现代焊接设备综合测试系统
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摘要
现代焊接设备指的是应用越来越广泛的逆变式焊机,焊机电源专用检测设备是认识弧焊电源性能的必需工具。基于对日益涌现的新型弧焊电源性能的认识与快速精确测试的需要,本论文在弧焊电源电参数检测方面进行了研究,并研制开发了一套交、直流弧焊电源测试系统,在此平台上对不同类型的弧焊电源做了电参数测量和分析的实验工作。
论文研制开发的多功能弧焊电源测试系统以虚拟仪器为技术平台,系统整合了包括电子技术、计算机技术、传感和检测技术、数字技术和虚拟仪器技术等在内的现代信息技术。使用霍尔传感器采集到焊机的电压电流信号,经过了信号调理之后,通过数据采集卡,工业控制计算机最终测试到了焊机的电参数。开发了功能完备的测试软件,来分析和处理原始数据,并以图形和文本的形式呈现出来。系统不仅具有测量外特性、动特性、静态参数等传统电焊机测试台所有的功能,同时又具有波形显示、自动调节负载、全自动测试与信息管理等特点;并具有焊机动特性的评测、输入端的电压电流谐波等参数分析功能。
针对CO_2电弧焊电源的动特性评测的需要,综合国内目前动特性测试技术的研究现状,使用了统计方法研究了焊机的动特性和统计参数以及焊接质量的关系。通过大量的焊接实验表明,使用统计方法可以定性的分析焊接过程的稳定性,但是并不能准确地评定CO_2电弧焊电源的动特性,在焊接分析技术领域,尚缺乏统一的标准和有效的手段,需要对CO_2电弧焊电源的动特性的评定方法进行深入研究,寻找能准确评定CO_2电弧焊电源动特性的新方法与指标。
谐波是电力电子设备的重要特征,也是一大危害。由于逆变焊机电源的主电路经过多次整流逆变,谐波问题较为严重。基于对焊机电源谐波特性认识的需要,本论文开发了谐波分析模块。该模块基于快速傅立叶变换,将输入电压电流信号在频域内展开,从而得到各次谐波的幅值,以及功率因数、波形畸变率等。并对各型焊机进行了实际测试,深入了解了焊机的谐波特性。
本课题所研制的焊机测试系统,对交、直流弧焊电源进行了大量实验分析,表明完全能够符合目前焊机生产线对焊机测试自动化的要求,系统的稳定性和实用性得到了验证。同时对焊机动特性和谐波特性做了大量研究和实验,深化了对弧焊电源动特性和弧焊电源性能的认识,在理论和实际应用两个方面都具有重要的意义。
Modern welding equipment is the contravariant welding machine applying more and more widespread. Welding power supply testing equipment for arc welding power source is the is necessary to completely cognize the performance of arc welding power supply. Based the demand to deeply congnize the performances of arc welding power supply, some researches on test of electric parameters of arc welding power supply are made, and a test system to test AC/DC arc welding power supply have been developed. Some measurements and analyses of the electric parameters of arc welding power supply have been done using this system.
The system is based on virtual instrument technology, and integrating many new technologies including the technology of digital, computer, control, and test. Hall sensor gathers welding machine's voltage electric current signal, after a signal conditioning, through the data acquisition card, the industrial control computer tested welding machine's electrical parameter finally. A fully functional test software has been developed , to analyse and process the raw data, and display in the form of graphics and text emerged. Measurement system not only can measure the outer and dynamic characteristics and static electric parameters , but also has waveform display, automatic load regulation, automatic testing and information management features, and the dynamic characteristics of a welder evaluation, input parameters such as voltage and current harmonic analysis function. The system not only can measure the outer and dynamic characteristics and static electric parameters, but also can measure three-phase power factor, input harmonic current and frequency spectrum, and efficiency of arc welding machine.
For the needs of the dynamic evaluation of CO_2 arc welding power supply, dynamic characteristics test technology is integrated at. home and abroad currently, the statistical method is used to reasearch the relationship between the quality of welding and dynamic characteristics of the welding parameters. Through a great deal of welding experiments, it shows that the use of statistical methods can be qualitative analysis of the stability of the welding process, but can not accurately assess CO_2 arc welding power dynamic characteristics. In the welding of technology, the lack of uniform standards and effective means, the need for CO_2 arc welding power of the dynamic method of assessing the conduct in-depth studies to identify accurately assess CO_2 arc welding power dynamic characteristics of the new methods and targets. In the welding parsing technique domain, the unification the standard and the effective method still lack, it needs to conduct the deep research to the CO_2 arc welding power source's dynamic characteristic evaluation method, seek new method which can evaluate the CO_2 arc welding power source dynamic characteristic accurately.
Harmonic is a characteristic of power electron device. As the main power inverter welder after several rectifiers inverter circuit , harmonic problem is much serious. In order to research the characteristics of harmonic of arc welding power supply. The module to analyze frequency is based on FFT. In this system, we can observe and record get the harmonic amplitudes, as well as power factor, waveform distortion rate. And the various types of welding machine have been tested actually, to deepen understanding of the welding machine harmonic characteristics.
A large number of experiments was carried out in the welding machine test system, which indicated that it definitely meet test automation requirement in the present welding machine production line. The system's stability and practicality have been verified. At the same time welding characteristics and harmonic mobility has done a lot of research and experiments, and deepened understanding of the dynamic characteristics of arc welding power. In theory and practical application, there is of great significance.
论文研制开发的多功能弧焊电源测试系统以虚拟仪器为技术平台,系统整合了包括电子技术、计算机技术、传感和检测技术、数字技术和虚拟仪器技术等在内的现代信息技术。使用霍尔传感器采集到焊机的电压电流信号,经过了信号调理之后,通过数据采集卡,工业控制计算机最终测试到了焊机的电参数。开发了功能完备的测试软件,来分析和处理原始数据,并以图形和文本的形式呈现出来。系统不仅具有测量外特性、动特性、静态参数等传统电焊机测试台所有的功能,同时又具有波形显示、自动调节负载、全自动测试与信息管理等特点;并具有焊机动特性的评测、输入端的电压电流谐波等参数分析功能。
针对CO_2电弧焊电源的动特性评测的需要,综合国内目前动特性测试技术的研究现状,使用了统计方法研究了焊机的动特性和统计参数以及焊接质量的关系。通过大量的焊接实验表明,使用统计方法可以定性的分析焊接过程的稳定性,但是并不能准确地评定CO_2电弧焊电源的动特性,在焊接分析技术领域,尚缺乏统一的标准和有效的手段,需要对CO_2电弧焊电源的动特性的评定方法进行深入研究,寻找能准确评定CO_2电弧焊电源动特性的新方法与指标。
谐波是电力电子设备的重要特征,也是一大危害。由于逆变焊机电源的主电路经过多次整流逆变,谐波问题较为严重。基于对焊机电源谐波特性认识的需要,本论文开发了谐波分析模块。该模块基于快速傅立叶变换,将输入电压电流信号在频域内展开,从而得到各次谐波的幅值,以及功率因数、波形畸变率等。并对各型焊机进行了实际测试,深入了解了焊机的谐波特性。
本课题所研制的焊机测试系统,对交、直流弧焊电源进行了大量实验分析,表明完全能够符合目前焊机生产线对焊机测试自动化的要求,系统的稳定性和实用性得到了验证。同时对焊机动特性和谐波特性做了大量研究和实验,深化了对弧焊电源动特性和弧焊电源性能的认识,在理论和实际应用两个方面都具有重要的意义。
Modern welding equipment is the contravariant welding machine applying more and more widespread. Welding power supply testing equipment for arc welding power source is the is necessary to completely cognize the performance of arc welding power supply. Based the demand to deeply congnize the performances of arc welding power supply, some researches on test of electric parameters of arc welding power supply are made, and a test system to test AC/DC arc welding power supply have been developed. Some measurements and analyses of the electric parameters of arc welding power supply have been done using this system.
The system is based on virtual instrument technology, and integrating many new technologies including the technology of digital, computer, control, and test. Hall sensor gathers welding machine's voltage electric current signal, after a signal conditioning, through the data acquisition card, the industrial control computer tested welding machine's electrical parameter finally. A fully functional test software has been developed , to analyse and process the raw data, and display in the form of graphics and text emerged. Measurement system not only can measure the outer and dynamic characteristics and static electric parameters , but also has waveform display, automatic load regulation, automatic testing and information management features, and the dynamic characteristics of a welder evaluation, input parameters such as voltage and current harmonic analysis function. The system not only can measure the outer and dynamic characteristics and static electric parameters, but also can measure three-phase power factor, input harmonic current and frequency spectrum, and efficiency of arc welding machine.
For the needs of the dynamic evaluation of CO_2 arc welding power supply, dynamic characteristics test technology is integrated at. home and abroad currently, the statistical method is used to reasearch the relationship between the quality of welding and dynamic characteristics of the welding parameters. Through a great deal of welding experiments, it shows that the use of statistical methods can be qualitative analysis of the stability of the welding process, but can not accurately assess CO_2 arc welding power dynamic characteristics. In the welding of technology, the lack of uniform standards and effective means, the need for CO_2 arc welding power of the dynamic method of assessing the conduct in-depth studies to identify accurately assess CO_2 arc welding power dynamic characteristics of the new methods and targets. In the welding parsing technique domain, the unification the standard and the effective method still lack, it needs to conduct the deep research to the CO_2 arc welding power source's dynamic characteristic evaluation method, seek new method which can evaluate the CO_2 arc welding power source dynamic characteristic accurately.
Harmonic is a characteristic of power electron device. As the main power inverter welder after several rectifiers inverter circuit , harmonic problem is much serious. In order to research the characteristics of harmonic of arc welding power supply. The module to analyze frequency is based on FFT. In this system, we can observe and record get the harmonic amplitudes, as well as power factor, waveform distortion rate. And the various types of welding machine have been tested actually, to deepen understanding of the welding machine harmonic characteristics.
A large number of experiments was carried out in the welding machine test system, which indicated that it definitely meet test automation requirement in the present welding machine production line. The system's stability and practicality have been verified. At the same time welding characteristics and harmonic mobility has done a lot of research and experiments, and deepened understanding of the dynamic characteristics of arc welding power. In theory and practical application, there is of great significance.
引文
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[3].张军.基于虚拟仪器的弧焊电源检测及分析方法[D].华南理工大学博士论文,2004:1-2.
[4]姜志玲.虚拟仪器技术在测控领域中的应用[J].电子工程师,2003,(08):33-35.
[5]黄亚媛,王瑞军.微计算机在直流电焊机测试系统中的应用[J].电测与仪表,2001,(03):12-15.
[6]王笑川,杨宗辉.基于虚拟仪器的CO_2弧焊分析仪的研制[J].仪表技术,2005(02):44-45.
[7]薛海涛,李俊岳,张晓囡,李国华.焊接电弧信息测试分析系统[J].焊接学报,2003,(01):19-22.
[8]Rehfeldt D,Bollmann A,Korbe T,et al.Computer-aided quality control by process analyzing monitoring and documentation[J].Internationd Journal for the Joining of Materials,1991,3(1):11-16.
[9]张军,宋永伦,陈志翔,苏东,杨庆轩,支楠.新一代信息化电焊机检测系统[J].电焊机,2005,(05):17-19.
[10]苏景军,庄中霞.低频信号屏蔽地子系统不同接地方式屏蔽效果比较[J].广东水利电力职业技术学院学报,2003,(03):17-18.
[11]于爱民,王兰花,宋岩.弱电回路屏蔽信号线屏蔽层接地方式[J].电力自动化设备,2001,(11):61-63.
[12]李正军.计算机测控系统设计与应用[M].北京:机械工业出版社,2004.
[13]杨运强,宋永伦,殷树,张军,杨庆轩,支楠.基于虚拟仪器技术的新型焊机检测装置[J].焊接学报,2004,(02):103-106.
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