摘要
逆变技术和软开关技术的结合使得弧焊电源实现了高频化、轻量化、大容量化;而数字信号处理器(DSP)的采用则使电源真正迈向了数字化,使电源的抗干扰能力、运算能力、实时性、集成度在很大程度上得到了改善。本课题的主要目的在于研究一台基于DSP的数字化软开关逆变弧焊电源。
本文首先介绍了弧焊电源的发展历史,论述了逆变电源的国内外发展现状和未来的发展趋势和研究方向,同时对数字化焊接电源的特点进行了阐述,在此基础上给出了数字化逆变弧焊电源的设计思想,详细介绍了逆变弧焊电源主电路和控制电路的设计。主电路由IGBT作为逆变电路主开关元件,采用能够输出较大功率的全桥式逆变结构,并配以高频变压器和高频整流电路构成。通过谐振技术和移相控制技术的结合使领先桥臂实现了零电压开关,滞后桥臂实现了零电流开关,克服了零电压全桥逆变电路中滞后桥臂软开关范围窄、占空比损失大等缺点。同时文中还详细地分析了主电路的运行状态,讨论了高频变压器和谐振元件参数的设计,并对输入、输出整流电路进行了设计与分析。控制系统采用2407 DSP为核心控制器件,脉冲发生电路以UC3879为基础设计。采用闭环反馈和参数自调整模糊PID方法实现对输出电弧的恒流控制,并详细介绍了参数自调整模糊PID控制器的设计过程。论文中还介绍了采样电路、DSP应用系统、驱动电路和保护电路的设计。
针对论文中设计的主电路和控制电路,通过Matlab Simulink工具箱搭建了系统的仿真模型,并给出了主电路中IGBT的工作波形、变压器初级电压电流波形和控制系统的仿真波形,对波形进行了分析。在论文的最后,还对系统的可靠性和抗干扰措施进行了分析和设计。
The combination of inverter technology and soft-switching technology makes the welding power to carry out high frequency, light weight and big capacity. But the adoption of the digital signal processor(DSP) makes power supply really to head into numeral, makes the anti- interference ability of the power supply, compute ability, real-time ability and integrated level to get an improvement to a large extent. The main purpose of this paper lies in researching a numeral soft-switching welding inverter based on DSP.
This paper firstly introduces the development history, actuality about the arc- welding inverter and forecasts the foreground and trend of it. In the meantime, we discuss the characteristics of welding power supply, and then we give the design ideas of numeral welding power, introduce the design methods of main circuit and control circuit of it in detail. A full-bridge configuration which cooperates with high frequency transformer and commutator is used to be main circuit, and IGBT is the primary switch component. The leading leg achieves ZVS, and the lagging leg is ZCS by the combination of soft-switching and inverter technology, which gets over the drawback of FB-ZVS-PWM circuit. The run-state of main circuit is analysed. The parameters of transformer and resonant components are calculated. The input and output rectifier is designed. We take UC3879 as the core of PWM controlling to carry out soft-switching and TMS320LF2407A as the core of all controlling system. The peripheral circuits are given in the paper. These circuits include the microprocessor circuit, the circuit used to give parameters and to show them, the PWM circuit and the safeguard circuit. The control strategy adopts Fuzzy-PID control, it’s design method is shown in the paper.
For the main circuit and control circuit in the paper, we construct the simulated model through Matlab/Simulink tools, and give the simulated waves. In order to protect the reliability of the system, we used many anti-jamming measures.
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