CN101913015A - Thin double-wire digital soft switch inverter welding power source system and control method thereof - Google Patents
Thin double-wire digital soft switch inverter welding power source system and control method thereof Download PDFInfo
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Abstract
The invention relates to the technical field of welding equipment, in particular to a thin double-wire digital soft switch inverter welding power source system and a control method thereof. The system comprises over-voltage under-voltage protection and detection circuits placed in the same welding power source case by adopting an integrated structure, a man-machine interaction system, an ARM master controller in which a welding process expert database software system is placed, two limited bipolar soft switch full-bridge inverter main circuits with the same structure, and two drive and detection circuits with the same structure, wherein the limited bipolar soft switch full-bridge inverter main circuits take insulated gate bipolar transistors (IGBT) as switching elements. The system can improve the welding efficiency on the premise of ensuring the welding quality and the welding stability, effectively reduce the influence of electromagnetic interference of a welding site and eliminate mutual electromagnetic interference between two welding wires, has high safety performance, can reduce equipment volume and lower equipment cost, and is comparatively energy-saving.
Description
Technical field:
The present invention relates to technical field of welding equipment, relate in particular to a kind of thin double-wire digital soft switch inverter welding power source system and control method thereof.
Background technology:
Manufacturing high speed development has promoted the generation and the development of new and effectiveization automatic welding technique.Traditional monofilament weldering system enhances productivity by the mode that increases heat input, can bring a lot of problems but the monofilament weldering increases operating current excessively, mainly weld defects such as hump welding bead and undercut can occur.
The sign of high efficiency welding is to improve welding efficiency under the prerequisite that guarantees welding quality.For the high efficiency welding method of the existing multiple maturation of the welding of cut deal, wherein mariages/multifibres weldering is a kind of main mode of high efficiency welding.Compare with single arc welding technology, with the Double Wire Welding is example, because two electric arcs burn on a molten bath jointly, not only improved total welding heat input, and the characteristics of change heat distribution, when carrying out High Speed Welding, can effectively avoid number of drawbacks such as undercut, can improve speed of welding and production efficiency greatly, and can obtain high-quality weld seam attractive in appearance.
The main technique form of Double Wire Welding has two kinds: a kind of Twin of being arc (synchronously two arc), another kind is Tandem (a separate double arc).Twin Arc adopts two identical pulse sources of welding current, two cover wire feeders, the ignition tip (two root bead silks are not mutually insulateds) that can hold two root bead silks, and a molten bath.During welding, two power supply output pulse frequencies are identical, and the electric current that mariages passes through is also identical, and promptly two rhizoids are melted in the molten bath with identical speed.The advantage of Twin Arc is to utilize arc self-regulation, need not telegon between two power supplys, and system is simple relatively; But its shortcoming is also clearly, the poor controllability of electric arc, and the power that influences each other between welding wire is bigger, is difficult to the accurately fusing and the droplet transfer of control two root bead silks.Tandem Double Wire Welding technology is wherein to use at most also the most ripe a kind of welding method.This Tandem Double Wire Welding technology is placed on two root bead silks in the specially designed welding gun by certain angle, two root bead silks are independently-powered by power supply separately, mutually insulated, can difference except that wire feed rate, other all parameter be all independently of one another, the diameter of two root bead silks, material in addition with or without pulse, can be different, can control electric arc best like this, under the prerequisite that guarantees the arc stability burning, drop to the phase mutual interference of two electric arcs minimum.There is German Cloos in the manufacturer that uses Tandem Double Wire Welding technology in the world, Austrian Fronius and U.S. Lincoln company, and the operation of this technology and parameter are regulated all more or less freely, are accepted extensively by the user.The Tandem mariages high-speed welding equipment of Cloos company has been applied in the fields such as locomotive, shipbuilding, steel construction at present; The twin-wire MIG of Austria Fronius company exploitation/MAG weldering system also has numerous users at home and abroad.The shortcoming of these High Speed Welding equipment is split-type structurals, needs mutual communication to realize coordinating control, and is high to the communication speed requirement, be vulnerable to weld the influence that on-the-spot intense electromagnetic is disturbed, and equipment volume is big, the cost height.In addition, in above-mentioned High Speed Welding equipment, inversion welding source equipment is the hard switching mode mostly, be in firmly during work open, hard off state, have bigger potential safety hazard, and not energy-conservation.And in the above-mentioned Double Wire Welding method, no matter all also there is certain problem in which kind of method at welding stability and weldquality method, mainly is that mutual electromagnetic interference is difficult to eliminate between the two root bead silks, and it is bigger to splash.
Summary of the invention:
The objective of the invention is at the deficiencies in the prior art, a kind of thin double-wire digital soft switch inverter welding power source system is provided, this system can improve welding efficiency under the prerequisite that guarantees welding quality and welding stability, can effectively reduce the influence of the on-the-spot electromagnetic interference of welding, eliminate mutual electromagnetic interference between the two root bead silks, the security performance height, and can reduce equipment volume, reduction equipment cost, and more energy-conservation.
Another object of the present invention is at the deficiencies in the prior art, a kind of control method of thin double-wire digital soft switch inverter welding power source system is provided, this method can improve welding efficiency and security performance under the prerequisite that guarantees welding quality and welding stability, and can effectively reduce the influence of the on-the-spot electromagnetic interference of welding, eliminate mutual electromagnetic interference between the two root bead silks.
For achieving the above object, the present invention is achieved through the following technical solutions:
A kind of thin double-wire digital soft switch inverter welding power source system, it comprises adopts that integral structure is built-in to be installed on over-and under-voltage protection testing circuit, the man-machine interactive system in the same source of welding current cabinet, the ARM master controller that is built-in with welding procedure expert database software systems, finite both soft switch full inverter main circuit that the two-way circuit structure is identical, and identical driving and the testing circuit of two-way circuit structure;
Described finite both soft switch full inverter main circuit with insulated gate bipolar transistor IGBT as switch element; Described finite both soft switch full inverter main circuit comprises a current rectifying and wave filtering circuit, high-frequency inverter circuit, power transforming circuit, the secondary rectification smoothed filter circuit that connects successively;
Described driving and testing circuit comprise that temperature sensing circuit, switching tube drive circuit, over-current detection circuit, mariages current-voltage sampling detect and feedback circuit;
The ARM master controller drives with temperature sensing circuit, switching tube drive circuit, over-current detection circuit and the detection of mariages current-voltage sampling of testing circuit with two-way respectively and is connected with feedback circuit; The ARM master controller is connected with over-and under-voltage protection testing circuit; The ARM master controller is connected by serial ports with man-machine interactive system;
A current rectifying and wave filtering circuit of over-and under-voltage protection testing circuit and two-way finite both soft switch full inverter main circuit all connects same three-phase alternating current input power supply; Each road finite both soft switch full inverter main circuit is corresponding with testing circuit with one tunnel driving respectively, high-frequency inverter circuit is connected with corresponding switching tube drive circuit, the primary side of power transforming circuit is connected with corresponding over-current detection circuit, and the secondary rectification smoothed filter circuit of each road finite both soft switch full inverter main circuit and corresponding a road drives with the mariages current-voltage sampling detection of testing circuit and is connected same arc load with feedback circuit.
Wherein, the model of described ARM master controller is LM3S8962.
Wherein, described man-machine interactive system comprises CPLD chip, main control chip, digital encoder input circuit, key circuit, LED lamp, charactron, demonstration and input equipment; The I/O interface control connection LED lamp and the charactron of described CPLD chip, communication is connected between CPLD chip and the main control chip, main control chip is connected with digital encoder input circuit, key circuit and demonstration and input equipment, and main control chip connects TX, the RX pin position of ARM master controller by serial ports.
Wherein, described switching tube drive circuit comprises four switching tube driver elements that are made of optocoupler and peripheral circuit, and each optocoupler all is connected with the ARM master controller.
Wherein, the A/D interface of described ARM master controller detects with the mariages current-voltage sampling and is connected with feedback circuit.
Wherein, the PWM module of described ARM master controller drives with two-way respectively and is connected with the switching tube drive circuit of testing circuit.
Wherein, the GPIO interface of described ARM master controller is connected with over-and under-voltage protection testing circuit, temperature sensing circuit, over-current detection circuit respectively.
Wherein, described temperature sensing circuit comprises the temperature sensor that is connected with radiator, and signal comparator circuit and optical coupling isolation circuit.
A kind of control method of thin double-wire digital soft switch inverter welding power source system, it may further comprise the steps:
Steps A, system boot, systematic parameter initialization;
Step B, the ARM master controller sends the welding commencing signal to the man-machine interactive system of people, and the ARM master controller receives and obtains welding parameter simultaneously;
Step C, ARM master controller call striking impulse waveform function, the beginning striking;
Step D if striking is unsuccessful, returns step C;
If the striking success then enters normal welding process, enter step e;
Step e is judged selected welding manner, carries out the control corresponding subprogram according to the welding manner of selecting, and comprising:
If welding manner is a pulse MIC welding, enter pulse MIC welding control subprogram, the arc parameters to two-way finite both soft switch full inverter main circuit carries out instantaneous energy control respectively;
If welding manner is a dipulse weldering aluminium, then enter dipulse weldering aluminium control subprogram, respectively two-way finite both soft switch full inverter main circuit is carried out constant current control;
If welding manner is CO
2/ MAG gas shielded arc welding then enters CO
2Weldering control subprogram is carried out constant voltage control to two-way finite both soft switch full inverter main circuit respectively;
Step F, if arc welding gun switch unclamps, or the welding process end, then the ARM master controller calls the receipts arc function, enters into to receive the arc stage;
Step G receives arc and finishes, and the ARM master controller sends the welding end signal to man-machine interactive system, and system enters the state that order is welded in wait next time.
Wherein, in the step e, describedly respectively the arc parameters of two-way finite both soft switch full inverter main circuit is carried out instantaneous energy control and be specially: ARM main controller controls first via finite both soft switch full inverter main circuit output peak point current, control the second road finite both soft switch full inverter main circuit output background current simultaneously, when first via finite both soft switch full inverter main circuit output peak point current finishes to enter the background current output state, the second road finite both soft switch full inverter main circuit enters the peak point current output state, so circulation makes the power pulse output phase of two-way finite both soft switch full inverter main circuit differ 180 ° repeatedly.
Beneficial effect of the present invention is:
A kind of thin double-wire digital soft switch inverter welding power source system of the present invention, it comprises adopts that integral structure is built-in to be installed on over-and under-voltage protection testing circuit 109, the man-machine interactive system 110 in the same source of welding current cabinet, the ARM master controller 108 that is built-in with welding procedure expert database software systems, finite both soft switch full inverter main circuit that the two-way circuit structure is identical, and identical driving and the testing circuit of two-way circuit structure; Described finite both soft switch full inverter main circuit with insulated gate bipolar transistor IGBT as switch element.Above-mentioned a kind of thin double-wire digital soft switch inverter welding power source system has been realized totally digitilized mariages welding machine control, directly to the Collaborative Control of mariages, makes welding machine have better uniformity, dynamic response performance by ARM master controller 108; Its characteristics are exactly that mariages is in same main frame, utilize same ARM master controller 108 directly to control two-way finite both soft switch full inverter main circuit simultaneously, it no longer is traditional master-slave mode mariages machine structure, save volume on the one hand, reduce cost, reduce the problem that signal post brings in addition on the one hand; The present invention also realizes FR soft switch, has significantly reduced the switching loss and the electric stress of power tube, in Synergistic and energy-saving, has reduced electromagnetic interference, has improved the Electro Magnetic Compatibility and the reliability of inverter type welder; The present invention can also make the control of welding process more accurate, thereby realizes stable welding process, improves welding quality.In sum, a kind of thin double-wire digital soft switch inverter welding power source system of the present invention can improve welding efficiency under the prerequisite that guarantees welding quality and welding stability, can effectively reduce the influence of the on-the-spot electromagnetic interference of welding, eliminate mutual electromagnetic interference between the two root bead silks, the security performance height, and it is can reduce equipment volume, reduce equipment cost, and more energy-conservation.
The control method of a kind of thin double-wire digital soft switch inverter welding power source system of the present invention, it utilizes same ARM master controller 108 directly to control the mode of two-way finite both soft switch full inverter main circuit simultaneously, after entering normal welding process, judge selected welding manner, and, can be applicable to pulse MIC welding, dipulse weldering aluminium, CO according to the welding manner execution control corresponding subprogram of selecting
2Welding manners such as/MAG gas shielded arc welding.This method can improve welding efficiency and security performance under the prerequisite that guarantees welding quality and welding stability, and can effectively reduce the influence of the on-the-spot electromagnetic interference of welding, eliminates mutual electromagnetic interference between the two root bead silks.
Description of drawings:
Fig. 1 is a structured flowchart of the present invention;
Fig. 2 is an operation principle block diagram of the present invention;
Fig. 3-1 is the wherein part of the circuit structure diagram of mariages current-voltage sampling detection of the present invention and feedback circuit;
Fig. 3-2 is another part of the circuit structure diagram of mariages current-voltage sampling detection of the present invention and feedback circuit;
Fig. 4 is the circuit structure diagram of over-current detection circuit of the present invention;
Fig. 5 is the circuit structure diagram of over-and under-voltage protection testing circuit of the present invention;
Fig. 6 is the circuit structure diagram of temperature sensing circuit of the present invention;
Fig. 7 is the operation principle block diagram of man-machine interactive system of the present invention;
Fig. 8 is the flow chart of a kind of thin double-wire digital soft switch inverter welding power source system control method of the present invention.
The specific embodiment:
The present invention is further illustrated below in conjunction with drawings and Examples:
Embodiment one
A kind of thin double-wire digital soft switch inverter welding power source system; as shown in Figure 1; it comprises adopts that integral structure is built-in to be installed on over-and under-voltage protection testing circuit 109, the man-machine interactive system 110 in the same source of welding current cabinet, the ARM master controller 108 that is built-in with welding procedure expert database software systems, finite both soft switch full inverter main circuit 2 that the two-way circuit structure is identical, and identical driving and the testing circuit 3 of two-way circuit structure.
Wherein, described finite both soft switch full inverter main circuit 2 with insulated gate bipolar transistor IGBT as switch element; Described finite both soft switch full inverter main circuit 2 comprises a current rectifying and wave filtering circuit 101, high-frequency inverter circuit 102, power transforming circuit 103, the secondary rectification smoothed filter circuit 104 that connects successively.Main characteristic in finite both soft switch full inverter main circuit 2 design is the optimization by filtering parameter on output filter circuit, the waveform of guaranteeing the current/voltage exported does not have High-frequency Interference, makes that the Waveform Control of pulse MIC welding, dipulse weldering aluminium etc. is more accurate.
Described driving and testing circuit 3 comprise that temperature sensing circuit 106, switching tube drive circuit 105, over-current detection circuit 111, mariages current-voltage sampling detect and feedback circuit 107; ARM master controller 108 drives with temperature sensing circuit 106, switching tube drive circuit 105, over-current detection circuit 111 and the detection of mariages current-voltage sampling of testing circuit 3 with two-way respectively and is connected with feedback circuit 107; ARM master controller 108 is connected with over-and under-voltage protection testing circuit 109; ARM master controller 108 and man-machine interactive system 110 are connected by serial ports; A current rectifying and wave filtering circuit 101 of over-and under-voltage protection testing circuit 109 and two-way finite both soft switch full inverter main circuit 2 all connects same three-phase alternating current input power supply 4; Each road finite both soft switch full inverter main circuit 2 is corresponding with testing circuit 3 with one tunnel driving respectively, high-frequency inverter circuit 102 is connected with corresponding switching tube drive circuit 105, the primary side of power transforming circuit 103 is connected with corresponding over-current detection circuit 111, and the secondary rectification smoothed filter circuit 104 of each road finite both soft switch full inverter main circuit 2 and corresponding a road drives with the mariages current-voltage sampling detection of testing circuit 3 and is connected same arc load 5 with feedback circuit 107.
As shown in Figure 2, as preferred implementation, the model of described ARM master controller 108 is LM3S8962.Wherein, described switching tube drive circuit 105 comprises four switching tube driver elements that are made of optocoupler and peripheral circuit, and each optocoupler all is connected with ARM master controller 108.The A/D interface of described ARM master controller 108 detects with the mariages current-voltage sampling and is connected with feedback circuit 107, finishes the sampling of analog signal and is converted to data signal.The mariages current-voltage sampling detects with feedback circuit 107 and detects output current by Hall element, obtains current sampling signal, is input to the A/D port of ARM master controller 108 through dividing potential drop, filtering, pressure limiting.In addition, can deliver to man-machine interactive system 110 simultaneously, be undertaken demonstrating dynamic actual welding electric current, magnitude of voltage in the welding process after the A/D conversion by it through the current-voltage sampling signal after the conditioning.
The PWM module of described ARM master controller 108 drives with two-way respectively and is connected with the switching tube drive circuit 105 of testing circuit 3, utilize the two-way pwm signal of PWM module output, after filtering, isolation and amplification, control two switching tube drive circuits 105 respectively and produce the required pwm control signal of the soft switch of finite both, drive two full bridge soft switch circuits respectively, comprise the driver element of the full-bridge soft-switching that a slice UC3846 and peripheral circuit constitute in each circuit, generate four road PWM finite both pwm control signals by it.The GPIO interface of described ARM master controller 108 is connected with over-and under-voltage protection testing circuit 109, temperature sensing circuit 106, over-current detection circuit 111 respectively.Wherein, described temperature sensing circuit 106 comprises the temperature sensor that is connected with radiator, and signal comparator circuit and optical coupling isolation circuit.ARM master controller 108 is as the core of control, mariages short circuit and arc welding gun switch signal input ARM master controller 108, the D/A module of ARM master controller 108 transfers out mariages wire feed signal, wherein sample rate current and given signal compare the back computing in ARM, determine to drive the size of signal, export 8 road pulse-width signals, thus the output of control two-way finite both soft switch full inverter main circuit 2.
Above-mentioned a kind of thin double-wire digital soft switch inverter welding power source system is to control two-way finite both soft switch full inverter main circuit 2 respectively by an ARM master controller 108, two-way finite both soft switch full inverter main circuit 2 is installed in the same source of welding current cabinet, adopt incorporate structure, the problem of having avoided existing split-type structural need communicate with one another and bring, satisfy the requirement of communication speed, when any one road power supply breaks down, can handle immediately, avoid split type the needs to judge the delay that brings again by main frame behind the master-slave communication.
As preferred embodiment, be depicted as the mariages current-voltage sampling as Fig. 3-1 and Fig. 3-2 and detect circuit structure with feedback circuit 107, wherein the A interface of the A interface of Fig. 3-1 and Fig. 3-2 joins, and wherein the B interface of the B interface of Fig. 3-1 and Fig. 3-2 joins.The mariages current-voltage sampling detects the sampling feedback effect of mainly playing current/voltage with feedback circuit 107, to realize closed-loop control.In detection of mariages current-voltage sampling and the feedback circuit 107, adopted current Hall sensor IFB at power output end.By adopting suitable resistive element, make when welding current when 0-600A changes, the signal excursion after the feedback circuit processing is 0-4V.Pass through dividing potential drop again, filtering obtains the signal code feedback signal after the adjustment such as pressure limiting, gives ARM master controller 108, carries out computing by ARM master controller 108.In addition, the current-voltage sampling signal that conditions out also can be delivered to the ADC port of man-machine interactive system, is carried out the A/D conversion and shown actual welding electric current, magnitude of voltage on man-machine interactive system 110 by it.
As preferred embodiment, be illustrated in figure 4 as the circuit structure of over-current detection circuit 111, by amplifier, elements such as optocoupler constitute, and when occurring because of the main transformer magnetic bias and being subjected to electromagnetic interference and causing overcurrent, turn-off IGBT immediately.Over-current detection circuit 111 mainly detects the electric current of the primary side of power transforming circuit 103.When elementary electric current surpasses certain value, produce over-current signal, the optocoupler conducting, the CURRENT-EXC level is dragged down, and ARM master controller 108 does not need to be about to pwm signal through program to cut off, and cutting-off process is finished by ARM master controller 10 hardware.The I/O mouth GPIO12/TZ1 level of ARM master controller 108 is dragged down also can trigger an interruption simultaneously, and in interrupt routine, ARM master controller 108 can be further processed and move.Wherein, the sensor of over-current detection circuit 111 is connected on the primary coil of power transforming circuit 103; The mariages current-voltage sampling detects with the current sensor of feedback circuit 107 and is connected the acquisition current sampling signal with arc load 5, and voltage signal is directly obtained from arc load 5 two ends parallel resistor.
As preferred embodiment, be illustrated in figure 5 as the circuit structure of over-and under-voltage protection testing circuit 109.Over-and under-voltage protection testing circuit 109 mainly plays the effect of turn-offing pwm signal output when the fluctuation of line voltage; by amplifier; elements such as optocoupler constitute, and when the voltage ripple of power network scope surpasses preset threshold, turn-off finite both soft switch full inverter main circuit 2.Three-phase alternating current input power supply 4 through the transformer step-down, be rectified into direct current signal VFB, so the VFB direct proportion is in line voltage.Be higher than setting value or be lower than when setting value when VFB crosses, two comparator comparative results are done the phase AND operation, the result is low level " 0 ", the VOLTAGE-EXC level is drawn high, the I/O mouth GPIO13/TZ2 level that is ARM master controller 10 is drawn high, ARM master controller 10 turn-offs pwm signal output, and carries out troubleshooting.
As preferred embodiment, be illustrated in figure 6 as the circuit structure of temperature sensing circuit 106.P18 is connected with temperature sensor TH1.The temperature sensor of temperature sensing circuit 106 is installed on the radiator of IGBT place, whether surpasses ormal weight in order to detect the IGBT heating, in case occur overheatedly, finite both soft switch full inverter main circuit 2 is cut off in the temperature sensor action.Temperature sensor is a normally closed switch, disconnect if trigger then, produce heat alarm, make the conducting of light lotus root, the CURRENT-EXC level is dragged down, the I/O mouth GPIO16/TZ5 level that is ARM master controller 10 is dragged down, and can according to this I/O judge whether produce heat alarm in ARM master controller 10 programs this moment, and handle.
As Fig. 2 and shown in Figure 7, wherein, described man-machine interactive system 110 comprises CPLD chip, main control chip, digital encoder input circuit, key circuit, LED lamp, charactron, demonstration and input equipment; The I/O interface control connection LED lamp and the charactron of described CPLD chip, communication is connected between CPLD chip and the main control chip, main control chip is connected with digital encoder input circuit, key circuit and demonstration and input equipment, main control chip is by TX, the RX pin position of serial ports connection ARM master controller 108, and serial port protocol is RS232.
Man-machine interactive system 110 main effects are to be used for realizing the given input of digitized parameter and to be used to show that digitlization shows the various parameters of the course of work, it utilizes with the abundant I/O interface of CPLD chip and controls LED and charactron, and be responsible for handling the operation of keyboard and encoder, the selection and the input of parameter by main control chip, realize receiving the welding switch command, and the mariages current-voltage sampling is detected the welded condition parameter that is produced with feedback circuit 107 carry out sampling processing, and utilize the RS232 universal serial bus to communicate by letter with ARM master controller 108 with the GPIO pin.Its main characteristic is the control mode that main control part and man-machine interactive system adopt two ARM respectively, can make ARM master controller 108 be absorbed in the control of welding dynamic process, guarantees the real-time requirement of controlling; In addition, the mariages current-voltage sampling detects with feedback circuit 107 and also can link to each other with the main control chip of the man-machine interactive system 110 of man-machine system the while, has reduced the data communication amount, and the while has guaranteed that also the current-voltage information demonstration is stable and do not glimmered.The main control module of man-machine interactive system 110 is taked the control mode of ARM+CPLD, with main control chip as control core, as preferred implementation, the main control chip model is ARM-S3C2440, and assist and expand its I/O interface quantity with the CPLD chip, its main characteristic is to take intelligent recognition technology in encoder control, can regulate the electric current step pitch according to the speed of operator's rotary encoder speed, but the big quick adjustment of step pitch was to desired current value when rotary speed was fast, and the step pitch I accurately was adjusted to needed current value when rotary speed was slow.Model is the operation that the main control chip of ARM9-S3C2440 is handled touch screen module, can control the touch screen module duty by SYNC or DE model selection, carry out the selection and the input of parameter by the GPIO interface, the welded condition order that receives, and the mariages current-voltage sampling is detected the welded condition parameter that is produced with feedback circuit 107 carry out sampling processing.LCD display is used to show corresponding operating and welded condition.
The operation principle of a kind of thin double-wire digital soft switch inverter welding power source system of the present invention is: during application, man-machine interactive system 110 is selected welding manner and setup parameter, three-phase alternating current input power supply 4 is through a current rectifying and wave filtering circuit 101, enter high-frequency inverter circuit 102 after becoming the smooth direct current electricity, ARM controller 108 is according to the electric current of mariages current-voltage sampling detection with feedback circuit 107 detected arc loads 5, voltage signal and given parameter compare, PI computing through ARM controller 108, produce the two-way pwm signal, through filtering, deliver to double switch tube drive circuit 105 respectively after isolation and the amplification, wherein a way switch tube drive circuit 105 amplifies switching tube the turning on and off under no-voltage that high-frequency inverter circuit 102 is controlled in the back, 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 transforming circuit 103, obtain more level and smooth direct current through secondary rectification smoothed filter circuit 104 again.The primary current of over-current detection circuit 111, power transforming circuit 103, as overcurrent condition appears, then ARM controller 108 sends an interrupt signal, closes high-frequency inverter circuit 102, protection finite both soft switch full inverter main circuit 2 trouble free services.Over-and under-voltage protection testing circuit 109 detects the voltage of three-phase alternating current input power supply 4, as overvoltage or under-voltage phenomenon occur, then triggers ARM controller 108 and interrupts, and closes high-frequency inverter circuit 102.
The control method of a kind of thin double-wire digital soft switch inverter welding power source system of the present invention is:
Steps A, system boot, systematic parameter initialization;
Step B, ARM master controller 108 sends the welding commencing signal to the man-machine interactive system 110 of people, and ARM master controller 108 receives and obtains welding parameter simultaneously;
Step C, ARM master controller 108 call striking impulse waveform function, the beginning striking;
Step D if striking is unsuccessful, returns step C;
If the striking success then enters normal welding process, enter step e;
Step e is judged selected welding manner, carries out the control corresponding subprogram according to the welding manner of selecting, and comprising:
If welding manner is a pulse MIC welding, enter pulse MIC welding control subprogram, the arc parameters to two-way finite both soft switch full inverter main circuit 2 carries out instantaneous energy control respectively;
If welding manner is a dipulse weldering aluminium, then enter dipulse weldering aluminium control subprogram, respectively two-way finite both soft switch full inverter main circuit 2 is carried out constant current control;
If welding manner is CO
2/ MAG gas shielded arc welding then enters CO
2Weldering control subprogram is carried out constant voltage control to two-way finite both soft switch full inverter main circuit 2 respectively;
Step F, if arc welding gun switch unclamps, or the welding process end, then ARM master controller 108 calls the receipts arc function, enters into to receive the arc stage;
Step G receives arc and finishes, and ARM master controller 108 sends the welding end signal to man-machine interactive system 110, and system enters the state that order is welded in wait next time.
Above-mentioned a kind of thin double-wire digital soft switch inverter welding power source system has been realized integral structure, with embedded dsp ARM chip LM3S8962 at a high speed is core, make full use of the superior function of ARM chip aspect embedded Control, adopt modularization, transplantable method for designing, realize output characteristic of power source control, welding control waveform, man-machine interactive system 110 by software programming.Adopt integral structure, more superior performance and more light structure are arranged than in the past master-slave mode Double Wire Welding facility.The eight-path PWM signal of two finite both soft switch full inverter main circuits 2 is all directly exported by programming mode by ARM master controller 108, finally realizes the full-digital control of Arc Welding Power.A control of controlling core to two main circuits has reduced links such as communication, makes the Double Wire Welding facility that better uniformity, dynamic response performance and extensibility be arranged.The present invention has better energy saving, owing to adopt the soft switch I GBT inversion transformation technique of finite both, realize that by the finite both mode IGBT module no-voltage turns on and off, make IGBT under the electric current and power surges of switching process, the loss that turns on and off is low, further improve inversion efficiency and energy conversion efficiency, conserve energy, reduce the electromagnetic interference of inverter type welder, improve its Electro Magnetic Compatibility.The present invention has multi-functional feature, because mariages CO can be provided
2Multiple functions such as/MAG weldering, pulse MIC welding, Double-wire pulsed welding aluminium by changing the process in the full-digital control system, can be applied to different process environments.The present invention has realized precision, the high-speed computation and the data-handling capacity of ARM embedded microprocessor have been made full use of, the instantaneous energy of welding arc is gathered in real time and analyzed, automatically control the output characteristics of the source of welding current in real time according to conditions at the arc, to reach purpose to instantaneous ability optimization output of welding arc and adjusting, secondly by detecting feedback output current voltage, variation responds fast to electric arc, and in time adjust and export energy, make control more accurate, with the welding quality of acquisition high-quality, and utilize the intermediate value waveform controlling method to carry out accurate Waveform Control.The present invention has intellectuality, and integrated existing welding procedure expert database system by the mode of unified adjusting, is realized the automatic adjusting of mariages parameter, has solved the too much problem of mariages technological parameter effectively.
In sum, a kind of thin double-wire digital soft switch inverter welding power source system of the present invention can improve welding efficiency under the prerequisite that guarantees welding quality and welding stability, can effectively reduce the influence of the on-the-spot electromagnetic interference of welding, eliminate mutual electromagnetic interference between the two root bead silks, the security performance height, and it is can reduce equipment volume, reduce equipment cost, and more energy-conservation.
Embodiment two
As shown in Figure 8, the control method of a kind of thin double-wire digital soft switch inverter welding power source system of the present invention, it may further comprise the steps:
Steps A, system boot, systematic parameter initialization;
Step B, ARM master controller 108 sends the welding commencing signal to the man-machine interactive system 110 of people, and ARM master controller 108 receives and obtains welding parameter simultaneously;
Step C, ARM master controller 108 call striking impulse waveform function, the beginning striking;
Step D if striking is unsuccessful, returns step C;
If the striking success then enters normal welding process, enter step e;
Step e is judged selected welding manner, carries out the control corresponding subprogram according to the welding manner of selecting, and comprising:
If welding manner is a pulse MIC welding, enter pulse MIC welding control subprogram, the arc parameters to two-way finite both soft switch full inverter main circuit 2 carries out instantaneous energy control respectively;
If welding manner is a dipulse weldering aluminium, then enter dipulse weldering aluminium control subprogram, respectively two-way finite both soft switch full inverter main circuit 2 is carried out constant current control;
If welding manner is CO
2/ MAG gas shielded arc welding then enters CO
2Weldering control subprogram is carried out constant voltage control to two-way finite both soft switch full inverter main circuit 2 respectively;
Step F, if arc welding gun switch unclamps, or the welding process end, then ARM master controller 108 calls the receipts arc function, enters into to receive the arc stage;
Step G receives arc and finishes, and ARM master controller 108 sends the welding end signal to man-machine interactive system 110, and system enters the state that order is welded in wait next time.
Wherein, in the step e, describedly respectively the arc parameters of two-way finite both soft switch full inverter main circuit 2 is carried out instantaneous energy control and be specially: ARM master controller 108 control first via finite both soft switch full inverter main circuits 2 output peak point currents, control the second road finite both soft switch full inverter main circuit, 2 output background currents simultaneously, when first via finite both soft switch full inverter main circuit 2 output peak point currents finish to enter the background current output state, the second road finite both soft switch full inverter main circuit 2 enters the peak point current output state, so circulation makes the power pulse output phase of two-way finite both soft switch full inverter main circuit 2 differ 180 ° repeatedly.
Above-mentioned control method utilizes same ARM master controller 108 directly to control the mode of two-way finite both soft switch full inverter main circuit 2 simultaneously, after entering normal welding process, judge selected welding manner, and, can be applicable to pulse MIC welding, dipulse weldering aluminium, CO according to the welding manner execution control corresponding subprogram of selecting
2Welding manners such as/MAG gas shielded arc welding.This method can improve welding efficiency and security performance under the prerequisite that guarantees welding quality and welding stability, and can effectively reduce the influence of the on-the-spot electromagnetic interference of welding, eliminates mutual electromagnetic interference between the two root bead silks.
The above only is preferred embodiment of the present invention, so all equivalences of doing according to the described structure of patent claim of the present invention, feature and principle change or modify, is included in the patent claim of the present invention.
Claims (10)
1. thin double-wire digital soft switch inverter welding power source system, it is characterized in that: it comprises adopts that integral structure is built-in to be installed on over-and under-voltage protection testing circuit, the man-machine interactive system in the same source of welding current cabinet, the ARM master controller that is built-in with welding procedure expert database software systems, finite both soft switch full inverter main circuit that the two-way circuit structure is identical, and identical driving and the testing circuit of two-way circuit structure;
Described finite both soft switch full inverter main circuit with insulated gate bipolar transistor IGBT as switch element; Described finite both soft switch full inverter main circuit comprises a current rectifying and wave filtering circuit, high-frequency inverter circuit, power transforming circuit, the secondary rectification smoothed filter circuit that connects successively;
Described driving and testing circuit comprise that temperature sensing circuit, switching tube drive circuit, over-current detection circuit, mariages current-voltage sampling detect and feedback circuit;
The ARM master controller drives with temperature sensing circuit, switching tube drive circuit, over-current detection circuit and the detection of mariages current-voltage sampling of testing circuit with two-way respectively and is connected with feedback circuit; The ARM master controller is connected with over-and under-voltage protection testing circuit; The ARM master controller is connected by serial ports with man-machine interactive system;
A current rectifying and wave filtering circuit of over-and under-voltage protection testing circuit and two-way finite both soft switch full inverter main circuit all connects same three-phase alternating current input power supply; Each road finite both soft switch full inverter main circuit is corresponding with testing circuit with one tunnel driving respectively, high-frequency inverter circuit is connected with corresponding switching tube drive circuit, and the primary side of power transforming circuit is connected with corresponding over-current detection circuit; The secondary rectification smoothed filter circuit of each road finite both soft switch full inverter main circuit and corresponding one road drives with the mariages current-voltage sampling detection of testing circuit and is connected same arc load with feedback circuit.
2. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 1 is characterized in that: the model of described ARM master controller is LM3S8962.
3. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 2 is characterized in that: described man-machine interactive system comprises CPLD chip, main control chip, digital encoder input circuit, key circuit, LED lamp, charactron, demonstration and input equipment; The I/O interface control connection LED lamp and the charactron of described CPLD chip, communication is connected between CPLD chip and the main control chip, main control chip is connected with digital encoder input circuit, key circuit and demonstration and input equipment, and main control chip connects TX, the RX pin position of ARM master controller by serial ports.
4. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 2, it is characterized in that: described switching tube drive circuit comprises four switching tube driver elements that are made of optocoupler and peripheral circuit, and each optocoupler all is connected with the ARM master controller.
5. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 2 is characterized in that: the A/D interface of described ARM master controller detects with the mariages current-voltage sampling and is connected with feedback circuit.
6. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 2 is characterized in that: the PWM module of described ARM master controller drives with two-way respectively and is connected with the switching tube drive circuit of testing circuit.
7. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 2 is characterized in that: the GPIO interface of described ARM master controller is connected with over-and under-voltage protection testing circuit, temperature sensing circuit, over-current detection circuit respectively.
8. a kind of thin double-wire digital soft switch inverter welding power source system according to claim 7 is characterized in that: described temperature sensing circuit comprises the temperature sensor that is connected with radiator, and signal comparator circuit and optical coupling isolation circuit.
9. the control method of the described a kind of thin double-wire digital soft switch inverter welding power source system of claim 1 is characterized in that, it may further comprise the steps:
Steps A, system boot, systematic parameter initialization;
Step B, the ARM master controller sends the welding commencing signal to the man-machine interactive system of people, and the ARM master controller receives and obtains welding parameter simultaneously;
Step C, ARM master controller call striking impulse waveform function, the beginning striking;
Step D if striking is unsuccessful, returns step C;
If the striking success then enters normal welding process, enter step e;
Step e is judged selected welding manner, carries out the control corresponding subprogram according to the welding manner of selecting, and comprising:
If welding manner is a pulse MIC welding, enter pulse MIC welding control subprogram, the arc parameters to two-way finite both soft switch full inverter main circuit carries out instantaneous energy control respectively;
If welding manner is a dipulse weldering aluminium, then enter dipulse weldering aluminium control subprogram, respectively two-way finite both soft switch full inverter main circuit is carried out constant current control;
If welding manner is CO
2/ MAG gas shielded arc welding then enters CO
2Weldering control subprogram is carried out constant voltage control to two-way finite both soft switch full inverter main circuit respectively;
Step F, if arc welding gun switch unclamps, or the welding process end, then the ARM master controller calls the receipts arc function, enters into to receive the arc stage;
Step G receives arc and finishes, and the ARM master controller sends the welding end signal to man-machine interactive system, and system enters the state that order is welded in wait next time.
10. the control method of thin double-wire digital soft switch inverter welding power source system according to claim 9, it is characterized in that: in the step e, describedly respectively the arc parameters of two-way finite both soft switch full inverter main circuit is carried out instantaneous energy control and be specially: ARM main controller controls first via finite both soft switch full inverter main circuit output peak point current, control the second road finite both soft switch full inverter main circuit output background current simultaneously, when first via finite both soft switch full inverter main circuit output peak point current finishes to enter the background current output state, the second road finite both soft switch full inverter main circuit enters the peak point current output state, so circulation makes the power pulse output phase of two-way finite both soft switch full inverter main circuit differ 180 ° repeatedly.
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| CN102208866A (en) * | 2011-07-01 | 2011-10-05 | 无锡市南方电器制造有限公司 | Intermediate frequency inversion DC and variable frequency AC resistance welding power supply |
| CN102528224A (en) * | 2011-12-19 | 2012-07-04 | 湖南科技大学 | Alternating and direct current and voltage signal detection device for double-wire welding |
| CN103170710A (en) * | 2013-03-27 | 2013-06-26 | 无锡洲翔成套焊接设备有限公司 | Multifunctional digital consumable electrode electric welding machine |
| CN105499752A (en) * | 2016-01-21 | 2016-04-20 | 广州长胜机电有限公司 | Efficient quasi ion arc welding machine |
| CN108890105A (en) * | 2018-09-05 | 2018-11-27 | 河北科技大学 | A kind of filament stainless steel is to welding machine and flat welding process |
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| CN111250828A (en) * | 2020-02-19 | 2020-06-09 | 河北科技大学 | High-frequency AC/DC double-wire MIG welder power supply |
| CN113977044A (en) * | 2021-10-21 | 2022-01-28 | 华南理工大学 | Integrated double-wire medium-value pulse MIG welding power supply system and multi-phase control method |
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