波形控制CO_2逆变焊接电源的研制
摘要
为了研制高效节能、性能优越的CO_2焊接电源，本文引入逆变技术针对电源的主电路、控制电路、驱动电路和送丝电路进行了研究和设计。在主电路设计中，选用输出功率大的全桥式拓扑结构，对以IGBT和中频变压器为核心的功率器件进行了详尽的参数计算，并分析、论述了IGBT的保护措施。控制电路基于SG3526的PWM控制技术，采用电压闭环负反馈产生平硬的电源外特性，采用电流闭环负反馈对短路过渡过程进行波形控制。提出采用电压、电流双环切换的办法实现波形控制的设想。在建立控制系统结构框图和数学模型基础上，借助MATLAB对系统进行仿真，设计了电子电抗器系统，用以控制电源动特性。文中还对采用微机系统参与焊接过程自动控制进行了软硬件设计。为了克服脉冲变压器式门极驱动电路制作、调试困难的缺点，设计了线路简单易调的光耦式驱动电路。在详细分析了IGBT上电流、电压波形和主电路输出波形的基础上，对实验结果进行了评估，解释了实验中出现的特殊现象。试验表明，主电路设计结构合理，器件工作可靠，输出波形良好。最后，设计了PWM调速电路配合印刷直流电机的送丝调速系统，试验表明，送丝速度误差在±5％以内，符合标准JB／T9533-1999。
To build an efficient carbon dioxide (CO2) welding power resource with excellent property, the inversion technology is applied to design the main circuit, the control circuit and the driver circuit. The full bridge structure is used in main circuit in order to reinforce the power provided by the CO2 welder. The parameters of the power components including IGBT and transformer are carefully calculated, and the means of protection of IGBT (Insulted Gate Bipolar Transistor) is specially analyzed. Both the control of PWM (Pulse Width Modulation) generated by chip SG3526 and the closed-loop circuit with the negative feedback by voltage is applied to create strong static feature of the CO2 welder, which make its voltage stable when its load is changing. The block diagram and mathematical model of the system are built for the simulation by the software MATLAB, and the result of the simulation aids the designing of an electrical inductor, which can control the dynamic feature of the CO2 welder. The idea of controlli
ng the current waveform by means of switching the current closed-loop or the voltage close-loop in different circuit state is brought out. The hardware and software of the microcomputer system are designed in order to control the welding process automatically. The driver circuit with pulse transformer has trouble to be made or adjusted, so the driver circuit used of photoelectric coupler is designed and made. By analyzing the current and voltage waveforms from the IGBT and the output of the CO2 welder in the tests, the conclusions have been drawn that the structure of the main circuit is valid and the components used in the main circuit are credible. In the end, the circuit of feeding wire of consistent velocity based on the technology of PWM is designed and tested in the experiment. The results of the experiment meet the standard of JB/T9533-1999.
To build an efficient carbon dioxide (CO2) welding power resource with excellent property, the inversion technology is applied to design the main circuit, the control circuit and the driver circuit. The full bridge structure is used in main circuit in order to reinforce the power provided by the CO2 welder. The parameters of the power components including IGBT and transformer are carefully calculated, and the means of protection of IGBT (Insulted Gate Bipolar Transistor) is specially analyzed. Both the control of PWM (Pulse Width Modulation) generated by chip SG3526 and the closed-loop circuit with the negative feedback by voltage is applied to create strong static feature of the CO2 welder, which make its voltage stable when its load is changing. The block diagram and mathematical model of the system are built for the simulation by the software MATLAB, and the result of the simulation aids the designing of an electrical inductor, which can control the dynamic feature of the CO2 welder. The idea of controlli
ng the current waveform by means of switching the current closed-loop or the voltage close-loop in different circuit state is brought out. The hardware and software of the microcomputer system are designed in order to control the welding process automatically. The driver circuit with pulse transformer has trouble to be made or adjusted, so the driver circuit used of photoelectric coupler is designed and made. By analyzing the current and voltage waveforms from the IGBT and the output of the CO2 welder in the tests, the conclusions have been drawn that the structure of the main circuit is valid and the components used in the main circuit are credible. In the end, the circuit of feeding wire of consistent velocity based on the technology of PWM is designed and tested in the experiment. The results of the experiment meet the standard of JB/T9533-1999.
引文
[1] 殷树言．CO_2焊接设备原理与调试[M]．北京：机械工业出版社，2000
[2] 姜f焕中．电弧焊机电渣焊[M]．北京：机械工业出版社，1988
[3] 薛勇．减少气体保护焊飞溅的研究现状与展望[J]．电焊机，32(6)：1-4
[4] 赵家瑞．逆变焊接与切割电源[M]．北京：机械工业出版社，1995
[5] 张军红．CO_2气体保护焊波形控制法的研究与发展[J]．电焊机，29(1)：5-8
[6] 王振民．弧焊逆变技术的研究现状与展望[J]．电焊机，30(8)：3-6
[7] 彭伟民．IGBT逆变焊机的现状和未来[J]．电焊机，1996(5)：6-8
[8] 何德孚．逆变控制焊机电源的主电路结构设计分析[J]．电力电子技术，31(1)：67-71．
[9] 陈树君．双零开关弧焊逆变电源[J]．焊接学报,23(3)：1-5
[10] 薛家祥．电流模式控制零电压开关弧焊逆变器[J]．焊接学报,23(4)：35-36
[11] 张光先．软开关逆变式弧焊电源的设计[J]．焊接学报，23(1)：14-18
[12] 朱志明．新型CO_2焊接方法的研究[J]．电焊机，1994，(6)：12-15
[13] 盛祖权．IGBT模块驱动及保护[J]．电焊机，30(11)：6-13
[14] 屈稳太．大功率TGBT高频逆变电焊机的研究[J]．电力电子技术，35(2)：31-33
[15] 吴保芳．通用型IGBT变频电源的研制[J]．电力电子技术，32(4)：51-54
[16] 张鹏贤．波形控制逆变CO_2焊接电源的可靠性研究[J]．电焊机，33(4)：12-15
[17] 杨莉莎．单相桥式逆变电路输出变压器直流偏磁的抑制[J]．37(2)：44-45
[18] 杨荫福．SPWM逆变电压输出变压器直流不平衡问题[J]．华中理工大学学报,27(6)：72-73
[19] 刘嘉．弧焊逆变电源的数字化控制[D]．北京工业大学博士论文
[20] 黄石生．逆变理论与弧焊逆变器[M]．北京：机械工业出版社，1995
[21] 毕耀宗．纳米晶材料在逆变焊机上的应用[J]．电焊机，2002，32(10)：8-11
[22] 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
[23] 熊腊森．逆变式弧焊电源主电路的选择与设计[J]．电焊机，31(1)：4-6
[24] 陈祝年．焊接设计简明手册[M]．北京：机械工业出版社，1997
[25] 徐晓峰．IGBT逆变器吸收电路的研究[J]．电力电子技术，1998，32(3)：43-47
[26] 薛家祥．大功率IGBT等离子喷涂逆变器的研制[J]．中山大学学报论丛，1997，141-142
[27] 杜贵平．逆变焊机的高频干扰分析及抑制方法探讨[J]．电焊机，2001，31(8)：31-34
[28] 丁浩华．带过流和短路保护的IGBT驱动电路研究[J]．电力电子技术，1997，2：30-32
[29] 赖金福．线性与接口集成电路简明手册[M]．北京：电子工业出版社，1996
[30] 陈善本．焊接过程现代控制技术[M]．哈尔滨：哈尔滨大学出版社．2001
[31] SG3526 ON Semiconductor http://onsemi.com
[32] 潘际銮．现代弧焊控制[M]．北京：机械工业出版社．2000
[33] Katsuhiko Ogata．现代控制工程[M]．北京：电子工业出版社．2000
[34] Elliott K.Stava. A new, low-spatter arc welding machine[J].Welding Joural,1993,56(1):25-29
[35] ATMEL公司网站资料 Rev．0265G-02／00
[36] 李华．MCS-51系列单片机实用接口技术[M]．北京：北京航空航天大学出版社．1993
[37] 张友德．单片微型机原理、应用与实验(第三版)(M)．上海：复旦大学出版社．2000
[2] 姜f焕中．电弧焊机电渣焊[M]．北京：机械工业出版社，1988
[3] 薛勇．减少气体保护焊飞溅的研究现状与展望[J]．电焊机，32(6)：1-4
[4] 赵家瑞．逆变焊接与切割电源[M]．北京：机械工业出版社，1995
[5] 张军红．CO_2气体保护焊波形控制法的研究与发展[J]．电焊机，29(1)：5-8
[6] 王振民．弧焊逆变技术的研究现状与展望[J]．电焊机，30(8)：3-6
[7] 彭伟民．IGBT逆变焊机的现状和未来[J]．电焊机，1996(5)：6-8
[8] 何德孚．逆变控制焊机电源的主电路结构设计分析[J]．电力电子技术，31(1)：67-71．
[9] 陈树君．双零开关弧焊逆变电源[J]．焊接学报,23(3)：1-5
[10] 薛家祥．电流模式控制零电压开关弧焊逆变器[J]．焊接学报,23(4)：35-36
[11] 张光先．软开关逆变式弧焊电源的设计[J]．焊接学报，23(1)：14-18
[12] 朱志明．新型CO_2焊接方法的研究[J]．电焊机，1994，(6)：12-15
[13] 盛祖权．IGBT模块驱动及保护[J]．电焊机，30(11)：6-13
[14] 屈稳太．大功率TGBT高频逆变电焊机的研究[J]．电力电子技术，35(2)：31-33
[15] 吴保芳．通用型IGBT变频电源的研制[J]．电力电子技术，32(4)：51-54
[16] 张鹏贤．波形控制逆变CO_2焊接电源的可靠性研究[J]．电焊机，33(4)：12-15
[17] 杨莉莎．单相桥式逆变电路输出变压器直流偏磁的抑制[J]．37(2)：44-45
[18] 杨荫福．SPWM逆变电压输出变压器直流不平衡问题[J]．华中理工大学学报,27(6)：72-73
[19] 刘嘉．弧焊逆变电源的数字化控制[D]．北京工业大学博士论文
[20] 黄石生．逆变理论与弧焊逆变器[M]．北京：机械工业出版社，1995
[21] 毕耀宗．纳米晶材料在逆变焊机上的应用[J]．电焊机，2002，32(10)：8-11
[22] 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
[23] 熊腊森．逆变式弧焊电源主电路的选择与设计[J]．电焊机，31(1)：4-6
[24] 陈祝年．焊接设计简明手册[M]．北京：机械工业出版社，1997
[25] 徐晓峰．IGBT逆变器吸收电路的研究[J]．电力电子技术，1998，32(3)：43-47
[26] 薛家祥．大功率IGBT等离子喷涂逆变器的研制[J]．中山大学学报论丛，1997，141-142
[27] 杜贵平．逆变焊机的高频干扰分析及抑制方法探讨[J]．电焊机，2001，31(8)：31-34
[28] 丁浩华．带过流和短路保护的IGBT驱动电路研究[J]．电力电子技术，1997，2：30-32
[29] 赖金福．线性与接口集成电路简明手册[M]．北京：电子工业出版社，1996
[30] 陈善本．焊接过程现代控制技术[M]．哈尔滨：哈尔滨大学出版社．2001
[31] SG3526 ON Semiconductor http://onsemi.com
[32] 潘际銮．现代弧焊控制[M]．北京：机械工业出版社．2000
[33] Katsuhiko Ogata．现代控制工程[M]．北京：电子工业出版社．2000
[34] Elliott K.Stava. A new, low-spatter arc welding machine[J].Welding Joural,1993,56(1):25-29
[35] ATMEL公司网站资料 Rev．0265G-02／00
[36] 李华．MCS-51系列单片机实用接口技术[M]．北京：北京航空航天大学出版社．1993
[37] 张友德．单片微型机原理、应用与实验(第三版)(M)．上海：复旦大学出版社．2000