CN101462197A - High-frequency inversion stud welding equipment and controlling means thereof - Google Patents
High-frequency inversion stud welding equipment and controlling means thereof Download PDFInfo
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- CN101462197A CN101462197A CN 200810216924 CN200810216924A CN101462197A CN 101462197 A CN101462197 A CN 101462197A CN 200810216924 CN200810216924 CN 200810216924 CN 200810216924 A CN200810216924 A CN 200810216924A CN 101462197 A CN101462197 A CN 101462197A
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Abstract
The invention discloses a device for welding a high-frequency inverter stud and a method for controlling the same. The device for welding the high-frequency inverter stud comprises a triphase rectifying circuit, an inversing circuit, a high-frequency transformer, a rectifying and filtering circuit, a DSP controller and a current feedback circuit. The current feedback circuit samples from the output end of the rectifying and filtering circuit, and a sampling value is input to the signal input end of the DSP controller; the inversing circuit comprises an IGNT bridge switching circuit and an isolated drive circuit; and the DSP controller can generate PWM signals, and the on-off of the IGNT bridge switching circuit is controlled by the isolated drive circuit. The invention provides the device for welding the high-frequency inverter stud and the method for controlling the same, and the device has the advantages of small volume and high power of the transformer, relative simple hardware circuit, high control accuracy, long service life of electrical elements, and good reliability and stability.
Description
[technical field]
The present invention relates to welding equipment, relate in particular to a kind of high-frequency inversion stud welding equipment and control method thereof, high-frequency inversion stud welding equipment is used for the welding between hardware and the double-screw bolt, is mainly used at production fields such as automobile, boats and ships, sheet metal manufacturing industry.
[background technology]
Stud welding machine divides three major types, and the one, energy storage stud welding machine, the 2nd, the long period stud welding machine, weld interval, arcing time factor was about 30% at 300-2000mS; The 3rd, the short period stud welding machine, weld interval, arcing time factor was about 10% at 30-200mS, was used for the welding of double-screw bolt usually in automobile, boats and ships, sheet metal manufacturing industry.Commonly used in the market have thyristor controlled arc stud welding machine of power frequency and a three-phase inversion hf electric arc stud welding machine, divides simulation control and MCU to control two kinds by control mode.
Power frequency controllable silicon arc stud welding machine, moves and uses all inconveniently bulky heaviness, and weld interval and Current Control precision are not high, and welding efficiency is low, welding effect is bad.
The high-frequency inversion stud welding machine of domestic production utilizes MCU that welding sequential and switching value are managed, and utilizes pulse width modulating chip that IGBT is controlled.In the hardware circuit that uses pulse width modulating chip, the hardware circuit complexity, welding performance is adjusted inconvenient.Pulse width signal to required width adjustment, so the speed of its adjustment is difficult to grasp and control is easy to produce the high frequency spike IGBT, diode are damaged, has reduced the reliability of complete machine from maximum at work.Because adjusting frequency of the sample frequency of pulse width modulating chip and pwm signal all lower (only having 20000 times/second and 1000 times/second), make that regulating the speed of output current and voltage is slow, the Current Control precision is not high, welding effect is bad, its response speed can not satisfy the requirement of short period stud welding machine, be difficult to realize complicated welding procedure, welding quality can not get guaranteeing.The welding current of the high-frequency inversion stud welding machine of domestic production at present mostly below 1500A, is difficult to meet the needs of production.
[summary of the invention]
The technical problem to be solved in the present invention provides that a kind of hardware circuit is simple relatively, control accuracy is high, the electrical equipment life-span long, the good high-frequency inversion stud welding equipment of reliability and stability of equipment.
The technical problem that the present invention further will solve provides the high-frequency inversion stud welding equipment that a kind of volume is little, output current is big, power output is high.
The present invention also will provide the control method of the good high-frequency inversion stud welding equipment of the reliability and stability of a kind of control accuracy height, equipment.
In order to solve the problems of the technologies described above, the technical solution used in the present invention is, a kind of high-frequency inversion stud welding equipment, comprise rectified three-phase circuit, inverter circuit, high frequency transformer, current rectifying and wave filtering circuit, described rectified three-phase circuit is transformed into direct current with three-phase alternating current, inverter circuit converts the direct current of rectified three-phase circuit output to high-frequency alternating current, after the high frequency transformer step-down, produce the pulsating direct current welding current by current rectifying and wave filtering circuit, comprise the dsp controller and first current feedback circuit, first current feedback circuit is imported sampled value the signal input part of dsp controller from the output sampling of current rectifying and wave filtering circuit; Described inverter circuit comprises IGBT bridge circuit on-off circuit and isolated drive circuit; Described dsp controller produces pwm signal, through the break-make of isolated drive circuit control IGBT bridge circuit on-off circuit.
Above-described high-frequency inversion stud welding equipment comprises first voltage feedback circuit, and described first voltage feedback circuit is imported sampled value respectively the signal input part of dsp controller from the output sampling of current rectifying and wave filtering circuit.
Above-described high-frequency inversion stud welding equipment comprises second current feedback circuit, and described second current feedback circuit is imported sampled value the signal input part of dsp controller from the output sampling of inverter circuit.
Above-described high-frequency inversion stud welding equipment, described rectified three-phase circuit is followed successively by electromagnetic compatibility circuit, three-phase alternating current rectification circuit, soft starting circuit and current rectifying and wave filtering circuit, described electromagnetic compatibility circuit absorbs the due to voltage spikes that suppresses on the three-phase alternating current bus, reduces electromagnetic interference; Described three-phase alternating current rectification circuit is converted to direct current with the three-phase alternating current of electromagnetic compatibility circuit output; Described current rectifying and wave filtering circuit comprises filter capacitor, and the direct current that the three-phase alternating current rectification circuit is exported carries out filtering; Described soft starting circuit control three-phase alternating current rectification circuit output major loop just makes the major loop energising after described filter capacitor charges to busbar voltage.
Above-described high-frequency inversion stud welding equipment, the electromagnetic compatibility circuit is in series with input inductance respectively on the phase line of three-phase electricity, be parallel with peak clipping electric capacity between phase line respectively.
Above-described high-frequency inversion stud welding equipment, described high frequency transformer primary coil and secondary coil replace coiling with the thin copper belt layering, between layer and the layer insulating barrier are arranged; The primary coil layer is 2 layers, and 2 layers of primary coil layer are connected mutually; Every layer of primary coil layer has 2 layers of internal layer secondary wire ring layer and 2 layers of outer secondary wire ring layer; The secondary wire ring layer of internal layer is connected mutually, the current opposite in direction of adjacent layer; Outer field secondary wire ring layer is series connection mutually also, and the sense of current of adjacent layer is also opposite; The serial connection point of secondary coil adjacent layer all connects the centre cap of transformer output, and the end of the same name of each layer of secondary coil also connects, and connects the transformer output.
The control method of high-frequency inversion stud welding equipment of the present invention may further comprise the steps:
701) first current feedback circuit simulation signal that sampling is obtained is delivered to the AD conversion input port of dsp controller, compares the generation current error signal with default welding current value after AD converts current digital signal to;
702) described current error signal generates control signal through digital PI algorithm process then, and the pulsewidth of IGBT is controlled, and realizes constant current output; The formation cycle of described control signal is with the switch periods of IGBT bridge circuit on-off circuit.
The control method of above-described high-frequency inversion stud welding equipment, comprise first voltage feedback circuit, described first voltage feedback circuit is imported the signal input part of dsp controller respectively with sampled value, and be may further comprise the steps from the output sampling of current rectifying and wave filtering circuit:
801) first voltage feedback circuit simulation signal that sampling is obtained is delivered to the AD conversion input port of dsp controller, compares the generation voltage error signal with default welding voltage value after AD converts voltage digital signal to;
802) described voltage error signal generates control signal through digital PI algorithm process then, and the pulsewidth of IGBT is controlled, and realizes constant voltage output; The formation cycle of described control signal is with the switch periods of IGBT bridge circuit on-off circuit.
The control method of above-described high-frequency inversion stud welding equipment may further comprise the steps:
901) obtain power signal from current digital signal and voltage digital signal, compare the generation power error signal with the bonding power value of presetting;
902) described power error signal generates control signal through digital PI algorithm process then, and the pulsewidth of IGBT is controlled, and realizes permanent power output; The formation cycle of described control signal is with the switch periods of IGBT bridge circuit on-off circuit.
The control method of above-described high-frequency inversion stud welding equipment comprises second current feedback circuit, and described second current feedback circuit is imported the signal input part of dsp controller with sampled value, and be may further comprise the steps from the output sampling of inverter circuit:
1001) second voltage feedback circuit simulation signal that sampling is obtained is delivered to the AD conversion input port of dsp controller, compare with default inverter circuit output limit value after AD converts current digital signal to and produce inverter circuit output current error signal, the formation cycle of inverter circuit output current error signal is half of switch periods of IGBT bridge circuit on-off circuit;
1002) after inverter circuit output current error signal superposes with control signal, the pulsewidth of IGBT is controlled the current changing rate and the peak point current of restriction high frequency transformer.
The present invention adopts the DSP control technology that feedback signal is handled, and controls pulse-width signal, directly drives IGBT by DSP through driver module, has simplified hardware circuit, and makes control more flexible; Adjusting frequency of the sample frequency of dsp controller and pwm signal is higher than pulse width modulating chip, improved response speed and control accuracy, hardware circuit of the present invention is simple relatively, control accuracy is high, the electrical equipment life-span long, the reliability and stability of equipment all are improved.
The formation cycle of control signal of the present invention is identical with the switch periods of IGBT bridge circuit on-off circuit, is 25-50 microseconds, and electric current and voltage-controlled response speed height have improved control accuracy, the reliability and stability of equipment.
[description of drawings]
The present invention is further detailed explanation below in conjunction with the drawings and specific embodiments.
Fig. 1 is an embodiment of the invention high-frequency inversion stud welding equipment principle block diagram.
Fig. 2 is the main loop circuit schematic diagram of embodiment of the invention high-frequency inversion stud welding equipment.
Fig. 3 is the double-screw bolt autoloader structure chart of embodiment of the invention high-frequency inversion stud welding equipment
Fig. 4 is the Mathematical Modeling figure of embodiment of the invention high-frequency inversion stud welding equipment feedback control loop.
Fig. 5 embodiment of the invention high-frequency inversion stud welding equipment PI software program flow chart.
Fig. 6-the 1st, embodiment of the invention high-frequency inversion stud welding equipment constant current PID logic chart.
Fig. 6-the 2nd, embodiment of the invention high-frequency inversion stud welding equipment constant current pressure limiting PID logic chart.
Fig. 6-the 3rd, the permanent power P ID of embodiment of the invention high-frequency inversion stud welding equipment logic chart.
Fig. 7-the 1st, the main transformer winding structure figure of embodiment of the invention high-frequency inversion stud welding equipment.
Fig. 7-the 2nd, embodiment of the invention high-frequency inversion stud welding equipment main transformer coiling wiring diagram.
Fig. 7-the 3rd, embodiment of the invention high-frequency inversion stud welding equipment main transformer schematic diagram.
[specific embodiment]
The composition of the embodiment of high-frequency inversion stud welding equipment of the present invention comprises as shown in Figure 1
(1) electromagnetic compatibility circuit, (2) three-phase alternating current rectification circuit, (3) soft starting circuit, (4) current rectifying and wave filtering circuit, (5) IGBT isolated drive circuit, (6) IGBT bridge circuit on-off circuit, (7) high frequency transformer, (8) rectifier filter circuit, (9) IGBT accessory power supply, (10) control power supply, (11) welding gun, (12) dsp controller, (13) man-machine interface are LCD display, (14) 485 communication interfaces, (15) double-screw bolt autoloader.
The operation principle of the embodiment of high-frequency inversion stud welding equipment of the present invention as shown in Figure 2.Three-phase alternating current through the electromagnetic compatibility circuit, utilize capacitor C A, CB, CC; Inductance L 1-1, L1-2, L1-3 absorb the due to voltage spikes that suppresses on the three-phase alternating current bus, also prevent from that due to voltage spikes that this machine high-frequency inversion is produced from leaking to loose simultaneously to produce high frequency in the electric power network and pollute.Provide electric energy the direct current that the three-phase alternating current of 380V changes 520V into to high-frequency inverter through the three phase rectifier bridge chip then.Soft starting circuit 2 at first charges the direct current on the dc bus to filter capacitor C2, when being charged to 80% left and right sides of busbar voltage to voltage to the capacitor two ends, the Time Delay Opening controllable silicon has also alleviated when can reduce capacitor C 1, IGBT (Q1, Q2, Q3, Q4) impact like this electrical network has been brought influence to the power supply of high-frequency inversion bridge circuit.Filter capacitor is made up of aluminium electroloysis C1 and high frequency capacitance C2, like this can be when the IGBT switch the high frequency transformer leakage inductance among energy and filter capacitor C1, the C2 energy exchange to reach the purpose of the power factor that improves complete machine.IGBT bridge switch (Q1, Q2, Q3, Q4) circuit drives the isolated drive circuit 7 that chip is formed by the M57962L of four isolation, finishes the inversion of power supply under the control of DSP pulse-width signal by high frequency transformer B1.After behind the high frequency fast diode D5, D6 rectification, weld through 12 pairs of double-screw bolts of double-screw bolt autoloader 11, semi-automatic stud welding gun (or manually stud welding gun), the voltage of its welding gun output up to 55V about, produce the arc-welding electric current of 200---2000A.
Electric current, voltage control automatically are by three feedback control loops, the one, be used for controlling the maximum of IGBT operating current and the problem of high frequency main transformer magnetic bias by current transformer B2 (or Hall current sensor) at primary current sample loop.The 2nd, control setting electric current at current output terminal by current divider 4 (or Hall current sensor), reach the purpose of constant current with this.The 3rd, setting voltage is controlled at current output terminal by Hall voltage sensor 6, reach the purpose of constant current pressure limiting with this.The 10th, isolation logic control, but Butt welding gun control signal and protective gas etc. are controlled.Man-machine interface 8 shows welding parameter and fault message by touch-screen.The input welding parameter.
The composition of double-screw bolt autoloader is as shown in Figure 3: (1) power circuit; (2) PIC controller; (3) sweep the nail control circuit; (4) binding control circuit; (5) send the nail control circuit; (6) blow the nail control circuit; (7) Rolling motor control circuit; (8) slideway testing circuit; (9) cylinder testing circuit; (10) safety detection circuit (motor overload detects, supply voltage detects, the nail amount detects, follow closely lock detection, pot cover detection etc.).
4, double-screw bolt autoloader operation principle;
Utilize PIC micro-control technology, to overload, motor positive and inverse, overcurrent, overvoltage, nail amount, lack nail, bail, sweep situation such as nail signal and carried out comprehensive monitoring, according to contact, vertical and button rifle signal to the binding of autoloader, send that the nail magnetic valve carries out that SECO finishes double-screw bolt send nail and welding automatically.
Some explanation to the embodiment of high-frequency inversion stud welding equipment of the present invention:
(1) high frequency transformer is the important devices of whole equipment, and the performance quality directly affects the size of output current and the safety of IGBT; Little leakage inductance can reduce loss, reduce the requirement of IGBT electric current and voltage stress.The leakage inductance of high frequency transformer should be controlled at below the 10UH.The magnetic core air gap should be at the 0.2---0.8 millimeter, otherwise will enter the magnetic saturation state by magnetic core, is unfavorable for the work of high frequency transformer.The fundamental characteristics of material is an initial magnetic permeability 2500, and saturation flux density 390mT/100 ℃, remanent magnetism are that 120mT, coercivity are 10A/M.Just, inferior lead all is to adopt 0.2 millimeter copper belt multilayer to replace coiling to form, first no-load voltage ratio is 6:1.Fig. 7-1, Fig. 7-2, Fig. 7-3 are seen in winding method and wiring, wherein secondary 21,22; 24,25; 26,27; 29,30 and elementary 23; 28 all are made up of multiturn (or multilayer) copper strips.The leading-out terminal of primary only has A and B; Secondary leading-out terminal only has C, D, E.Magnetic core can adopt E or U type.Monnolithic case is that the iron sheet case forms with the insulating cement pouring.
(2) IGBT drives by the quick isolation drive module of M57962L, and it has overprotection, soft start and alarm function, also is added with negative pressure when IGBT turn-offs, and has improved the antijamming capability of IGBT like this.
(3) on front and back bridge heat sink and transformer, be provided with temperature sensor,, and it monitored and overtemperature protection by the temperature of DSP monitoring IGBT, supper-fast diode and transformer.
(4) repay on the line the direct current mother, control on the power supply, be provided with electric voltage observation circuit on the driving power, monitor and alarm by DSP.Man-machine interface has adopted very color touch-screen, flexible and convenient operation.
(5) the DSP inverter controller adopts the TMS320F2812 chip, and four road PMW signals by DSP drive bridge circuit IGBT after four M57962L amplify, then through the transformation of high frequency transformer, rectification, filtering output welding current.Signal feedback circuit has three loops, a current inner loop: an electric current outer shroud and an outer voltage.Its effect is: current inner loop B2 is a PID current controlled circuit of response fast, be to utilize current transformer that the instant value of the elementary operating current of high frequency transformer is sampled, handle through DSP then the working condition of major loop is monitored, be used for controlling the current changing rate and the peak current value size of high frequency transformer, the stress that can reduce the voltage and current of IGBT is used for preventing the high frequency transformer magnetic bias, IGBT's is straight-through, improve the stability and the reliability of main circuit, its sample frequency of current inner loop is 50 times a main circuit switch frequency, the loop controlled frequency is 2 times of main circuit switch frequencies, it has ratio and regulates, the control action that differential and integration are regulated has response speed fast, the characteristics that control accuracy is high.Second feedback control loop is the electric current outer shroud of a PI high accuracy control, is that current divider 4 (or Hall current sensor) is sampled to output current, through the DSP digital processing output welding current carried out constant current control then; The 3rd feedback control loop is the outer voltage of a PI high accuracy control, is to utilize 6 pairs of output voltages of Hall voltage sensor to sample, and handles through DSP then weldingvoltage is carried out pressure limiting control.Second and third two loops all have the control action that ratio is regulated and integration is regulated, and the appropriate processing by digital PI just can have less deviation and response speed faster, with the demand for control of satisfied constant current of welding, constant current pressure limiting.Second and third feedback control loop sample frequency also is 50 times of inverter circuit main circuit switch frequencies, and the controlled frequency of curtage is an inverter circuit main circuit switch frequency.
The present invention has adopted the TMS320F2812 chip, dominant frequency is up to 150MHZ, the current sample frequency is brought up to 500000 times/second, pwm signal is pursued week control, and the control cycle of pwm signal is brought up to the switch periods of major loop, (25-50 microsecond), make electric current and voltage-controlled response speed satisfy the requirement of short period stud welding machine, current inner loop is implemented every half cycle control once, improve the response speed and the control accuracy of feedback, satisfy the requirement of short period stud welding machine with this.
The dsp software behavioral illustrations:
(1) feedback control loop Mathematical Modeling
The AD conversion input port that backfeed loop is delivered to DSP to the simulation signal that adopts compares the generation error signal with welding current value that touch-screen is set after AD converts data signal to, form control signal UK (n) through digital PI algorithm process then, after control signal UK (n) adds up with maximum current limit error signal F (i), pulsewidth (pwm signal) to IGBT is controlled, thereby reach the current changing rate of control appliance output current, output voltage and restriction high frequency transformer, the purpose of peak point current, the FEEDBACK CONTROL Mathematical Modeling is seen Fig. 4.
(2) Mathematical Modeling of PID processing is: " ratio ", " integration ", " differential " three compositions, use the mode of difference equation to be expressed as:
Wherein
ΔE
(n)=E
(n)-E
(n-1), poor for adjacent two inputs.The PID model is adopted delta algorithm, order
ΔU
K (n)=U
K (n)-U
K (n-1), then can obtain:
(3) the PI Mathematical Modeling when constant current, pressure limiting control:
When controlling, outer shroud can not introduce differential term at the rate of change that can limit pulse-width signal in the control of DSP, so that improve the stability of control.Remove differential term like this PI outer shroud mathematics of control model then arranged:
ΔU
k(n)＝K
p×(
ΔE
(n)-
ΔE
(n-1))+K
i×
ΔE
(n)
U
k(n)＝U
k(n-1)+K
p×(
ΔE
(n)-
ΔE
(n-1))+K
i×
ΔE
(n)
" ratio ", " integration " digital regulated model of having formed the most basic outer shroud PI.
(4) the PI dead band explanation is set: for the The dead time of this PI control algolithm, with
ΔE ± 0.01 conduct control dead band, when
ΔThe numerical value of E in ± 0.01 in, will
ΔU
kBe set to zero.
(5) ratio amplification coefficient: ratio amplification coefficient K
pBe set to 0.01.Proportional helps
ΔDuring the E sudden change, reduce the influence of integration.
(6) stage of integral coefficient is divided (meet limit and weaken integration): the amplification coefficient K of integration
iScope is set to 0.01～0.1
When |
ΔE| 〉=0.5 o'clock,
ΔU
k=0.05,
ΔU
kBe constant value ± 0.05;
When 0.3≤|
ΔE|≤0.5 o'clock, K
i=0.06,
ΔU
kCalculate according to the PI formula;
When 0.1≤|
ΔE|≤0.3 o'clock, K
i=0.04,
ΔU
kCalculate according to the PI formula;
When |
ΔE|≤0.1 o'clock, K
i=0.02,
ΔU
kCalculate according to the PI formula;
(7) amplitude limit that the PI control algolithm is exported:
ΔU
kMaximum magnitude be ± 0.05, to guarantee to export not overshoot.
(8) processing of PWM export-restriction in algorithm: the PWM modulation signal by DSP directly sends is subjected to U
kDirect control.According to the requirement of hardware circuit, the duty factor of PWM does not allow to exceed this scope in 0.1～0.9 scope.So, U
kScope be 0.1≤U
k≤ 0.9.After the output of PID reached minimax output, when still can not satisfy the demand of current stabilization, controller was clamped down on output in minimax output, and at this moment, the closed-loop control condition is with destroyed, and main frame is with limit output services.
(9) dsp software PI control flow explanation
1. the logic flow of PI as Fig. 6-1 shown in shown in the 6-3.
This PI program is constant current control, and is the control flow under " external error, alarm signal " is invalid.Having under " external error, alarm signal " situation, computer will be carried out an other cover exception handler, no longer carry out this control program, and logic judgment part this program outside this block is only carried out read-write operation to inner limited RAM to any external hardware generation operation.
The DSP computing cycle is 50uS, 1 pwm pulse signal of DSP output during this.At ordinary times, DSP does not move the PI control algolithm, and only after DSP received to allow order, the PI control algolithm just started.
Constant current PID:
When enabling signal was not allowed to, program was in wait state.
When enabling signal allowed, program kept 50% pulse output in 3 cycles (150uS), to give initial current of system and state.After finishing, program is judged output current, if electric current is greater than 200A, according to selecting " constant current " Mathematical Modeling, calculate the output variable quantity, device is judged the output current rate of change again, surpass setting, then reduce the output variable quantity, deposit output quantity in engineering data base then.Check after finishing to start to allow signal, effectively then repeat, otherwise return to initial state.
Constant current pressure limiting PID:
When enabling signal was not allowed to, program was in wait state.
When enabling signal allowed, program kept 50% pulse output in 3 cycles (150uS), to give initial current of system and state.After finishing, program is judged output current, if electric current is greater than 200A, then judge output voltage U max (this parameter can onlinely be adjusted), select " constant voltage " and " constant current " two kinds of Mathematical Modelings, calculate the output variable quantity according to condition, device is judged the output current rate of change again, surpass setting, then reduce the output variable quantity, deposit output quantity in engineering data base then.Check after finishing to start to allow signal, effectively then repeat, otherwise return to initial state.
Permanent power P ID:
When enabling signal was not allowed to, program was in wait state.
When enabling signal allowed, program kept 50% pulse output in 3 cycles (150uS), to give initial current of system and state.After finishing, program is judged output current, if electric current is less than Imin (this parameter can onlinely be adjusted), whether judge power output greater than given power, if less than given power, according to " permanent power " Mathematical Modeling, calculate the output variable quantity, if greater than given power, " constant current " Mathematical Modeling according to Imin being set-point calculates the output variable quantity.
When electric current during greater than Imin, program continues to judge output current, if electric current is greater than Imax (this parameter can onlinely be adjusted), whether judge power output greater than given power, if greater than given power, according to " permanent power " Mathematical Modeling, calculate the output variable quantity, if less than given power, " constant current " Mathematical Modeling according to Imax being set-point calculates the output variable quantity.
When electric current when Imin is between Imax, judge output voltage, if output voltage greater than Umax (this parameter can onlinely be adjusted), then according to " constant voltage " Mathematical Modeling that with Umax is set-point, calculates the output variable quantity.When voltage the time,, calculate the output variable quantity according to " permanent power " Mathematical Modeling less than Umax.
After finishing above-mentioned steps, judge the output current rate of change again, surpass setting, then reduce the output variable quantity, deposit output quantity in engineering data base then.Check after finishing to start to allow signal, effectively then repeat, otherwise return to initial state.
2., the explanation of pwm signal generation
This program is that PWM interrupts sample program.DSP calculates the dutycycle Uk of PWM output, and scope is 10%～90%, and the interrupt routine generation time is the dead band intermediate point of positive and negative group of PWM.Program is done PWM and is stopped, exporting control, scope control etc.
Pwm signal produces the explanation of Fig. 5: 1, being the inlet that PWM interrupts, also is the place of the beginning of program; 2, be to judge whether PWM output allows, and allows to enter the 2nd step, does not allow, and enters for the 9th step; 3, be Uk in the judgment data storehouse〉90%, greater than entering for the 4th step, less than entering for the 5th step; 4, be that Uk is changed to 90% by force, entered for the 5th step; 5, be Uk＜10% in the judgment data storehouse, greater than entering for the 6th step, less than entering for the 7th step; 6, be that Uk is changed to 10% by force, entered for the 7th step; 7, be carrier wave according to PWM generator, computed duty cycle counter fiducial value entered for the 8th step; 8, be that fiducial value is inserted the PWM counter register, the 10th step; 9, be to close PWM output, the 10th step EOI.
Claims (10)
1. high-frequency inversion stud welding equipment, comprise rectified three-phase circuit, inverter circuit, high frequency transformer, current rectifying and wave filtering circuit, described rectified three-phase circuit is transformed into direct current with three-phase alternating current, inverter circuit converts the direct current of rectified three-phase circuit output to high-frequency alternating current, after the high frequency transformer step-down, produce the pulsating direct current welding current by current rectifying and wave filtering circuit, it is characterized in that, comprise the dsp controller and first current feedback circuit, first current feedback circuit is imported sampled value the signal input part of dsp controller from the output sampling of current rectifying and wave filtering circuit; Described inverter circuit comprises IGBT bridge circuit on-off circuit and isolated drive circuit; Described dsp controller produces pwm signal, through the break-make of isolated drive circuit control IGBT bridge circuit on-off circuit.
2. high-frequency inversion stud welding equipment according to claim 1, it is characterized in that, comprise first voltage feedback circuit, described first voltage feedback circuit is imported sampled value respectively the signal input part of dsp controller from the output sampling of current rectifying and wave filtering circuit.
3. high-frequency inversion stud welding equipment according to claim 2 is characterized in that, comprises second current feedback circuit, and described second current feedback circuit is imported sampled value the signal input part of dsp controller from the output sampling of inverter circuit.
4. according to the described high-frequency inversion stud welding of arbitrary claim equipment in the claim 1 to 3, it is characterized in that, described rectified three-phase circuit is followed successively by electromagnetic compatibility circuit, three-phase alternating current rectification circuit, soft starting circuit and current rectifying and wave filtering circuit, described electromagnetic compatibility circuit absorbs the due to voltage spikes that suppresses on the three-phase alternating current bus, reduces electromagnetic interference; Described three-phase alternating current rectification circuit is converted to direct current with the three-phase alternating current of electromagnetic compatibility circuit output; Described current rectifying and wave filtering circuit comprises filter capacitor, and the direct current that the three-phase alternating current rectification circuit is exported carries out filtering; Described soft starting circuit control three-phase alternating current rectification circuit output major loop just makes the major loop energising after described filter capacitor charges to busbar voltage.
5. high-frequency inversion stud welding equipment according to claim 4 is characterized in that the electromagnetic compatibility circuit is in series with input inductance respectively on the phase line of three-phase electricity, is parallel with peak clipping electric capacity between phase line respectively.
6. according to the described high-frequency inversion stud welding of arbitrary claim equipment in the claim 1 to 3, it is characterized in that described high frequency transformer primary coil and secondary coil replace coiling with the thin copper belt layering, between layer and the layer insulating barrier is arranged; The primary coil layer is 2 layers, and 2 layers of primary coil layer are connected mutually; Every layer of primary coil layer has 2 layers of internal layer secondary wire ring layer and 2 layers of outer secondary wire ring layer; The secondary wire ring layer of internal layer is connected mutually, the current opposite in direction of adjacent layer; Outer field secondary wire ring layer is series connection mutually also, and the sense of current of adjacent layer is also opposite; The serial connection point of secondary coil adjacent layer all connects the centre cap of transformer output, and the end of the same name of each layer of secondary coil also connects, and connects the transformer output.
7. the control method of the described high-frequency inversion stud welding of claim 1 equipment is characterized in that, may further comprise the steps:
701) first current feedback circuit simulation signal that sampling is obtained is delivered to the AD conversion input port of dsp controller, compares the generation current error signal with default welding current value after AD converts current digital signal to;
702) described current error signal generates control signal through digital PI algorithm process then, and the pulsewidth of IGBT is controlled, and realizes constant current output; The formation cycle of described control signal is with the switch periods of IGBT bridge circuit on-off circuit.
8. the control method of high-frequency inversion stud welding equipment according to claim 7, it is characterized in that, comprise first voltage feedback circuit, described first voltage feedback circuit is from the output sampling of current rectifying and wave filtering circuit, sampled value is imported the signal input part of dsp controller respectively, and may further comprise the steps:
801) first voltage feedback circuit simulation signal that sampling is obtained is delivered to the AD conversion input port of dsp controller, compares the generation voltage error signal with default welding voltage value after AD converts voltage digital signal to;
802) described voltage error signal generates control signal through digital PI algorithm process then, and the pulsewidth of IGBT is controlled, and realizes constant voltage output; The formation cycle of described control signal is with the switch periods of IGBT bridge circuit on-off circuit.
9. the control method of high-frequency inversion stud welding equipment according to claim 8 is characterized in that, may further comprise the steps:
901) obtain power signal from current digital signal and voltage digital signal, compare the generation power error signal with the bonding power value of presetting;
902) described power error signal generates control signal through digital PI algorithm process then, and the pulsewidth of IGBT is controlled, and realizes permanent power output; The formation cycle of described control signal is with the switch periods of IGBT bridge circuit on-off circuit.
10. according to the control method of the described high-frequency inversion stud welding of arbitrary claim equipment in the claim 7 to 9, it is characterized in that, comprise second current feedback circuit, described second current feedback circuit is from the output sampling of inverter circuit, sampled value is imported the signal input part of dsp controller, and may further comprise the steps:
1001) second voltage feedback circuit simulation signal that sampling is obtained is delivered to the AD conversion input port of dsp controller, compare with default inverter circuit output limit value after AD converts current digital signal to and produce inverter circuit output current error signal, the formation cycle of inverter circuit output current error signal is half of switch periods of IGBT bridge circuit on-off circuit;
1002) after inverter circuit output current error signal superposes with control signal, the pulsewidth of IGBT is controlled the current changing rate and the peak point current of restriction high frequency transformer.
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Denomination of invention: High frequency inverter stud welding equipment and its control method Effective date of registration: 20210507 Granted publication date: 20130306 Pledgee: Shenzhen hi tech investment small loan Co.,Ltd. Pledgor: Shenzhen Hongbai Technology Industrial Co.,Ltd. Registration number: Y2021980003312 |