应用实践[M].北京:电子工业出版社,2005:Ⅰ-Ⅱ.
53 刘嘉. 弧焊逆变电源控制系统的研究. 北京工业大学博士学位论文,2002:105～108
2 潘际銮.现代弧焊控制[M].北京:机械工业出版社,2000.6:3-8.
3 M.Amin.Synergic Pulse MIG Welding[J].Metal Construction,1981,13 (6):349–353.
4 殷树言,刚铁,卜华金.协同式脉冲 MIG 焊的微机控制系统[J].焊接学报,1991,12(1):46-52.
5 廖平. 薄板铝合金 VP PMIG 焊接设备及电弧稳定性研究[D].北京工业大学博士学位论文,2007,
6 王其隆,殷树言,张九海.关于熔化极气体保护焊熔滴自由过渡的分类与名词问题[J].焊接学报,1983,4(3):149-154.
7 Hongjun Tong,Ichizo Yazawa,Tomoyuki Ueyama.High Speed Welding of Aluminum AlloySheets Using Laser Assisted AC Pulsed MIG Process[C].2003 汽车焊接国际论坛论文集.上海,2003:133-142.
8 Y.M.Zhang,P.J.Li.Modified active control of metal transfer and pulsed GMAW oftitanium.Welding Journal, 2001,80(2):54-s-61-s.
9 童诗白, 华成英. 模拟电子技术基础(第三版). 高等教育出版社, 2001: 352~353
10 (美)Donald A. Neamen著, 赵桂钦, 卜艳萍译. 电子电路分析与设计. 电子工业出版社,2003: 742~745
11 Tong,T.Ueyama,M.Tanaka,at al. Observations of the phenomenon of abnormal arc voltageoccurring in pulsed metal inert gas welding of aluminium alloy[J].Science and Technology ofWelding and Joining,2005,10(6):695-700.
12 方臣富.VPTIG 焊接电源与电弧稳定性研究[D].北京工业大学博士学位论文,2005.
13 杭争翔 , 殷树言 , 方臣富 .AC MIG 与 DC MIG 焊接工艺及控制的分析 [J]. 电焊机,2001,31(9):17-21.
14 焦向东,潘际銮,张骅.双凹波形脉冲氩弧焊的焊接电源[J].焊接学报 1996,17(1):56-61.
15 焦 向 东 , 潘 际 銮 , 张 骅 .AC/DCRP 交 替 MIG 焊 接 方 法 的 研 究 [J]. 中 国 机 械 工程,1996,7(2):88-89.
16 焦向东等.新型交流脉冲 MIG 焊接法的研究[J].石油机械,2002,30(9):8-10.
17 Texas Instruments. TMS320C28x DSP CPU and Instruction Set Reference Guide Rev.2004:1～12
18 TMS320F28x Analog to Digital Converter (ADC) Reference Guide. Texas Instruments, 05Nov 2004: 12~21
19 杭 争 翔 , 殷 树 言 , 黄 鹏 飞 . 交 流 脉 冲 MIG 弧 焊 电 源 及 弧 长 控 制 [J]. 焊 接 学报,2003,24(2):83-85,88.
20 杭争翔,殷树言,黄鹏飞,等.逆变弧焊电源输出变极性过程[J].电焊机,2003,33(6):13-15,38.
21 廖日坤,CPLD/FPGA 嵌入式应用开发技术白金手册,中国电力出版社,2005:182～297.
22 [美]Texas Instruments Incorporated 著, 张卫宁编译. TMS320C28X 系列 DSP 的 CPU 与外设(上). 北京:清华大学出版社, 2004: 13~15.
23 杭争翔,汪江,李利,等.变极性脉冲 MIG 焊的控制[J].电焊机,2006,36(2):30-32.
24 杭 争 翔 , 宋 政 . 交 流 脉 冲 MIG 电 弧 稳 定 性 及 其 控 制 [J]. 沈 阳 工 业 大 学 学报,2002,24(5):374-377.
25 杭争翔,宋政,常小芳.AC PMIG 电源动特性[J].沈阳工业大学学报,2004,26(3):254-257.
26 杭争翔 , 殷树言 , 宋政 . 交流脉冲 MIG 焊接铝合金薄板的工艺特性 [J]. 焊接学报,2004,25(2):99-106.
27 都岛贞雄,滕田治男,岩见博志.大电流 AC-MIG 溶接法の开发(第二报)[J].溶接学会论文集,1992,10(1):88-94.
28 都岛贞雄,大北茂.AC-MIG 溶接法にぉける Ti-B 系溶接金属の韧性にぉよぼす酸素の影响[J].溶接学会论文集,1992,10(2):54-63.
29 H.Tong, T.Ueyama, S.Harada, at al.Quality and productivity improvement in aluminium alloythin sheet welding using alternating current pulsed metal inert gas welding system[J]. Scienceand Technology of Welding and Joining,2001,6(4):203-208.
30 Tomoyuki Ueyama,Hongjun Tong,Shoji Harada.Improve Sheet Metal Welding Quality &Productivity with AC Pulsed MIG Welding System[C].IIW DOC.Ⅻ-1629-00.
31 仝红军,上山智之.低频调制型脉冲 MIG 焊接工艺方法的特点[J].焊接,2001(11):33-40.
32 仝红军,上山智之.交流脉冲 MIG 焊接机器人系统的工艺特点[J].焊接,2002(1):20-22.
33 黄石生.逆变理论与弧焊逆变器[M].北京:机械工业出版社,1995:151-168.
34 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,2000:117-129.
35 TMS320C6000 Code Composer Studio Getting Started Guide. Texas Instruments. Aug, 2003:
1～12
36 Texas Instruments. TMS320C28x DSP Event Manager (EV) Reference Guide. Rev.November 2003:4～48
37 TMS320F2810/F2812 Alpha Flash Programming Utilities, Alpha Release 1.0. SpectrumDigital Inc. www.spectrumdigital.com
38 赵家瑞.逆变焊接与切割电源[M].北京:机械工业出版社,1995:200-234.
39 李爱文,张承慧.现代逆变技术及其应用[M].北京:科学出版社,2000:140-154.
40 苏奎峰,吕强,耿庆,等.TMS320F2812 原理与开发[M].北京:电子工业出版社,2005:156-225.
41 彭启琮,管庆.DSP 集成开发环境[M].北京:电子工业出版社,2004:8-175.
42 ( 美 )H.M.Deitel, P.J.Deitel. C 程序设计教程 [M]. 薛万鹏译 . 北京 : 机械工业出版社,2004:41-92.
43 刘和平,王维俊,江渝,等.TMS320LF240x DSP C 语言开发应用[M].北京:北京航空航天大学出版社,2003:236-238.
44 陶永华.新型 PID 控制及其应用[M].北京:机械工业出版社,2003:2-17.
45 李朝青.单片机&DSP 外围数字 IC 技术手册[M].北京:北京航空航天大学出版社,2002:256-260.
46 TMS320 F2812 DEMO Board User's Manual, SEED Nov, 2003:1～20
47 D.D.Hwrwing, J.E.Dierksheide, D.Yapp,at al. Droplet Burnoff Rate Measurements on theVP-GMAW Process[C]. IIW Doc.Ⅻ-1858-05.
48 D.Bohme,W.Rosenfeld,L.Baum,at al.MIG-welding of Very Thin Al-Sheets by AC PulsedArc[C].IIW Doc.Ⅻ-1720-02.
49 Hitoshi Matsui,Shoji Harada,Masao Ushio.Current Topics on Sheet Metal Welding in theJapanese Automobile Industry Pulsed GMA Welding of Hot-dip Galvanized Steel and ACPulsed GMA Welding of Al Alloys[C].IIW Doc.Ⅻ-1674-00.
50 Jan Axeison. Serial Port Complete:Programming and Circuits for RS-232 and RS-485 Linksand Networks. Independent Publishers Group. 2001, (1):115~123
51 +5V-Powered, Multi channel RS-232 Drivers/Receivers. MAXIM, Nov, 1999
52 徐爱钧, 彭秀华.Keil Cx51 V7.0 单片机高级语言编程与μVision2 应用实践[M].北京:电子工业出版社,2005:Ⅰ-Ⅱ.
53 刘嘉. 弧焊逆变电源控制系统的研究. 北京工业大学博士学位论文,2002:105～108