锂电池极耳焊接机控制系统的研究与实现
摘要
锂离子电池在各行各业中应用广泛,在国民经济中具有重要地位。国内锂电池设备厂家,仍以半自动化、单机自动化设备为主,与国外产品相比有较大差距。锂电池极耳焊接机是卷绕电芯成型方案中的关键设备之一,且不同的客户对同一设备还有特殊要求,需要把设备做成模块化、系列化、可以灵活组合,因此研究一套高性能、低成本、具有开放式体系的锂电池极耳焊接机控制系统显得十分重要。
本课题从锂电池极耳焊接机的原理和电气结构入手,分析了系统的功能需求,提出了锂电池极耳焊接机多任务控制系统的的整体设计方案。采用基于x86架构的工业PC(简称PC/104)和FPGA多功能扩展电路为核心器件,以CPLD(EPM1270)作为I/O扩展模块,完成了主控电路、电机驱动电路、I/O扩展电路及AD/DA电路的设计,并进行了大量的调试工作。
在软件设计方面,将控制系统任务进行层次化、模块化分割,基于RTAI的实时操作系统,引入硬件抽象层(HAL,Hardware Abstraction Layer)技术,将各模块以软件构件的形式进行封装,实现任务处理、实时计算、轨迹插补,位置控制以及IO管理的功能,同时引入具有实时特性的开源软PLC系统,用于顺序控制、定时控制、计数控制、闭环过程控制等,利用Linux下图形库,自主开发了适用的人机界面。
目前,采用该方案的锂电池极耳焊接机已通过项目验收,所研制的多轴控制系统能够实现了锂离子电池制片工艺的极耳焊接和贴胶纸、全自动收放料、自动纠偏,并且具有较高的效率和精度,系统运行情况良好。基于HAL构件的软件设计方法,具有较好的开放性,能很好地满足变化的锂电池制造工艺需求。
论文结尾对本课题进行了工作总结,并针对锂电池极耳焊接机及锂电池生产设备发展趋势和以后的工作努力方向作出了展望。
By far, Lithum-ion battery has been widely used in the world plays an important role in the national economy.Domestic lithium battery equipment manufacturers,still based on semi-automation equipment,have a wide gap compared with foreign manufacturers.Lithium electrode welding machine is a high-precision Li-ion production equipment and one of the critical equipment for the forming of winding lithium batteries.Different customers have special requirements on the same equipment,so the facilities need to be made modular、series and can be combined flexibly.Thus,the R & D of the high-performance、low costs、and have a open architecture of lithum electrode welding machine control system is very important in the domestic companies.
This article obtaining from the lithum electrode welding machine’s principle and the function,introduce the process and electrical structure,established the main tasks of control system,gives a overall design base on multi-tasks control system of lithum electrode welding machine.Base on the X86 architecture of industrial PC(referred as PC/104) and FPGA as the main controller,expansion CPLD circuit as I/O module,designed the circuit of main controller, microstep control and driver,the AD/DA convert circuits.Besides the motion control circuit was realized by means of FPGA programming,which is mainly composed of high-speed pulse generator and the servo motor control module.
Refering to the software design, division the control system hierarchical and modular, designed the independent and collaborative between functional modules,independent modular programming,based on RTAI real-time operating system with the hardware abstraction layer technology,package each modules in the form of components,to achieve the control division the task processing,real-time computation,trajectory interpolation,position control,and IO management modules,mean-while,introduce open source soft-PLC system which has real-time characteristics,for the switch logic control,sequential control,timing control, counting control,closed loop process control,also use the Linux graphics library to design the user interface.
So far, the design of the control system of lithium electrode welding machine was put into experiment, research and the result shows that the control system already has achieved multi-axis coordinated control and satisfied the precise electrode welding and adhesive stickers,to achieve automatic discharge and correction.Based on the HAL component method to design open embedded system is more suitable for the battery technology to meet the rapidly changing requirements.
The end of this paper summary of the work carried out,and analysis the trends of lithium battery production equipment,including some suggestions for next work.
本课题从锂电池极耳焊接机的原理和电气结构入手,分析了系统的功能需求,提出了锂电池极耳焊接机多任务控制系统的的整体设计方案。采用基于x86架构的工业PC(简称PC/104)和FPGA多功能扩展电路为核心器件,以CPLD(EPM1270)作为I/O扩展模块,完成了主控电路、电机驱动电路、I/O扩展电路及AD/DA电路的设计,并进行了大量的调试工作。
在软件设计方面,将控制系统任务进行层次化、模块化分割,基于RTAI的实时操作系统,引入硬件抽象层(HAL,Hardware Abstraction Layer)技术,将各模块以软件构件的形式进行封装,实现任务处理、实时计算、轨迹插补,位置控制以及IO管理的功能,同时引入具有实时特性的开源软PLC系统,用于顺序控制、定时控制、计数控制、闭环过程控制等,利用Linux下图形库,自主开发了适用的人机界面。
目前,采用该方案的锂电池极耳焊接机已通过项目验收,所研制的多轴控制系统能够实现了锂离子电池制片工艺的极耳焊接和贴胶纸、全自动收放料、自动纠偏,并且具有较高的效率和精度,系统运行情况良好。基于HAL构件的软件设计方法,具有较好的开放性,能很好地满足变化的锂电池制造工艺需求。
论文结尾对本课题进行了工作总结,并针对锂电池极耳焊接机及锂电池生产设备发展趋势和以后的工作努力方向作出了展望。
By far, Lithum-ion battery has been widely used in the world plays an important role in the national economy.Domestic lithium battery equipment manufacturers,still based on semi-automation equipment,have a wide gap compared with foreign manufacturers.Lithium electrode welding machine is a high-precision Li-ion production equipment and one of the critical equipment for the forming of winding lithium batteries.Different customers have special requirements on the same equipment,so the facilities need to be made modular、series and can be combined flexibly.Thus,the R & D of the high-performance、low costs、and have a open architecture of lithum electrode welding machine control system is very important in the domestic companies.
This article obtaining from the lithum electrode welding machine’s principle and the function,introduce the process and electrical structure,established the main tasks of control system,gives a overall design base on multi-tasks control system of lithum electrode welding machine.Base on the X86 architecture of industrial PC(referred as PC/104) and FPGA as the main controller,expansion CPLD circuit as I/O module,designed the circuit of main controller, microstep control and driver,the AD/DA convert circuits.Besides the motion control circuit was realized by means of FPGA programming,which is mainly composed of high-speed pulse generator and the servo motor control module.
Refering to the software design, division the control system hierarchical and modular, designed the independent and collaborative between functional modules,independent modular programming,based on RTAI real-time operating system with the hardware abstraction layer technology,package each modules in the form of components,to achieve the control division the task processing,real-time computation,trajectory interpolation,position control,and IO management modules,mean-while,introduce open source soft-PLC system which has real-time characteristics,for the switch logic control,sequential control,timing control, counting control,closed loop process control,also use the Linux graphics library to design the user interface.
So far, the design of the control system of lithium electrode welding machine was put into experiment, research and the result shows that the control system already has achieved multi-axis coordinated control and satisfied the precise electrode welding and adhesive stickers,to achieve automatic discharge and correction.Based on the HAL component method to design open embedded system is more suitable for the battery technology to meet the rapidly changing requirements.
The end of this paper summary of the work carried out,and analysis the trends of lithium battery production equipment,including some suggestions for next work.
引文
[1]郭炳焜,徐徽.锂离子电池[M].长沙:中南大学出版社. 2002:16
[2]章少华,谢冰.锂离子电池的研究进展[J].佛山陶瓷. 2003,(8):2~5
[3]杨林.中、日、韩三国锂离子电池发展概况[J].电池工业. 2003,(3):4~5
[4]胡绍杰,徐保伯.锂离子电池工业的发展与展望[J].电池. 2000,30(8):171-173
[5]郎鹏,任剑.发展我国锂离子动力电池关键工艺设备思考[J].电子工业专用设备. 2009,178(11):24~25
[6] Inaba M. Ogumi Z. Up-to-date Development of Lithium-ion Batteries in Japan IEEE Electrical Insulation Magazine. 2001, 17(6):6~20.
[7]赵东林.国内外锂离子动力电池极片制造专用设备的新进展[J].新材料产业.2006(9) 65~69.
[8] Kazuo Tagwa, Akiya Kozawa, Ralph Brodd. Production Processes for Lithium Batteries. ITE Letters. 2001, 2(5):16~19.
[9]张世超.锂离子电池产业现状与研究开发热点[J].新材料产业. 2004, (1):23~25.
[10] Ohaman M, Johansson, Stefan, Arzen, Karl-Erik.Implementation Aspects of the PLC Standard IEC 1131-3. Control Engineering Practice. 1998, 6(8):547~555
[11] The EMC Team. EMC History. http://www.linuxcnc.org/content/view/6/5/lang.en/
[12]戴志诚.工业控制中嵌入式系统软件的设计与实现[D].湖北:华中科技大学. 2004
[13]谢林菲,游林儒,王立松.基于PC104与PLC的锂电池全自动卷绕机控制器设计[J].组合机床与自动化加工技术. 2009,428(10):65~66
[14]鲁五一,赵望达,五莉.用PC/104和PLC构成的空压机组智能监测控制系统[J].制造业自动化. 2000(12)
[15]方艺.基于PC104总线的六自由度平台控制系统研究[D].成都:西南交通大学,2003
[16]陈岗,栾丽君.集成化PC数控系统中软PLC的研究开发[J].辽宁工程技术大学学报. 2006,(11) 25
[17] Mario de.Sousa.Linux-Based PLC for Industrial Control.Embedded Linux Journal. 2001,3:29-32
[18]李爽.基于开放式数控系统的软PLC开发系统的研究及实现.2006
[19] The EMC Team. EMC2_User_Manual.V2.2. http://www.linuxcnc.org.2008.04
[20] The EMC Team. EMC2_Intergrator_Manual. V2.2.http://www.linuxcnc.org.2008.04
[21] The EMC Team. EMC2_Developer_ManualV2.2. http://www.linuxcnc.org. 2008.04
[22]赵毅峰.基于PC104及FPGA的多功能脉冲接口卡的实现[J].电子工程师. 2005,31(7):46
[23]王建国,刘兰军,王玉辉.基于CPLD技术的PC104总线多功能扩展卡设计[J].微计算机信息. 2005,21(9):19~20
[24]梅红伟,吴学杰,商秋芳.基于PC104和CPLD的高速/多通道数据采集系统的设计与实现[J].现代电子技术. 2007, 244:151~154
[25] RTAPI.http://www.linuxcnc.org/docview/html//man/man3/intro.3rtapi.html.2010.04
[26]麦向习,裴海龙.基于Linux及Tcl/Tk的数控系统人机界面的实现[J].计算机应用研究. 2006,(02):122-124
[27]吉华,李彦,王强,朱达宇.基于RTLinux的开放式软件PLC的研究[J].计算机应用研究[J]. 2005,(05):48-49
[28]廖永刚.一种实时Linux操作系统-RTAI的分析及扩展[J].福建电脑.2005,(5) 75～76
[29]杨杰,唐伯尧,李从心.基于实时Linux-RTAI位置控制系统研究[J].机床与液压. 2005,(10):163~164
[30]陈永茂,刘少君,裴海龙. RTAI的实时性测试及在CNC控制器的应用[J].微计算机信息. 2008,24(51):156-157.
[31] Brent B Welch. Tcl /Tk编程权威指南[M].崔凯.北京:中国电力出版社, 2002,285-287
[32]马龙华,彭哲.基于Scilab的ARM-Linux嵌入式计算及应用[M].科学出版社,2008:94～105.
[33]戴维康,孙传伟,李靖谊.直升机飞行品质评估系统的Tcl/Tk和C/C++混合编程[J].东华大学学报.2005.31(8):46-47
[34]王坚,金革. Tcl/Tk和C语言的接口[J].计算机应用. 2000,20(12):20-21
[35]黄穗.用Tcl/Tk开发Linux下的图形界面应用[J].计算机工程与应用.2002, 23(1): 52-53
[36]刘莉,符红光.基于TK资源数据库的GUI设计[J].计算机应用. 2002,22(3):51-52
[37]梁伟杰,蒋科艺,吕剑锋.Tcl/Tk命令与C/C++的集成研究[J].微计算机信息. 2006,22(3):79-81
[38] JohnK.Outsterhout, Tcl and the Tk Tool kit [M]. Addison-Wdsley publishing company, 1994:387
[39] BrentWelch. Practical Programming in Tcl and Tk [M]. PrenticeHall, 1995:483
[40]黄义源.机械设备电气与数字控制[M].北京:中央广播电视大学出版社. 1995
[41]陶永华.新型PID控制及其应用[M].机械工业出版社. 2002:35~56
[42]刘金混.先进PID控制及其MATLAB仿真[M].电子工业出版社. 2003:42~68
[43]焦振学.微机数控技术[M].北京:北京理工大学出版社. 2000:309-311
[44]黄明琪,冯济缨,王福平.可编程序控制器[M].重庆:重庆大学出版社,2003
[45]吴玉香,周东霞,林锦赘.嵌入式软PLC系统的研究和实现[J].计算机工程. 2009, 35(10):235-237.
[46]黄延延,林跃,于海斌.软PLC技术研究及实现[J].计算机工程, 2004,30(01):165-167
[47]高金刚,陈建春,刘雄伟.数控系统的软PLC系统开发[J].计算机测量与控制, 2004,(03):254-256
[2]章少华,谢冰.锂离子电池的研究进展[J].佛山陶瓷. 2003,(8):2~5
[3]杨林.中、日、韩三国锂离子电池发展概况[J].电池工业. 2003,(3):4~5
[4]胡绍杰,徐保伯.锂离子电池工业的发展与展望[J].电池. 2000,30(8):171-173
[5]郎鹏,任剑.发展我国锂离子动力电池关键工艺设备思考[J].电子工业专用设备. 2009,178(11):24~25
[6] Inaba M. Ogumi Z. Up-to-date Development of Lithium-ion Batteries in Japan IEEE Electrical Insulation Magazine. 2001, 17(6):6~20.
[7]赵东林.国内外锂离子动力电池极片制造专用设备的新进展[J].新材料产业.2006(9) 65~69.
[8] Kazuo Tagwa, Akiya Kozawa, Ralph Brodd. Production Processes for Lithium Batteries. ITE Letters. 2001, 2(5):16~19.
[9]张世超.锂离子电池产业现状与研究开发热点[J].新材料产业. 2004, (1):23~25.
[10] Ohaman M, Johansson, Stefan, Arzen, Karl-Erik.Implementation Aspects of the PLC Standard IEC 1131-3. Control Engineering Practice. 1998, 6(8):547~555
[11] The EMC Team. EMC History. http://www.linuxcnc.org/content/view/6/5/lang.en/
[12]戴志诚.工业控制中嵌入式系统软件的设计与实现[D].湖北:华中科技大学. 2004
[13]谢林菲,游林儒,王立松.基于PC104与PLC的锂电池全自动卷绕机控制器设计[J].组合机床与自动化加工技术. 2009,428(10):65~66
[14]鲁五一,赵望达,五莉.用PC/104和PLC构成的空压机组智能监测控制系统[J].制造业自动化. 2000(12)
[15]方艺.基于PC104总线的六自由度平台控制系统研究[D].成都:西南交通大学,2003
[16]陈岗,栾丽君.集成化PC数控系统中软PLC的研究开发[J].辽宁工程技术大学学报. 2006,(11) 25
[17] Mario de.Sousa.Linux-Based PLC for Industrial Control.Embedded Linux Journal. 2001,3:29-32
[18]李爽.基于开放式数控系统的软PLC开发系统的研究及实现.2006
[19] The EMC Team. EMC2_User_Manual.V2.2. http://www.linuxcnc.org.2008.04
[20] The EMC Team. EMC2_Intergrator_Manual. V2.2.http://www.linuxcnc.org.2008.04
[21] The EMC Team. EMC2_Developer_ManualV2.2. http://www.linuxcnc.org. 2008.04
[22]赵毅峰.基于PC104及FPGA的多功能脉冲接口卡的实现[J].电子工程师. 2005,31(7):46
[23]王建国,刘兰军,王玉辉.基于CPLD技术的PC104总线多功能扩展卡设计[J].微计算机信息. 2005,21(9):19~20
[24]梅红伟,吴学杰,商秋芳.基于PC104和CPLD的高速/多通道数据采集系统的设计与实现[J].现代电子技术. 2007, 244:151~154
[25] RTAPI.http://www.linuxcnc.org/docview/html//man/man3/intro.3rtapi.html.2010.04
[26]麦向习,裴海龙.基于Linux及Tcl/Tk的数控系统人机界面的实现[J].计算机应用研究. 2006,(02):122-124
[27]吉华,李彦,王强,朱达宇.基于RTLinux的开放式软件PLC的研究[J].计算机应用研究[J]. 2005,(05):48-49
[28]廖永刚.一种实时Linux操作系统-RTAI的分析及扩展[J].福建电脑.2005,(5) 75～76
[29]杨杰,唐伯尧,李从心.基于实时Linux-RTAI位置控制系统研究[J].机床与液压. 2005,(10):163~164
[30]陈永茂,刘少君,裴海龙. RTAI的实时性测试及在CNC控制器的应用[J].微计算机信息. 2008,24(51):156-157.
[31] Brent B Welch. Tcl /Tk编程权威指南[M].崔凯.北京:中国电力出版社, 2002,285-287
[32]马龙华,彭哲.基于Scilab的ARM-Linux嵌入式计算及应用[M].科学出版社,2008:94～105.
[33]戴维康,孙传伟,李靖谊.直升机飞行品质评估系统的Tcl/Tk和C/C++混合编程[J].东华大学学报.2005.31(8):46-47
[34]王坚,金革. Tcl/Tk和C语言的接口[J].计算机应用. 2000,20(12):20-21
[35]黄穗.用Tcl/Tk开发Linux下的图形界面应用[J].计算机工程与应用.2002, 23(1): 52-53
[36]刘莉,符红光.基于TK资源数据库的GUI设计[J].计算机应用. 2002,22(3):51-52
[37]梁伟杰,蒋科艺,吕剑锋.Tcl/Tk命令与C/C++的集成研究[J].微计算机信息. 2006,22(3):79-81
[38] JohnK.Outsterhout, Tcl and the Tk Tool kit [M]. Addison-Wdsley publishing company, 1994:387
[39] BrentWelch. Practical Programming in Tcl and Tk [M]. PrenticeHall, 1995:483
[40]黄义源.机械设备电气与数字控制[M].北京:中央广播电视大学出版社. 1995
[41]陶永华.新型PID控制及其应用[M].机械工业出版社. 2002:35~56
[42]刘金混.先进PID控制及其MATLAB仿真[M].电子工业出版社. 2003:42~68
[43]焦振学.微机数控技术[M].北京:北京理工大学出版社. 2000:309-311
[44]黄明琪,冯济缨,王福平.可编程序控制器[M].重庆:重庆大学出版社,2003
[45]吴玉香,周东霞,林锦赘.嵌入式软PLC系统的研究和实现[J].计算机工程. 2009, 35(10):235-237.
[46]黄延延,林跃,于海斌.软PLC技术研究及实现[J].计算机工程, 2004,30(01):165-167
[47]高金刚,陈建春,刘雄伟.数控系统的软PLC系统开发[J].计算机测量与控制, 2004,(03):254-256