变极性PMIG焊接设备辅助控制系统研制
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摘要
变极性脉冲MIG焊是一种新的焊接工艺方法,其综合了DCEP脉冲MIG焊熔深较大、可以减少焊缝的熔合不良、电弧稳定性好和DCEN MIG焊焊缝熔深浅、焊丝熔化速度较快的特点,减小了焊缝的熔深,增加了焊丝的熔化速度,是一种适合于薄板铝合金焊接的新方法。
研究薄板铝合金变极性脉冲MIG焊接技术,更有效地控制焊接电流、电压输出和熔滴过渡过程,提高焊接过程的稳定性、提高焊接速度,对于提高焊接效率和焊接产品质量具有重要的意义。本课题是“变极性脉冲MIG焊设备及焊接稳定性研究”课题的一部分,主要针对变极性脉冲MIG焊设备完成辅助控制电路设计。主要包括:数字化的人机交互系统设计;送丝稳定、动态性能良好的送丝调速系统。
首先,人机交互系统选用AT89S8252为核心控制芯片,选用具有串行总线接口的SD7218A键盘/显示芯片完成了数字化人机交互系统软、硬件设计;采用RS-485总线实现主控系统和人机交互系统的数据交互;系统采用数字编码器和键盘配合的方式实现焊接参数的选择和设定,同时还具有最优参数存储、调用等功能。对研制的人机交互系统进行了抗高频干扰试验,证明具有良好的抗干扰性能。
其次,本文用采样速度均方差值作为衡量送丝系统的动态稳定性指标,采用LabVIEW软件设计了送丝机性能评估软件,利用该软件不但可以对送丝调速系统做出评价,还可以指导调速系统的设计。
再次,从控制论的角度对转速负反馈、电压负反馈、电压负反馈配合电流正反馈等三种转速调节方式进行了分析论述,采用电枢电压负反馈配合电流正反馈方式设计了送丝机调速控制系统,并采用送丝机性能评估软件对调速系统进行了优化。设计了与主控系统的接口隔离电路,采用线性光耦对模拟信号进行隔离,普通光耦对数字信号进行隔离。
最后,对本文设计的送丝机调速系统与NBC-350焊机的调速系统进行了对比试验,试验证明本文设计的调速控制系统具有良好的动态稳定性和良好的控制精度。
The variable polarity pulsed MIG is a new welding technology. It has the predominance of DCEP MIG and DCEN MIG. The DCEP MIG has the characteristic of deeper penetration which can reduce defective fusion and good arc stabilization. The DCEN MIG has the characteristic of shallow penetration of welding seam, and the welding wire has a high melting speed. So the variable polarity pulsed MIG is a new technology for the welding of aluminium alloy sheet.
It has important significance to study the welding technology of variable polarity pulsed MIG for high efficiency weding and good quality of welding products. We should control the welding current, output voltage and the process of melting drop more effectively. The paper is s sub-topic of the research of variable polarity pulsed MIG welding device and its welding stabilization. The main content is design of digital man-machine interface system, a speed regulating system of good stabilization and dynamic performance; software for appraising the performance of wire feeder.
The first, a digital man-machine interface system using AT89S8252 singlechip is designed. The system uses SD7218A keyboard/display chip with serial bus interface. The welding parameters can be seleted and regulated easily with the cooperation of digital encoder and keystoke. At the same time the system has the function of storage and call of optimum parameters. The man-machine interface system communicates with the master system using RS-485 bus. Aimming at the man-machine interface system, we have done high frequency anti-interference experiment, it proves that the system has good performance of anti-interference.
The second, we adopt the mean-squared deviation of speed as the index of dynamic stability and design an appraisal software of the performance of wire feeder. The software can not only appraise the performance of wire feeder but direct the design of speed regulating system.
The third, the paper analyses and expatiates three mode of speed regulating which are speed negative feedback, voltage negative feedback and voltage negative feedback plus cuttent positive feedback and designs a speed regulating control system adopting the mode of voltage negative feedback plus cuttent positive feedback. At the same time we optimize the speed regulating system using the appraisal software of the performance of wire feeder. Finally designs the interface cirvuit with the master control system. The analog singal is isolated by linear optical isolator and the digital signal is isolated by common optical isolator.
Finally, a comparison experiment is performed between the speed regulating system this paper designed and the speed regulating system of NBC-350 welding power source. The result indicates that the system this paper designed has good dynamic stability and control accuracy.
研究薄板铝合金变极性脉冲MIG焊接技术,更有效地控制焊接电流、电压输出和熔滴过渡过程,提高焊接过程的稳定性、提高焊接速度,对于提高焊接效率和焊接产品质量具有重要的意义。本课题是“变极性脉冲MIG焊设备及焊接稳定性研究”课题的一部分,主要针对变极性脉冲MIG焊设备完成辅助控制电路设计。主要包括:数字化的人机交互系统设计;送丝稳定、动态性能良好的送丝调速系统。
首先,人机交互系统选用AT89S8252为核心控制芯片,选用具有串行总线接口的SD7218A键盘/显示芯片完成了数字化人机交互系统软、硬件设计;采用RS-485总线实现主控系统和人机交互系统的数据交互;系统采用数字编码器和键盘配合的方式实现焊接参数的选择和设定,同时还具有最优参数存储、调用等功能。对研制的人机交互系统进行了抗高频干扰试验,证明具有良好的抗干扰性能。
其次,本文用采样速度均方差值作为衡量送丝系统的动态稳定性指标,采用LabVIEW软件设计了送丝机性能评估软件,利用该软件不但可以对送丝调速系统做出评价,还可以指导调速系统的设计。
再次,从控制论的角度对转速负反馈、电压负反馈、电压负反馈配合电流正反馈等三种转速调节方式进行了分析论述,采用电枢电压负反馈配合电流正反馈方式设计了送丝机调速控制系统,并采用送丝机性能评估软件对调速系统进行了优化。设计了与主控系统的接口隔离电路,采用线性光耦对模拟信号进行隔离,普通光耦对数字信号进行隔离。
最后,对本文设计的送丝机调速系统与NBC-350焊机的调速系统进行了对比试验,试验证明本文设计的调速控制系统具有良好的动态稳定性和良好的控制精度。
The variable polarity pulsed MIG is a new welding technology. It has the predominance of DCEP MIG and DCEN MIG. The DCEP MIG has the characteristic of deeper penetration which can reduce defective fusion and good arc stabilization. The DCEN MIG has the characteristic of shallow penetration of welding seam, and the welding wire has a high melting speed. So the variable polarity pulsed MIG is a new technology for the welding of aluminium alloy sheet.
It has important significance to study the welding technology of variable polarity pulsed MIG for high efficiency weding and good quality of welding products. We should control the welding current, output voltage and the process of melting drop more effectively. The paper is s sub-topic of the research of variable polarity pulsed MIG welding device and its welding stabilization. The main content is design of digital man-machine interface system, a speed regulating system of good stabilization and dynamic performance; software for appraising the performance of wire feeder.
The first, a digital man-machine interface system using AT89S8252 singlechip is designed. The system uses SD7218A keyboard/display chip with serial bus interface. The welding parameters can be seleted and regulated easily with the cooperation of digital encoder and keystoke. At the same time the system has the function of storage and call of optimum parameters. The man-machine interface system communicates with the master system using RS-485 bus. Aimming at the man-machine interface system, we have done high frequency anti-interference experiment, it proves that the system has good performance of anti-interference.
The second, we adopt the mean-squared deviation of speed as the index of dynamic stability and design an appraisal software of the performance of wire feeder. The software can not only appraise the performance of wire feeder but direct the design of speed regulating system.
The third, the paper analyses and expatiates three mode of speed regulating which are speed negative feedback, voltage negative feedback and voltage negative feedback plus cuttent positive feedback and designs a speed regulating control system adopting the mode of voltage negative feedback plus cuttent positive feedback. At the same time we optimize the speed regulating system using the appraisal software of the performance of wire feeder. Finally designs the interface cirvuit with the master control system. The analog singal is isolated by linear optical isolator and the digital signal is isolated by common optical isolator.
Finally, a comparison experiment is performed between the speed regulating system this paper designed and the speed regulating system of NBC-350 welding power source. The result indicates that the system this paper designed has good dynamic stability and control accuracy.
引文
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2 殷树言, 张九海. 气体保护焊工艺. 哈尔滨工业大学出版社, 1989: 93~96
3 潘际銮. 现代弧焊控制. 机械工业出版社, 2000.6: 3~8
4 焦向东. 交流脉冲 MIG 焊接法. 清华大学博士学位论文.1994.4: 98~105
5 焦向东, 潘际銮, 张烨. 交流 MAG 焊接电弧稳定性及其控制. 焊接学报, 1998, 19(1): 47~53
6 张烨, 焦向东, 潘际銮. 交流 MIG 焊电弧稳定性控制. 中国机械工程, 1994, 5(6): 67~68
7 焦向东, 潘际銮, 张烨. 交流 MIG 焊接控制系统的研究. 电焊机, 1994,(2): 9~11
8 焦向东, 潘际銮, 张烨. AC/DCEP 交替 MIG 焊接方法的研究. 中国机械工程, 1996, 7(2): 88~89
9 焦向东, 潘际銮, 张烨. 双凹波形脉冲氩弧焊的焊接电源. 焊接学报, 1996, 17(3): 56~61
10 仝红军, 上山智之. 交流脉冲 MIG 焊接机器人系统的工艺特点. 焊接, 2002(1):20~22
11 P.J.Modenesi, R.C.de Avelar. The Influence of Small Variations of Wire Characteristics on Gas Metal Arc Welding Process Stability. Journal of Materials Processing Technology. 1999, (86): 226~232
12 C .C. Chan, W.Xia. Permanent Magnet Brushless Drives. IEEE industry Applications Magazine. 1998: 29~32
13 Michael J.Burridge, Zhihua Qu. An Improved Nonlinear Control Design for Series DC Motors. Computers and Electrical Engineering. 2003, (29): 273~288
14 汤文博, 陶玲. 数显开关型送丝电源的研制. 电焊机, 2000(3): 34~35
15 王刚, 李景波, 纪连权. 一种新型的送丝电路. 电焊机, 1999, 29(7): 21~22
16 杨昱, 叶振忠. GMAW 送丝速度稳定性研究. 焊接技术, 2002, 31(3): 48~49
17 张广军, 耿正, 吴林. GTAW 用送丝装置研制.电焊机, 2000, 30(4): 28~30
18 王睿. 全数字化焊接电源控制系统研究. 兰州理工大学硕士学位论文. 2005.5: 8~9
19 霍发仁. 人机界面设计研究. 武汉理工大学硕士学位论文. 2003.11: 55~56
20 高福祥, 张君. 接口技术. 东北大学出版社, 1999: 175~177
21 陈露晨. 计算机通信接口技术. 电子科技大学出版社, 1999: 125~128
22 张常年, 郭书军, 左歧. 计算机通信与工业控制. 化学工业出版, 2002: 200~202
23 李朝青. 单片机&DSP 外围数字 IC 技术手册. 北京航空航天大学出版社, 2002: 256~260
24 徐爱钧, 彭秀华. Keil Cx51 V7.0 单片机高级语言编程与μVision2 应用实践. 电子工业出版社, 2005: Ⅰ~ Ⅱ
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27 丁京柱. 全数字化 CO2 气体保护焊机研究. 北京工业大学博士论文. 2002: 32~34
28 李鹤歧. 微机控制脉冲 MIG 焊机控制系统抗干扰设计. 甘肃工业大学学报. 2002, 28(4): 10~13
29 李爱文. 逆变式弧焊电源的抗干扰分析和设计. 焊接设备与材料, 1996, (3): 24~26
30 毛三可. 逆变弧焊电源电磁干扰防护的探讨. 电焊机, 1996, (4): 11~13
31 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. 2001: 39~49
32 华学明, 焦馥杰, 吴毅雄. 数字信号处理器控制焊接电源的抗干扰设计. 电焊机, 2002, (32): 27~29
33 Deb, G.K. Low EMI Design of Microprocessor Based PCB——a Case Study. Electromagnetic Compatibility. 1998. 2: 614~618
34 Shahparnia, S. Ramahi, O.M. Electromagnetic Interference (EMI) Reduction from Printed Circuit Boards (PCB) Using Electromagnetic Bandgap Structures. Electromagnetic Compatibility, IEEE Transactions on. 2004, 46(4): 580~587
35 Yuan, F.Y. Analysis of Power/Ground Noises and Decoupling Capacitors in Printed Circuit Board Systems, Electromagnetic Compatibility. IEEE 1997 International Symposium. 1997: 425~430
36 Bawa, H.P.S. EMC in Digital Circuit Design. Electromagnetic Interference and Compatibility. 1995: 44~47
37 Wu XinPong, M.H. Lee. Reduction of EMI by Electric Field Method, Applied Power Electronics Conference and Exposition. APEC '99. 1999. 1: 135~138
38 Li Shufang. EMC Application in Printed Circuit Boards with the Attached Cables. Electromagnetic Compatibility. 2002: 779~783
39 JB2754 -81. MIG/MAG 弧焊机中送丝速度、焊接速度的变化率: 不详
40 ZB J64 021- 89, 焊机送丝装置技术条件: 不详
41 JB / T 8748- 1998 . MIG/MAG 弧焊机: 不详
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44 董翔云, 刘宇杰, 周元钧等. 航空高速宽范围调速电机的转速测量方法研究. 计算机测量与控制, 2005, 13(2): 106~108
45 何勋. 印刷电机在电焊机上的应用. 电焊机, 1992,(6): 31~33
46 殷树言. CO2 焊接设备原理与调试. 机械工业出版社,2000.1: 115~223
47 陈隆昌, 阎志安, 刘新正等. 控制电机(第三版). 西安电子科技大学出版社. 2000: 56~57
48 田松亚, 顾公兵, 龙火军等. 基于 TL494 的 PWM 等速送丝电路的设计. 河海大学学报, 2004, 32(3): 25~27
49 常云龙, 程韬波, 曾敏. 新型焊接电源实用技术. 中国教育文化出版社, 2003: 75~77
50 Philips Semiconductors. The I2C-Bus Specification. Version2.1. 2000: 10~11
51 Jan Axeison. Serial Port Complete:Programming and Circuits for RS-232 and RS-485 Links and Networks. Independent Publishers Group. 2001, (1): 115~123
52 X.M. Zeng, Msc,A.B. Parker, PHD,J. Lucas, Dsc, Ceng. High-frequency TIG-welding Power Supply with Microprocessor Control. IEEE Processing. 1990, 137(4): 184~192
53 David Blanchard, NikQla Sorak. Electromagnetic Interference (EMI) is Everybody's Concern. Where is it in the Engineering and Technology Curriculum. Frontiers in Education Conference. 1994: 452~455
54 National Instruments Corporation. Getting Started with LabVIEW, 2003: 1~5
55 National Instruments Corporation. LabVIEW User Manual, 2003: 1~3
56 Agilent Technologies. HCNR200/201 Technical Data. 1999: 14~17
2 殷树言, 张九海. 气体保护焊工艺. 哈尔滨工业大学出版社, 1989: 93~96
3 潘际銮. 现代弧焊控制. 机械工业出版社, 2000.6: 3~8
4 焦向东. 交流脉冲 MIG 焊接法. 清华大学博士学位论文.1994.4: 98~105
5 焦向东, 潘际銮, 张烨. 交流 MAG 焊接电弧稳定性及其控制. 焊接学报, 1998, 19(1): 47~53
6 张烨, 焦向东, 潘际銮. 交流 MIG 焊电弧稳定性控制. 中国机械工程, 1994, 5(6): 67~68
7 焦向东, 潘际銮, 张烨. 交流 MIG 焊接控制系统的研究. 电焊机, 1994,(2): 9~11
8 焦向东, 潘际銮, 张烨. AC/DCEP 交替 MIG 焊接方法的研究. 中国机械工程, 1996, 7(2): 88~89
9 焦向东, 潘际銮, 张烨. 双凹波形脉冲氩弧焊的焊接电源. 焊接学报, 1996, 17(3): 56~61
10 仝红军, 上山智之. 交流脉冲 MIG 焊接机器人系统的工艺特点. 焊接, 2002(1):20~22
11 P.J.Modenesi, R.C.de Avelar. The Influence of Small Variations of Wire Characteristics on Gas Metal Arc Welding Process Stability. Journal of Materials Processing Technology. 1999, (86): 226~232
12 C .C. Chan, W.Xia. Permanent Magnet Brushless Drives. IEEE industry Applications Magazine. 1998: 29~32
13 Michael J.Burridge, Zhihua Qu. An Improved Nonlinear Control Design for Series DC Motors. Computers and Electrical Engineering. 2003, (29): 273~288
14 汤文博, 陶玲. 数显开关型送丝电源的研制. 电焊机, 2000(3): 34~35
15 王刚, 李景波, 纪连权. 一种新型的送丝电路. 电焊机, 1999, 29(7): 21~22
16 杨昱, 叶振忠. GMAW 送丝速度稳定性研究. 焊接技术, 2002, 31(3): 48~49
17 张广军, 耿正, 吴林. GTAW 用送丝装置研制.电焊机, 2000, 30(4): 28~30
18 王睿. 全数字化焊接电源控制系统研究. 兰州理工大学硕士学位论文. 2005.5: 8~9
19 霍发仁. 人机界面设计研究. 武汉理工大学硕士学位论文. 2003.11: 55~56
20 高福祥, 张君. 接口技术. 东北大学出版社, 1999: 175~177
21 陈露晨. 计算机通信接口技术. 电子科技大学出版社, 1999: 125~128
22 张常年, 郭书军, 左歧. 计算机通信与工业控制. 化学工业出版, 2002: 200~202
23 李朝青. 单片机&DSP 外围数字 IC 技术手册. 北京航空航天大学出版社, 2002: 256~260
24 徐爱钧, 彭秀华. Keil Cx51 V7.0 单片机高级语言编程与μVision2 应用实践. 电子工业出版社, 2005: Ⅰ~ Ⅱ
25 孙玉才, 王荣兴, 孙华芳. 新型 AT89S52 系列单片机及其应用. 清华大学出版社, 2005: 92~96
26 李广弟, 朱月秀, 王秀山. 单片机基础(修订版). 北京航天航空大学出版社, 2004: 36~37
27 丁京柱. 全数字化 CO2 气体保护焊机研究. 北京工业大学博士论文. 2002: 32~34
28 李鹤歧. 微机控制脉冲 MIG 焊机控制系统抗干扰设计. 甘肃工业大学学报. 2002, 28(4): 10~13
29 李爱文. 逆变式弧焊电源的抗干扰分析和设计. 焊接设备与材料, 1996, (3): 24~26
30 毛三可. 逆变弧焊电源电磁干扰防护的探讨. 电焊机, 1996, (4): 11~13
31 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. 2001: 39~49
32 华学明, 焦馥杰, 吴毅雄. 数字信号处理器控制焊接电源的抗干扰设计. 电焊机, 2002, (32): 27~29
33 Deb, G.K. Low EMI Design of Microprocessor Based PCB——a Case Study. Electromagnetic Compatibility. 1998. 2: 614~618
34 Shahparnia, S. Ramahi, O.M. Electromagnetic Interference (EMI) Reduction from Printed Circuit Boards (PCB) Using Electromagnetic Bandgap Structures. Electromagnetic Compatibility, IEEE Transactions on. 2004, 46(4): 580~587
35 Yuan, F.Y. Analysis of Power/Ground Noises and Decoupling Capacitors in Printed Circuit Board Systems, Electromagnetic Compatibility. IEEE 1997 International Symposium. 1997: 425~430
36 Bawa, H.P.S. EMC in Digital Circuit Design. Electromagnetic Interference and Compatibility. 1995: 44~47
37 Wu XinPong, M.H. Lee. Reduction of EMI by Electric Field Method, Applied Power Electronics Conference and Exposition. APEC '99. 1999. 1: 135~138
38 Li Shufang. EMC Application in Printed Circuit Boards with the Attached Cables. Electromagnetic Compatibility. 2002: 779~783
39 JB2754 -81. MIG/MAG 弧焊机中送丝速度、焊接速度的变化率: 不详
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