CN102091850A - Aluminum alloy digital welding machine with smooth transition double-pulse parameters - Google Patents
Aluminum alloy digital welding machine with smooth transition double-pulse parameters Download PDFInfo
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Abstract
The invention discloses an aluminum alloy digital welding machine with smooth transition double-pulse parameters, which comprises a power main circuit, a main control mother board, a main control micro controller unit (MCU), a wire feed driving circuit, an advanced RISC machine (ARM) controlled human-machine interactive system and a hardware proportion integration differentiation (PID) controller, wherein the hardware PID controller, the wire feed driving circuit and the main control MCU are arranged on the main control mother board; the wire feed driving circuit is connected with the main control MCU; the hardware PID controller is connected with the main control MCU and the control port of the power main circuit; the current input end of the power main circuit is connected with the utility power; and the current output end of the power main circuit is connected with a welding load. The MCU and the ARM are used as control cores, pulse width modulation (PWM) is generated through the hardware PID controller to realize driving control of the main circuit, the work load of the main control MCU is reduced, the main control MCU quickly and stably completes welding process flow control and double-pulse waveform database management task, the welding efficiency is improved, and stable welding of aluminum alloy from low current to high current is realized.
Description
Technical field
The present invention relates to dipulse aluminium alloy digitlization welding machine technical field, particularly a kind of have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter.
Background technology
Development along with Power Electronic Technique, digitizing technique, high performance single-chip microcomputer (MCU) is all being obtained epoch-making breakthrough aspect function, processing speed and the disposal ability, theory of digital signal processing and realization means have obtained unprecedented development, become one of subject current with fastest developing speed.After high-grade single-chip microprocessor MCU is successfully introduced source of welding current control field, provide possibility, provide opportunity for attempting new welding procedure for further improving welding technological properties.MCU makes digitlization, intelligent Arc Welding Power arise at the historic moment with the optimal selection device that its stability, repeatability, real time digital signal are handled, flexibility programming, characteristics such as extensive integrated become source of welding current control and Digital Signal Processing.
Abroad, be the well-known in the world welding equipment company of representative with the KEMPPI company of Austrian FRONIUS, German EWM, Finland, all developed a series of digitlization welder systems that have expert database, the fetch long price of these welding.Domestic digitlization welding machine is in development at present, and the companies such as Tangshan Panasonic, Shanxi nebula, Beijing epoch, the big Ao Tai in mountain that mainly contain are in exploitation, and part is released digitlization welding machine product.Aspect the welding of dipulse aluminium alloy, be the aluminium alloy welding machine comparative maturity that European countries were produced of representative with Austrian FRONIUS company, welding process is stable.And domestic production producer does not obtain substantive breakthroughs at present as yet all also in the dipulse solder technology of exploring aluminium alloy, mainly is to also do not find inherent law in the design of dipulse parameter.Tracing it to its cause, mainly is that mutual proper fit needs a large amount of engineer testings because the welding parameter of dipulse is many, and the aluminium alloy rapid heat dissipation, welding process is extremely unstable; In addition, electric arc arc length instability, welding wire easily flashes back, short circuit, and the low easy evaporation of welding wire fusing point all causes conditions at the arc very unstable.
Summary of the invention
The objective of the invention is to provide and have the aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter at the deficiencies in the prior art, the main control MCU of its bonding machine can be finished welding process flow control and dipulse waveform database management role fast and stable, the welding efficiency height has been realized the stable welding of aluminium alloy from little electric current to big electric current.
Purpose of the present invention realizes by following technical measures:
Has the aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, comprise the power main circuit, main control backplane, main control MCU, the wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, the wire feed drive circuit, main control MCU is arranged at main control backplane, the wire feed drive circuit is connected with main control MCU, hardware PID controller and main control MCU, the control port of power main circuit connects, power main circuit current input is electrically connected with the city, the current output terminal of power main circuit is connected with weld load, and ARM control man-machine interactive system is connected with main control MCU.
Wherein, the power main circuit comprises that passive harmonic wave suppresses current rectifying and wave filtering circuit, IGBT full bridge inverter, intermediate-frequency transformer, rectification circuit, the input that passive harmonic wave suppresses current rectifying and wave filtering circuit is electrically connected with the city, the output that passive harmonic wave suppresses current rectifying and wave filtering circuit is connected with the current input terminal of IGBT full bridge inverter, the current output terminal of IGBT full bridge inverter is connected with the input of intermediate-frequency transformer, the output of intermediate-frequency transformer is connected with current rectifying and wave filtering circuit, and the rectifying and wave-filtering output is connected with weld load.
Wherein, also comprise current sampling circuit, voltage sampling circuit, hardware PID controller input is connected with current sampling circuit, voltage sampling circuit, and hardware PID controller feeds back to main control MCU with the information of voltage of voltage collection circuit collection, the current information that current sampling circuit detects collection.
Wherein, also comprise 3846 drive circuits; 3846 drive circuits comprise main control chip U3; 5 pin of U3 are connected with hardware PID controller; 14 pin of U3; 11 pin; 4 pin are connected with the control signal input of IGBT full bridge inverter; 4 pin of U3 are connected with the primary current feedback end of IGBT full bridge inverter; 16 pin of U3 are connected with the guard signal input; voltage signal is handled the back through main control MCU and is transmitted into U3 by hardware controls PID controller; the primary current feedback information that U3 comes according to the IGBT full bridge inverter feedback that 4 pin receive; and the current/voltage feedback signal after the calculation process of the process main control MCU received of 5 pin of U3, regulate the switching tube that output voltage drives the IGBT full bridge inverter jointly.
Wherein, the model of the main control chip U3 of 3846 drive circuits is UC3846, and 3846 drive circuits are realized the soft switch control of finite both IGBT full bridge inverter.
Wherein, main control MCU adopts decides frequency and frequency conversion computational methods based on the dipulse MIG weld ripples shape of Mathematical Modeling design, realize little electric current to the meticulous adjusting of big electric current, change according to the average current size adaptation in little electric current strong and weak pulse number and base value size in the adjustment process of big electric current.
Wherein, based on the dipulse MIG weld ripples shape of Mathematical Modeling design decide frequency and the frequency conversion computational methods are specially: establish the cycle that T is an impulse train, T is by force the flash time in the pulse period, be that weak pulse in a pulse period is towards the time a little less than the T, t1 is flash group's the base value time, t2 is the base value time of weak impulse train, a is a flash group background current, b is weak impulse train background current, c is a peak current level, and n1 is a pulse number among the flash group, and n2 is a pulse number among the weak pulse group, f represents the double pulse modulation frequency, and I is an average current; In pulse period T weak=T is strong=T/2=500/f;
At first set n1, n2 initial value, the unit pulse time is t ms, then has;
Obtain average current
When flash different mountain value electric current, weak pulse towards different mountain value electric current, flash group background current, weak impulse train background current fixedly the time, there are relation one to one in n1, n2 and t1, t2, establish n1, and n2 strengthens gradually, then t1, t2 reduce gradually, the subfunction of power taking stream
As follows:
M is the constant greater than 0, and m is a or b, all less than c;
Then
Promptly along with x reduces gradually,
The slope steepening tends towards stability during to a certain position, progressively strengthen n1 according to certain rule, n2, then corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed gradually and to be accelerated, thereby realizes that welding current can regulate continuously, and along with its increase of progressively increasing of electric current is faster.
Wherein, ARM control man-machine interactive system comprises the ARM module, CPLD module, button, encoder, LED and charactron display module, LED and charactron display module, encoder are connected with the CPLD module, button, CPLD module are connected with the ARM module, and the ARM module is connected with the SCI interface of main control MCU.
Wherein, the main control MCU model is STC89C58RD+.
Beneficial effect of the present invention is: have the aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, comprise the power main circuit, main control backplane, main control MCU, the wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, the wire feed drive circuit, main control MCU is arranged at main control backplane, the wire feed drive circuit is connected with main control MCU, hardware PID controller and main control MCU, the control port of power main circuit connects, power main circuit current input is electrically connected with the city, the current output terminal of power main circuit is connected with weld load, and ARM control man-machine interactive system is connected with main control MCU.It is the control core that the present invention adopts MCU+ARM, and produce PWM by hardware PID controller and realize that the driving control of main circuit greatly reduces the live load of main control MCU, the main control MCU of bonding machine can be finished welding process flow control and dipulse waveform database management role fast and stable, improved welding efficiency, realized the stable welding of aluminium alloy from little electric current to big electric current.
Description of drawings
Fig. 1 is a control system structure chart of the present invention;
Fig. 2 is a power main circuit diagram of the present invention;
Fig. 3 is 3846 drive circuit figure of the present invention;
Fig. 4 is a main control MCU structure chart of the present invention;
Fig. 5 is wire feeding circuit figure of the present invention;
Fig. 6 man-machine interactive system hardware block diagram of the present invention;
Fig. 7 is the dipulse current waveform graph parameter schematic diagram of invention;
Fig. 8 is the aluminium alloy dipulse welding machine software systems software flow pattern based on Mathematical Modeling of invention;
Dipulse waveform when Fig. 9 is a little electric current of the present invention;
Dipulse waveform when Figure 10 is a medium current of the present invention;
Dipulse waveform when Figure 11 is a big electric current of the present invention.
The specific embodiment
The present invention is further illustrated below in conjunction with accompanying drawing.
Present embodiment provides has the aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, comprise the power main circuit, main control backplane, main control MCU, the wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, the wire feed drive circuit, main control MCU is arranged at main control backplane, the wire feed drive circuit is connected with main control MCU, hardware PID controller and main control MCU, the control port of power main circuit connects, power main circuit current input is electrically connected with the city, the current output terminal of power main circuit is connected with weld load, and ARM control man-machine interactive system is connected with main control MCU.It is the control core that the present invention adopts MCU+ARM, and produce PWM by hardware PID controller and realize that the driving control of main circuit greatly reduces the live load of main control MCU, the main control MCU of bonding machine can be finished welding process flow control and dipulse waveform database management role fast and stable, improved welding efficiency, realized the stable welding of aluminium alloy from little electric current to big electric current.
The power main circuit of present embodiment comprises that passive harmonic wave suppresses current rectifying and wave filtering circuit, IGBT full bridge inverter, intermediate-frequency transformer, rectification circuit, the input that passive harmonic wave suppresses current rectifying and wave filtering circuit is electrically connected with the city, the output that passive harmonic wave suppresses current rectifying and wave filtering circuit is connected with the current input terminal of IGBT full bridge inverter, the current output terminal of IGBT full bridge inverter is connected with the input of intermediate-frequency transformer, the output of intermediate-frequency transformer is connected with current rectifying and wave filtering circuit, and the rectifying and wave-filtering output is connected with weld load.
Present embodiment also comprises current sampling circuit, voltage sampling circuit, hardware PID controller input is connected with current sampling circuit, voltage sampling circuit, and hardware PID controller feeds back to main control MCU with the information of voltage of voltage collection circuit collection, the current information that current sampling circuit detects collection.
Present embodiment also comprises 3846 drive circuits; 3846 drive circuits comprise main control chip U3; 5 pin of U3 are connected with hardware PID controller; 14 pin of U3; 11 pin; 4 pin are connected with the control signal input of IGBT full bridge inverter; 4 pin of U3 are connected with the primary current feedback end of IGBT full bridge inverter; 16 pin of U3 are connected with the guard signal input; voltage signal is handled the back through main control MCU and is transmitted into U3 by hardware controls PID controller; the primary current feedback information that U3 comes according to the IGBT full bridge inverter feedback that 4 pin receive; and the current/voltage feedback signal after the calculation process of the process main control MCU received of 5 pin of U3, regulate the switching tube that output voltage drives the IGBT full bridge inverter jointly.
The model of the main control chip U3 of 3846 drive circuits of present embodiment is UC3846, and 3846 drive circuits are realized the soft switch control of finite both IGBT full bridge inverter.
The main control MCU of present embodiment adopts decides frequency and frequency conversion computational methods based on the dipulse MIG weld ripples shape of Mathematical Modeling design, realize little electric current to the meticulous adjusting of big electric current, change according to the average current size adaptation in little electric current strong and weak pulse number and base value size in the adjustment process of big electric current.
The ARM control man-machine interactive system of present embodiment comprises the ARM module, CPLD module, button, encoder, LED and charactron display module, LED and charactron display module, encoder are connected with the CPLD module, button, CPLD module are connected with the ARM module, and the ARM module is connected with the SCI interface of main control MCU.
The main control MCU model of present embodiment is STC89C58RD+.
The process control of the welding process of the aluminium alloy the realized dipulse of present embodiment, and dipulse Waveform Control expert database system.Based on 3846 chip controls, adopt the ripe soft switch of finite both.Only need given output voltage as Fig. 3 institute, just can generate PWM and drive, can be regarded as " black box " of realizing the V-PWM conversion, add the primary current protection, reliable and stable.Hardware PID drives the live load that greatly reduces main control MCU, and main control MCU can be finished flow process control and data administration tasks fast and stable.Main control backplane is the core of dipulse welding machine hardware.Peripheral discharge circuit and wire feeding circuit part are set, and purpose is to export precisely stable dipulse signal to drive plate, matches the wire feed rate of suitable current simultaneously, thereby reaches unified welding.
Present embodiment based on the dipulse MIG weld ripples shape of Mathematical Modeling design decide frequency and the frequency conversion computational methods are specially: establish the cycle that T is an impulse train, T is by force the flash time in the pulse period, be that weak pulse in a pulse period is towards the time a little less than the T, t1 is flash group's the base value time, t2 is the base value time of weak impulse train, a is a flash group background current, b is weak impulse train background current, c is a peak current level, n1 is a pulse number among the flash group, n2 is a pulse number among the weak pulse group, and f represents the double pulse modulation frequency, and I is an average current; In pulse period T weak=T is strong=T/2=500/f;
At first set n1, n2 initial value, the unit pulse time is 2ms, then have,
Obtain average current
When flash different mountain value electric current, weak pulse towards different mountain value electric current, flash group background current, weak impulse train background current fixedly the time, there are relation one to one in n1, n2 and t1, t2, establish n1, and n2 strengthens gradually, then t1, t2 reduce gradually, the subfunction of power taking stream
As follows:
M is the constant greater than 0, and m is a or b, all less than c;
Then
Promptly along with x reduces gradually,
The slope steepening tends towards stability during to a certain position, progressively strengthen n1 according to certain rule, n2, then corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed gradually and to be accelerated, and has realized that based on decide frequency and the frequency conversion computational methods of the dipulse MIG weld ripples shape of Mathematical Modeling design welding current can regulate continuously, and along with its increase of progressively increasing of electric current is faster.
The dipulse parameter mathematical modeling method of deciding frequency accent electric current of present embodiment.As shown in Figure 7, be the mathematical modeling operation principle that example explanation is decided frequency dipulse parameter with double pulse modulation frequency f=3.3 Hz commonly used, T is strong=and T is weak=T/2=500/3.3 ms, T
By force, T
A little less thanBe respectively between the flash group time in an impulse train cycle, weak pulse group time; The unit pulse time is got 2ms.
T1, t2 are respectively the base value time of flash group, weak impulse train, and n1, n2 are respectively the number of pulse in flash group, the weak impulse train, and a, b, c are respectively flash group background current size, weak impulse train background current size, peak current level.Be brought into current expression by Fig. 7 according to the relation between n and the t:
Can get:
Know easily that by top expression formula under the condition of fixing strong and weak impulse train peak point current, background current size, t1, t2 have become two factors of decision welding current size.Yet, because t1, t2 have strengthened the difficulty of design in the problem that has not directly perceived and the collimation error that reads of welding waveform acquisition feedback.Can obtain n1, n2 and t1, t2 from Fig. 7 and have relation one to one, n1, n2 read convenient directly perceived in the test waveform feedback simultaneously, and n1, n2 are integer, can improve the operation efficiency of chip thus greatly, the more important thing is the programming of having simplified expert database, strengthened the readability of program greatly.Therefore, choose n1, n2 independent variable as the continuity adjustable current.
For satisfying the target that electric current increases gradually, we can set n1, and n2 strengthens gradually, and then t1, t2 reduce gradually, the subfunction of power taking stream
As follows:
Then
Promptly along with x reduces gradually,
The slope steepening tends towards stability during to a certain position.
By reasonable given strong and weak pulse number n1, the initial value of n2 progressively strengthens n1 according to certain rule, n2, and then corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed gradually and to be accelerated.Based on this, realized on this model theory that welding current can regulate continuously, and, reached the purpose that hommization is regulated along with its increase of progressively increasing of electric current is faster.Thereby proved the feasibility of aluminium alloy dipulse MIG weldering expert database under the fixed condition frequently of exploitation.
Present embodiment in the constant dipulse parameter mathematical modeling method of frequency conversion average current for will suppose that the low frequency frequency is f, all the other dipulse parameters as mentioned above, the similar fixed thinking of the modeling frequently equation that is easy to get:
As can be seen from the above equation, the frequency factor of the size of current under the frequency conversion condition has been offset, and it is in full accord with the equation under the fixed condition frequently.Therefore, under the situation of other parameter constants of dipulse waveform, the change of frequency does not influence the adjusting of size of current.
Can get thus: the adjusting of low frequency frequency does not influence the adjustable current scope of dipulse MIG weldering, thereby has realized converter technique.
Aspect the parameter designing of converter technique, with n1, n2 is main independent variable, and t1, t2 are by frequency and set n1, and n2 can determine, thereby the continuity that can design low frequency frequency under the different average pulse electric currents is regulated.
Present embodiment can change the low frequency modulations frequency in the constant situation of average pulse electric current, promptly under the condition that keeps certain speed of welding, needs by the operator, can be by changing dipulse low frequency frequency, when obtaining high-quality weld seam attractive in appearance, can regulate the width of weld seam scalelike mark, satisfy the demand of different occasions, make aluminium alloy dipulse welding machine reach the requirement of maturation, system, commercialization.
Realized deciding under frequency and the frequency conversion condition, average pulse electric current accurately regulating continuously from little electric current to big electric current, can also realize slow, big fast " hommization " regulating effect of electric current governing speed of the medium and small electric current governing speed of welding process, this " hommization " regulating effect mainly mates the parameter configuration of corresponding electric current automatically according to the Mathematical Modeling that designs in advance in the software, can get through peripheral hardware circuit amplifier.Can obtain scalelike mark clearly through the designed dipulse aluminium alloy welding machine of verification experimental verification patent of the present invention, the welding process good stability, appearance of weld is attractive in appearance.
The related aluminium alloy dipulse digital welding machine of patent of the present invention carries out continuity according to certain rule and can regulate variation based on the base value a of strong and weak impulse train and b's, the strong and weak pulse number n1 of auxiliary adjustment, and n2, can expand the welding current scope effectively, thereby but realize continuity adjusting relative broad range welding current.In the strong and weak pulse transition stage, the pulse base value is taked the mode of gradual change, makes that the transition of strong and weak pulse is more smoothly smooth and easy simultaneously, and welding process is more stable.
The dipulse parameter optimization, it is 2ms that the burst length is chosen in test, pulse current is 250A.The value of regulating n1 and n2 by certain rules can realize the variation of the ladder great-jump-forward of welding current from little electric current to big electric current, yet can not realize that but the continuity of electric current changes.Along with pulse number n1, when n2 was increased to some, pulse number was than comparatively dense, under the condition of low frequency fixed-frequency, continuing to increase pulse number has been a kind of worthless way, and it is the thing of a difficulty that promptly certain electric current continues to increase electric current when arriving size.
Based on the base value a and the b of impulse train, carry out continuity according to certain rule and can regulate variation, auxiliary adjustment pulse number n1 and n2 change, and can expand the welding current scope effectively, thus but the purpose that realization wide region continuity is regulated welding current.
The present invention compared with prior art has following advantage and beneficial effect:
1. the present invention is based on Mathematical Modeling and calculate pulse base value gradual change amount in the strong and weak pulse transition, thereby realize level and smooth strong and weak impulse train conversion, compare with the mode of the strong and weak pulse Direct Transform of routine, guaranteed the stationarity of aluminum alloy welding termination process in the strong and weak impulse transfer.
2. the present invention's adjusting step pitch minor adjustment when medium and small dipulse electric current is regulated gets meticulousr, when big dipulse electric current, regulate the big required adjusting current value of faster arrival of step pitch, can realize seamlessly transitting of pulse current voltage waveform in the strong and weak impulse waveform transfer process, guaranteed the stability of aluminum alloy welding termination process, have more hommization with the adjusting of common double pulse parameter control method electric current.
3. the present invention is based on the dipulse aluminium alloy welding machine waveform expert database system that Mathematical Modeling is set up, obtained scalelike mark clearly on the digitlization welding machine, is a kind of digitlization welding machine expert database method of setting up of novelty.
As shown in Figure 1, this system comprises parts such as current rectifying and wave filtering circuit, IGBT full-bridge inverting main circuit, control circuit, wire feed driving, man-machine interactive system.Design fundamentals: adopt 3846 ripe relatively driving chips to realize the soft switch control of finite both IGBT full-bridge inverting main circuit.The high-performance main control MCU is controlled core as flow process, finishes mainly that overcurrent protection, overvoltage protection, overheat protector, electric current are given, voltage given, wire feed rate are given, the control of technology logical order, serial communication, data storage, expert system generates and function such as management.Adopt the ARM+CPLD pattern, the encoder on the control panel, button, LED lamp, table and serial communication.
As shown in Figure 2, three-phase alternating current 380V, the 50Hz HVDC through about the low ripple 550V of one-tenth after three-phase commutation bridge rectification, the filtering offers IGBT full-bridge inverting main circuit then and main transformer T1 carries out the DC-AC conversion.Full bridge inverter Q1, Q2, Q3, Q4 provide the drive waveforms alternate conduction by control circuit, after transformer T1 step-down, become the voltage of intermediate frequency of 20KHz again.The rectification circuit of being made up of D1, D2 is rectified into direct current then, passes through the filter action of reactance and electric capacity again, for the welding arc load provides institute's energy requirement.
As shown in Figure 3, the current/voltage feedback signal is input to 5 pin of UC3846 through calculation process, and the primary current feedback signal is input to 4 pin of UC3846, regulates output voltage jointly; 11,14 pin are the anti-phase fully pwm signal output of two-way; 16 pin are the guard signal input pin, when voltage surpasses 350mV, turn-off the output pulse, and the switching tube of protection IGBT full-bridge inverting main circuit can not damage because of overcurrent; It is 20kHz that C12, R24 can set the inversion operating frequency.
As shown in Figure 4, the high-performance MCU 89C58RD+ that adopts STC Corporation is as main control chip, this single-chip microcomputer be STC release of new generation superpower anti-interference, at a high speed, the low-power consumption product, have following characteristics: instruction code is traditional 8051 single-chip microcomputers of compatibility fully, and operating frequency can reach more than the 50MHz.Configuration comprises 36 I/O mouths, the Flash program's memory space of 32K, the E2PROM of 16K+, the RAM of integrated 1280 bytes on the sheet, ISP function, UART, 8 road A/D passages, house dog, the special-purpose reset circuit of inner integrated MAX810 etc.
As shown in Figure 5, the window comparator among the figure in " welding gun crawl wire feed signal circuit " has following characteristic: (1) C place input voltage is more than 10V, and when promptly not pressing any button, D and E place are low level; (2) C place input voltage is promptly pressed crawl wire feed button when 5V ~ 10V, and this moment, D was a low level, and E is a high level; (3) when C place input voltage during at 0 ~ 5V, promptly press arc welding gun switch, this moment, the D place was a high level, and the E place is a low level.By above characteristic as can be known, welding gun signal and crawl wire feed signal can be realized its function well by this circuit.
As shown in Figure 6, adopt LM3S818, realize the input of code device signal and the control of LED lamp in conjunction with CPLD as the control core, and the scanning of button, and utilize the RS232 universal serial bus to communicate by letter with main control chip DSP with the GPIO pin.
As shown in Figure 7, t1, t2 are respectively the base value time of flash group, weak impulse train, and n1, n2 are respectively the number of pulse in flash group, the weak impulse train, a, b, c are respectively flash group background current size, weak impulse train background current size, peak current level.
As shown in Figure 8, test according to above-mentioned Mathematical Modeling design aluminium alloy expert dipulse database, show through a large amount of engineer testing checkings: only need rotatory current setting knob from small to large, dipulse welding current under this fixed design frequently can cover in the category from 55A to 300A and be accurate to all electric currents of 1A, thereby has confirmed that this Mathematical Modeling expert database levels of precision enough satisfies dipulse and produces the continuously adjustable requirement of welding current.
As shown in Figure 9, for little electric current, flash group number and weak impulse train number are fewer, and the corresponding time of base value separately, the form of expression was that strong and weak impulse train is more sparse on current waveform all than broad, and simultaneously, background current and peak current value are all less.
Shown in Figure 10, middle current waveform is comparatively speaking than comparatively dense, and background current and peak current value are also along with increase.
As shown in figure 11, big current waveform is more intensive, and background current and peak current value further increase.Above mentality of designing must guarantee that simultaneously dipulse low frequency modulations frequency is constant.
Should be noted that at last; above embodiment is only in order to illustrate technical scheme of the present invention; but not limiting the scope of the invention; although the present invention has been done to explain with reference to preferred embodiment; those of ordinary skill in the art is to be understood that; can make amendment or be equal to replacement technical scheme of the present invention, and not break away from the essence and the scope of technical solution of the present invention.
Claims (9)
1. has the aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, it is characterized in that: comprise the power main circuit, main control backplane, main control MCU, the wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, the wire feed drive circuit, main control MCU is arranged at main control backplane, the wire feed drive circuit is connected with main control MCU, hardware PID controller and main control MCU, the control port of power main circuit connects, power main circuit current input is electrically connected with the city, the current output terminal of power main circuit is connected with weld load, and ARM control man-machine interactive system is connected with main control MCU.
2. according to claim 1 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, it is characterized in that: the power main circuit comprises that passive harmonic wave suppresses current rectifying and wave filtering circuit, the IGBT full bridge inverter, intermediate-frequency transformer, rectification circuit, the input that passive harmonic wave suppresses current rectifying and wave filtering circuit is electrically connected with the city, the output that passive harmonic wave suppresses current rectifying and wave filtering circuit is connected with the current input terminal of IGBT full bridge inverter, the current output terminal of IGBT full bridge inverter is connected with the input of intermediate-frequency transformer, the output of intermediate-frequency transformer is connected with current rectifying and wave filtering circuit, and the rectifying and wave-filtering output is connected with weld load.
3. according to claim 2 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, it is characterized in that: also comprise current sampling circuit, voltage sampling circuit, hardware PID controller input is connected with current sampling circuit, voltage sampling circuit, and hardware PID controller feeds back to main control MCU with the information of voltage of voltage collection circuit collection, the current information that current sampling circuit detects collection.
4. according to claim 3 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter; it is characterized in that: also comprise 3846 drive circuits; 3846 drive circuits comprise main control chip U3; 5 pin of U3 are connected with hardware PID controller; 14 pin of U3; 11 pin; 4 pin are connected with the control signal input of IGBT full bridge inverter; 4 pin of U3 are connected with the primary current feedback end of IGBT full bridge inverter; 16 pin of U3 are connected with the guard signal input; voltage signal is handled the back through main control MCU and is transmitted into U3 by hardware controls PID controller; the primary current feedback information that U3 comes according to the IGBT full bridge inverter feedback that 4 pin receive; and the current/voltage feedback signal after the calculation process of the process main control MCU received of 5 pin of U3, regulate the switching tube that output voltage drives the IGBT full bridge inverter jointly.
5. according to claim 4 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, it is characterized in that: the model of the main control chip U3 of 3846 drive circuits is UC3846, and 3846 drive circuits are realized the soft switch control of finite both IGBT full bridge inverter.
6. according to claim 5 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, it is characterized in that: main control MCU adopts decides frequency and frequency conversion computational methods based on the dipulse MIG weld ripples shape of Mathematical Modeling design, realize little electric current to the meticulous adjusting of big electric current, change according to the average current size adaptation in little electric current strong and weak pulse number and base value size in the adjustment process of big electric current.
7. according to claim 6 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, it is characterized in that: based on the dipulse MIG weld ripples shape of Mathematical Modeling design decide frequency and the frequency conversion computational methods are specially: establish the cycle that T is an impulse train, T is by force the flash time in the pulse period, be that weak pulse in a pulse period is towards the time a little less than the T, t1 is flash group's the base value time, t2 is the base value time of weak impulse train, a is a flash group background current, b is weak impulse train background current, c is a peak current level, and n1 is a pulse number among the flash group, and n2 is a pulse number among the weak pulse group, f represents the double pulse modulation frequency, and I is an average current; In pulse period T weak=T is strong=T/2=500/f;
At first set n1, n2 initial value, the unit pulse time is t ms, then has;
Obtain average current
When flash different mountain value electric current, weak pulse towards different mountain value electric current, flash group background current, weak impulse train background current fixedly the time, there are relation one to one in n1, n2 and t1, t2, establish n1, and n2 strengthens gradually, then t1, t2 reduce gradually, the subfunction of power taking stream
As follows:
Then
Promptly along with x reduces gradually,
The slope steepening tends towards stability during to a certain position, progressively strengthen n1 according to certain rule, n2, then corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed gradually and to be accelerated, thereby realizes that welding current can regulate continuously, and along with its increase of progressively increasing of electric current is faster.
8. describedly has an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter according to any one of claim 1-7, it is characterized in that: ARM control man-machine interactive system comprises the ARM module, CPLD module, button, encoder, LED and charactron display module, LED and charactron display module, encoder are connected with the CPLD module, button, CPLD module are connected with the ARM module, and the ARM module is connected with the SCI interface of main control MCU.
9. according to claim 8 have an aluminium alloy digitlization welding machine that seamlessly transits the dipulse parameter, and it is characterized in that: the main control MCU model is STC89C58RD+.
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