基于DSP的双丝焊机及人机界面研究
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摘要
双丝脉冲焊是一种高效节能、优质经济的焊接工艺方法,能够提高焊接生产效率和焊接质量,在我国乃至国际具有广阔的发展前景,是目前国际焊接界研究和推广的热点之一。本论文在在国家自然科学基金(项目编号:50875088)及广东省科技攻关项目(项目编号:2010B010700001)的支持下,研制了基于DSP的双丝焊机及其人机界面,并对其进行了电路调试和性能测试。
本文首先确定了双丝焊接电源的总体设计方案,确定了以TMS320F2808 DSP为核心的硬件控制系统,包括DSP控制电路、主电路控制方案、信号反馈电路、软开关电路、驱动电路、检测以及保护电路。
其次,设计了双丝焊接电源的软件系统,包括软件控制系统流程图,I/O初始化程序,A/D中断采样程序等。
再次,确定了基于ARM的触摸屏人机界面系统总体方案,先从硬件平台设计入手,确定ARM9芯片为控制核心,根据需求进行电路裁剪,设计硬件电路。包括基于ARM9的触摸屏控制电路,触摸屏与主控制板的串口通讯电路设计,人机交互软件流程设计,焊接过程控制图文显示以及人机交互界面设计等。
最后,利用实验室设备搭建测试平台,进行双丝脉冲焊接电源性能测试,包括系统外特性测试,PWM波形等,验证了系统设计的科学性和准确性,为以后的进一步研究打下坚实基础。
Double-wire pulse welding is a welding technique with high energy efficiency, high quality and low economic cost. It can raise working production efficiency and welding quality. Since it has been one of the research and extension hot spots in the international welding industry, it will have an expansively developing prospect in China and even in the world. Supported by the project of NSFC (NO.50875088) and GDSTC (NO. 2010B010700001), a DSP-based double-wire welding machine and its human-machine interface was developed, and then, circuit and properties test experiments were conducted.
In this paper, a general design of double-wire welding power supply was firstly identified, and then the hardware control system based on DSP TMS320F2808 was determined, which includes DSP control circuit, main circuit control program, the signal feedback circuit, soft-switching circuit, drive circuit, detection and protection circuit.
Secondly, a double-wire welding power software system was designed, including the software control system flowchart, I/O initialization procedures, A/D interrupt sampling procedures, etc.
Thirdly, the program of touch-screen human-machine interface system based on ARM was determined. Started with the hardware platform design, the ARM9 chip control of the core was made, the circuit was cut and hardware circuit was designed, including touch-screen control circuit based on ARM9, the serial communication circuit design of touch-screen and the main control panel, human-machine interactive software process design, welding process control graphic displays and human-machine interface design, etc.
Finally, using the test platform built by the equipment of laboratory, the power performance test of the double-wire pulse welding machine was made, which includes the system external features test and PWM waveforms, etc. This research has validated the science and accuracy of systemic design and built a solid foundation of further study.
本文首先确定了双丝焊接电源的总体设计方案,确定了以TMS320F2808 DSP为核心的硬件控制系统,包括DSP控制电路、主电路控制方案、信号反馈电路、软开关电路、驱动电路、检测以及保护电路。
其次,设计了双丝焊接电源的软件系统,包括软件控制系统流程图,I/O初始化程序,A/D中断采样程序等。
再次,确定了基于ARM的触摸屏人机界面系统总体方案,先从硬件平台设计入手,确定ARM9芯片为控制核心,根据需求进行电路裁剪,设计硬件电路。包括基于ARM9的触摸屏控制电路,触摸屏与主控制板的串口通讯电路设计,人机交互软件流程设计,焊接过程控制图文显示以及人机交互界面设计等。
最后,利用实验室设备搭建测试平台,进行双丝脉冲焊接电源性能测试,包括系统外特性测试,PWM波形等,验证了系统设计的科学性和准确性,为以后的进一步研究打下坚实基础。
Double-wire pulse welding is a welding technique with high energy efficiency, high quality and low economic cost. It can raise working production efficiency and welding quality. Since it has been one of the research and extension hot spots in the international welding industry, it will have an expansively developing prospect in China and even in the world. Supported by the project of NSFC (NO.50875088) and GDSTC (NO. 2010B010700001), a DSP-based double-wire welding machine and its human-machine interface was developed, and then, circuit and properties test experiments were conducted.
In this paper, a general design of double-wire welding power supply was firstly identified, and then the hardware control system based on DSP TMS320F2808 was determined, which includes DSP control circuit, main circuit control program, the signal feedback circuit, soft-switching circuit, drive circuit, detection and protection circuit.
Secondly, a double-wire welding power software system was designed, including the software control system flowchart, I/O initialization procedures, A/D interrupt sampling procedures, etc.
Thirdly, the program of touch-screen human-machine interface system based on ARM was determined. Started with the hardware platform design, the ARM9 chip control of the core was made, the circuit was cut and hardware circuit was designed, including touch-screen control circuit based on ARM9, the serial communication circuit design of touch-screen and the main control panel, human-machine interactive software process design, welding process control graphic displays and human-machine interface design, etc.
Finally, using the test platform built by the equipment of laboratory, the power performance test of the double-wire pulse welding machine was made, which includes the system external features test and PWM waveforms, etc. This research has validated the science and accuracy of systemic design and built a solid foundation of further study.
引文
[1]薛家祥.多功能双丝高速焊的协同控制及其关键技术--可行性报告,2007.
[2]李远波.软开关逆变式双丝高速脉冲MAG焊装备及其数字化协同控制技术研究(博士学位论文)[D].广州:华南理工大学, 2004.
[3]曹梅青,邹增大,张顺善,等.双丝电弧焊研究现状及进展.山东科技大学学报(自然科学版), 2008(2): 88-91.
[4] http://www.gkong.com/html/news/2008/7/24112.Html.
[5] http://baike.baidu.com/view/18554.htc.
[6] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[7] A. Scotti, C. O. Morais & L. O. Vilarinho. The Effect of Out-of-Phase Pulsing on Metal Transfer in Twin-wire GMA Welding at High Current Level [J]. Welding Journal, 2006, 85: 225-230.
[8] cloos.http://www.114ku.com/tradeinfo/tra/w6/2007122417120216952.html.
[9] http:// www.fronius.com http://www.gdweld.com/kanwu/200112/2001121.html.
[10]殷树言.高效弧焊技术的研究进展[J].焊接, 2006, (10): 7-14.
[11]李桓,杨秀娟,李幸呈,等.高效双丝MIG/MAG脉冲焊系统及工艺[J].焊接, 2005(10): 24-27.
[12] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[13]路浩,张世平,刘雪松,等.双丝焊铝合金平板残余应力梯度超声波法建立[J].焊接学报, 2008, 29(2): 61-64.
[14]王振民,黄石生,薛家祥,等.双电弧共熔池脉冲GMAW电源的复合外特性[J].焊接学报, 2007, 28(2): 13-16.
[15] M. Dorigo & G. Di. Caro. The Ant Colony Optimization Meta-heuristic. D. Corne, M. Dorigo & F. Glover. New Ideas in Optimization [M]. London: UK, 1999: 11-32.
[16]吴斌,史忠植.一种基于蚁群算法的TSP问题分段求解算法[J].计算机学报, 2001, 24(12): 1328-1333.
[17]陈峻,沈洁,秦玲.蚁群算法求解连续空间优化问题的一种新方法[J].软件学报,2002, 13(12): 2317-2322.
[18]汪镭,吴启迪.蚁群算法在系统辨识中的应用[J].自动化学报, 2003, 29(1): 102-109.
[19]林丽红,胡小建.逆变弧焊电源外特性控制技术[J].现代焊接, 2008, 64(4): 18-20.
[20]黄石生.电子控制的弧焊电源[M].北京:机械工业出版社, 1990.
[21]徐德进.微机控制多功能逆变焊机的研制(硕士学位论文)[D].兰州:兰州理工大学, 2003.
[22]陶永华,尹怡欣,葛芦生.新型PID控制及其应用[M].北京:机械工业出版社, 1998.
[23]自芳,虞鹤松.微机控制系统及其应用[M].西安:西安交通大学出版社, 1998.
[24]刘和平,严利平,张学锋,等. TMS320LF240XDSP结构、原理及应用[M].北京:北京航空航天大学出版社, 2002.
[25]王振民,黄石生,薛家祥.软开关双丝脉冲熔化极活性气体保护焊逆变电源[J ] .华南理工大学学报(自然科学版), 2006, 34(7): 31-34.
[26] Lassaline, E. Narrow Groove Twin-wire GMAW of High-strength Steel [J]. Welding Journal, 1989, 68( 9): 53-57.
[27]王元良,周友龙,梁明,等.药芯焊丝自动双丝焊工艺研究[J].焊管, 2001, 24(6): 14-19.
[28]孙远芳.双焊丝悬臂送丝CO2气体保护焊新工艺[J ].焊接技术, 1992(6): 627.
[29]王克鸿,贾阳,钱锋.铝合金双丝MIG焊熔池图像采集与处理[J].焊接学报, 2007, 28(1): 53-56.
[30]VOLODIN V S. Automatic Welding with Two Electrodes[J] . The Welding Journal,1955 (3) :103-111.
[31] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[32]殷树言.高效弧焊技术的研究进展[J].焊接, 2006, (10): 7-14.
[33] Tuesk, J. Raising Arc Welding Productivity [J]. Welding Review International, 1996, 15(3): 102-105.
[34] Michie K,Blackman S & Ogunbiyi T E B. Twin-wire GMAW: Process Characteristics and Application[J]. Welding Journal, 1999, 78(5): 31-34.
[35]孟庆国,方洪渊,徐文立.铝合金双丝焊应力场的数值模拟[J].焊接学报, 2005, 26(8): 43-46.
[36]王振民,黄石生,薛家祥,等.双电弧共熔池脉冲GMAW电源的复合外特性[J].焊接学报, 2007, 28(2): 13-16.
[37]何秀华,杨景红.大功率IGBT驱动电路的设计[J].电子工程师, 2008, 34(9): 20-22.
[38] David M. Alter. Using PWM Output as a Digital-to-Analog Converter on a TMS320F280X Digital Signal Controller. Texas Instruments. Application Report, 2006(2).
[39] Lucas B. FCAW. Multi-wire and Gas Selection-techniques to Enhance MIG Productivity [J] . Welding and Metal Fabrication, 1997, 65(5): 10-12.
[40] Mc Connell L. Lifting Productivity Using Tandem Wire Welding[J]. Welding and Metal Fabrication, 2000, 68(2): 16-18.
[41] Tsushima S., Kitamura M. Tandem Electrode AC-MIG Welding—Development of AC-MIG Welding Process (report 4) [J]. Welding Research Abroad, 1996, 42 (2): 26-32.
[42]魏占静,李少农,周大胜. TANDEM双丝焊在造船拼板焊接中的应用[J].焊接, 2007 (5): 71-72.
[43] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[44] Luminary Micro. Inc. LM3S828 Microcontroller Data Sheet. 2007
[45]卜艳萍,周伟.计算机组成与系统结构[M].北京:清华大学出版社, 2008.
[46]黄石生.电子控制的弧焊电源[M].北京:机械工业出版社, 1990.
[47]王元良,屈金山,胡久富,等.高效节能的细丝自动焊设备的研究[J].电焊机, 2002, 32(3): 9-12, 29.
[48]魏占静.先进的TANDEM高速、高效MIG/ MAG双丝焊技术[J].机械工人(热加工) , 2002(5): 22, 37.
[49] Lancaster J. F. The Physics of Welding[M]. New York: Pergamon Press, 1984: 257-262.
[50] Stefan T.提高生产效率的焊接机器人.高效化焊接国际论坛论文集.北京:中国机械工程学会, 2002. [51 ]ARM9S3C2440芯片使用手册.
[52] DSPTMS320F2808芯片使用手册.
[53] Fluke 43B示波器使用手册.
[2]李远波.软开关逆变式双丝高速脉冲MAG焊装备及其数字化协同控制技术研究(博士学位论文)[D].广州:华南理工大学, 2004.
[3]曹梅青,邹增大,张顺善,等.双丝电弧焊研究现状及进展.山东科技大学学报(自然科学版), 2008(2): 88-91.
[4] http://www.gkong.com/html/news/2008/7/24112.Html.
[5] http://baike.baidu.com/view/18554.htc.
[6] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[7] A. Scotti, C. O. Morais & L. O. Vilarinho. The Effect of Out-of-Phase Pulsing on Metal Transfer in Twin-wire GMA Welding at High Current Level [J]. Welding Journal, 2006, 85: 225-230.
[8] cloos.http://www.114ku.com/tradeinfo/tra/w6/2007122417120216952.html.
[9] http:// www.fronius.com http://www.gdweld.com/kanwu/200112/2001121.html.
[10]殷树言.高效弧焊技术的研究进展[J].焊接, 2006, (10): 7-14.
[11]李桓,杨秀娟,李幸呈,等.高效双丝MIG/MAG脉冲焊系统及工艺[J].焊接, 2005(10): 24-27.
[12] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[13]路浩,张世平,刘雪松,等.双丝焊铝合金平板残余应力梯度超声波法建立[J].焊接学报, 2008, 29(2): 61-64.
[14]王振民,黄石生,薛家祥,等.双电弧共熔池脉冲GMAW电源的复合外特性[J].焊接学报, 2007, 28(2): 13-16.
[15] M. Dorigo & G. Di. Caro. The Ant Colony Optimization Meta-heuristic. D. Corne, M. Dorigo & F. Glover. New Ideas in Optimization [M]. London: UK, 1999: 11-32.
[16]吴斌,史忠植.一种基于蚁群算法的TSP问题分段求解算法[J].计算机学报, 2001, 24(12): 1328-1333.
[17]陈峻,沈洁,秦玲.蚁群算法求解连续空间优化问题的一种新方法[J].软件学报,2002, 13(12): 2317-2322.
[18]汪镭,吴启迪.蚁群算法在系统辨识中的应用[J].自动化学报, 2003, 29(1): 102-109.
[19]林丽红,胡小建.逆变弧焊电源外特性控制技术[J].现代焊接, 2008, 64(4): 18-20.
[20]黄石生.电子控制的弧焊电源[M].北京:机械工业出版社, 1990.
[21]徐德进.微机控制多功能逆变焊机的研制(硕士学位论文)[D].兰州:兰州理工大学, 2003.
[22]陶永华,尹怡欣,葛芦生.新型PID控制及其应用[M].北京:机械工业出版社, 1998.
[23]自芳,虞鹤松.微机控制系统及其应用[M].西安:西安交通大学出版社, 1998.
[24]刘和平,严利平,张学锋,等. TMS320LF240XDSP结构、原理及应用[M].北京:北京航空航天大学出版社, 2002.
[25]王振民,黄石生,薛家祥.软开关双丝脉冲熔化极活性气体保护焊逆变电源[J ] .华南理工大学学报(自然科学版), 2006, 34(7): 31-34.
[26] Lassaline, E. Narrow Groove Twin-wire GMAW of High-strength Steel [J]. Welding Journal, 1989, 68( 9): 53-57.
[27]王元良,周友龙,梁明,等.药芯焊丝自动双丝焊工艺研究[J].焊管, 2001, 24(6): 14-19.
[28]孙远芳.双焊丝悬臂送丝CO2气体保护焊新工艺[J ].焊接技术, 1992(6): 627.
[29]王克鸿,贾阳,钱锋.铝合金双丝MIG焊熔池图像采集与处理[J].焊接学报, 2007, 28(1): 53-56.
[30]VOLODIN V S. Automatic Welding with Two Electrodes[J] . The Welding Journal,1955 (3) :103-111.
[31] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[32]殷树言.高效弧焊技术的研究进展[J].焊接, 2006, (10): 7-14.
[33] Tuesk, J. Raising Arc Welding Productivity [J]. Welding Review International, 1996, 15(3): 102-105.
[34] Michie K,Blackman S & Ogunbiyi T E B. Twin-wire GMAW: Process Characteristics and Application[J]. Welding Journal, 1999, 78(5): 31-34.
[35]孟庆国,方洪渊,徐文立.铝合金双丝焊应力场的数值模拟[J].焊接学报, 2005, 26(8): 43-46.
[36]王振民,黄石生,薛家祥,等.双电弧共熔池脉冲GMAW电源的复合外特性[J].焊接学报, 2007, 28(2): 13-16.
[37]何秀华,杨景红.大功率IGBT驱动电路的设计[J].电子工程师, 2008, 34(9): 20-22.
[38] David M. Alter. Using PWM Output as a Digital-to-Analog Converter on a TMS320F280X Digital Signal Controller. Texas Instruments. Application Report, 2006(2).
[39] Lucas B. FCAW. Multi-wire and Gas Selection-techniques to Enhance MIG Productivity [J] . Welding and Metal Fabrication, 1997, 65(5): 10-12.
[40] Mc Connell L. Lifting Productivity Using Tandem Wire Welding[J]. Welding and Metal Fabrication, 2000, 68(2): 16-18.
[41] Tsushima S., Kitamura M. Tandem Electrode AC-MIG Welding—Development of AC-MIG Welding Process (report 4) [J]. Welding Research Abroad, 1996, 42 (2): 26-32.
[42]魏占静,李少农,周大胜. TANDEM双丝焊在造船拼板焊接中的应用[J].焊接, 2007 (5): 71-72.
[43] Lin Sanbao, Gang Tie & Yang Chunli, et al. An Initial Study on Welding Procedure Using Tandem MIG Welding of High Strength Aluminum Alloy [J]. China Welding, 2004, 13(2): 81-85.
[44] Luminary Micro. Inc. LM3S828 Microcontroller Data Sheet. 2007
[45]卜艳萍,周伟.计算机组成与系统结构[M].北京:清华大学出版社, 2008.
[46]黄石生.电子控制的弧焊电源[M].北京:机械工业出版社, 1990.
[47]王元良,屈金山,胡久富,等.高效节能的细丝自动焊设备的研究[J].电焊机, 2002, 32(3): 9-12, 29.
[48]魏占静.先进的TANDEM高速、高效MIG/ MAG双丝焊技术[J].机械工人(热加工) , 2002(5): 22, 37.
[49] Lancaster J. F. The Physics of Welding[M]. New York: Pergamon Press, 1984: 257-262.
[50] Stefan T.提高生产效率的焊接机器人.高效化焊接国际论坛论文集.北京:中国机械工程学会, 2002. [51 ]ARM9S3C2440芯片使用手册.
[52] DSPTMS320F2808芯片使用手册.
[53] Fluke 43B示波器使用手册.