单相逆变空气等离子切割电源的研究
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摘要
逆变切割技术是针对切割电弧负载特性和切割工艺要求,应用现代电力电子学理论和自动控制理论,实现电能的高效变换和控制的一门应用学科。其研究内容横跨焊接电弧物理、切割工艺学、功率电子和电磁器件、开关电路拓扑、逆变电源系统控制技术及其建模、分析和计算机仿真等各个领域。切割逆变电源现在正向着高效、节能、优质的小型化切割电源方向发展。
本文对便携式小功率切割电源的研制进行了分析,并对其主电路、工作原理、控制电路及保护系统做了较详尽的介绍,比较成功地设计出一种小功率高可靠性的逆变切割电源。
该电源采用MOSFET(设计开关频率为100kHz)逆变式全桥型主电路,控制系统部分采用了脉宽调制技术(PWM),PWM芯片为SG3525,MOSFET驱动电路采用脉冲变压器进行驱动,控制电路与主电路之间通过变压器进行隔离,提高了系统的可靠性和安全性。设计脉宽调制电路并对其原理进行分析,还设计了开关管缓冲电路、过流保护、过热保护及过压保护等具有保护功能的电路,同时设计了高频引弧电路及其程序控制电路。
本文通过理论计算和实验分析证明切割电源的工作状态符合要求,该切割电源实现了小型化,具有比较稳定可靠的性能。
With the development of modern industrial production and science technology, cutting technique progressed unremittingly. The high quality cutting work does not get away from the high-quality cutting equipments. The advanced technology and high-quality in the field of cutting are more and more reflected in the high-tech cutting equipment and modernization extent. The plasma cutting technique has a huge function in the production of industry. It can cut all black or non-ferrous, including various high melting point metals and the metals that other cutting methods can not cut, such as stainless, heat-resistant steel, cast iron, copper, aluminum and its alloys. When using non-transfer arc, the workpiece is not link power, under such circumstances, it can cut a variety of non-conductive materials, non-metallic materials such as refactory bricks, concrete and so on.
The plasma arc use for cutting is different with the common welding arc. First, its electric arc is compressed. Secondly, the plasma arc use for cutting is longer. Along with the thickness of the cutting work piece increasing, the arc length is also increasing. The work voltage of cutting can be up to 100～200V. The non-load voltage of the cutting power supply can be up to 200～300V, for the stability of arc and igniting arc easily. In this paper, the work voltage of cutting is 95V, and the non-load voltage of the cutting power is up to 230V.
With the development of the electric power electronics and the micro-electronics, the new devices, the advanced control technique and the constant introduction of new technology. The cutting technique gets the most advance by leaps and bounds of development. High speed, efficient, digital and the intelligent are the main development direction of the modern cutting technology. In recent years, with the continuous development of inverter technology, cutting inverter power becomes the development trend of cutting power. Inverter cutting machine with small size, light weight, energy saving, high performance control and dynamic response speed, which easily to control in the cutting process.
Presently, three-phase cutting machine is very weight, not easy to carry, according to the needs of manufacturers, design the single-phase inverter air plasma cutting power. Detailed analysis the structure and principles about the inverter air plasma cutting power.Optimizate the reasonable layout and design, including the complete research tasks such as the main circuit, the control circuit, pulse width modulation circuit, driving circuit, high-frequency arc circuit, the protection circuit, the process control circuit and cutting power debugging.The inverter power frequency and load sustained rate are high, energy saving, low power consumption, small size, light weight,easy to carry, particularly suitable for outdoor mobile operations.
In this paper, analyze the implementation of the program and integral part of the cutting power.This text carries on experiment analysis in the implement and project of power supply. Give the experiment records in the process of data and relate wave form. Carry on analytical research in the process of problems and put forward solution. The experiment results show that the inverter cutting machine main circuit has rapid response-speed, the control circuit is simple and reliable,continuous adjustable cutting current, accurate intuitive, built-in buffer, overhested,over-current, over-voltage protection circuit. The power compared with the flame cutting, use cheap compressed air to cut, low cost and high speed. Compared with the traditional cutting machine, the inverter power has high success rate arc, arc voltage, and energy concentration, cutting ability, and cutting speed, slotted narrow, smooth and small deformation. The design is meet concept and requirements.
本文对便携式小功率切割电源的研制进行了分析,并对其主电路、工作原理、控制电路及保护系统做了较详尽的介绍,比较成功地设计出一种小功率高可靠性的逆变切割电源。
该电源采用MOSFET(设计开关频率为100kHz)逆变式全桥型主电路,控制系统部分采用了脉宽调制技术(PWM),PWM芯片为SG3525,MOSFET驱动电路采用脉冲变压器进行驱动,控制电路与主电路之间通过变压器进行隔离,提高了系统的可靠性和安全性。设计脉宽调制电路并对其原理进行分析,还设计了开关管缓冲电路、过流保护、过热保护及过压保护等具有保护功能的电路,同时设计了高频引弧电路及其程序控制电路。
本文通过理论计算和实验分析证明切割电源的工作状态符合要求,该切割电源实现了小型化,具有比较稳定可靠的性能。
With the development of modern industrial production and science technology, cutting technique progressed unremittingly. The high quality cutting work does not get away from the high-quality cutting equipments. The advanced technology and high-quality in the field of cutting are more and more reflected in the high-tech cutting equipment and modernization extent. The plasma cutting technique has a huge function in the production of industry. It can cut all black or non-ferrous, including various high melting point metals and the metals that other cutting methods can not cut, such as stainless, heat-resistant steel, cast iron, copper, aluminum and its alloys. When using non-transfer arc, the workpiece is not link power, under such circumstances, it can cut a variety of non-conductive materials, non-metallic materials such as refactory bricks, concrete and so on.
The plasma arc use for cutting is different with the common welding arc. First, its electric arc is compressed. Secondly, the plasma arc use for cutting is longer. Along with the thickness of the cutting work piece increasing, the arc length is also increasing. The work voltage of cutting can be up to 100～200V. The non-load voltage of the cutting power supply can be up to 200～300V, for the stability of arc and igniting arc easily. In this paper, the work voltage of cutting is 95V, and the non-load voltage of the cutting power is up to 230V.
With the development of the electric power electronics and the micro-electronics, the new devices, the advanced control technique and the constant introduction of new technology. The cutting technique gets the most advance by leaps and bounds of development. High speed, efficient, digital and the intelligent are the main development direction of the modern cutting technology. In recent years, with the continuous development of inverter technology, cutting inverter power becomes the development trend of cutting power. Inverter cutting machine with small size, light weight, energy saving, high performance control and dynamic response speed, which easily to control in the cutting process.
Presently, three-phase cutting machine is very weight, not easy to carry, according to the needs of manufacturers, design the single-phase inverter air plasma cutting power. Detailed analysis the structure and principles about the inverter air plasma cutting power.Optimizate the reasonable layout and design, including the complete research tasks such as the main circuit, the control circuit, pulse width modulation circuit, driving circuit, high-frequency arc circuit, the protection circuit, the process control circuit and cutting power debugging.The inverter power frequency and load sustained rate are high, energy saving, low power consumption, small size, light weight,easy to carry, particularly suitable for outdoor mobile operations.
In this paper, analyze the implementation of the program and integral part of the cutting power.This text carries on experiment analysis in the implement and project of power supply. Give the experiment records in the process of data and relate wave form. Carry on analytical research in the process of problems and put forward solution. The experiment results show that the inverter cutting machine main circuit has rapid response-speed, the control circuit is simple and reliable,continuous adjustable cutting current, accurate intuitive, built-in buffer, overhested,over-current, over-voltage protection circuit. The power compared with the flame cutting, use cheap compressed air to cut, low cost and high speed. Compared with the traditional cutting machine, the inverter power has high success rate arc, arc voltage, and energy concentration, cutting ability, and cutting speed, slotted narrow, smooth and small deformation. The design is meet concept and requirements.
引文
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[3]盛新江，常用等离子切割方法及其选用，化工机械，第29卷第三期．
[4]黄石生等，弧焊逆变电源的研究与展望，电焊机，1999，6：6～10．
[5]郭峰， 焊接逆变电源的应用与发展现状，现代焊接，2006．11．
[6]钟伟强，现代逆变技术的广泛应用，东方电器评论第18卷第4期．
[7]刘胜利，现代高频开关电源实用技术，北京：电子工业出版社，2004．3．
[8]李爱文，张承慧现代逆变技术及其应用，科学出版社，2000年9月，17．
[9]常云龙，汪殿龙，信雷，陈俊良，逆变式等离子切割机主变压器设计， 电焊机，V01．31，2001(7)：10～12．．
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[11]陈燕，脉冲变压器铁心的研究，江苏电器，2001．NO．5，28~29．
[12]Smith，C．H．IEEE Transaction on Nuclear Science．
[13]胡君臣，高频变压器的设计与制作，电气开关，2005．NO．1，8～13．
[14]张乃国，小型变压器及扼流圈的设计与绕制，北京：人民邮电出版社，1955．1．
[15]电子变压器专业委员会，电子变压器手册，辽宁科学技术出版社，2003， 379．
[16]Middlebrook R D，Cuk S．A General unified approach to modeling switchingconveRter power stages，in Proc．IEEE Power Electronics Specialists Conf,1976：18-34．
[17]Luo Ping，Li Zhaoji，Xiong Fugui，Chen Guangju．Fuzzy pulse skip modulation mode in DC／DC converter．2004 IEEE International Power Electronics Congress，CIEP04，CELAYA，Mexico，17～22，October，2004：87～91．
[18]张占松，蔡宣三，开关电源的原理与设计，电子工业出版社，2001：1 16～123
[19]李宏，电力电子设备用器件与集成电路应用指南第一册，北京：机械工业出版社，2001．4，92~98．
[20]Baliga BJ．Evolution of MOS—bipolar power semiconductor technology[J]．Proceeding ofIEEE，1998，76(4)：409~418．
[21]E J Dede，J V Gonzalez，J ALinares．Conception ofPar-allel ResonantTransistorized Generalors for Induction Heating[A]．Proc．ofthePCC—Yokohama Conel993[C]．1991，(1)：390~393．
[22]王志强，吕东波，一种与逆变焊机配用的高频引弧器，电焊机，2000(2)．
[23]Schiedermayer，Marv．Improving the reliability ofinverter based weldingmachines．Welding Jounal，1997，76(2)：25-29．
[24]Bruce Carsten．Design Techniques for Transformer Active Reset Circuits at HighFrequencies and Power Levels．HFPC Proceedings，1990：235～246．
[25]Robert W. Erickson．Fundamentals ofPower Electronics．Kluwer AcademicPublishers Group．Norwell．1977．
[26]R．D．Middle brook．Design—Oriented Analysis ofFeedback Amplifiers．Proceedings National Conference．Oct．1993．135-139．
[27]梁桂芳，气割，机械工业出版社1983年2月北京第一版．
[28]郝喜海，吴若梅，张继红，激光切割技术在机械制造中的应用及发展[J]。 机械制造，1999，(8)：9—11．
[29]李亚江等，切割技术及应用，化学工业出版社，2004，109—111．
[30]戴上觉，陈嘉民，气焊与气割，辽宁科学技术出版社，1982年10月第一 版
[31]Steen W M．Laser Material Processing．London：Springer-Verlag LondonLimited，2003．
[32]杨波，几种新型特种切割方法及其特性对比，煤矿机械，2005年第10期
[33]杭争翔，刘桂秋，李文，等离子切割技术的最新发展，电焊机，1998，28 (3)：8～11．
[34]VASIL—EV K V.Plasma arc cutting a promising method ofthermal cutting．Intermational welding，2003，17(2)：147-151．
[35]赵家瑞，等离子弧切割技术的发展动向．石油工程建设，1998(5)：6-7．
[36]赵家瑞，李中友，赵举东，空气等离子切割机的原理和设计，机械工业出 版社．1997：1-3．
[37]陈苗荪，焊接切割论坛Cutting Forum 2006年第九期．
[38]郑宜庭，黄石生，弧焊电源，北京：机械工业出版社，2002：3～4．
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