CN101791733B - Aluminium alloy twin-wire dipulse welding method and welding power supply thereof - Google Patents
Aluminium alloy twin-wire dipulse welding method and welding power supply thereof Download PDFInfo
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- CN101791733B CN101791733B CN2009101935674A CN200910193567A CN101791733B CN 101791733 B CN101791733 B CN 101791733B CN 2009101935674 A CN2009101935674 A CN 2009101935674A CN 200910193567 A CN200910193567 A CN 200910193567A CN 101791733 B CN101791733 B CN 101791733B
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Abstract
The invention discloses an aluminium alloy twin-wire dipulse welding method and a welding power supply thereof. The specific method is as follows: carrying out low frequency modulation on pulse wave shapes on the basis of high frequency to obtain periodically varied pulse bursts; and carrying out efficient and superior welding on aluminium alloy through the active phase match of two branches of the pulse bursts. The welding power supply comprises IGBT soft switching main circuits which are integrated into a whole, a DSP control circuit and a man-machine interactive system. The invention puts forward realizing dipulse aluminum alloy welding on a twin-wire welding machine for the first time, realizes all digital control, directly generates eight branches of PWM signals by utilizing a software module, controls the two main circuits, and reduces the control problems caused by communication; and simultaneously, the two main circuits are concentrated on the same welding machine so that the overall structure is much smaller than the master-slave mode welding machine, in addition methods such as instantaneous energy control and the like are adopted to realize the fine control of dipulse.
Description
Technical field
The invention belongs to aluminium alloy high speed arc-welding processing technique field, particularly aluminum alloy twin-wire dipulse welding technology field specifically is meant a kind of aluminum alloy twin-wire dipulse welding method and the source of welding current thereof.
Background technology
Aluminium and alloy thereof not only have the characteristics that proportion is little, intensity is high, corrosion resistance is strong; And have good extrusion performance, good solderability, higher ratio is strong; So be widely used in every field such as Aeronautics and Astronautics, nuclear energy and war industry in recent years, and the development that corresponding thereupon aluminum alloy solder technology is also being advanced by leaps and bounds.According to prior art, its welding procedure of aluminium and aluminium alloy and method be except the direct current pulse MIG weldering, below also having several kinds.
(1) TIG weldering (Tungsten Inert Gas)
The TIG weldering is to use the widest a kind of welding method in the aluminium alloy welding.Be divided into straight polarity direct current TIG weldering, dc reverse connection TIG weldering and the weldering of AC-TIG WELDING aluminium from welding procedure characteristic.Straight polarity direct current TIG weldering; Tungsten electrode can bear very big electric current and not by scaling loss, keep the stability of tungsten electrode end shape over a long time, is easy to the consistent welding point of obtained performance; But do not have the negative electrode atomizing, be difficult for disposing the oxide-film that produces in the welding process.Dc reverse connection TIG weldering, aluminum alloy surface cathode protection energy density is high, and the electron work functon of oxide-film is little; The arc cathode spot is set up on it easily; When receiving the bump of the very big cation of quality, the broken evaporation of surface film oxide is eliminated, thereby reaches the purpose of cathode cleaning.AC-TIG WELDING aluminium welds preferably, and fusion penetration is respectively the fundamental characteristics that positive and negative polarity tungsten electrode gas is protected weldering with removing oxide-film; The tungsten electrode gas of use AC power is protected to be welded on this two specific character and has been obtained balance; Half cycle in positive polarity; Electric arc has been abolished the aluminum oxide film attached to material surface effectively, and at the half cycle of negative polarity, then material is fused.
(2) exchange the MIG weldering
Exchange MIG weldering development early, it can effectively overcome the arc blow of direct-current arc.Exchanging the MIG weldering can regard as and switch alternately that DCEP PMIG electric arc and DCEN PMIG electric arc forms.The characteristics of its arc force and arc heat are between DCEP PMIG and DCEN PMIG, and its fusion penetration helps stabilized welding process and welding quality between between the two.In many countries, particularly Japan is still constantly strengthening, is improving it, like zero passage technology, arc technology or the like.Exchange the MIG weldering and can be used for welding extremely thin aluminium sheet.When welding wire is positioned at negative pole, can accelerate the burn-off rate of welding wire.When welding wire is positive pole, can realize the negative electrode fragmentation, therefore can regulate current waveform very neatly and satisfy the on-the-spot requirement of welding.
(3) aluminium alloy plasma arc welding with adjustable polarity parameters (VPPA)
In the Aeronautics and Astronautics field; The manufacture process of aircraft often relates to the welding of thick of aluminium alloy, because TIG welding heat efficient is lower, generally can only weld the aluminum alloy plate materials below the 3mm; Thickness increases necessary bevel; Need adopt the method for multilayer welding when thickness reaches certain value, greatly reduce production efficiency, and electrode erosion be very fast.Adopt the plasma arc welding with adjustable polarity parameters technology to address the above problem effectively.Plasma arc welding with adjustable polarity parameters connects method and compares with argon tungsten-arc welding (arc temperature 8000K); Have concentration of energy, arc temperature high (16000～33000K), characteristics such as strong, the good stability of penetrability, speed of welding be fast; Weldquality is good, the heat affected area is little, is out of shape advantages such as little, the aluminum alloy plate materials of the disposable through welding 12mm of ability; And, improved welding production efficiency greatly without bevel.Can eliminate weld defects such as pore through pinhole type vertical position welding technology, realize " zero defect " welding, thereby can solve insoluble for a long time aluminium alloy element welding quality problem of unstable.
(4) low frequency modulations type impulse welding (dipulse MIG weldering)
The impulse welding of low frequency modulations type is to modulate with the peak value and the time of the low-frequency pulse of the 0.5-50Hz unit pulse higher to frequency (pulse of control droplet transfer); The intensity that makes unit pulse strong and weak between the switching of low-frequency cycle property; Obtain periodically variable strong and weak impulse train, input correspondingly also changes with the low frequency modulations frequency arc force with heat.Be used to weld aluminium and alloy thereof, can not only obtain fish scale shape face of weld, and can enlarge the gap excursion that can weld welding point, reduce the welding pore, the refinement weld grain reduces bead crack sensitiveness.
(5) Laser Welding
The Laser Welding equipment that is used for aluminium alloy divides from medium, mainly contains two kinds, and a kind of is CO
2Laser aid has been developed the complete machine power that is used for industrial welding at present and has been reached 45KW; Another kind is the laser Nd:YAG device of the neodymium monocrystal rod of a band yttrium-aluminium-garnet coating, and the complete machine power of having developed has reached 5KW.The main feature of Laser Welding is that weldering speed is high, be out of shape for a short time, is prone to realize the automation of welding, the for example welding of aluminum car body.The welding that Laser Welding is used for steel and iron parts is very successful, but when being used for the welding job of aluminium, will go wrong.Because the aluminum component surface to the reflex of laser and the high thermoconductivity of aluminium, needs to increase laser energy density, in the laser aid that has, through focusing on, its energy density is greater than 107W/cm
2At CO
2In the laser aid, energy density should be greater than 4 * 106W/cm
2, otherwise the weldering bundle lacks penetration power; Weld porosity is more, and is easy to generate crackle.In the Nd:YAG laser aid, because the optical maser wavelength that is produced is shorter, be 1.06 μ m, aluminum alloy surface is less to the reflex of its generation, so above problem is still not outstanding.
Wherein, low frequency modulations type impulse welding (dipulse MIG weldering) productivity ratio is high, be prone to realize automation, is aluminum alloy welding one of the main technique method of producing of delivering a child.The research of nearly all impulse welding in the past and to use all be to steel, and along with the extensive use of aluminium, also gradually increase about the aluminum alloy pulse Study of Welding recent years.But in the aluminium welding applications of reality, still exist a lot of problems, in order to obtain better welding quality, process characteristic research of dipulse MIG being welded aluminium has great importance.
Dipulse MIG weldering is a kind of new technology that on the basis of conventional pulse MIC welding technology, designs to the aluminium alloy welding.If parameter is provided with proper, just can reduce the pore incidence, the refinement weld grain is widened the plumb joint interstice coverage, thereby is guaranteeing under the prerequisite of welding quality, realizes higher welding efficiency.Yet; The parameter that when carrying out dipulse MIG weldering, need regulate is very many; So it also is a relatively complicated technology. some important parameters, like the base value peak current level and the time of strong and weak pulse, the frequency of strong and weak pulse and dutycycle; Wire feed rate and speed of welding etc. all have direct influence for the stability and the appearance of weld of welding process.If before each welding, correctly match all parameters, brought huge challenge to welding personnel undoubtedly.And the physical characteristic of aluminium alloy and steel difference are bigger, and the collocation of welding parameters requires than higher, and any one parameter selects the unreasonable welding effect that all might cause sharply to worsen.So how to carry out the rational Match of parameters, and form the expert database of unified adjusting, be the important topic of pendulum in face of the welding field researcher.Can find out, digital controlly in the middle of this process, can play significant effect.Therefore, on MIG welder plants the basis of studying, carry out the digital control research of aluminium alloy dipulse MIG weldering, the aluminium alloy that obtains excellence is welded effect automatically be extremely important.
Abroad, FRONIUS company and CLOOS company have all developed a series of digitlization contravariant pulse MIG/MAG welding machines that have expert database, and these welding machine prices are high, and its core technology is exactly the expert database that wherein can constantly upgrade.But at home, among dipulse weldering aluminum technology was being studied, domestic product welding machine all can't carry out the stable welding of dipulse MIG weldering, say nothing of mariages have dipulse welding expert storehouse system welding machine.
Summary of the invention
The objective of the invention is to development trend to aluminum alloy solder technology; For enlarging the source of welding current scope of application and improving welding efficiency; Provide a kind of and be applicable to what aluminium alloy dipulse MIG welded, the stability of a system is good, welding efficiency is high, debugging is convenient, have the excellent operation interface, use aluminum alloy twin-wire dipulse digital soft switch inverter welding power source simple, that have welding expert system.
To achieve these goals, welding system of the present invention comprises: a kind of by the phase-shift soft switch full-bridge inverting main circuit of insulated gate bipolar transistor (IGBT) as switch element, DSP control circuit and man-machine interactive system.
Said aluminum alloy twin-wire dipulse welding method is meant on the basis of high frequency; Again the high frequency electric waveform is carried out low frequency modulations; The intensity that makes unit pulse strong and weak between the switching of low-frequency cycle property; Obtain periodically variable strong and weak impulse train, realize the high-efficiency high-quality welding of aluminium alloy through the cooperation of two-way impulse train phase place.Specifically comprise the steps:
1) behind the parameter initialization, DSP control software module is sent the welding commencing signal to man-machine interactive system, receives and obtains welding parameter, carries out unified adjusting according to this parameter simultaneously, obtains other corresponding welding parameter automatically.The parameter of every road impulse train comprises respectively: flash peak point current Ips and time T ps, flash background current Ibs and time T bs, weak pulse towards peak point current Ipw and time T pw, weak pulse towards background current Ibw and time T bw, flash time T s and weak pulse towards time T w; Wherein pulsew representes weak impulse train, and pulses representes the flash crowd;
2) striking success back gets into the During normal welding process, in this process, carries out instantaneous energy droplet transfer Waveform Control.Instantaneous energy refers to the transient current of electric arc and the product of instantaneous voltage, and system is through detecting and transient current, the voltage waveform of adjustment power supply output, and the energy of control molten drop reduces to splash and the purpose of the consistent even transition of control molten drop size to reach;
3) DSP at first controls main circuit 1 and gets into the flash stage, and main circuit 2 lags behind the phase bit entering flash control stage than main circuit 1, and a is adjustable for this phase relation, through control phase relation control bead contour;
4) main circuit 1 is alternately controlled with peak value, base value that main circuit 2 carries out flash respectively; Finish until the flash control stage; DSP control main circuit 1 gets into weak pulse towards the control stage; Main circuit 2 is than main circuit 1 phase place of flash during the stage that still lag behind, and main circuit 1 carries out weak pulse towards the alternately control of peak value, base value with main circuit 2, finishes towards the control stage until weak pulse;
5) if welding gun does not unclamp, then proceed the alternately instantaneous energy droplet transfer Waveform Control of strong and weak pulse, if welding gun unclamps, then enter into and receive the arc stage, receive arc and finish coomand modes to be welded such as welding machine entering;
6) if system does not receive concrete welding parameter, welding machine carries out work according to the parameter of setting last time so.
Said main circuit is made up of the rectification filtering module, high-frequency inversion module, power transformation module, the level and smooth module of rectification that connect successively.The rectifying and wave-filtering input module links to each other with three-phase alternating current, connects the high-frequency inversion module again, and the output of high-frequency inversion module connects power transformation module.The level and smooth module of rectification links to each other with load.Simultaneously, the sensor of over-current detection module is connected on the power transformation module primary coil; Sensor is connected the acquisition current sampling signal with load, voltage signal is directly obtained from the load two ends.
Said DSP control circuit mainly is made up of with peripheral circuit dsp controller TI DSP 2808.Comprise over-and under-voltage protection detection module, dsp controller, current-voltage sampling detection and feedback module, high-frequency drive module, over-current detection module and temperature detecting module, also have a JTAG mouth to be used for the download burning of program in addition.Dsp controller is connected with the over-current detection module with feedback module, over-and under-voltage protection detection module with high-frequency drive module, current-voltage sampling detection respectively.Said current-voltage sampling detects and also is connected with load with the other end of feedback module.The other end of over-and under-voltage protection detection module also is connected with the three-phase alternating current input.The high-frequency drive module also is connected with the high-frequency inversion module.Elementary the linking to each other of the other end of over-current detection module and power transformation module.The other end of temperature detecting module also is connected with radiator.Dsp controller also is connected with man-machine interactive system, and current-voltage sampling detects and also links to each other with man-machine interactive system with feedback module.Simultaneously, also be provided with a DSP control software module in the dsp controller.
Said high-frequency drive module mainly plays digital-to-analogue isolates and the power amplification effect, comprises 4 high frequency drive unit that are made up of optocoupler TLP250 and peripheral circuit in the module.Optocoupler input EPWM3A receives the PWM output I/O mouth of dsp controller; By the pwm signal that four road phase differences are adjustable, Dead Time is adjustable of dsp controller output, isolate and amplify after become the four road complementary in twos driving signals that can drive the IGBT power device.
Said current-voltage sampling detects with feedback module and detects output current by Hall element, obtains sampled signal, and through dividing potential drop, filtering, pressure limiting is to dsp controller.The voltage sample feedback circuit directly links to each other with load, and output end voltage is taken a sample, and signal is given DSP through filtering, amplifier, the isolation of light lotus root, dividing potential drop and pressure limiting.In addition, the current-voltage sampling signal that conditioning is come out also can be delivered to man-machine interactive system, by its value of carrying out the A/D conversion and on man-machine interactive system, showing actual welding electric current, voltage.
Said over-current detection module mainly detects the electric current of the primary side of power transformation module, and by amplifier, elements such as optocoupler constitute.
Said over-and under-voltage protection detection module mainly plays the effect of when the fluctuation of line voltage, turn-offing pwm signal output, and by amplifier, elements such as optocoupler constitute.
Said temperature detecting module comprises temperature sensor, overheated optocoupler, peripheral circuit, and the one of which end is connected with temperature sensor on the radiator, and the other end links to each other with the interruption input pin of dsp controller.
It is that the numeral that is used for the various parameters of given numeral input of parameter and Power Operating Process shows that said man-machine interactive system mainly acts on; Its with a LM3S818 as control core; Realize receiving the welding switch command in conjunction with CPLD, handle the operation of keyboard and encoder, be responsible for parameters of choice and input; And current-voltage sampling is detected the welded condition parameter that is produced with feedback module carry out sampling processing, and utilize the RS232 universal serial bus to communicate by letter with main control chip DSP with the GPIO pin.Simultaneously; This panel adopts idea of modular, has good portability, and this panel comprises power supply and communication interface module, digital encoder input module; Demonstration and key-press module, main control module, wherein main control module comprises ARM and CPLD minimum system.
Wherein, LM3S818 receives the welding switch command that the DSP control circuit sends, and handles the operation of keyboard and encoder, is responsible for parameters of choice and input, and current-voltage sampling is detected the welded condition parameter that is produced with feedback module carry out sampling processing.After EPM240T100 CPLD CPLD carried out programmed process; Between LM3S818 and the CPLD through the SPI folk prescription to communicating by letter; Send idsplay order by ARM to CPLD, CPLD makes control through compiling back logarithmic code pipe and LED, makes the Display And Keyboard operation corresponding.
Man-machine interactive system control system has adopted the design of MCU+CPLD to come the input-output equipment of digitlization panel is controlled; So both can utilize the control of MCU and the input-output operation of operational capability counter plate to carry out programme-control, produce corresponding control command; But can utilize the characteristics of abundant I/O pin of CPLD and flexible programming again, the order of sending MCU is converted into the demonstration of charactron and corresponding LED on the panel.GPIO F1～F5 of LM3S818 is connected with the PA2 of CPLD EPM240T100～PA4 pin, carries out SPI communication, and transmission needs data presented.The A of orthogonal encoder, B pin are connected with G3, the G2 pin of CPLD; Input signal to encoder carries out the deburring processing; Signal after will handling is then sent into the QEI interface of MCU, and promptly the G0 of CPLD links to each other with PC6, the PC7 of LM3S818 with G1, changes the value of parameter with encoder.CPLD is controlling the demonstration of LED lamp and 2 charactrons all on the panel simultaneously, and button is then controlled by the ARM controller.The ARM controller also is connected with MAX232, is used to accept the order of master control DSP and the parameter that sets to its transmission man-machine interactive system.
The idiographic flow that described DSP control software module is controlled power-supply system is:
1) behind the parameter initialization, sends the welding commencing signal, receive and obtain the parameter that panel is set, and carry out unified setting, obtain other corresponding parameter automatically by expert system according to the parameter of having set to man-machine interactive system;
2) get into starting the arc subprogram, the beginning striking, striking success back gets into the During normal welding process, and begin to get into the Waveform Control stage instantaneous energy droplet transfer this moment;
3) DSP at first controls main circuit 1 and gets into the flash stage, and main circuit 2 lags behind the phase bit entering flash control stage than main circuit 1, and this phase place is adjustable;
4) main circuit 1 is introduced into the peak value control stage of flash, and main circuit 2 gets into the base value control stage;
5) the main circuit 1 flash peak value control time in stage arrives, and then gets into the flash base value control stage, and main circuit 2 gets into the flash peak value control stage;
6) main circuit 1 is alternately controlled with peak value, base value that main circuit 2 carries out flash respectively, finishes until the 1 flash control stage of main circuit;
7) DSP control main circuit 1 gets into weak pulse towards the control stage, and main circuit 2 still gets into weak pulse towards the control stage than main circuit 1 hysteresis respective phase after accomplishing the flash control stage;
8) main circuit 1 is introduced into weak pulse and controls the stage towards peak value, and main circuit 2 gets into the base value control stage;
9) main circuit 1 weak pulse arrived towards the peak value control time, then got into weak pulse and controlled the stage towards base value, and main circuit 2 gets into weak pulses and controls the stage towards peak value;
10) main circuit 1 carries out peak value, the alternately control of base value that weak pulse dashes respectively with main circuit 2, finishes towards the control stage until main circuit 1 weak pulse;
11) if welding gun does not unclamp, then proceed 3)-10) the instantaneous energy droplet transfer Waveform Control that replaces of said strong and weak pulse; If welding gun unclamps, then finish Waveform Control stage instantaneous energy droplet transfer, main circuit 1 enters into simultaneously with main circuit 2 and receives the arc stage, receives the arc end and sends welding end signal, coomand modes to be welded such as welding machine entering to man-machine interactive system.
In DSP control software module, also comprise expert system.Said expert system is the expert system that welding is set up to the aluminium alloy dipulse; Can carry out the weldability analysis according to the dipulse welding procedure characteristic to all kinds of aluminium alloys; Welding personnel can inquire analysis result easily, can also browse, revise, add, delete the weldability analysis result that system provides simultaneously.The reference conditions of also built-in various welding characteristics and the term of reference of various parameters can directly select corresponding welding condition to carry out unified adjusting in the expert system, also can in expert system recommended parameter scope, select voluntarily, be provided with and adjust.
In DSP control software module, also comprise instantaneous energy droplet transfer Waveform Control process and wavelet filtering control algolithm.Said instantaneous energy refers to the transient current of electric arc and the product of instantaneous voltage, and its size has determined the length of electric arc and the interim form of molten drop, and its butt welded seam is shaped, splashes, the mechanical property of weld defect and weld seam has very big influence.Native system is through detecting transient current, the voltage waveform of power supply output, and the energy of control molten drop reduces to splash and the uniform purpose of the molten drop consistent transition of size to reach.
In the Waveform Control process of paired pulses peak value and base value; Need carry out the wavelet filtering algorithm controls to the detection sampled signal of electric current or voltage; Behind wavelet filtering, obtain more accurate sampled signal, require signal to compare, adjustment output next time with given control.
The present invention compared with prior art has following advantage and beneficial effect:
1) the present invention proposes and has realized totally digitilized mariages dipulse welding method and welding machine exploitation at home first, directly to the Collaborative Control of mariages, makes welding machine have better uniformity, dynamic response performance through DSP TMS320F2808.Utilize software to realize the control of dipulse waveform, thereby make the welding waveform more accurate;
2) to be different from characteristics of existing Double Wire Welding machine technology be exactly that mariages is in same main frame in the present invention; Utilize directly two welding machines of control of same DSP; It no longer is traditional master-slave mode mariages machine structure; Practice thrift volume on the one hand, reduce cost, reduce the problem that signal post brings in addition on the one hand;
3) patent of the present invention has realized the Waveform Control of dipulse through software, and through a large amount of experiments, has roughly confirmed the phase matched relation of two-way pulse; Secondly the quantitative relationship of early-stage Study achievement-instantaneous energy droplet transfer Waveform Control, wavelet filtering control algolithm, speed of welding and appearance of weld etc. is used in the impulse waveform control procedure; In expert system, designed the reference interval of parameter; Can make the control of welding process more accurate, the parameter setting is more reliable.Thereby realize stable welding process, improve welding quality;
4) patent of the present invention is numerous to mariages dipulse welding control waveform parameter; The complicated present situation of control parameter regulation; Design has also been developed mariages dipulse technology expert system; Utilize intelligence Implementation of Expert System the unified adjusting of parameter, improved the degree of intelligence of welding machine greatly, reduced operation easier.
Description of drawings
Fig. 1 is that the system of a specific embodiment of the present invention forms structured flowchart;
Fig. 2 is the circuit theory diagrams of the soft switch main circuit of a specific embodiment of the present invention;
Fig. 3 is the driving of a specific embodiment of the present invention and the circuit theory diagrams of pulse width modulation module;
Fig. 4 is the dsp controller circuit theory diagrams of a specific embodiment of the present invention;
Fig. 5 (a) is the detection and the protection ring economize on electricity road schematic diagram of a specific embodiment of the present invention;
Fig. 5 (b) is the detection and the protection ring economize on electricity road schematic diagram of a specific embodiment of the present invention;
Fig. 5 (c) is the detection and the protection ring economize on electricity road schematic diagram of a specific embodiment of the present invention;
Fig. 5 (d) is the detection and the protection ring economize on electricity road schematic diagram of a specific embodiment of the present invention;
Fig. 6 is the man-machine interactive system theory diagram of a specific embodiment of the present invention;
Fig. 7 is the man-machine interactive system control system circuit diagram of a specific embodiment of the present invention;
Fig. 8 is the course of work software control flow chart of a specific embodiment of the present invention.
The specific embodiment
Below in conjunction with accompanying drawing and embodiment, the present invention is done further detailed description, but implementation method of the present invention is not limited thereto with the scope that requires protection.
As shown in Figure 1, be the soft switch source of welding current of multifunctional digital mariages of the present invention, by main circuit 1 and main circuit 2; Drive and testing circuit 1 and driving and testing circuit 2; Dsp controller 108, over-and under-voltage protection detection module 109, and man-machine interactive system 110 constitutes.Wherein, it is identical that the structure of main circuit 1 and main circuit 2 is formed, and driving and testing circuit 1 also are like this with driving and testing circuit 2.With main circuit 1 is example, forms by connecting rectification filtering module 101, high-frequency inversion module 102, power transformation module 103, the level and smooth module 104 of rectification successively.Rectification filtering module 101 is connected with three-phase alternating current input power supply, and the level and smooth module 104 of rectification is connected with load.In addition, driving is detected with feedback module 107 by temperature detecting module 106, high-frequency drive module 105, over-current detection module 111, current-voltage sampling with testing circuit 1 and forms.Dsp controller 108 detects with feedback module 107, over-and under-voltage protection detection module 109 with high-frequency drive module 105, current-voltage sampling respectively and is connected with over-current detection module 111; Current-voltage sampling detects and also is connected with load with the other end of feedback module 107; The other end of over-and under-voltage protection detection module 109 also is connected with the three-phase alternating current input; High-frequency drive module 105 also is connected with high-frequency inversion module 102, elementary the linking to each other of the other end of over-current detection module 111 and power transformation module 103.Dsp controller 108 also is connected with man-machine interactive system 110, temperature detecting module 106 respectively.Wherein, temperature detecting module 106 comprises temperature sensor, overheated optocoupler, peripheral circuit, and the one of which end is connected with temperature sensor on the radiator, and the interruption input pin of the other end and dsp controller 108 mutually.Man-machine interactive system 110 comprises given signal, the processing of output signal and display circuit.
As shown in Figure 2, be example with main circuit 1, three-phase alternating current input power supply connects the rectifier bridge of rectification module 101, connects filtering device L then
1, C
5-8, connect the inverter bridge VT of high-frequency inversion module 102 again
1-4, C
11-14, R
5-8, wherein, R
5-8In side circuit, replace C with the zero resistance line
11-14Be external resonant capacitance.The high-frequency power transformer T1 of the output connection power transformation module 103 of high-frequency inversion module 102 is elementary, and transformer secondary output is through high frequency full-wave rectifying circuit D
1-4, filtering link L
2, C
9-10, C
15-16, YR
1-2, R
9Back output DC, above link constitutes the power main circuit.High-frequency inversion module 102 comprises TR1 and two inverter bridge legs of TR2 (be respectively leading-bridge and brachium pontis) afterwards, and each brachium pontis has comprised the IGBT of two unit.Simultaneously, the sensor H1 of over-current detection module 111 is connected on power transformation module 103 primary coils; Current-voltage sampling detects with feedback module 107 and obtains current sampling signal for sensor H2 is connected with load, and voltage signal is directly obtained from the load two ends.Another main circuit 2 is identical therewith.
Like Fig. 3, shown in 4, high-frequency drive module 105 mainly plays digital-to-analogue isolates and the power amplification effect, comprises 4 high frequency drive unit that are made up of optocoupler TLP250 and peripheral circuit in the module.Fig. 3 is one road circuit diagram that drives wherein; Optocoupler input EPWM3A receives the PWM output I/O mouth of dsp controller 108; The pwm signal that four road phase differences are adjustable, Dead Time is adjustable by dsp controller 108 outputs; Isolation through high-frequency drive module 105 and amplify after become the four road complementary in twos driving signals that can drive the IGBT power device, drive the lead and lag inverter bridge leg TR1 in the monolateral main circuit, four IGBT switching device VT of TR2
1-VT
4, the pwm signal that provides by dsp controller 108 through high-frequency drive module 105 isolate amplify after, change the amplitude+15V of positive half-wave into, the alternating-current pulse signal of negative half-wave lowest amplitude-15V can satisfy the reliable needs of opening and turn-offing of high-power IGBT.Through controlling the phase difference of leading arm and lagging leg; Also promptly control the phase shifting angle of PWM; The stray inductance of external resonant capacitance, parasitic capacitance and power transformer in the inversion major loop, leakage inductance etc. have constituted a LC resonant tank; In the device for power switching switching process, realize the change of current of no-voltage resonance, switching loss is low, and the electromagnetic stress of device reduces significantly.
As shown in Figure 4, dsp controller is mainly interconnected by DSP TMS320F2808 minimum system and serial ports level transferring chip MAX3232 to be formed, and also has a JTAG mouth to be used for the download burning of program in addition.ADCINA0～ADCINA5 of DSP is connected with the current/voltage detection module, accomplishes the conversion of the analog signal of sampling to data signal; GPIO4～GPIO11 exports 8 road pwm signals and is connected with high-frequency drive module 105; GPIO12, GPIO13, GPIO16 are connected with primary electricity over-current detection module 111 stream detection modules, over-and under-voltage protection detection module 109, temperature detecting module 106 respectively.DSP TMS320F2808 is as the core of control, and sampled signal and given signal carry out computing in DSP, confirm that pwm signal shifts to size, export 4 the tunnel and shift to pulse-width signal, thereby control the output of power supply.I/O port GPIO14/SCITXDB, the GPIO15/SCIRXDB of DSP are connected with DOUT1 with the pin DIN1 of MAX3232 respectively, be used for and man-machine interactive system 110 between communication.
Shown in Fig. 4,5 (a), current-voltage sampling detects the sampling feedback effect of mainly playing current/voltage with feedback module 107, to realize closed-loop control.In current sample detection and the feedback circuit, adopted current Hall sensor H2 at power output end, P15 links to each other with H2, and when current Hall sensor acquisition end electric current was 100A, current output sensor was 100mA.Through adopting suitable resistive element, make when welding current when 0-400A changes, the signal excursion after the feedback circuit processing is 0-4V.Pass through dividing potential drop again, filtering obtains signal CURRENT-FBK and gives DSP after the adjustment such as pressure limiting, carry out computing by DSP.Directly output end voltage is taken a sample in voltage sample detection and the feedback circuit; Remove the high-frequency signal in the signal through LPF, isolate through amplifier, light lotus root again, nurse one's health into the d. c. voltage signal of 0-5V; Obtain signal VOLTAGE-FBK through dividing potential drop and pressure limiting more at last, give DSP.In addition, the current-voltage sampling signal that conditioning is come out also can be delivered to the ADC port of man-machine interactive system, by its value of carrying out the A/D conversion and on man-machine interactive system, showing actual welding electric current, voltage.
Shown in Fig. 4,5 (b), P7 is connected with sensor H1, and the over-current detection module mainly detects the electric current of the primary side of power transformation module 103.When elementary electric current surpasses certain value, produce over-current signal, the optocoupler conducting, the CURRENT-EXC level is dragged down, and DSP need the program of passing through not be about to the pwm signal cut-out, and cutting-off process is accomplished by DSP hardware.The I/O mouth GPIO12/TZ1 level of DSP is dragged down also can trigger an interruption simultaneously, and in interrupt routine, DSP can further handle and move.
Shown in Fig. 4,5 (c), P18 is connected with temperature sensor TH1.The temperature sensor of temperature detecting module is installed on the radiator of IGBT module place, whether surpasses ormal weight in order to detect the IGBT heating.Temperature sensor is a normally closed switch, breaks off if trigger then, produces heat alarm; Make overheated smooth lotus root conducting, the CURRENT-EXC level is dragged down, and promptly the I/O mouth GPIO16/TZ5 level of DSP is dragged down; Can according to this I/O judge whether produce heat alarm in the DSP program this moment, and handle.
Shown in Fig. 4,5 (d), over-and under-voltage protection detection module 109 mainly plays the effect of when the fluctuation of line voltage, turn-offing pwm signal output.Three-phase circuit through the transformer step-down, be rectified into direct current signal VFB, so the VFB direct proportion is in line voltage.When VFB crosses when being higher than setting value or being lower than setting value, two comparator comparative results are done the phase AND operation, and the result is low level " 0 "; The VOLTAGE-EXC level is drawn high; The I/O mouth GPIO13/TZ2 level that is DSP is drawn high, and DSP turn-offs pwm signal output, and carries out troubleshooting.
As shown in Figure 6, man-machine interactive system 110 main effects are that the numeral that is used for the various parameters of given numeral input of parameter and Power Operating Process shows.LM3S818 receives the welding switch command that dsp controller 108 sends, and handles the operation of keyboard and encoder, is responsible for parameters of choice and input, and current-voltage sampling is detected the welded condition parameter that is produced with feedback module 107 carry out sampling processing.After the EPM240T100CPLD CPLD carried out programmed process; Between LM3S818 and the CPLD through the SPI folk prescription to communicating by letter; Send idsplay order by ARM to CPLD, CPLD makes control through compiling back logarithmic code pipe and LED, makes the Display And Keyboard operation corresponding.
As shown in Figure 7, man-machine interactive system 110 control systems have adopted the design of MCU+CPLD to come the input-output equipment of digitlization panel is controlled.So both can utilize the control of MCU and the input-output operation of operational capability counter plate to carry out programme-control, produce corresponding control command; But can utilize the characteristics of abundant I/O pin of CPLD and flexible programming again, the order of sending MCU is converted into the demonstration of charactron and corresponding LED on the panel.GPIO F1～F5 of LM3S818 is connected with the PA2 of CPLD EPM240T100～PA4 pin, carries out SPI communication, and transmission needs data presented.The A of orthogonal encoder, B pin are connected with G3, the G2 pin of CPLD; Input signal to encoder carries out the deburring processing; Signal after will handling is then sent into the QEI interface of MCU, and promptly the G0 of CPLD links to each other with PC6, the PC7 of LM3S818 with G1, changes the value of parameter with encoder.CPLD is controlling the demonstration of LED lamp and 2 charactrons all on the panel simultaneously, and button is then controlled by the ARM controller.The ARM controller also is connected with MAX232, is used to accept the order of master control DSP and the parameter that sets to its transmission man-machine interactive system.
Be illustrated in figure 8 as the control software flow pattern, behind the parameter initialization, DSP control software module is sent the welding commencing signal to man-machine interactive system; And welding parameter is obtained in reception; Simultaneously carry out unified adjusting, obtain other corresponding welding parameter automatically, the beginning striking according to this parameter; Striking success back gets into the During normal welding process, in this process, carries out instantaneous energy droplet transfer Waveform Control.DSP at first controls main circuit 1 and gets into the flash stage, and main circuit 2 lags behind the phase bit entering flash control stage than main circuit 1, and this phase place is adjustable.Main circuit 1 is alternately controlled with peak value, base value that main circuit 2 carries out flash respectively, finishes until the flash control stage.DSP control main circuit 1 gets into weak pulse towards the control stage, and main circuit 2 is than main circuit 1 phase place of flash during the stage that still lag behind.Main circuit 1 carries out weak pulse towards the alternately control of peak value, base value with main circuit 2, finishes towards the control stage until weak pulse.If welding gun does not unclamp, then proceed the alternately instantaneous energy droplet transfer Waveform Control of strong and weak pulse, if welding gun unclamps, then enter into simultaneously and receive the arc stage, receive arc and finish coomand modes to be welded such as then welding machine entering.
When using the soft switch source of welding current of multifunctional digital mariages of the present invention; Man-machine interactive system 110 is selected welding manner and setup parameter; The three-phase main-frequency alternating current gets into high-frequency inversion module 102 after becoming the smooth direct current electricity behind the filtration module 101; Dsp controller 108 compares according to current-voltage sampling detection and electric current, voltage signal and the given parameter that feedback module 107 detects load; Through the PI computing of dsp controller 108, produce four road phase-shift PWM signals in complementary band dead band in twos, this four road pwm signal amplifies switching tube the turning on and off under no-voltage of back control high-frequency inversion modules 102 through high-frequency drive module 105; Realize soft switch; Thereby obtain the 25KHz high-frequency high-voltage, high-frequency high-voltage converts the alternating-current pulse electric current of big current low voltage again to through overpower transformation module 103, obtains more level and smooth dc pulse current through rectification module 104 again.The primary current of over-current detection module 111 detection power transformation modules 103, as overcurrent condition appears, high-frequency inversion module 102 is closed in the interruption of the DSP that then sets out, protection main circuit trouble free service.Over-and under-voltage protection detection module 109 detects three-phase main-frequency voltage, as overvoltage or under-voltage phenomenon occur, then triggers DSP and interrupts, and closes high-frequency inversion module 102.
The present invention has embodied the characteristic of light high speed.Present embodiment is a core with embedded dsp DSP TMS320F2808 at a high speed first; Make full use of the superior function of dsp chip aspect embedded Control; Adopt modularization, transplantable method for designing, realize output characteristic of power source control, welding control waveform, man-machine interactive system through software programming.8 tunnel phase-shift PWM signals of two main circuits are all directly exported through programming mode by DSP, finally realize the full-digital control of Arc Welding Power.Secondly through same control core realization the control of two main circuits, two main circuits concentrate in the same power supply, with in the past mariages master-slave structure bigger difference are arranged, and through the appropriate design of butt welding machine structure, power volume are reduced more than 30%.In addition, no longer need communication between principal and subordinate's machine, make mariages dipulse welding machine have better uniformity, dynamic response performance and extensibility.Global design has demonstrated fully the characteristic of light high speed.
The present invention has realized energy-efficient.Present embodiment adopts two root bead silks, through the cooperation of height frequency pulse, realizes the dipulse Double Wire Welding.When obtaining good welding quality, utilize the Double Wire Welding technology can obtain higher welding efficiency.In addition, utilize achievement-soft switch mariages welding technology in early stage, energy utilization rate is reached more than 90%, in the efficient that further improves mariages dipulse welding machine, effectively reduce energy resource consumption.
The present invention controls accurately.Present embodiment has made full use of the high-speed computation and the data-handling capacity of DSP embedded microprocessor; The instantaneous energy of welding arc is gathered in real time and analyzed; According to the output characteristics of the automatic in real time control source of welding current of conditions at the arc, to reach purpose to instantaneous ability optimization output of welding arc and adjusting.Secondly through detecting feedback output current voltage, electric arc is changed responding fast, and the energy of adjustment output in time, make control more accurate, to obtain the welding quality of high-quality.Next utilizes the droplet transfer waveform controlling method to carry out accurate Waveform Control.
The present invention has the pleasant characteristic of intelligence.Integrated dipulse Welding procedure expert system in the present embodiment; Can realize the automatic adjusting of dipulse parameter through the mode of unified adjusting, efficiently solve the too much problem of dipulse welding condition; Reduce operation easier, realized the system intelligent operation.Secondly, by ARM control core, developed special-purpose man-machine interactive system, thereby strengthened the pleasant property of system.
The present invention can realize the high-quality attractive in appearance of product.Present embodiment can obtain to obtain more careful scalelike mark than general dipulse welding through to the phase controlling between the two root bead silks, can also pass through to regulate the phase difference between the mariages, thereby the spacing of control scalelike mark obtains profile more attractive in appearance.Secondly the further cooperation of mariages phase place reduces pore incidence, refinement weld grain, reduces crack sensitivity, makes weldquality better.
To sum up; The invention provides a kind of aluminium alloy welding of being applicable to, have that the stability of a system is good, welding efficiency is high, debugging is convenient, have the excellent operation interface, use simply, have a mariages dipulse digital soft switch welding power source system of welding expert system.
In this specification, the present invention is described with reference to its certain embodiments.But, still can make various modifications and conversion obviously and not deviate from the spirit and scope of the present invention.Therefore, specification and accompanying drawing are regarded in an illustrative, rather than a restrictive.
Claims (9)
1. aluminum alloy twin-wire dipulse welding method; It is characterized in that two main circuits produce one tunnel dipulse waveform respectively, the dipulse waveform refers on the basis of high frequency, again the high frequency electric waveform carried out low frequency modulations; The intensity that makes unit pulse strong and weak between the switching of low-frequency cycle property; Obtain periodically variable strong and weak impulse train, the two-way impulse train cooperates the high-efficiency high-quality welding that realizes aluminium alloy through phase place, and concrete method comprises the steps:
1) behind the parameter initialization, DSP control software module is sent the welding commencing signal to man-machine interactive system, receives and obtains welding parameter, carries out unified adjusting according to this parameter simultaneously, obtains other corresponding welding parameter automatically; The parameter of every road impulse train comprises respectively: flash peak point current Ips and time T ps, flash background current Ibs and time T bs, weak pulse towards peak point current Ipw and time T pw, weak pulse towards background current Ibw and time T bw, flash time T s and weak pulse towards time T w;
2) striking success back gets into the During normal welding process, in this process, carries out instantaneous energy droplet transfer Waveform Control; Instantaneous energy refers to the transient current of electric arc and the product of instantaneous voltage, and system is through detecting and transient current, the voltage waveform of adjustment power supply output, and the energy of control molten drop reduces to splash and the purpose of the consistent even transition of control molten drop size to reach;
3) DSP at first controls main circuit 1 and gets into the flash stage, and main circuit 2 lags behind the phase bit entering flash control stage than main circuit 1, and a is adjustable for this phase relation, through control phase relation control bead contour;
4) main circuit 1 is alternately controlled with peak value, base value that main circuit 2 carries out flash respectively; Finish until the flash control stage; DSP control main circuit 1 gets into weak pulse towards the control stage; Main circuit 2 is than main circuit 1 phase place of flash during the stage that still lag behind, and main circuit 1 carries out weak pulse towards the alternately control of peak value, base value with main circuit 2, finishes towards the control stage until weak pulse;
5) if welding gun does not unclamp, then proceed the alternately instantaneous energy droplet transfer Waveform Control of strong and weak pulse, if welding gun unclamps, then enter into and receive the arc stage, receive arc and finish coomand modes to be welded such as welding machine entering;
6) if system does not receive concrete welding parameter, welding machine carries out work according to the parameter of setting last time so.
2. aluminum alloy twin-wire dipulse welding power source system; It is characterized in that, form by dsp controller, over-and under-voltage protection detection module, man-machine interactive system, two structures that the soft switch main circuit of identical IGBT is formed identical driving with two structures and testing circuit constitutes; Wherein, The soft switch main circuit of described IGBT is made up of the rectification filtering module, high-frequency inversion module, power transformation module, the level and smooth module of rectification that connect successively; Rectification filtering module is connected with three-phase alternating current input power supply, and the level and smooth module of rectification is connected with load; Drive with testing circuit and form with feedback module by temperature detecting module, high-frequency drive module, over-current detection module, current-voltage sampling detection; Dsp controller is connected with man-machine interactive system with feedback module, over-and under-voltage protection detection module, and comprises a JTAG mouth with temperature detecting module, high-frequency drive module, over-current detection module, current-voltage sampling detection respectively; Current-voltage sampling detects and is connected with load with the other end of feedback module; The other end of over-and under-voltage protection detection module is connected with three-phase alternating current input power supply; The high-frequency drive module is connected with the high-frequency inversion module, elementary the linking to each other of the other end of over-current detection module and power transformation module.
3. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 2; It is characterized in that; Described temperature detecting module comprises temperature sensor, overheated optocoupler, peripheral circuit; One end of temperature detecting module is connected with radiator, and the other end links to each other with the interruption input pin of dsp controller.
4. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 2; It is characterized in that; Described dsp controller is connected with the over-current detection module with feedback module, over-and under-voltage protection detection module, temperature detecting module with high-frequency drive module, current-voltage sampling detection respectively; Simultaneously, dsp controller is connected with man-machine interactive system, and the current-voltage sampling detection is connected with man-machine interactive system with feedback module; Elementary the linking to each other of the other end of described over-current detection module and power transformation module; Said current-voltage sampling detects and is connected with load with the other end of feedback module, and the other end of described over-and under-voltage protection detection module is connected with the three-phase alternating current input, and described high-frequency drive module is connected with the high-frequency inversion module.
5. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 2; It is characterized in that; The sensor of described over-current detection module is connected on the power transformation module primary coil; Sensor is connected the acquisition current sampling signal with load, voltage signal is directly obtained from the load two ends.
6. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 2; It is characterized in that; Described high-frequency drive module comprises 4 high frequency drive unit that are made up of optocoupler TLP250 and peripheral circuit, and wherein the input of each optocoupler all links to each other with the output of dsp controller.
7. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 2; It is characterized in that; Described man-machine interactive system comprises power supply and communication interface module, digital encoder input module, demonstration and key-press module, main control module; Wherein main control module comprises ARM LM3S818 and CPLD, and said man-machine interactive system, is communicated by letter with the DSP control circuit with the GPIO pin with the RS232 universal serial bus as the control core with an ARM LM3S818; Between described ARM LM3S818 and the CPLD through the SPI folk prescription to communicating by letter, and send instruction to CPLD by ARMLM3S818.
8. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 2 is characterized in that described man-machine interactive system comprises a human-computer interactive control system.
9. a kind of aluminum alloy twin-wire dipulse welding power source system according to claim 8 is characterized in that, described man-machine interactive system adopts the control mode of MCU+CPLD.
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