微机控制等离子弧焊系统研究
摘要
等离子弧焊接是采用等离子弧作为高温热源的焊接方法,具有焊接速度快、工艺参数调节范围宽、热影响区窄、焊接变形小等优点。在研究开发现代化的电源和控制技术条件下,等离子弧焊技术是一种质量最佳、经济有效、重复性好的连接工艺。
针对目前国内等离子弧焊接系统体积庞大笨重的现状,本文采用逆变电源,控制系统采用单片机控制技术代替传统的模拟控制技术,设计出了一套微机控制的小型化的等离子弧焊系统。主电路为两个逆变电源供电,控制系统以高性能单片机80C196KC为核心,实现对焊接过程的自动控制。
文中阐述了等离子弧焊接设备的组成,并分析了各部分机械装置、气路、水路、焊枪在焊接中的作用,以及各组件在设计中应特别注意的问题;同时针对硅整流电源存在体积大可靠性差等问题,系统主电路采用两台逆变电源供电,这样既便于电弧工艺规范的调节,又增强系统的稳定性。
详细阐述了所研制的等离子弧焊接系统中单片机控制系统的设计。分别就控制器的选型、单片机最小系统、开关量输入输出电路作了详细的分析,并从软硬件两个方面给予系统的阐述。同时,在等离子弧焊控制电路部分都进行了可靠性与抗干扰设计。分析了影响等离子弧焊接设备正常工作的各种干扰因素,并在原理图设计、PCB制作、信号传输以及程序编制的过程中采取了相应的软硬件抗干扰措施。
最后,对等离子弧焊接系统的各个组成部分进行了调试分析,并给出了在试验过程中记录的照片。调试结果表明:所设计的等离子弧焊控制系统合理可行,工作稳定可靠,操作方便,抗干扰能力强,能够实现等离子弧焊接过程的自动控制。
Plasma arc welding (PAW) is an advanced welding method, which adopts plasma arc as high temperature source. It has advantages comparing with other welding methods, such as high welding speed, narrow heat effect zone, little deformation of workpiece and so on. Plasma arc welding will become a kind of top-quality, economical and efficient joining technics in the conditions of the advanced electrical source and controlling technology.
This paper introduces the PAW system controlled by microcontroller. Because the equipment of PAW used in our country now is more bulky, we put forward the conception of replacing it with the inverter and adopting single-chip technology instead of traditional analog technology in order to design a set of miniature PAW system. The main circuit is supplied by two power source. To realize controlling the welding process automatically, an advanced microcontroller 80C196KC is used for the center of control circuit.
The constitution of plasma arc welding system, each component played roles in this system and some questions being attention to are introduced in this paper. Aimed at the shortcomings of widely application of silicon rectifier domestic, which makes the system more bulky and bad reliability, two inverter power sources are introduced as the power of PAW in main circuit. This designing not only gained convenience of adjusting parameter, but also enhanced stability of system.
The designing of software and hardware about MCU controlling system is introduced in detailed in the paper, besides type choosing of controller, circuit of switch input and output are respectively analyzed. Hardware and software are both expatiated systematically. Meanwhile, Reliability and anti-interference designs are also involved in all PAW control circuits. Various noises probably appearing in the PAW process, as well as their mechanism, are analyzed systematically. Subsequently, in order to reduce their bad infections to great extent, some hardware and software measures are adopted while designing schematic chart, PCB board, code transferring and compiling program code.
At last, through offline and online debugging of each component of the system, locale photos are attained and analyzed. The experiment results show that the combined control system has many advantages such as strong anti-interference ability, easy operation and reliable performance. It can meet the need of realizing automatic PAW process.
针对目前国内等离子弧焊接系统体积庞大笨重的现状,本文采用逆变电源,控制系统采用单片机控制技术代替传统的模拟控制技术,设计出了一套微机控制的小型化的等离子弧焊系统。主电路为两个逆变电源供电,控制系统以高性能单片机80C196KC为核心,实现对焊接过程的自动控制。
文中阐述了等离子弧焊接设备的组成,并分析了各部分机械装置、气路、水路、焊枪在焊接中的作用,以及各组件在设计中应特别注意的问题;同时针对硅整流电源存在体积大可靠性差等问题,系统主电路采用两台逆变电源供电,这样既便于电弧工艺规范的调节,又增强系统的稳定性。
详细阐述了所研制的等离子弧焊接系统中单片机控制系统的设计。分别就控制器的选型、单片机最小系统、开关量输入输出电路作了详细的分析,并从软硬件两个方面给予系统的阐述。同时,在等离子弧焊控制电路部分都进行了可靠性与抗干扰设计。分析了影响等离子弧焊接设备正常工作的各种干扰因素,并在原理图设计、PCB制作、信号传输以及程序编制的过程中采取了相应的软硬件抗干扰措施。
最后,对等离子弧焊接系统的各个组成部分进行了调试分析,并给出了在试验过程中记录的照片。调试结果表明:所设计的等离子弧焊控制系统合理可行,工作稳定可靠,操作方便,抗干扰能力强,能够实现等离子弧焊接过程的自动控制。
Plasma arc welding (PAW) is an advanced welding method, which adopts plasma arc as high temperature source. It has advantages comparing with other welding methods, such as high welding speed, narrow heat effect zone, little deformation of workpiece and so on. Plasma arc welding will become a kind of top-quality, economical and efficient joining technics in the conditions of the advanced electrical source and controlling technology.
This paper introduces the PAW system controlled by microcontroller. Because the equipment of PAW used in our country now is more bulky, we put forward the conception of replacing it with the inverter and adopting single-chip technology instead of traditional analog technology in order to design a set of miniature PAW system. The main circuit is supplied by two power source. To realize controlling the welding process automatically, an advanced microcontroller 80C196KC is used for the center of control circuit.
The constitution of plasma arc welding system, each component played roles in this system and some questions being attention to are introduced in this paper. Aimed at the shortcomings of widely application of silicon rectifier domestic, which makes the system more bulky and bad reliability, two inverter power sources are introduced as the power of PAW in main circuit. This designing not only gained convenience of adjusting parameter, but also enhanced stability of system.
The designing of software and hardware about MCU controlling system is introduced in detailed in the paper, besides type choosing of controller, circuit of switch input and output are respectively analyzed. Hardware and software are both expatiated systematically. Meanwhile, Reliability and anti-interference designs are also involved in all PAW control circuits. Various noises probably appearing in the PAW process, as well as their mechanism, are analyzed systematically. Subsequently, in order to reduce their bad infections to great extent, some hardware and software measures are adopted while designing schematic chart, PCB board, code transferring and compiling program code.
At last, through offline and online debugging of each component of the system, locale photos are attained and analyzed. The experiment results show that the combined control system has many advantages such as strong anti-interference ability, easy operation and reliable performance. It can meet the need of realizing automatic PAW process.
引文
[1]陈裕川.等离子弧焊技术的新发展(一)[J].现代焊接,2008(8):5-10
[2]朱学.物质的第四态—离子体[J].常州信息职业技术学院学报,2004(9):24-26
[3]赵家瑞.逆变焊接与切割电源[M].北京:机械工业出版社,1996:261-262
[4]董文宁,陈国余.高效等离子焊接技术及其应用[J].电焊机,2007,37(9):8-16
[5]陈裕川.等离子弧焊技术的新发展(二)[J].现代焊接,2008(9):6-11
[6]黄石生,王振民,吴详淼等.新型大功率等离子喷涂逆变器的研究[J].中国表面工程,2001(2):36-39
[7]李春旭,陈克选,张志坚.单片机控制等离子喷涂(焊)电源研制[J].甘肃工业大学学报,2000(2):9-11
[8]王振民,黄石生,薛家祥等.弧焊逆变技术的研究现状与展望[J].电焊机,2000,30(8):3-6
[9]Lyon Van Der Merwe,Gawie J Merwe.Inverters-The investigation to the optimal topology to the designing of a sinewave inverter range for the use in static as well as mobile aoolications |J].IEEE,1998:51-56
[10]杨光.焊接自动化技术的现状与展望[J].现代制造,2004(11):36-37
[11]逯燕玲,周好斌,张骁勇.可编程序控制器在等离子喷焊机上的应用[J].西安石油学院学报,1997(3):39-43
[12]Yaowen Wang,Qiang Chen.On-line quality monitoring in plasma-arc welding[J].Materials Proceessing Technology,2002(120):270-274
[13]H Wang and R Kovacevic.On-line monitoring of the keyhole welding pool in variable polarity plasma arc welding[J].Engineering Manufacture.2002:1265-1276
[14]陈迎春,张义顺,董晓强,李德元.等离子喷涂过程自动控制及PLC编程[J].沈阳工业大学学报,2003(2):14-17
[15]Rong-Ho(Ron)Lin,Gary W.Fischer.An on-line arc welding quality monitor and process control system[J].2002:22-29.
[16]Matthew Miller,Bao Mi,Akio Kita,I.Charles Ume.Development of automated real-time data acquisition system for robotic weld quality monitoring[J].M.Miller et al./Mechatronics 2002(12):1259-1269
[17]薛钧义,武自芳.微机控制系统及其应用[M].西安:西安交通大学出版社,2003,60-62
[18]X.M.Zeng,MSc,A.B.Parker.PhD,J.Lucas.DSc.CEng.High-frequency TIG-welding power supply with microprocessor control[J].IEE PROCEEDINGS,1990,137(4):184-192
[19]凌幸福,董翠萍,吴忠萍等,雷宇.LK—2(3)型微机控制等离子喷焊设备的技术改造以及工艺改进[J].江西冶金,2000(6):31-35
[20]江世明.用可编程控制器改造等离子喷焊机[J].邵阳高等专科学校学报,2001(9):188-190
[21]李京龙,田丽,林谦生.多功能等离子弧装置[J].电焊机,1996(4):22-24
[22]朱六妹.等离子弧喷焊的可编程序控制系统[J].电焊机,1992(6):8-11
[23]D.R.Gabe,Principles of Metal Surface Treatment and Protection[J].Weld,Pergamon Press,1972(2):30-31
[24]刘美俊.可编程控制器应用技术[J].家电科技,2005(10):38-40
[25]王志强,吕东波.一种与逆变焊机配用的高频引弧器[J].电焊机,2000(2):41-42
[26]韩俭,胡绳荪,韩敬华等.等离子弧焊机PLC系统的研制[J].电焊机,2004,34(8):42-44
[27]何德孚,俞海良,唐新华.PLC控制等离子弧全自动焊机设计及研制[J].焊管,1997,20(5):52-55
[28]王伟,朱六妹,于勇涌,尚小刚.等离子弧喷焊分布式微机控制系统的研究[J].电焊机,1997(5):22-25
[29]陈粤初,窦振中.单片机应用系统设计与实践[M].北京:北京航空航天大学出版社,1991:12-16
[30]毛文杰,王加友,陈刚.等离子喷涂及喷焊自动控制系统的研制[J].华东船舶工业学院学报,1995(3):69-74
[31]吴毅雄,黄坚,赵颖.单片机控制热继电器自动等离子弧焊接系统[J].低压电器,1997(1):55-57
[32]张立,赵永健.现代电力电子技术—器件、电路及应用[M].北京:科学出版社,1992,12-15
[33]杨春利,林三宝.电弧焊基础[M].哈尔滨工业大学出版社.2003:117
[34]高荣发,马小雄.等离子弧喷焊[M].北京:机械工业出版社,1979:1-2
[35]赫晓龙.微机控制等离子喷焊系统研究.[兰州理工大学硕士论文].兰州:兰州理工大学,2004:5-13
[36]H.C.Dickey,T.T.Meek,Active electronic devices fabricated by DC plasma arc spray process[J],2000(59):179-184
[37]李春旭,陈克选,张成.微机控制的等离子喷焊设备抗高频干扰的研究[J].甘肃工业大学学报,1996(2):6-8
[38]B.Irving,HVIF process improves densities of many thermal sprayed coatings, Weld.J.2000(2):42-44
[39]孙廷才,王杰等著.工业控制计算机组成原理[M].北京:清华大学出版社.2001:1-21
[40]田悦新,曹海燕.工业控制机的特点及在机电—体化中的应用[J].石家庄经济学院学报,1997,20(6):602-606
[41]张晓坤.可编程序控制器原理及应用[M].西安:西北工业大学出版社,1998:1-33
[42]陈在平,赵相宾.可编程序控制器技术与应用系统设计[M].北京:机械工业出版社,2002:3-23
[43]徐爱卿.Intel16位单片机(修订版)[M].北京:北京航空航天大学出版社,2002:152-153
[44]孙涵芳.Intel16位单片机[M].北京:北京航空航天大学出版社,1995
[45]MAXIM技术书册,微系统监控电路
[46]李伯成,侯伯亨,张毅坤等.微型计算机原理及应用[M].西安电子科技大学出版社.2004:193-203
[47]栗广亮,胡雪,韩庆晟,孙存钊.单片机的干扰因素分析及对策[J].中国设备工程2008(2):40-41
[48]雷思孝,冯育长.单片机系统设计及工程应用[M].西安电子科技大学出版社.2005:215
[49]Organ David.A handbook for EMC Testing and Measurement.Landon:Petter Peregrinus Ltd.On behalf of the Institute of Electrical Engineers,1993:5-13
[50]郑湘蒙,单片机控制TIG逆变焊机的研制.[北京工业大学硕士论文].北京:北京工业大学.2001:45-46
[51]王幸之,王雷,翟成等.单片机应用系统抗干扰技术[M].北京:北京航空航天大学出版社.2000:52-82
[2]朱学.物质的第四态—离子体[J].常州信息职业技术学院学报,2004(9):24-26
[3]赵家瑞.逆变焊接与切割电源[M].北京:机械工业出版社,1996:261-262
[4]董文宁,陈国余.高效等离子焊接技术及其应用[J].电焊机,2007,37(9):8-16
[5]陈裕川.等离子弧焊技术的新发展(二)[J].现代焊接,2008(9):6-11
[6]黄石生,王振民,吴详淼等.新型大功率等离子喷涂逆变器的研究[J].中国表面工程,2001(2):36-39
[7]李春旭,陈克选,张志坚.单片机控制等离子喷涂(焊)电源研制[J].甘肃工业大学学报,2000(2):9-11
[8]王振民,黄石生,薛家祥等.弧焊逆变技术的研究现状与展望[J].电焊机,2000,30(8):3-6
[9]Lyon Van Der Merwe,Gawie J Merwe.Inverters-The investigation to the optimal topology to the designing of a sinewave inverter range for the use in static as well as mobile aoolications |J].IEEE,1998:51-56
[10]杨光.焊接自动化技术的现状与展望[J].现代制造,2004(11):36-37
[11]逯燕玲,周好斌,张骁勇.可编程序控制器在等离子喷焊机上的应用[J].西安石油学院学报,1997(3):39-43
[12]Yaowen Wang,Qiang Chen.On-line quality monitoring in plasma-arc welding[J].Materials Proceessing Technology,2002(120):270-274
[13]H Wang and R Kovacevic.On-line monitoring of the keyhole welding pool in variable polarity plasma arc welding[J].Engineering Manufacture.2002:1265-1276
[14]陈迎春,张义顺,董晓强,李德元.等离子喷涂过程自动控制及PLC编程[J].沈阳工业大学学报,2003(2):14-17
[15]Rong-Ho(Ron)Lin,Gary W.Fischer.An on-line arc welding quality monitor and process control system[J].2002:22-29.
[16]Matthew Miller,Bao Mi,Akio Kita,I.Charles Ume.Development of automated real-time data acquisition system for robotic weld quality monitoring[J].M.Miller et al./Mechatronics 2002(12):1259-1269
[17]薛钧义,武自芳.微机控制系统及其应用[M].西安:西安交通大学出版社,2003,60-62
[18]X.M.Zeng,MSc,A.B.Parker.PhD,J.Lucas.DSc.CEng.High-frequency TIG-welding power supply with microprocessor control[J].IEE PROCEEDINGS,1990,137(4):184-192
[19]凌幸福,董翠萍,吴忠萍等,雷宇.LK—2(3)型微机控制等离子喷焊设备的技术改造以及工艺改进[J].江西冶金,2000(6):31-35
[20]江世明.用可编程控制器改造等离子喷焊机[J].邵阳高等专科学校学报,2001(9):188-190
[21]李京龙,田丽,林谦生.多功能等离子弧装置[J].电焊机,1996(4):22-24
[22]朱六妹.等离子弧喷焊的可编程序控制系统[J].电焊机,1992(6):8-11
[23]D.R.Gabe,Principles of Metal Surface Treatment and Protection[J].Weld,Pergamon Press,1972(2):30-31
[24]刘美俊.可编程控制器应用技术[J].家电科技,2005(10):38-40
[25]王志强,吕东波.一种与逆变焊机配用的高频引弧器[J].电焊机,2000(2):41-42
[26]韩俭,胡绳荪,韩敬华等.等离子弧焊机PLC系统的研制[J].电焊机,2004,34(8):42-44
[27]何德孚,俞海良,唐新华.PLC控制等离子弧全自动焊机设计及研制[J].焊管,1997,20(5):52-55
[28]王伟,朱六妹,于勇涌,尚小刚.等离子弧喷焊分布式微机控制系统的研究[J].电焊机,1997(5):22-25
[29]陈粤初,窦振中.单片机应用系统设计与实践[M].北京:北京航空航天大学出版社,1991:12-16
[30]毛文杰,王加友,陈刚.等离子喷涂及喷焊自动控制系统的研制[J].华东船舶工业学院学报,1995(3):69-74
[31]吴毅雄,黄坚,赵颖.单片机控制热继电器自动等离子弧焊接系统[J].低压电器,1997(1):55-57
[32]张立,赵永健.现代电力电子技术—器件、电路及应用[M].北京:科学出版社,1992,12-15
[33]杨春利,林三宝.电弧焊基础[M].哈尔滨工业大学出版社.2003:117
[34]高荣发,马小雄.等离子弧喷焊[M].北京:机械工业出版社,1979:1-2
[35]赫晓龙.微机控制等离子喷焊系统研究.[兰州理工大学硕士论文].兰州:兰州理工大学,2004:5-13
[36]H.C.Dickey,T.T.Meek,Active electronic devices fabricated by DC plasma arc spray process[J],2000(59):179-184
[37]李春旭,陈克选,张成.微机控制的等离子喷焊设备抗高频干扰的研究[J].甘肃工业大学学报,1996(2):6-8
[38]B.Irving,HVIF process improves densities of many thermal sprayed coatings, Weld.J.2000(2):42-44
[39]孙廷才,王杰等著.工业控制计算机组成原理[M].北京:清华大学出版社.2001:1-21
[40]田悦新,曹海燕.工业控制机的特点及在机电—体化中的应用[J].石家庄经济学院学报,1997,20(6):602-606
[41]张晓坤.可编程序控制器原理及应用[M].西安:西北工业大学出版社,1998:1-33
[42]陈在平,赵相宾.可编程序控制器技术与应用系统设计[M].北京:机械工业出版社,2002:3-23
[43]徐爱卿.Intel16位单片机(修订版)[M].北京:北京航空航天大学出版社,2002:152-153
[44]孙涵芳.Intel16位单片机[M].北京:北京航空航天大学出版社,1995
[45]MAXIM技术书册,微系统监控电路
[46]李伯成,侯伯亨,张毅坤等.微型计算机原理及应用[M].西安电子科技大学出版社.2004:193-203
[47]栗广亮,胡雪,韩庆晟,孙存钊.单片机的干扰因素分析及对策[J].中国设备工程2008(2):40-41
[48]雷思孝,冯育长.单片机系统设计及工程应用[M].西安电子科技大学出版社.2005:215
[49]Organ David.A handbook for EMC Testing and Measurement.Landon:Petter Peregrinus Ltd.On behalf of the Institute of Electrical Engineers,1993:5-13
[50]郑湘蒙,单片机控制TIG逆变焊机的研制.[北京工业大学硕士论文].北京:北京工业大学.2001:45-46
[51]王幸之,王雷,翟成等.单片机应用系统抗干扰技术[M].北京:北京航空航天大学出版社.2000:52-82