CN101574757B - Control system of ultrasonic welding machine - Google Patents
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- CN101574757B CN101574757B CN 200910098289 CN200910098289A CN101574757B CN 101574757 B CN101574757 B CN 101574757B CN 200910098289 CN200910098289 CN 200910098289 CN 200910098289 A CN200910098289 A CN 200910098289A CN 101574757 B CN101574757 B CN 101574757B
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- 238000003466 welding Methods 0.000 title claims abstract description 42
- 238000012545 processing Methods 0.000 claims abstract description 53
- 238000000034 method Methods 0.000 claims description 12
- 238000001914 filtration Methods 0.000 claims description 4
- 230000001105 regulatory effect Effects 0.000 claims description 4
- 238000001514 detection method Methods 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims description 3
- 230000000306 recurrent effect Effects 0.000 claims description 3
- 230000009897 systematic effect Effects 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 description 7
- 230000003044 adaptive effect Effects 0.000 description 3
- 230000010355 oscillation Effects 0.000 description 3
- 238000011161 development Methods 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- 230000003321 amplification Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000011217 control strategy Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000003745 diagnosis Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000005669 field effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000004021 metal welding Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000003199 nucleic acid amplification method Methods 0.000 description 1
- 238000004023 plastic welding Methods 0.000 description 1
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Abstract
The invention belongs to the technical field of welding and relates to a control system of an ultrasonic welding machine. The control system solves the problems of poor working stability, low efficiency, low working quality and the like of the existing ultrasonic welding machine. The control system of the ultrasonic welding machine comprises an inverter, an ultrasonic transducer and a central processing unit; the inverter is respectively connected with the central processing unit and the ultrasonic transducer; a frequency tracking control system is connected between the inverter and the ultrasonic transducer; a sensor which is used for detecting a frequency signal and arranged at a tool head is connected between the ultrasonic transducer and the central processing unit; the inverter inputsvoltage and current signal parameters to the central processing unit, and the sensor inputs the frequency signal parameters at the tool head to the central processing unit, the processing is carried out, and the controlled quantity is calculated; and a pulse generator which is used for generating a frequency pulse signal according to the controlled quantity is further connected between the inverter and the central processing unit. The control system of the ultrasonic welding machine has the advantages of simple structure, good stability, high working efficiency and quality and the like.
Description
Technical field
The invention belongs to welding technology field, relate to the control system of a kind of welder, particularly a kind of ultrasonic welding machine.
Background technology
Ultrasonic power provides the supersonic frequency ac signal to ultrasonic transducer, and it realizes that circuit claims again ultrasonic drive circuit.In 20th century, in the time of along with the fast development of electronic technology, ultrasonic wave inverter power device used has experienced electron tube, and IGCT, transistor and IGBT be totally 4 stages.Used in recent years novel circuit topological structure and New Type Power Devices in circuit design, the uniformity of the reliability of ultrasonic power, workload-adaptability, product is further enhanced, and efficient also improves greatly simultaneously, and the volume of product also reduces at any time.
Traditional ultrasonoscope is that to adopt oscillator to produce hyperacoustic, and to adopt electron tube be power device.Its shortcoming be bulky, heavy, thermal losses is large, reactive power is large.The eighties in 20th century, change ambipolar high power transistor, switch frequency 20kHz commonly used into.Adopted again afterwards insulator gate bipolar transistor (IGBT), operating voltage and operating current quota (being the single tube capacity) have increased significantly.To the nineties in 20th century, because the technological progress of power field effect pipe MOSFET is widely adopted, the switch frequency reaches 100kHz.Over past ten years, ultrasonic power adopts HF switch AC power technology, and inner integrated various chips or large scale integrated circuit are realized the dynamic control to bandwidth frequency, and its development trend must be high efficiency, and as power supply, efficient is one of important indicator.Efficient is high, and the heating loss is little, and heat radiation is easily just easily accomplished the vibration of large power supersonic and high power.
In the supersonic welding termination process, variation due to various factors such as the temperature of weld load and vibrational system, rigidity, bonding area, processing wearing and tearing, make system frequency drift about, if frequency generator is not followed variation, certainly will cause the imbalance of whole system, this just requires supersonic generator to have the automatic frequency tracking function.Traditional ultrasonic welding machine adopts vacuum tube oscillator to produce high-frequency signal, directly produces power ultrasonic after power amplification, thereby is difficult to realize can not adapt to the variation of weld load by frequency-tracking.For rapidity and the accuracy that realizes better frequency-tracking, people have carried out various explorations on its mode.Common ultrasonic bonding supply frequency automatic following control system has following control mode.
1, the self-oscillation mode of electricity feedback.Because it is simple and easy, use quite extensive, representational method is to adopt differential variable bridge circuit that PZT (piezoelectric transducer) electricity arm is compensated, make electrical feedback signal depend on robotic arm, reach frequency from motion tracking, simultaneously circuit can improve and satisfy self-oscillatory phase condition, is built into 1 self-oscillation loop, self-oscillation frequency accidental tool resonance point is synchronously changed, realize from motion tracking.
2, phase-locked VCO mode.Phase-locked this frequency tracking method of VCO mode is the phase difference signal of taking out voltage and current, and with its control signal as excited vibration system resonance change of frequency, and a phase control system of realizing.
3, electric current dynamical feedback mode.In the situation that be 1 two-port network with the ultrasonic transducer equivalence, the relation of output amplitude and size of current when deriving resonance, the transducer current virtual value is regulated reverse frequency as feedback quantity, realize ultrasonic system resonance control box amplitude constant output control.
In fact, all there is its weak point in above-mentioned various control methods.Such as, for the self-oscillation mode, if PZT (piezoelectric transducer) has multiple mode of resonance, this method is just unreliable; The phase-lock mode automatic frequency tracking will drive loop increase transducing reactor compensating element; And for dynamical feedback frequency-tracking mode, the direction that frequency is adjusted also is difficult to hold, and is difficult to realize automation control.In addition, in various frequency-tracking modes, feedback signal is all from ultrasonic transducer or oscillation control signal, ignored the first-class ultrasonic device of ultrasonic transformer and instrument to the impact of resonance, not detecting actual frequency output situation (can obviously change output frequency usually add load after) at the tool heads place, number is that CN201147869Y is called " high-power ultrasonics metal welding machine self-adapting signal source " as the Chinese patent Granted publication.According to above analysis, the embodiment of high-power ultrasonics welding processing control at present is all undesirable, all has defective.
Summary of the invention
The objective of the invention is for the existing the problems referred to above of existing technology, and a kind of Self Adaptive Control ring feedback control mode of automatic frequency tracking of realizing in the process of welding is provided, thereby the power output that realizes welding is constant and adjustable, efficient is high, harmonic pollution is little, the control system of stable and reliable working performance, ultrasonic welding machine that the adaptive load ability is strong.
purpose of the present invention can realize by following technical proposal: a kind of control system of ultrasonic welding machine, comprise inverter, ultrasonic transducer and central processing unit, described inverter is connected with ultrasonic transducer with central processing unit respectively, it is characterized in that, feed back the frequency-tracking control system that real-time is controlled when being connected with for resonance between described inverter and ultrasonic transducer, be connected with the sensor for detection of frequency signal that is arranged on tool heads between described ultrasonic transducer and central processing unit, above-mentioned inverter is with voltage, current signal parameter and sensor with the frequency signal parameter at tool heads place all be input to process in central processing unit after and calculate controlled quentity controlled variable, also be connected with between inverter and central processing unit for produce the impulse generator of frequency pulse signal according to controlled quentity controlled variable.
The control system of this ultrasonic welding machine has creatively realized the dicyclo control mode, wherein by the frequency-tracking control system is set between ultrasonic transducer and inverter, ultrasonic transducer can send by the frequency-tracking control system and feed back signal to inverter, making has a frequency-tracking closed-loop control feedback loop between the two, forms resonance and reaches real-time control.Another ring is comprised of inverter, transducer, sensor, central processing unit and impulse generator, and detect frequency signal and feed back on central processing unit by the sensor on tool heads, inverter work is exported and driven to the impulse generator of controlling oscillation frequency signal by central processing unit again, to obtain desirable frequency curve of output.this central processing unit has used the MCU microcontroller in addition, the modern technologies such as DDS Direct Digital Frequency Synthesizers, after three-phase alternating current input becomes alternating current by rectifier filter the alternating current that direct current becomes direct current by inverter welding use again and be input in central processing unit, wherein central processing unit is to voltage, electric current, the transducer amplitude, all multi-parameters such as voltage signal phase difference are carried out on-line measurement, identification, utilizing online recurrent least square method to carry out the parameter knowledge debates, while change control parameter, adopt minimum variance control law or pole placement control rule, and pass through Adaptable System, calculate controlled quentity controlled variable and according to the rules program changes systematic parameter according to the parameters that detects, controlled frequency with the DDS outputting standard comes regulating frequency, the frequency that makes impulse generator is the resonant frequency of tracking system well.
In the control system of above-mentioned ultrasonic welding machine, also be connected with step-up transformer between described inverter and ultrasonic transducer.The large voltage of using when becoming welding after by step-up transformer, alternating voltage being amplified here.
Be connected with step-up transformer between the inverter of this ultrasonic welding machine and ultrasonic transducer, step-up transformer will to amplifying from inverter alternating voltage out, use in the time of offering better the ultrasonic welding machine welding.
In the control system of above-mentioned ultrasonic welding machine, also be connected with detecting amplifier between described inverter and central processing unit, step-up transformer all with after detecting amplifier is connected is input in central processing unit with inverter.Here detecting amplifier is mainly voltage, current signal to be detected amplify rear and be input in central processing unit, facilitates central processing unit to process calculating.
The step-up transformer of this ultrasonic welding machine and inverter are input in central processing unit after amplifying electric current, voltage signal through detecting amplifier again, central processing unit is more convenient when analyzing and processing is calculated these signals like this, simultaneously also can improve accuracy in computation, the impulse generator that makes central processing unit control oscillation frequency signal is exported and is driven inverter and exports more suitably frequency, makes ultrasonic welding machine more stable, efficient, high-quality at work.
In the control system of above-mentioned ultrasonic welding machine, also be connected with wave filter between described sensor and central processing unit.Here wave filter mainly carries out filtering to the detected frequency signal of sensor at tool heads place.
This ultrasonic welding machine is connected with wave filter between sensor and central processing unit, the clutter that contains ectocine tool heads output frequency in the frequency signal that sensor detects, by wave filter, these clutters are got rid of, the frequency signal that arrives like this central processing unit can reflect the actual output frequency of tool heads self more realistically.
In the control system of above-mentioned ultrasonic welding machine, the input end of described inverter is connected with rectifier filter.Here rectifier filter is mainly that the voltage and current signal of inputting is carried out rectifying and wave-filtering.
This ultrasonic welding machine provides this ultrasonic bonding mechanomotive force with extraneous AC power, the alternating current that often is being mingled with a variety of frequencies in extraneous AC power, by rectifier filter, AC rectification is become direct current, the alternating current that by inverter, direct current is become again single-frequency improves quality and the stability of ultrasonic welding machine work greatly to provide stable power supply for ultrasonic welding machine.
In the control system of above-mentioned ultrasonic welding machine, also be connected with drive circuit between described impulse generator and inverter.Here can drive inverter work by drive circuit.
In this ultrasonic welding machine, inverter is by drive circuit driving work.
Compared with prior art, this ultrasonic welding machine the control system advantage be to adopt the dicyclo control mode, replace simulation to control with the Digital Control mode, realized the dynamic control to bandwidth frequency, can eliminate the shortcoming that the conventional simulation adjusters such as temperature drift are difficult to overcome, be conducive to parameter tuning and variable parameter control, be convenient to the change by program software, adjust easily control program and realize the various new control strategy, can reduce simultaneously number, the simplification hardware configuration of components and parts, thereby improve the reliability of system.Adopt in addition the topological structure of semi-bridge inversion, take the IGBT power device as the inversion element, make work be in soft on off state, and the new type ultrasonic plastic welding power supply that adopts the shift power control algolithm to develop, have from the motion tracking load resonant frequency, in addition, can also realize automatic storage and the automatic fault diagnosis of service data, help to realize the intellectuality of power electronic equipment operation.This ultrasonic welding machine control system ground power output constant and adjustable, efficient is high, harmonic pollution is little, stable and reliable working performance, the adaptive load ability is strong, and is easy to use, have very strong practicality, the technology of its application and product are representing the developing direction of ultrasonic-frequency power supply from now on.
Description of drawings
Fig. 1 be this ultrasonic welding machine the functional-block diagram of control system.
The specific embodiment
Be below specific embodiments of the invention and by reference to the accompanying drawings, technical scheme of the present invention is further described, but the present invention be not limited to these embodiment.
as shown in Figure 1, the control system of this ultrasonic welding machine, comprise inverter, ultrasonic transducer and central processing unit, be connected with step-up transformer and frequency-tracking control system between inverter and ultrasonic transducer, offering ultrasonic transducer after the voltage of inverter output boosts by step-up transformer uses, ultrasonic transducer can send by the frequency-tracking control system in real time and feed back signal to inverter, be connected with the sensor for detection of the tool heads output frequency that is arranged on tool heads between ultrasonic transducer and central processing unit, be connected with wave filter between sensor and central processing unit, inverter all is connected with central processing unit by detecting amplifier with step-up transformer, also be connected with the drive circuit of impulse generator and the work of driving inverter between inverter and central processing unit, inverter also is connected with rectifier filter, rectifier filter is connected with extraneous power supply.
during work, the intrinsic frequency signal feedback that ultrasonic transducer changes ultrasonic transducer in real time by the frequency-tracking control system is to inverter, after amplifying, the intrinsic frequency signal that will feed back to the variation of inverter by detecting amplifier is input to central processing unit, and carry out analyzing and processing with the frequency signal that feeds back to central processing unit after filter filtering that frequency signal and tool heads upper sensor from inverter output detects and calculate, central processing unit carries out on-line measurement to these frequency signals, identification, utilizing online recurrent least square method to carry out the parameter knowledge debates, while change control parameter, adopt the minimum variance control law, and pass through Adaptable System, calculate controlled quentity controlled variable and according to the rules program changes systematic parameter according to the parameters that detects, controlled frequency with the DDS outputting standard comes regulating frequency, the frequency that makes impulse generator is the resonant frequency of tracking system well, thereby guaranteed that ultrasonic welding machine is stable, efficiently, high-quality work.
The minimum variance control law that adopts in the present embodiment can also adopt the pole placement control rule.
Specific embodiment described herein is only to the explanation for example of the present invention's spirit.Those skilled in the art can make various modifications or replenish or adopt similar mode to substitute described specific embodiment, but can't depart from spirit of the present invention or surmount the defined scope of appended claims.
Claims (3)
1. the control system of a ultrasonic welding machine, comprise inverter, ultrasonic transducer and central processing unit, described inverter is connected with ultrasonic transducer with central processing unit respectively, it is characterized in that, feed back the frequency-tracking control system that real-time is controlled when being connected with for resonance between described inverter and ultrasonic transducer, be connected with the sensor for detection of frequency signal that is arranged on tool heads between described ultrasonic transducer and central processing unit, above-mentioned inverter is with voltage, current signal parameter and sensor with the frequency signal parameter at tool heads place all be input to process in central processing unit after and calculate controlled quentity controlled variable, also be connected with between inverter and central processing unit for produce the impulse generator of frequency pulse signal according to controlled quentity controlled variable, also be connected with drive circuit between described impulse generator and inverter, also be connected with step-up transformer between described inverter and ultrasonic transducer, also be connected with detecting amplifier between described inverter and central processing unit, step-up transformer all with after detecting amplifier is connected is input in central processing unit with inverter, adopt the topological structure of semi-bridge inversion, take the IGBT power device as inverter, this central processing unit comprises MCU microcontroller and DDS Direct Digital Frequency Synthesizers, the intrinsic frequency signal feedback that ultrasonic transducer changes ultrasonic transducer in real time by the frequency-tracking control system is to inverter, after amplifying, the intrinsic frequency signal that will feed back to the variation of inverter by detecting amplifier is input to central processing unit, and carry out analyzing and processing with the frequency signal that feeds back to central processing unit after filter filtering that frequency signal and tool heads upper sensor from inverter output detects and calculate, central processing unit carries out on-line measurement to these frequency signals, identification, utilizing online recurrent least square method to carry out the parameter knowledge debates, while change control parameter, adopt the minimum variance control law, and pass through Adaptable System, calculate controlled quentity controlled variable and according to the rules program changes systematic parameter according to the parameters that detects, controlled frequency with the DDS outputting standard comes regulating frequency.
2. the control system of a kind of ultrasonic welding machine according to claim 1, is characterized in that, also is connected with wave filter between described sensor and central processing unit.
3. the control system of a kind of ultrasonic welding machine according to claim 1 and 2, is characterized in that, the input end of described inverter is connected with rectifier filter.
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| Application Number | Priority Date | Filing Date | Title |
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| CN 200910098289 CN101574757B (en) | 2009-05-01 | 2009-05-01 | Control system of ultrasonic welding machine |
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| CN 200910098289 CN101574757B (en) | 2009-05-01 | 2009-05-01 | Control system of ultrasonic welding machine |
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| CN101574757A CN101574757A (en) | 2009-11-11 |
| CN101574757B true CN101574757B (en) | 2013-05-22 |
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| CN 200910098289 Expired - Fee Related CN101574757B (en) | 2009-05-01 | 2009-05-01 | Control system of ultrasonic welding machine |
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Cited By (1)
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| IT201900025810A1 (en) * | 2019-12-31 | 2021-07-01 | Sonic Italia S R L | ELECTRONIC DEVICE FOR PILOTING AND CONTROL OF A VIBRATING UNIT OF AN ULTRASONIC WELDING MACHINERY |
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| CN103051331B (en) * | 2012-12-14 | 2015-10-28 | 华南理工大学 | A kind of phase lock circuitry for ultrasonic power |
| TWI480111B (en) * | 2012-12-27 | 2015-04-11 | Metal Ind Res & Dev Ct | A vibration processing apparatus and a vibration driving module thereof |
| US20150122781A1 (en) * | 2013-11-04 | 2015-05-07 | Illinois Tool Works Inc. | System and method for selecting weld parameters |
| CN105954585A (en) * | 2016-04-22 | 2016-09-21 | 广东顺威精密塑料股份有限公司 | Ultrasonic power supply automatic frequency tracking system based on single-chip microcomputer (SCM) control |
| CN107160697A (en) * | 2017-06-09 | 2017-09-15 | 镇江宇神动力能源有限公司 | A kind of ultrasonic welding machine and application method |
| US11433475B2 (en) | 2017-11-29 | 2022-09-06 | Telsonic Holding Ag | Ultrasonic machining device, method for configuring an ultrasonic machining device, and system having an ultrasonic machining device of this type |
| CN108327296B (en) * | 2018-01-31 | 2020-08-04 | 大连交通大学 | Ultrasonic precise sealing device and method based on characteristic wavelets |
| CN108393574A (en) * | 2018-05-09 | 2018-08-14 | 北京航天东方科技发展有限公司 | ultrasonic welding machine |
| CN109290672B (en) * | 2018-10-09 | 2021-09-07 | 湖南机电职业技术学院 | Metal material welding method based on ultrasonic welding and control system |
| DE102019109262A1 (en) * | 2019-04-09 | 2020-10-15 | Lisa Dräxlmaier GmbH | DEVICE FOR DETERMINING A STATE OF AN ULTRASONIC WELDING PROCESS |
| CN110340050B (en) * | 2019-06-28 | 2021-09-07 | 中广核工程有限公司 | Welding-following cleaning and welding bead shaping device for branch pipe welding seam Overlay surfacing |
| CN111958098B (en) * | 2020-09-01 | 2022-04-19 | 河南理工大学 | Multifunctional adjustable ultrasonic welding system for tabs |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| IT201900025810A1 (en) * | 2019-12-31 | 2021-07-01 | Sonic Italia S R L | ELECTRONIC DEVICE FOR PILOTING AND CONTROL OF A VIBRATING UNIT OF AN ULTRASONIC WELDING MACHINERY |
| EP3845317A1 (en) * | 2019-12-31 | 2021-07-07 | Sonic Italia S.r.l. | Electronic device for driving and controlling a vibrating unit of an ultrasonic welding machine |
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