CN101249582A - Complete digital PWM controlled AC pulse MIG welding system - Google Patents

Complete digital PWM controlled AC pulse MIG welding system Download PDF

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Publication number
CN101249582A
CN101249582A CNA2008101028916A CN200810102891A CN101249582A CN 101249582 A CN101249582 A CN 101249582A CN A2008101028916 A CNA2008101028916 A CN A2008101028916A CN 200810102891 A CN200810102891 A CN 200810102891A CN 101249582 A CN101249582 A CN 101249582A
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circuit
control
welding
signal
cpld
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卢振洋
黄鹏飞
曾军辉
马琳
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Beijing University of Technology
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Beijing University of Technology
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Abstract

The invention relates to a full-digital PWM-controlled AC pulse MIG welding system, which belongs to the field of welding equipment and automation. The full-digital PWM-controlled AC pulse MIG welding system comprises a main circuit and a control circuit, wherein the control circuit comprises a kernel control section, a control execution section, etc. The kernel control section comprises a DSP system, a current sampling and filtering circuit, a voltage sampling and filtering circuit, a CPLD system and a protection circuit. The DSP system is respectively connected with the CPLD system, a welding parameter setting signal and a welding parameter display signal in a front panel input and display section, a welding torch switch signal in a wire feeding system, a valve switch quantity signal and a wire feeding setting signal, and the CPLD system is also connected with the protection circuit and a primary inversion drive circuit in the control execution section. By combining the DSP system and the CPLD system, the welding system can achieve full-numerical control, which has flexible control and accurate control in comparison with the analog control manner of D/A+SG3526.

Description

A kind of AC pulse MIG welding system of complete digital PWM control
Technical field
The present invention relates to a kind of AC pulse MIG welding system of complete digital PWM control, belong to welding equipment and automatic field.
Background technology
Exchanging the MIG weldering is a kind of new welding method that occurs the nineties in 20th century, and key problem in technology is to adopt which type of electric current output mode, how to realize the control to welding current, thereby controls the fusion penetration of droplet transfer, weld seam, the shaping of weld seam effectively.Tsing-Hua University's research early at home exchanges the MIG weldering, and it adopts the current waveform of a kind of being called as " double concave ", has from the stabilising arc function when electric arc reversal.
The characteristics of this AC pulse MIG weldering are, have adopted from the stabilising arc measure, need not increase arc stabilizer in addition, but during pulse current reverse, increased the burden of switching tube; Two pulses are all arranged in EN, EP polarity, easily cause a plurality of droplet transfers, be difficult to the accurate control of realization the droplet transfer.
Beijing University of Technology adopts single-chip microcomputer 80C196KC to be the control core in earlier stage, succeed in developing AC PMIG welding machine, it is to use Single-chip Controlling, data-handling capacity is limited, and available IO interface is not abundant, and PWM realizes with the DA+SG3526 mode of simulation, the mode of this simulation control realizes, intrinsic shortcoming is arranged: 1. circuit complexity, poor reliability, cost height; 2. the PWM frequency is by the decision of RC value, and electric capacity on the market and resistance precision are not high, causes the pwm signal frequency to be difficult to realize accurately control; 3. SG3526 produces triangular wave and is easy to vibration, further causes the instability of pwm signal.4. the digital-to-analogue conversion time of DAC7625 is 10us to the maximum, produces pwm signal frequency limited system for this reason.Also there is certain problem in the stability of this equipment, and the amplitude of EN polarity, EP polarity background current is identical, can not regulate separately, and the adjusting of welding parameter is very inconvenient, and the function of system is imperfection also, awaits further research and raising.
Summary of the invention
The objective of the invention is to overcome the above-mentioned deficiency of existing AC pulse MIG welding control system, proposed a kind of AC pulse MIG welding system of complete digital PWM control, this system has following advantage:
1) master controller adopts DSP to realize controlling function, his fast operation, and data-handling capacity is strong, and the IO mouth is abundant, can finish in real time accurately control.
2) adopt CPLD to realize Digital PWM, replace the PWM mode of original DA+SG3526, control is flexible, and antijamming capability is strong.
To achieve these goals, the present invention has taked following technical scheme.Include main circuit 1 and control circuit 2; Main circuit 1 includes current rectifying and wave filtering circuit 1.1, inverter circuit 1.2, secondary rectification circuit 1.3, secondary inverter circuit 1.4, arc energy output 1.5 and a high pressure arc static circuit 1.6; Control circuit 2 includes core control section A, control operating part B, front panel input and display part C and wire feed system D; Wherein, wire feed system includes arc welding gun switch signal D1, air valve switch amount signal D3, the given signal D2 of wire feed and wire-feed motor alignment circuit D4; Front panel input and display part C include the given C1 of welding parameter and welding parameter shows C2, control operating part B includes inverse changing driving circuit B1, a secondary inverse changing driving circuit B2 and stabilising arc drive circuit B3, inverse changing driving circuit B1 links to each other with a inversion 1.2 in the main circuit 1, secondary inverse changing driving circuit B2 links to each other with secondary inversion 1.4 in the main circuit 1, and stabilising arc drive circuit B3 links to each other with high pressure arc static circuit 1.6 in the main circuit 1; It is characterized in that: described core control section A includes dsp system A3, current sample and filter circuit A1, voltage and sampling filter circuit A2, the A5 of CPLD system and holding circuit A4; Current sample and filter circuit A1 link to each other with dsp system A3 with the end of voltage and sampling filter circuit A2, and the other end links to each other with LEM piece in the main circuit 1; Dsp system A3 respectively with input of the A4 of CPLD system, front panel and display part C in the given C1 of welding parameter, welding parameter show that arc welding gun switch signal D1, air valve switch amount signal D3 among C2, the wire feed system D link to each other with the given signal D2 of wire feed; the CPLD system also links to each other with an inverse changing driving circuit B1 among the control operating part B with holding circuit A4, and an inverse changing driving circuit B1 reception is from the Digital PWM signal of the A5 of CPLD system.
Compared with prior art, the present invention has the following advantages:
1) welding process is controlled in real time, process stabilization is reliable, does not almost have to splash, and arc stability is strong.Because the inventive method cooperates dsp system and CPLD system, reaches Digital Control completely, compare mode with the control of D/A+SG3526 simulation in the past, control flexibly, can reach accurate control, real-time is good, splashes so can improve arc stability and welding process is not almost had.
2) whole control is simple, digital-to-analogue conversion in the middle of need not to consider and simulation PWM process, and holding circuit also can be simplified greatly and control flexibly, greatly reduces the complexity and the difficulty of equipment and control method.According to the reality requirement that welding parameter is pre-set, in welding process, can reach accurately control in real time, good in anti-interference performance.
3) applied range; Can be applied to the welding of thin plate aluminium alloy, be with a wide range of applications.
Description of drawings
Fig. 1 welding system structure composition diagram
Fig. 2 AC pulse MIG weldering Current Waveform Control figure
Fig. 3 dsp system main program software scenario figure
The main program software scenario figure of Fig. 4 CPLD system
Fig. 5 digital dock frequency division program flow diagram
The synchronous shaping filter program flow diagram of Fig. 6
The specific embodiment
To describe present embodiment in conjunction with the accompanying drawings now.(embodiment carries out the welding of butt weld at the thick 3A21 aluminium alloy plate of 1mm)
The design philosophy of present embodiment is: dsp system and CPLD system are cooperated, require pre-designed weldingvoltage, current waveform according to actual welding, just configure voltage, electric current is given, adopt the pi computing of segmentation, make electric current, the voltage parameter of welding process follow preset parameters, in conjunction with special control method, realize stable welding process.Wherein two systems are cooperated core, i.e. Digital Control for present embodiment.
As shown in Figure 1, present embodiment comprises two parts: main circuit 1 and control circuit 2.Present embodiment includes main circuit part 1 and control circuit part 2.Main circuit 1 comprises current rectifying and wave filtering circuit 1.1, inverter circuit 1.2, secondary rectification 1.3, secondary inverter circuit 1.4, arc energy output 1.5 and a high pressure stabilising arc 1.6 again.Control circuit 2 mainly comprises core control section A, control operating part B, front panel input and display part C, wire feed system part D.Wherein, core control section A includes DSP control system A3 and coupled current sample and filter circuit A1, voltage and sampling filter circuit A2, and the other end of current sample and filter circuit A1, voltage and sampling filter circuit A2 is connected on the LEM piece of main circuit.The control operating part comprises inverse changing driving circuit B1, a secondary inverse changing driving circuit B2, stabilising arc drive circuit B3; An inverse changing driving circuit B1 reception is from the Digital PWM signal of CPLD, inverter circuit 1.2 of output control main circuit, secondary inverse changing driving circuit B2 receives the IO signal from DSP control system A3, output control secondary inversion 1.4, stabilising arc drive circuit B3 receives the IO signal from A3, output control arc static circuit.Before the welding beginning, DSP control system A3 receives the welding parameter from panel C1, and shows welding parameter C2 in welding process; Wire feed system comprises arc welding gun switch signal D1, given signal D2 of air valve switch amount signal D3 and wire feed and wire-feed motor alignment circuit D4.
Welding system comprises main circuit 1 and is control core circuit part 2 with TMS320F2812DSP+EPM7128CPLD.The main circuit input voltage is three-phase 380V; Input rectifying 1.1 adopts Fuji's rectifier bridge rectification, and model is FUJ 6RI100G-160; Inverter circuit 1.2 adopts the semi-bridge inversion structure, and the IGBT that is BSM150GB120DN2 by two models forms.The control system A3 that control circuit part 2 adopts based on TMS320F2812DSP; mainly finish calculation of parameter, proportional integral adjusting (PI) adjusting, SECO; and can communicate by letter with the panel Display Realization; adopt EPM7128 (A5) to realize the digital PWM signal of two-way mutual deviation 180 degree phase places; pwm signal is closed in realization overcurrent, overvoltage protection and overtemperature protection, realizes simultaneously the input signal of CPLD is carried out digital filtering.Below in conjunction with accompanying drawing it is elaborated.
Its job order is: after three-phase input 380V alternating current at first partly carries out rectifying and wave-filtering through 1.1 input rectifyings, become the direct current of 540V.After this become the alternating current of 20KHZ after this direct current is isolated through the step-down of (this is by 2 controls of control circuit part) inversion of 1.2 inverter circuits and intermediate-frequency transformer, then through becoming the used big current low voltage direct current of welding behind the 1.3 output rectifying and wave-filterings, secondary inversion by 1.4, supply with the output of 1.5 bonding powers, owing to be that the AC pulse MIG weldering is used and the welding of thin plate aluminium, there is cold cathode current over-zero problem, so the arc static circuit 1.6 that will add high pressure adopts full-bridge circuit here.Because the operating frequency of above circuit is 20KHZ, outputting inductance also very little (about 30 μ H) is adjusted the control that inverse switch frequency or pulsewidth can reach the microsecond level simultaneously, so the type power supply reaction speed is fast, dynamic property is good.
The composition and the function of welding system control circuit part 2 are respectively:
Core control section A mainly is made up of TMS320F2812DSP, comprises three importations.First importation be after inversion constant current control through the sample rate current of rectification 1.3 outputs and from electric arc two ends sampled voltage, the current sample of input and the signal of filtering A1 and voltage sample and filtering A2 are to obtain the real-time weldingvoltage current value of welding, wherein current sample and filtering A1 adopt the actual current value in the reflow termination process because PI controls (proportional plus integral control), adjust current deviation in real time, realize reaching closed-loop control; The actual voltage value that voltage sample and filtering A2 adopt in the reflow termination process is used for the arc length adjusting, can also reach the purpose of monitoring welded condition.Second importation is the arc welding gun switch signal D1 that obtains from part D.The 3rd importation derives from the input of front panel and the welding parameter of display part C presets C1, obtains the welding initial parameter.Part A is mainly finished the response of welding parameters input and external signal as the core control section, and handles, calculates and change the back B, C, D three parts are controlled through software, makes whole welding system co-ordination, finishes predetermined welding purpose.
Control operating part B, it is input as the Digital PWM part A 5 of core control section A, is input to IGBT drive circuit B1 after the pulsewidth modulation of CPLD software PWM, is input to inverter circuit 1.2 after treatment, finishes this control function.
Front panel input and display part C are peripheral unit control and operating part.Welding parameter presets C1 to core control section A input, realizes the setting of welding parameter, and shows that by welding parameter C2 shows.When welding, core control section A output welding current and voltage show C2 to welding parameter, make its energy real-time monitored welding parameter.
Wire feed system D is carrying out and is deriving from the input of arc welding gun switch D1 to part A, and part A is to the output of air valve D3 control, and the given dsp system A3 that gives of the wire feed rate of welding parameter C1 changes DSP and carries PWM output, and reaches the given D2 purpose of control wire feed.
Present embodiment has adopted the higher dsp chip TMS320F2812 of clock frequency, as VP PMIG welding control system core, finish when electric arc reversal, keep constant-current source current amplitude after the inversion, secondary inversion switching instant, stabilising arc pulse application time synchronously; Detect arc voltage in the welding process in real time, the arc length of electric arc is regulated, keep arc length stable; Lot of data is handled and is calculated in the control procedure.
Programme-control of the present invention divides two parts: programme-control of welding process dsp system and Digital PWM control are elaborated respectively below.
The programme-control of welding process dsp system is elaborated to this example with reference to program flow diagram:
VP PMIG weldering control system adopts software programming to realize control, both can reduce the complexity of hardware system, can strengthen the Flexible Control of system again.Thereby the software programming of Control Welding Process is the core that realizes thin plate aluminum alloy VP PMIG weldering.
Software section is made up of following components: main program, system initialization routine, keyboard scan program, sampling routine, PI regulate calculation procedure, striking program, welding procedure, short circuit removing program, current interruption ignite again program, receive arc program etc., the Control Welding Process main program flow is seen accompanying drawing 3.The concrete execution sequence of its main program is: behind the electrification reset, program brings into operation from initial address, and system carries out initialization subroutine earlier, finishes the initial value of each welding parameter and sets.Carry out the keyboard scan program then, preset wire feed rate V, EP polar impulse electric current I p, EP polar impulse current time T p, EP polarity base value electric current I B1, EP polarity base value current time T B1, EP polarity base value electric current I B2, EP polarity base value current time T B2, EN polarity base value electric current I En, welding parameter such as EN ratio is used for Control Welding Process, through display subroutine relevant parameter is set then to show.Judge then whether the welding switch is opened, and is then to open air valve D3, after a period of time in dsp system A3 a given little given D2 of wire feed rate control wire feed.Start timing sampling program and digital filter program then, enter each stage of welding, be introduced into big electric current and add the direct current striking stage, carry out corresponding PI algorithm, judge whether striking is successful, if striking success then enter welding procedure, welding procedure divides between base value time and time to peak and EN polarity chron in the different phase of welding, carry out different PI control, up to detecting the welding end signal, then implementation is closed pulsewidth modulation, disable motor after receiving the arc program, withdraws from welded condition.
In whole welding process; adopt digitized PWM control; different phase in welding; dsp system A3 gives the A5 of CPLD system the transfer of data through the PI computing; in the CPLD system, produce digitized PWM; and give an inverse changing driving circuit B1 according to the corresponding output pwm signal of the state of holding circuit A4, reach the constant current control of an inversion.
VP PMIG source of welding current major parameter recited above and parameter adjustable range are as follows:
Input voltage: 380V;
Output rated welding current: 400A;
EP polar impulse electric current I pAdjustable range: 100-400A;
EP polar impulse current time T pAdjustable range: 0-5ms;
EP polarity base value electric current I B1Adjustable range: 20-100A;
EP polarity base value current time T B1Adjustable range: 0-100ms;
EP polarity base value electric current I B2Adjustable range: 20-100A;
EP polarity base value current time T B2Adjustable range: 0-10ms;
EN polarity base value electric current I EnAdjustable range: 20-100A;
EN rate regulation scope: 0-50%;
Wire feed rate adjustable range: 1-10m/min;
Pulse current frequency adjustable range: 10-100Hz;
High pressure stabilising arc electric power output voltage scope: 300-400V.
The Digital PWM programme-control is elaborated to this example with reference to program flow diagram:
Software systems mainly comprise digital PWM program, clock division program, digital filter program and PWM defence program.
After system powered on, CPLD finished system initialization, in the welding various process, CPLD calls DSP through the data behind the PI, call the clock division program, the high frequency input clock signal is transformed into the low frequency clock signal, for the digital PWM defence program provides clock signal; Call the PWM defence program, detect holding circuit A4 state, call number PWM program realizes that input data signal converts the pwm signal that the two-way dutycycle is regulated in real time linearly to.The frequency of pwm signal can be regulated by the frequency that changes input clock signal; The call number filter on the one hand, can be eliminated the high frequency components signal in the input data signal; On the other hand, can eliminate the burr signal that produces because of the circuit competition in the PWM output signal; Produce the reliable pwm signal in the band dead band of two-way complementation thus, remove to control inverse changing driving circuit B1 one time.The circulation said process is returned in output then.
The input clock 12MHz of system of EPM7128 control circuit, the clock frequency that needs in the digital protection circuit program is smaller, need carry out the frequency division design to system clock.The frequency dividing circuit program flow diagram is seen Fig. 5, and this program is the example of one 5 frequency division, and process is for detecting the rising edge clock signal of the CPLD A5 of system, counting clock number.When counting puts 1 less than 3 time outputs, when counting 3 between 5 the time, output puts 0, when counting after 5, counter is clear 0, so circulation.
In combinational logic, owing to passed through different time-delays in the input signal path of door, the time that causes arriving this is inconsistent, and there is the branch of priority the time of a certain meeting point in the circuit of reaching, and this cries competition.Competition is inevitable.Because competition has produced burr in the design of digital circuit.Because competition makes circuit output that transient error take place, this has just produced risk.
If the burr in the pwm signal is not eliminated, will cause very serious consequence, may cause inversion 1.2 switching tubes to lead directly to and damage.Present embodiment adopts synchronous shaping to remove burr effectively.Shown in Figure 6, be synchronous shaping filter program flow diagram.
This program is at rising edge clock to the control signal state continuous detecting that will export to an inverse changing driving circuit B1 several times, stores its state then, and the high level number that counting occurs if surpass expection, then is judged to high level, otherwise is judged to low level.
This AC pulse MIG arc welding system pin can be used for the following plate sheet welding of 1mm, comprises the welding of aluminium and aluminium alloy plate.By analyzing the generation condition that realizes one in an arteries and veins, determine the scope of pulse current, voltage and background current, voltage, obtain the stable transition control of one in an arteries and veins.By the distribution rule of research arc energy between EN, EP polarity, aluminum alloy VP PMIG welds the rule that influences of EN rate of change butt welded seam fusion penetration, welding wire melting rate.On the basis of EN rate regulation, by changing the background current of EP, EN polarity, further adjust the distribution of arc energy on welding wire and workpiece, realize more accurate control to the arc heat input quantity.And these accurately realizations of control, need a perfect digitized platform, the present invention has adopted the digitized platform of DSP+CPLD to replace the mode of original simulation control, has improved the control effect on hardware system greatly, has realized accurately the purpose of control in real time.
The above is an example of native system and control method thereof, and we also can carry out some conversion to it.Can adopt full bridge inverter to replace the half-bridge form such as main circuit part, control section replaces TMS320F2812 to realize its function with other DSP or single-chip microcomputer or with CPLD replacement EPM7128 of other model or the like.As long as it is consistent that its system and control thought and the present invention are narrated, all should be considered as the included scope of the present invention.

Claims (1)

1. the AC pulse MIG welding system of a complete digital PWM control includes main circuit (1) and control circuit (2); Main circuit (1) includes current rectifying and wave filtering circuit (1.1), an inverter circuit (1.2), secondary rectification circuit (1.3), secondary inverter circuit (1.4), arc energy output (1.5) and high pressure arc static circuit (1.6); Control circuit (2) includes core control section (A), control operating part (B), front panel input and display part (C) and wire feed system (D); Wherein, wire feed system includes arc welding gun switch signal (D1), air valve switch amount signal (D3), the given signal of wire feed (D2) and wire-feed motor alignment circuit (D4); Front panel input and display part (C) include welding parameter given (C1) and welding parameter shows (C2), control operating part (B) includes an inverse changing driving circuit (B1), secondary inverse changing driving circuit (B2) and stabilising arc drive circuit (B3), an inverse changing driving circuit (B1) links to each other with a inversion (1.2) in the main circuit (1), secondary inverse changing driving circuit (B2) links to each other with secondary inversion (1.4) in the main circuit (1), and stabilising arc drive circuit (B3) links to each other with high pressure arc static circuit (1.6) in the main circuit (1); It is characterized in that: described core control section (A) includes dsp system (A3), current sample and filter circuit (A1), voltage and sampling filter circuit (A2), CPLD system (A5) and holding circuit (A4); One end of current sample and filter circuit (A1) and voltage and sampling filter circuit (A2) links to each other with dsp system (A3), and the other end links to each other with LEM piece in the main circuit (1); Dsp system (A3) respectively with the input of CPLD system (A4), front panel and display part (C) in welding parameter given (C1), welding parameter show that arc welding gun switch signal (D1), air valve switch amount signal (D3) and the given signal of wire feed (D2) in (C2), the wire feed system (D) link to each other; the CPLD system also links to each other with a inverse changing driving circuit (B1) in control operating part (B) with holding circuit (A4), and an inverse changing driving circuit (B1) reception is from the Digital PWM signal of CPLD system (A5).
CNA2008101028916A 2008-03-28 2008-03-28 Complete digital PWM controlled AC pulse MIG welding system Pending CN101249582A (en)

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CN103028815A (en) * 2012-11-29 2013-04-10 北京工业大学 Arc length regulating system of coupling electric arcs and control method of arc length regulating system
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CN103227578A (en) * 2013-04-03 2013-07-31 宁波中博电器有限公司 Low-power inverter circuit
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CN106914682A (en) * 2017-01-19 2017-07-04 上海广为焊接设备有限公司 For the control system and its control method of AC-DC argon arc welding machine
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CN112935474A (en) * 2021-02-03 2021-06-11 上海腾焊智能科技有限公司 Wire feeding device-based control system, welding control method and system
CN114951909A (en) * 2022-05-11 2022-08-30 华南理工大学 Integrated double-wire variable-polarity double-pulse MIG welding power supply system and control method
CN114951909B (en) * 2022-05-11 2023-12-22 华南理工大学 Integrated double-wire polarity-changing double-pulse MIG welding power supply system and control method

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