基于DSP数字化软开关弧焊电源控制系统研究
|
摘要
随着焊接工艺研究的深入以及焊接生产自动化和柔性化的发展,对焊接电源本身的控制精度提出了更高的要求。本文首先介绍了数字化焊接电源的基本概念、研究现状和发展前景,以及数字信号处理器DSP的基本原理以及应用范围。论文还重点介绍了数字化脉冲MIG焊软开关逆变弧焊电源的组成结构,并分别就软开关逆变焊机的主电路、控制电路、保护电路、驱动电路以及送丝电路做了详细的分析。
本文对全桥大功率软开关主电路进行了研究,指出目前焊接逆变电源所应用的大功率电路多采用硬开关电路,容易造成在功率器件导通和关断过程中产生很大的损耗,从而降低焊机的工作效率。结合软开关实现原理,通过MATLAB/SIMULINK软件仿真,分析研究了全桥移相零电压零电流(Zero Voltage Zero Current----ZVZCS)软开关电路,以及该电路的软开关实现过程,并给出了电路模型和关键元件的设计参数。
DSP的开发所需要的仿真环境是开发DSP系统所必需的,文中详细介绍了DSP的开发环境CCS使用。系统软件采用C语言编程,以模块化方法设计。文中详细介绍了主程序、中断服务程序以及子程序的功能和结构。
此外,进行了硬件和软件两个方面的多种抗干扰设计,显著的提高了系统的可靠性。
最后,论文对PI控制进行了仿真,比较了增加PI调节器与不加PI调节器条件下系统的响应速度和动态参数的变化。结果表明,智能控制技术在全桥软开关弧焊电源中可以起到关键作用并取得良好的控制效果。
The development of welding process research, welding automation and flexible welding manufacture system has raised an ever-increasing requirement for precision and the flexible control of the welding power source. According to the characteristics of digital signal processing, the digitalization of welding inverter and its future development on the basis of DSP's basic characteristics are introduced. Firstly, the development, control principle, characteristics and chip selection of DSP are introduced in the paper. The paper focuses on component part of digital pulse MIG welding inverter power. Main circuit, control circuit, pulse width modulation (PWM) circuit, drive circuit and wire feeding circuit are respectively analyzed. Furthermore, the software and hardware aspects are also addressed.
This paper researches the main circuit of the full bridge high power soft-switching. Nowadays, welding machines usually use the hard-switching, which causes the problems of higher energy loss and lower efficiency. The problem is much more critical when the inverter frequency is high. In a welding machine, the main circuit with the technology of the soft-switching is much more ideal than the hard-switching. By the theory of the soft-switching, with the help of the simulation software MATLAB/SIMULINK, this paper analyzes the main circuit of the full bridge shift-phased zero voltage zero current(ZVZCS) soft-switching. Then, the paper gives the on and off theory of the soft-switching, the model of the main circuit, key point and the parameters of the design.
The circumstance of simulation is necessary for designing DSP system. The paper illuminates DSP develop circumstance CCS2.0. The System software is coded with assemble language and designed by Modular approach. This paper introduces the main program, interrupt service procedures and routines of the function and structure in detail.
Besides, a variety of anti-interference designs about both hardware and software are accomplished, so reliability of system is increased prominently.
Finally, simulations are done for the PI control method. Comparing the change of response speed with dynamic parameters through increasing PI regulator and without it .That shows the technology of intelligent control plays a key role in the full bridge soft-switching power, and the system has good control efficiency.
本文对全桥大功率软开关主电路进行了研究,指出目前焊接逆变电源所应用的大功率电路多采用硬开关电路,容易造成在功率器件导通和关断过程中产生很大的损耗,从而降低焊机的工作效率。结合软开关实现原理,通过MATLAB/SIMULINK软件仿真,分析研究了全桥移相零电压零电流(Zero Voltage Zero Current----ZVZCS)软开关电路,以及该电路的软开关实现过程,并给出了电路模型和关键元件的设计参数。
DSP的开发所需要的仿真环境是开发DSP系统所必需的,文中详细介绍了DSP的开发环境CCS使用。系统软件采用C语言编程,以模块化方法设计。文中详细介绍了主程序、中断服务程序以及子程序的功能和结构。
此外,进行了硬件和软件两个方面的多种抗干扰设计,显著的提高了系统的可靠性。
最后,论文对PI控制进行了仿真,比较了增加PI调节器与不加PI调节器条件下系统的响应速度和动态参数的变化。结果表明,智能控制技术在全桥软开关弧焊电源中可以起到关键作用并取得良好的控制效果。
The development of welding process research, welding automation and flexible welding manufacture system has raised an ever-increasing requirement for precision and the flexible control of the welding power source. According to the characteristics of digital signal processing, the digitalization of welding inverter and its future development on the basis of DSP's basic characteristics are introduced. Firstly, the development, control principle, characteristics and chip selection of DSP are introduced in the paper. The paper focuses on component part of digital pulse MIG welding inverter power. Main circuit, control circuit, pulse width modulation (PWM) circuit, drive circuit and wire feeding circuit are respectively analyzed. Furthermore, the software and hardware aspects are also addressed.
This paper researches the main circuit of the full bridge high power soft-switching. Nowadays, welding machines usually use the hard-switching, which causes the problems of higher energy loss and lower efficiency. The problem is much more critical when the inverter frequency is high. In a welding machine, the main circuit with the technology of the soft-switching is much more ideal than the hard-switching. By the theory of the soft-switching, with the help of the simulation software MATLAB/SIMULINK, this paper analyzes the main circuit of the full bridge shift-phased zero voltage zero current(ZVZCS) soft-switching. Then, the paper gives the on and off theory of the soft-switching, the model of the main circuit, key point and the parameters of the design.
The circumstance of simulation is necessary for designing DSP system. The paper illuminates DSP develop circumstance CCS2.0. The System software is coded with assemble language and designed by Modular approach. This paper introduces the main program, interrupt service procedures and routines of the function and structure in detail.
Besides, a variety of anti-interference designs about both hardware and software are accomplished, so reliability of system is increased prominently.
Finally, simulations are done for the PI control method. Comparing the change of response speed with dynamic parameters through increasing PI regulator and without it .That shows the technology of intelligent control plays a key role in the full bridge soft-switching power, and the system has good control efficiency.
引文
[1]赵家瑞.逆变焊接与切割电源[M].机械工业出版社,1995.
[2]殷树言,陈树君,刘嘉,黄鹏飞,王冬平.逆变焊接技术的现状与发展[J].焊接技术,2002,31(SO):P29-32.
[3]刘嘉,卢振洋,殷树言,丁京柱.电焊机的数字化[J].焊接学报,2002,23(2):P88-92.
[4]李鹤岐,徐德进,李芳.脉冲MIG焊机数字化控制设计[J].电焊机,2002,32(8):P1.4.
[5]黄石生.弧焊电源及其数字化控制[M].机械工业出版社,2007.
[6]盖志武,彭涌涛,焦树人等. PWM弧焊逆变电源的MATLAB仿真研究[J].电焊机,2003(1):25.27.
[7]周志军.软开关电源设计与仿真研究[D].武汉大学硕士学位论文,2004.
[8] Guocheng Chen,Chunyu Xu,Chengbo Sun. Locus of Flux Linkage for Three-Phase ZVS Inverter[J]. Journal of Shanghai University,2005,9(6):522527.
[9] Chenfu Fang,Shuyan Yin,Runshi Hou. ZVS of Arc Welding Inverter in Light Load[J]. China Welding,2005,14(2):117120.
[10] Keqing Qu,Guocheng Chen,Cheng Sun. Current Polarity Detection and Current Compensation Strategy for PAC Based Three-Phase ZVS PWM Converter[J]. Journal of Shanghai University,2005,9(6):539543.
[11] Linquan Zhou,Xinbo Ruan. Zero-current and Zero-voltage Switching PWM Boost Full-bodge Converter[J]. Transaction of Nanjing University of Aeronautics & Astronautics,2003,20(1): 6066.
[12]黄石生编著.新型弧焊电源即其智能控制[M].北京:机械工业出版社,2000.
[13] Ushio Masao,Sugitani Yuji,Tanaka Manabu. Recent Development of High Efficiency Arc Welding Systems in Japan[J]. Journal of Lanzhou University of Technology,2005,31(3):2531.
[14] Jianping He,Chunbo Zhang,Guang Sun. Research on Menu-typed Man-machine Interaction System of Digital TIG Welding Machine[J]. China Welding,2004,13(2):128131.
[15] Xueming Hua,Yixiong Wu,Yong Zhang. Digital Controlling for GMA Welding Machine Based on DSP[J]. China Welding,2003,12(2):15861.
[16] Jian Gao,Jie Chen. Novel Multiple Function High-Speed Low-Power Multiply-Accumulate Unit for DSP Processor[J]. Journal of Electron Devices,2006,9(1):48~52.
[17] Yu Luo,De-an Deng,Xiaoling Jiang. Prediction of Welding Residual Stress in 2.25Cr-1Mo Steel Pipe[J]. Journal of Shanghai Jiaotong University,2006,11(1):7783.
[18] Guangjun Zhang,Shanben Chen,Zheng Geng. Sutton welding power source-used in intelligentcontrol system for weld pool shape in pulsed GTAW[J].China Welding,2001,10(2):111.115.
[19]倪倩,齐铂金,赵晶等.软开关全桥PWM主电路拓扑机构在逆变焊接电源中的应用[J].自动化与仪表,2002,12(1):4043.
[20]李鹤歧,高忠林,王睿等.数字化控制逆变焊接电源系统研究[J].电焊机,2004,34(12): 11.14.
[21]何建萍,张春波,吴毅雄等.数字化焊接电源系统特征及分析[J].焊接技术,2003,32(6):2.4.
[22]许小静,张勇,胡双平等.基于DSP的软开关点焊逆变电源控制系统硬件设计[J].电焊机,2004,34(12):2224.
[23]李春旭,路广,李虹等.基于DSP的全数字化IGBT逆变脉冲MIG/MAG焊机研制(一)——硬件电路设计[J].电焊机,2004,34(12):1518.
[24]章云,谢莉萍,熊红艳. DSP控制器及其应用[M].北京:机械工业出版社,2002.
[25]刘和平,严利平,张学锋,卓清锋. TMS320LF240xDSP结构、原理及应用[M].北京:北京航空航天大学出版社,2002.
[26]李哲英,骆丽,刘元盛. DSP基础理论与应用技术[M].北京航空航天大学出版社,2002.
[27]朱铭错,赵勇,甘泉. DSP应用系统设计[M].北京:电子工业出版社,2002.
[28] TMS320F24X高速数字信号处理器原理及应用[M].北京:北京闻亭科技发展有限责任公司,2002.
[29] Texas Instruments. TMS320C2xx User's Guide[M]. Literature Number: SPRU127B,1997.
[30]李芳.全数字IGBT逆变脉冲MIG/MAG焊接电源的研制[D].兰州理工大学,2004.
[31] Texas Instruments. TMS320F/24x DSP Controllers CPU and Instruction Set[M],2003.
[32] Texas Instruments. TMS320F/24x DSP Controllers System and Peripherals[M],2003.
[33]江思敏. TMS320LF240x DSP硬件开发教程[M].北京:机械工业出版社,2003.
[34] Texas Instruments. TMS320LF2407A , TMS320LF2406A , TMS320LF2403A ,TMS320LF2402A.
[35] Texas Instruments. TMS320LC2406A,TMS320LC2404A,TMS320LC2402A DSP Controllers. 2003,Literature Number,sprs145i.
[36]王庆田.软开关数字化焊接电源[D].哈尔滨工业大学硕士学位论文,2006.
[37]康劲松,郎玉峰,陶生贵. IGBT集成驱动模块的应用研究[J].电工技术杂志,2000(5):P36-38.
[38]华伟. IGBT驱动及短路保护电路M57959L[J].研究电力电子技术,1998,2(2):P88-91.
[39]李鹤岐,李春旭,高忠林,王睿.基于DSP- MCU实现焊接电源系统数字化控制的设计[J].焊接学报,2005.26(3):P17-18.
[40]董雅倩.基于DSP逆变直流焊机控制系统的研究[D].青岛大学硕士学位论文,2006.
[41]杨强.基于DSPTMS320LF2407控制的静电除尘三相电源[D].北京交通大学硕士学位论文,2007.
[42]田坤.波形控制CO2逆变焊机系统设计[D].兰州理工大学硕十学位论文,2004.
[43]宋东风.基于DSP的MIG焊弧长模糊控制的研究[D].天津大学学位硕士论文,2006.
[44]华学明,焦馥杰,吴毅雄,张勇.数字信号处理器控制焊接电源的抗干扰设计[J].电焊机,2002,32(9):P27-29.
[45]陈群阳,戴曙光,穆平安,黄杨晖. DSP系统抗干扰技术的研究[J].仪表技术,2004,4:P60-61.
[46]韩安太,刘峙飞,黄海. DSP控制器原理及其在运动控制系统中的应用[M].清华大学出版社,2003:28-31.
[47]尹勇,欧光军,关荣锋等编著. DSP集成开发环境CCS开发指南[M].北京航天航空大学出版社,2003.
[48]彭启踪,管庆等编著. DSP集成开发环境[M].电子工业出版社,2004,P8-10.
[49] Texas Instruments. TMS320C1x/C2x/C2xx/CSx Assembly Language Tools User's Guide[M]. Literature Number:SPRU018D,1995.
[50] ] Texas Instruments. TMS320C2xx/C24x Code Composer User's Guide[M]. Literature Number:SPRU490, 2000.
[51]李韬.全桥软开关智能控制电源的研究[D].湖南大学硕士学位论文,2007.
[52]卢亚静.基于DSP的脉冲焊数字控制系统的研究[D].天津大学硕士学位论文,2005.
[53]陶永华.新型PID控制及其应用(第2版)[M].北京:机械工业出版社,2003.2.
[54]薛令河.基于TMS320F2812 DSP的C02焊波形控制系统研究[D].北京工业大学工学硕士学位论文,2006.
[55]刘光武,刘东,姚志成.单片系统实用抗干扰技术[M].北京人民邮电出版社.2004.
[56]李吉.单片机应用技术选编[M].北京:北京航天航空大学出版社,1992.
[57]陈树君,殷树言,冯雷等.软开关弧焊逆变电源的计算机仿真与试验研究[J].焊接技术,1999,SO:26-29
[58]盖志武,李东升,马岩等.逆变式焊条电弧焊电源的SIMULINK仿真[J].焊接学报,2002 Vol. 23. No. 5:31.34
[59]任平平,王清,吴林.计算机仿真技术在逆变焊接电源中的应用[J].焊接,2002,Vol23.No.1:14~18.
[60]陈桂明,张明照,戚红雨等.应用MATLAB建模与仿真[M].北京:中国科学出版社,2001.
[61] Shujun Chen,Jun Wang,Pengfei Huang. Simulaion and Experimentation of the Arc Welding Inverter Using the Soft Switching Technique[J]. Chinese Journal of Mechanical Engineering. 2004,17(1):8284.
[62] S.J. Chen,S.Y Yin,L. Feng. Computerized Simulation and Experiment Research on Soft-switching Arc Welding Inverter Power Source[J]. ACTA Metellurgica Etallurgica. 2000,13(1):128-132.
[2]殷树言,陈树君,刘嘉,黄鹏飞,王冬平.逆变焊接技术的现状与发展[J].焊接技术,2002,31(SO):P29-32.
[3]刘嘉,卢振洋,殷树言,丁京柱.电焊机的数字化[J].焊接学报,2002,23(2):P88-92.
[4]李鹤岐,徐德进,李芳.脉冲MIG焊机数字化控制设计[J].电焊机,2002,32(8):P1.4.
[5]黄石生.弧焊电源及其数字化控制[M].机械工业出版社,2007.
[6]盖志武,彭涌涛,焦树人等. PWM弧焊逆变电源的MATLAB仿真研究[J].电焊机,2003(1):25.27.
[7]周志军.软开关电源设计与仿真研究[D].武汉大学硕士学位论文,2004.
[8] Guocheng Chen,Chunyu Xu,Chengbo Sun. Locus of Flux Linkage for Three-Phase ZVS Inverter[J]. Journal of Shanghai University,2005,9(6):522527.
[9] Chenfu Fang,Shuyan Yin,Runshi Hou. ZVS of Arc Welding Inverter in Light Load[J]. China Welding,2005,14(2):117120.
[10] Keqing Qu,Guocheng Chen,Cheng Sun. Current Polarity Detection and Current Compensation Strategy for PAC Based Three-Phase ZVS PWM Converter[J]. Journal of Shanghai University,2005,9(6):539543.
[11] Linquan Zhou,Xinbo Ruan. Zero-current and Zero-voltage Switching PWM Boost Full-bodge Converter[J]. Transaction of Nanjing University of Aeronautics & Astronautics,2003,20(1): 6066.
[12]黄石生编著.新型弧焊电源即其智能控制[M].北京:机械工业出版社,2000.
[13] Ushio Masao,Sugitani Yuji,Tanaka Manabu. Recent Development of High Efficiency Arc Welding Systems in Japan[J]. Journal of Lanzhou University of Technology,2005,31(3):2531.
[14] Jianping He,Chunbo Zhang,Guang Sun. Research on Menu-typed Man-machine Interaction System of Digital TIG Welding Machine[J]. China Welding,2004,13(2):128131.
[15] Xueming Hua,Yixiong Wu,Yong Zhang. Digital Controlling for GMA Welding Machine Based on DSP[J]. China Welding,2003,12(2):15861.
[16] Jian Gao,Jie Chen. Novel Multiple Function High-Speed Low-Power Multiply-Accumulate Unit for DSP Processor[J]. Journal of Electron Devices,2006,9(1):48~52.
[17] Yu Luo,De-an Deng,Xiaoling Jiang. Prediction of Welding Residual Stress in 2.25Cr-1Mo Steel Pipe[J]. Journal of Shanghai Jiaotong University,2006,11(1):7783.
[18] Guangjun Zhang,Shanben Chen,Zheng Geng. Sutton welding power source-used in intelligentcontrol system for weld pool shape in pulsed GTAW[J].China Welding,2001,10(2):111.115.
[19]倪倩,齐铂金,赵晶等.软开关全桥PWM主电路拓扑机构在逆变焊接电源中的应用[J].自动化与仪表,2002,12(1):4043.
[20]李鹤歧,高忠林,王睿等.数字化控制逆变焊接电源系统研究[J].电焊机,2004,34(12): 11.14.
[21]何建萍,张春波,吴毅雄等.数字化焊接电源系统特征及分析[J].焊接技术,2003,32(6):2.4.
[22]许小静,张勇,胡双平等.基于DSP的软开关点焊逆变电源控制系统硬件设计[J].电焊机,2004,34(12):2224.
[23]李春旭,路广,李虹等.基于DSP的全数字化IGBT逆变脉冲MIG/MAG焊机研制(一)——硬件电路设计[J].电焊机,2004,34(12):1518.
[24]章云,谢莉萍,熊红艳. DSP控制器及其应用[M].北京:机械工业出版社,2002.
[25]刘和平,严利平,张学锋,卓清锋. TMS320LF240xDSP结构、原理及应用[M].北京:北京航空航天大学出版社,2002.
[26]李哲英,骆丽,刘元盛. DSP基础理论与应用技术[M].北京航空航天大学出版社,2002.
[27]朱铭错,赵勇,甘泉. DSP应用系统设计[M].北京:电子工业出版社,2002.
[28] TMS320F24X高速数字信号处理器原理及应用[M].北京:北京闻亭科技发展有限责任公司,2002.
[29] Texas Instruments. TMS320C2xx User's Guide[M]. Literature Number: SPRU127B,1997.
[30]李芳.全数字IGBT逆变脉冲MIG/MAG焊接电源的研制[D].兰州理工大学,2004.
[31] Texas Instruments. TMS320F/24x DSP Controllers CPU and Instruction Set[M],2003.
[32] Texas Instruments. TMS320F/24x DSP Controllers System and Peripherals[M],2003.
[33]江思敏. TMS320LF240x DSP硬件开发教程[M].北京:机械工业出版社,2003.
[34] Texas Instruments. TMS320LF2407A , TMS320LF2406A , TMS320LF2403A ,TMS320LF2402A.
[35] Texas Instruments. TMS320LC2406A,TMS320LC2404A,TMS320LC2402A DSP Controllers. 2003,Literature Number,sprs145i.
[36]王庆田.软开关数字化焊接电源[D].哈尔滨工业大学硕士学位论文,2006.
[37]康劲松,郎玉峰,陶生贵. IGBT集成驱动模块的应用研究[J].电工技术杂志,2000(5):P36-38.
[38]华伟. IGBT驱动及短路保护电路M57959L[J].研究电力电子技术,1998,2(2):P88-91.
[39]李鹤岐,李春旭,高忠林,王睿.基于DSP- MCU实现焊接电源系统数字化控制的设计[J].焊接学报,2005.26(3):P17-18.
[40]董雅倩.基于DSP逆变直流焊机控制系统的研究[D].青岛大学硕士学位论文,2006.
[41]杨强.基于DSPTMS320LF2407控制的静电除尘三相电源[D].北京交通大学硕士学位论文,2007.
[42]田坤.波形控制CO2逆变焊机系统设计[D].兰州理工大学硕十学位论文,2004.
[43]宋东风.基于DSP的MIG焊弧长模糊控制的研究[D].天津大学学位硕士论文,2006.
[44]华学明,焦馥杰,吴毅雄,张勇.数字信号处理器控制焊接电源的抗干扰设计[J].电焊机,2002,32(9):P27-29.
[45]陈群阳,戴曙光,穆平安,黄杨晖. DSP系统抗干扰技术的研究[J].仪表技术,2004,4:P60-61.
[46]韩安太,刘峙飞,黄海. DSP控制器原理及其在运动控制系统中的应用[M].清华大学出版社,2003:28-31.
[47]尹勇,欧光军,关荣锋等编著. DSP集成开发环境CCS开发指南[M].北京航天航空大学出版社,2003.
[48]彭启踪,管庆等编著. DSP集成开发环境[M].电子工业出版社,2004,P8-10.
[49] Texas Instruments. TMS320C1x/C2x/C2xx/CSx Assembly Language Tools User's Guide[M]. Literature Number:SPRU018D,1995.
[50] ] Texas Instruments. TMS320C2xx/C24x Code Composer User's Guide[M]. Literature Number:SPRU490, 2000.
[51]李韬.全桥软开关智能控制电源的研究[D].湖南大学硕士学位论文,2007.
[52]卢亚静.基于DSP的脉冲焊数字控制系统的研究[D].天津大学硕士学位论文,2005.
[53]陶永华.新型PID控制及其应用(第2版)[M].北京:机械工业出版社,2003.2.
[54]薛令河.基于TMS320F2812 DSP的C02焊波形控制系统研究[D].北京工业大学工学硕士学位论文,2006.
[55]刘光武,刘东,姚志成.单片系统实用抗干扰技术[M].北京人民邮电出版社.2004.
[56]李吉.单片机应用技术选编[M].北京:北京航天航空大学出版社,1992.
[57]陈树君,殷树言,冯雷等.软开关弧焊逆变电源的计算机仿真与试验研究[J].焊接技术,1999,SO:26-29
[58]盖志武,李东升,马岩等.逆变式焊条电弧焊电源的SIMULINK仿真[J].焊接学报,2002 Vol. 23. No. 5:31.34
[59]任平平,王清,吴林.计算机仿真技术在逆变焊接电源中的应用[J].焊接,2002,Vol23.No.1:14~18.
[60]陈桂明,张明照,戚红雨等.应用MATLAB建模与仿真[M].北京:中国科学出版社,2001.
[61] Shujun Chen,Jun Wang,Pengfei Huang. Simulaion and Experimentation of the Arc Welding Inverter Using the Soft Switching Technique[J]. Chinese Journal of Mechanical Engineering. 2004,17(1):8284.
[62] S.J. Chen,S.Y Yin,L. Feng. Computerized Simulation and Experiment Research on Soft-switching Arc Welding Inverter Power Source[J]. ACTA Metellurgica Etallurgica. 2000,13(1):128-132.