CN102091850B - 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 aluminum alloy digital welding machine technical field, particularly a kind of aluminum alloy digital welding machine with smooth transition double-pulse parameters.
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 disposal ability, the theory of Digital Signal Processing with realize means and obtained unprecedented development, become one of the fastest subject of Developing.High-grade single-chip microprocessor MCU is successfully introduced after source of welding current control field, for further improving welding technological properties, provides possibility, for attempting new welding procedure, provides opportunity.MCU becomes the optimal selection device of source of welding current control and Digital Signal Processing with features such as its stability, repeatability, Real-time digital signal processing, flexibility programming, large-scale integrateds, digitlization, intelligent Arc Welding Power are arisen at the historic moment.
Abroad, the well-known welding equipment company in the world of take that the KEMPPI company of Austrian FRONIUS, German EWM, Finland is representative, has all developed a series of Study of digital welding machine systems with expert database, the fetch long price of these welding.Domestic Study of digital welding machine is in development at present, mainly contains Tangshan Panasonic, Shanxi nebula, Beijing epoch ,Shan great Ao Taideng company in exploitation, and part is released Study of digital welding machine product.Aspect dipulse Welded, take the aluminium alloy welding machine comparative maturity that European countries were produced that Austrian FRONIUS company is representative, welding process is stable.And domestic production producer is all also in the dipulse solder technology of exploring aluminium alloy, not yet obtain at present substantive breakthroughs, be mainly to also do not find inherent law in the design of double-pulse parameters.Tracing it to its cause, is mainly that mutual proper fit needs a large amount of engineer testings because the welding parameter of dipulse is many, and aluminium alloy rapid heat dissipation, welding process is extremely unstable; In addition, electric arc arc length is unstable, and 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 object of the invention is to provides the aluminum alloy digital welding machine with smooth transition double-pulse parameters for the deficiencies in the prior art, the main control MCU of its bonding machine can complete welding process flow fast and stable and control and dipulse waveform database management role, welding efficiency is high, has realized the stable welding of aluminium alloy from little electric current to large electric current.
Object of the present invention realizes by following technical measures:
The aluminum alloy digital welding machine with smooth transition double-pulse parameters, comprise power main circuit, main control backplane, main control MCU, wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, wire feed drive circuit, main control MCU is arranged at main control backplane, 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 to city, the current output terminal of power main circuit is connected with weld load, ARM controls man-machine interactive system and is connected with main control MCU.
Wherein, power main circuit comprises that passive harmonic suppresses current rectifying and wave filtering circuit, IGBT full bridge inverter, intermediate-frequency transformer, current rectifying and wave filtering circuit, the input that passive harmonic suppresses current rectifying and wave filtering circuit is electrically connected to city, the output that passive harmonic 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 output of current rectifying and wave filtering circuit 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 detects by the information of voltage of voltage sampling circuit collection, current sampling circuit the current information gathering and feeds back to main control MCU.
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 guard signal input, voltage signal transmits into U3 by hardware controls PID controller after main control MCU is processed, the primary current feedback information that the IGBT full bridge inverter feedback that U3 receives according to 4 pin is come, and the current/voltage feedback signal after the calculation process of main control MCU received of 5 pin of U3, common regulation output voltage drives the switching tube of IGBT full bridge inverter.
Wherein, the model of the main control chip U3 of 3846 drive circuits is UC3846, and 3846 drive circuits are realized the soft switch of finite both and controlled IGBT full bridge inverter.
Wherein, what main control MCU adopted dipulse MIG weld ripples shape based on Design of Mathematical Model determines frequency and frequency conversion computational methods, realize little electric current to the meticulous adjusting of large electric current, at little electric current, to strong and weak pulse number in the adjustment process of large electric current and base value size, according to average current size adaptation, change.
Wherein, dipulse MIG weld ripples shape based on Design of Mathematical Model determine frequency and frequency conversion computational methods are specially: establish the cycle that T is an impulse train, T is by force the flash time in the impulse train cycle, it a little less than T, is the weak burst length of an impulse train in the cycle, t1 is flash group's the base value time, t2 is the base value time of weak impulse train, a is flash group background current, b is weak impulse train background current, c is peak current level, and n1 is pulse number in flash group, and n2 is pulse number in weak pulse group, f represents double pulse modulation frequency, and I is average current; In impulse train cycle T weak=T is strong=T/2=500/f;
First set n1, n2 initial value, the unit pulse time is t ms, has;
Obtain average current
When flash group peak point current, weak pulse punching group peak point current, flash group background current, weak impulse train background current are fixedly time, there is relation one to one in n1, n2 and t1, t2, establishes n1, and n2 strengthens gradually, t1, t2 reduce gradually, the subfunction of obtaining current
as follows:
;
Along with x reduces gradually,
slope steepening tends towards stability when a certain position, according to certain rule, progressively strengthen n1, n2, corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed and accelerated gradually, can regulate continuously thereby realize welding current, and along with its increase of progressively increasing of electric current is faster.
Wherein, ARM controls man-machine interactive system and comprises ARM module, CPLD module, button, encoder, LED and charactron display module, LED and charactron display module, encoder are connected with CPLD module, button, CPLD module are connected with ARM module, and ARM module is connected with the SCI interface of main control MCU.
Wherein, main control MCU model is STC89C58RD+.
Beneficial effect of the present invention is: the aluminum alloy digital welding machine with smooth transition double-pulse parameters, comprise power main circuit, main control backplane, main control MCU, wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, wire feed drive circuit, main control MCU is arranged at main control backplane, 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 to city, the current output terminal of power main circuit is connected with weld load, ARM controls man-machine interactive system and is connected with main control MCU.It is control core that the present invention adopts MCU+ARM, and by hardware PID controller, produce the driving that PWM realizes main circuit and control the live load that greatly reduces main control MCU, the main control MCU of bonding machine can complete welding process flow fast and stable and control and dipulse waveform database management role, improve welding efficiency, realized the stable welding of aluminium alloy from little electric current to large electric current.
Accompanying drawing explanation
Fig. 1 is control system structure chart of the present invention;
Fig. 2 is power main circuit diagram of the present invention;
Fig. 3 is 3846 drive circuit figure of the present invention;
Fig. 4 is 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 little electric current of the present invention;
Dipulse waveform when Figure 10 is medium current of the present invention;
Dipulse waveform when Figure 11 is large electric current of the present invention.
The specific embodiment
Below in conjunction with accompanying drawing, the present invention is further illustrated.
The present embodiment provides the aluminum alloy digital welding machine with smooth transition double-pulse parameters, comprise power main circuit, main control backplane, main control MCU, wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, wire feed drive circuit, main control MCU is arranged at main control backplane, 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 to city, the current output terminal of power main circuit is connected with weld load, ARM controls man-machine interactive system and is connected with main control MCU.It is control core that the present invention adopts MCU+ARM, and by hardware PID controller, produce the driving that PWM realizes main circuit and control the live load that greatly reduces main control MCU, the main control MCU of bonding machine can complete welding process flow fast and stable and control and dipulse waveform database management role, improve welding efficiency, realized the stable welding of aluminium alloy from little electric current to large electric current.
The power main circuit of the present embodiment comprises that passive harmonic suppresses current rectifying and wave filtering circuit, IGBT full bridge inverter, intermediate-frequency transformer, current rectifying and wave filtering circuit, the input that passive harmonic suppresses current rectifying and wave filtering circuit is electrically connected to city, the output that passive harmonic 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 output of current rectifying and wave filtering circuit is connected with weld load.
The 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 detects by the information of voltage of voltage sampling circuit collection, current sampling circuit the current information gathering and feeds back to main control MCU.
The 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 guard signal input, voltage signal transmits into U3 by hardware controls PID controller after main control MCU is processed, the primary current feedback information that the IGBT full bridge inverter feedback that U3 receives according to 4 pin is come, and the current/voltage feedback signal after the calculation process of main control MCU received of 5 pin of U3, common regulation output voltage drives the switching tube of IGBT full bridge inverter.
The model of the main control chip U3 of 3846 drive circuits of the present embodiment is UC3846, and 3846 drive circuits are realized the soft switch of finite both and controlled IGBT full bridge inverter.
What the main control MCU of the present embodiment adopted dipulse MIG weld ripples shape based on Design of Mathematical Model determines frequency and frequency conversion computational methods, realize little electric current to the meticulous adjusting of large electric current, at little electric current, to strong and weak pulse number in the adjustment process of large electric current and base value size, according to average current size adaptation, change.
The ARM of the present embodiment controls man-machine interactive system and comprises ARM module, CPLD module, button, encoder, LED and charactron display module, LED and charactron display module, encoder are connected with CPLD module, button, CPLD module are connected with ARM module, and ARM module is connected with the SCI interface of main control MCU.
The main control MCU model of the present embodiment is STC89C58RD+.
The process of the welding process of the aluminium alloy the realized dipulse of the present embodiment is controlled, and dipulse Waveform Control expert database system.Based on 3846 chip controls, adopt the soft switch of ripe finite both.As Fig. 3 only needs given output voltage, just can generate PWM and drive, can be regarded as " black box " of realizing V-PWM conversion, add primary current protection, reliable and stable.Hardware PID drives the live load that greatly reduces main control MCU, and main control MCU can complete flow process fast and stable and control and data administration tasks.Main control backplane is the core of dipulse welding machine hardware.Peripheral discharge circuit and wire feeding circuit part are set, and object is to export smart metastable dipulse signal to drive plate, matches the wire feed rate of suitable current simultaneously, thereby reaches unified welding.
The dipulse MIG weld ripples shape based on Design of Mathematical Model of the present embodiment determine frequency and frequency conversion computational methods are specially: establish the cycle that T is an impulse train, T is by force the flash time in the impulse train cycle, it a little less than T, is the weak burst length of an impulse train in the cycle, t1 is flash group's the base value time, t2 is the base value time of weak impulse train, a is flash group background current, b is weak impulse train background current, c is peak current level, n1 is pulse number in flash group, n2 is pulse number in weak pulse group, and f represents double pulse modulation frequency, and I is average current; In impulse train cycle T weak=T is strong=T/2=500/f;
First set n1, n2 initial value, the unit pulse time is 2ms, have,
Obtain average current
When flash group peak point current, weak pulse punching group peak point current, flash group background current, weak impulse train background current are fixedly time, there is relation one to one in n1, n2 and t1, t2, establishes n1, and n2 strengthens gradually, t1, t2 reduce gradually, the subfunction of obtaining current
as follows:
M is greater than 0 constant, and m is a or b, is all less than c;
;
Along with x reduces gradually,
slope steepening tends towards stability when a certain position, according to certain rule, progressively strengthen n1, n2, corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed gradually and to be accelerated, determine frequency and the frequency conversion computational methods of the dipulse MIG weld ripples shape based on Design of Mathematical Model have realized welding current and can regulate continuously, and along with its increase of progressively increasing of electric current is faster.
The double-pulse parameters Mathematical Modeling Methods of determining frequency modulation electric current of the present embodiment.As shown in Figure 7, the mathematical modeling operation principle that double pulse modulation frequency f=3.3 Hz that commonly uses of take determines frequency double-pulse parameters as example explanation, T is strong=and T is weak=T/2=500/3.3 ms, T
by force, T
a little less thanbe respectively flash group time, the weak pulse group time of an impulse train in the cycle; 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, weak impulse train, a, and b, c is respectively flash group background current size, weak impulse train background current size, peak current level.By Fig. 7, according to the relation between n and t, be brought into current expression:
Can obtain:
By expression formula above, easily known, under the condition of fixing strong and weak impulse train peak point current, background current size, t1, t2 have become to determine two factors of welding current size.Yet, due to t1, the t2 problem that has not directly perceived and the collimation error that reads in welding waveform acquisition feedback, strengthened the difficulty of design.From Fig. 7, can obtain n1, n2 and t1, t2 exist relation one to one, n1, n2 read convenient directly perceived in test waveform feedback simultaneously, and n1, n2 are integer, can greatly improve the operation efficiency of chip thus, the more important thing is the programming of having simplified expert database, greatly strengthened the readability of program.Therefore, choose n1, n2 as the independent variable of continuity adjustable current.
The target increasing gradually for meeting electric current, we can set n1, and n2 strengthens gradually, and t1, t2 reduce gradually, the subfunction of obtaining current
as follows:
Along with x reduces gradually,
slope steepening tends towards stability when 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 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, in this model theory, having realized welding current can regulate continuously, and along with its increase of progressively increasing of electric current is faster, reaches the object that hommization regulates.Thereby proved the feasibility of aluminium alloy dipulse MIG weldering expert database under the fixed condition frequently of exploitation.
The present embodiment at the constant double-pulse parameters Mathematical Modeling Methods of frequency conversion average current for will suppose that Frequency is f, all the other double-pulse parameters as mentioned above, the similar fixed modeling approach frequently equation that is easy to get:
As can be seen from the above equation, the frequency factor of the size of current under frequency conversion condition has been offset, and it is in full accord with the equation under fixed condition frequently.Therefore,, the in the situation that of other parameter constants of dipulse waveform, the change of frequency does not affect the adjusting of size of current.
Can obtain thus: the adjusting of Frequency does not affect 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 be by frequency and set n1, and n2 can determine, thereby the continuity that can design Frequency under different average pulse electric currents regulates.
The present embodiment can change low frequency modulations frequency in the constant situation of average pulse electric current, keeping under the condition of certain speed of welding, by operator's needs, can be by changing dipulse Frequency, when obtaining high-quality weld seam attractive in appearance, can regulate the width of weld seam scalelike mark, meet the demand of different occasions, make aluminium alloy dipulse welding machine reach the requirement of maturation, system, commercialization.
Realized and having determined under frequency and frequency conversion condition, the continuous fine adjustment of average pulse electric current from little electric current to large electric current, can also realize slow, large fast " hommization " regulating effect of electric current governing speed of the medium and small electric current governing speed of welding process, the parameter configuration of the corresponding electric current of Mathematical Modeling Auto-matching designing in advance in this " hommization " regulating effect Main Basis software, can obtain through peripheral hardware circuit amplifier.Through the designed dipulse aluminium alloy welding machine of verification experimental verification patent of the present invention, can obtain scalelike mark clearly, welding process good stability, appearance of weld is attractive in appearance.
The base value a of the related aluminium alloy dipulse digital welding machine of patent of the present invention based on strong and weak impulse train and b carry out the adjustable variation of continuity according to certain rule, the strong and weak pulse number n1 of auxiliary adjustment, and n2, can effectively expand welding current scope, thereby realized, can continuity regulate relative broad range welding current.In the strong and weak pulse transition stage, pulse base value is taked the mode of gradual change, makes the transition of strong and weak pulse more smoothly smooth and easy simultaneously, and welding process is more stable.
Double-pulse parameters is optimized, and it is 2ms that the burst length is chosen in test, and pulse current is 250A.By certain rule, regulate the value of n1 and n2 can realize the variation of the ladder great-jump-forward of welding current from little electric current to large electric current, yet but can not realize the continuity variation of electric current.Along with pulse number n1, when n2 is increased to some, pulse number is than comparatively dense, under the fixing condition of Frequency, continuing to increase pulse number has been a kind of worthless way, and when certain electric current arrives size, continuing to increase electric current is a difficult thing.
Base value a and b based on impulse train, carry out the adjustable variation of continuity according to certain rule, and auxiliary adjustment pulse number n1 and n2 change, and can effectively expand welding current scope, thereby realize the object that can wide region continuity regulates welding current.
Compared with prior art, tool has the following advantages and beneficial effect in the present invention:
1. the present invention is based on Mathematical Modeling and calculate pulse base value gradual change amount in 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 strong and weak impulse transfer.
2. when medium and small dipulse electric current regulates, to regulate step pitch minor adjustment to obtain meticulousr in the present invention, when large dipulse electric current, regulate step pitch to arrive sooner greatly required adjusting current value, can realize seamlessly transitting of pulse current voltage waveform in strong and weak impulse waveform transfer process, guaranteed the stability of aluminum alloy welding termination process, regulate and have more hommization with common double pulse parameter control method electric current.
3. the dipulse aluminium alloy welding machine waveform expert database system that the present invention is based on Mathematical Models has obtained scalelike mark clearly on Study of digital welding machine, is a kind of Study of digital welding machine expert database method of setting up of novelty.
As shown in Figure 1, this system comprises the parts such as current rectifying and wave filtering circuit, IGBT bridge inverter main circuit, control circuit, wire feed driving, man-machine interactive system.Design fundamentals: adopt 3846 relatively ripe driving chips to realize the soft switch of finite both and control IGBT bridge inverter main circuit.High-performance main control MCU is as flow process control core, mainly completes that overcurrent protection, overvoltage protection, overheat protector, given value of current, voltage given, wire feed rate are given, the control of technique logical order, serial communication, data storage, expert system generates and the function such as management.Adopt ARM+CPLD pattern, the encoder on control panel, button, LED lamp, table and serial communication.
As shown in Figure 2, three-phase alternating current 380V, 50Hz become the HVDC of about low ripple 550V after three-phase commutation bridge rectification, filtering, then offer IGBT bridge inverter main circuit and main transformer T1 carries out DC-AC conversion.Full bridge inverter Q1, Q2, Q3, Q4 provide drive waveforms alternate conduction by control circuit, then after transformer T1 step-down, become the voltage of intermediate frequency of 20KHz.Then the current rectifying and wave filtering circuit being comprised of D1, D2 is rectified into direct current, then passes through the filter action of reactance and electric capacity, for welding arc load provides institute's energy requirement.
As shown in Figure 3, current/voltage feedback signal, through calculation process, is input to 5 pin of UC3846, and primary current feedback signal is input to 4 pin of UC3846, common regulation output voltage; 11,14 pin are the completely anti-phase pwm signal output of two-way; 16 pin are guard signal input pin, when voltage surpasses 350mV, turn-off output pulse, and the switching tube of protection IGBT bridge inverter main circuit can not damage because of overcurrent; It is 20kHz that C12, R24 can set inversion operating frequency.
As shown in Figure 4, adopt the high-performance MCU 89C58RD+ of STC Corporation as main control chip, this single-chip microcomputer be a new generation of releasing of STC superpower anti-interference, at a high speed, low-power consumption product, there is following characteristics: completely compatible traditional 8051 single-chip microcomputers of instruction code, more than operating frequency can reach 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 sheet, ISP function, UART, 8 road A/D passages, house dog, inner integrated MAX810 Special reset circuit etc.
As shown in Figure 5, the window comparator in figure in " welding gun crawl wire feed signal circuit " has following characteristic: (1) C place input voltage is more than 10V, and while not pressing any button, D and E place are low level; (2) C place input voltage, when 5V ~ 10V, is pressed crawl wire feed button, and now D is low level, and E is high level; (3) when C place input voltage is during at 0 ~ 5V, press arc welding gun switch, now D place is high level, and E place is low level.From above characteristic, welding gun signal and crawl wire feed signal can be realized its function well by this circuit.
As shown in Figure 6, adopt LM3S818 as control core, in conjunction with CPLD, realize the input of code device signal and the control of LED lamp, and the scanning of button, and utilize RS232 universal serial bus to communicate by letter with main control chip DSP with 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, weak impulse train, a, b, c is respectively flash group background current size, weak impulse train background current size, peak current level.
As shown in Figure 8, according to above-mentioned Design of Mathematical Model aluminium alloy expert dipulse database, test, through a large amount of engineer testing checkings, show: only need rotatory current setting knob from small to large, dipulse welding current under this fixed design frequently can cover all electric currents that are accurate to 1A in the category from 55A to 300A, thereby has confirmed that this Mathematical Modeling expert database levels of precision enough meets 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 is separately all wider, and on current waveform, the form of expression is that strong and weak impulse train is more sparse, and meanwhile, background current and peak current value are all less.
As 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, large current waveform is more intensive, and background current and peak current value further increase.Above mentality of designing must guarantee that dipulse low frequency modulations frequency is constant simultaneously.
Finally should be noted that; 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 modify or be equal to replacement technical scheme of the present invention, and not depart from essence and the scope of technical solution of the present invention.
Claims (7)
1. the aluminum alloy digital welding machine with smooth transition double-pulse parameters, it is characterized in that: comprise power main circuit, main control backplane, main control MCU, wire feed drive circuit, ARM controls man-machine interactive system, hardware PID controller, hardware PID controller, wire feed drive circuit, main control MCU is arranged at main control backplane, 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 to city, the current output terminal of power main circuit is connected with weld load, ARM controls man-machine interactive system and is connected with main control MCU,
Described power main circuit comprises that passive harmonic suppresses current rectifying and wave filtering circuit, IGBT full bridge inverter, intermediate-frequency transformer, current rectifying and wave filtering circuit, the input that passive harmonic suppresses current rectifying and wave filtering circuit is electrically connected to city, the output that passive harmonic 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 output of current rectifying and wave filtering circuit is connected with weld load;
Described aluminum alloy digital welding machine 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 detects by the information of voltage of voltage sampling circuit collection, current sampling circuit the current information gathering and feeds back to main control MCU.
2. the aluminum alloy digital welding machine with smooth transition double-pulse parameters according to claim 1, 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 guard signal input, voltage signal transmits into U3 by hardware PID controller after main control MCU is processed, the primary current feedback information that the IGBT full bridge inverter feedback that U3 receives according to 4 pin is come, and the current/voltage feedback signal after the calculation process of main control MCU received of 5 pin of U3, common regulation output voltage drives the switching tube of IGBT full bridge inverter.
3. the aluminum alloy digital welding machine with smooth transition double-pulse parameters according to claim 2, it is characterized in that: the model of the main control chip U3 of 3846 drive circuits is UC3846,3846 drive circuits are realized the soft switch of finite both and are controlled IGBT full bridge inverter.
4. the aluminum alloy digital welding machine with smooth transition double-pulse parameters according to claim 3, it is characterized in that: what main control MCU adopted dipulse MIG weld ripples shape based on Design of Mathematical Model determines frequency and frequency conversion computational methods, realize little electric current to the meticulous adjusting of large electric current, at little electric current, to strong and weak pulse number in the adjustment process of large electric current and base value size, according to average current size adaptation, change.
5. the aluminum alloy digital welding machine with smooth transition double-pulse parameters according to claim 4, it is characterized in that: the dipulse MIG weld ripples shape based on Design of Mathematical Model determine frequency and frequency conversion computational methods are specially: establish the cycle that T is an impulse train, T is by force the flash time in the impulse train cycle, it a little less than T, is the weak burst length of an impulse train in the cycle, t1 is flash group's the base value time, t2 is the base value time of weak impulse train, a is flash group background current, b is weak impulse train background current, c is peak current level, n1 is pulse number in flash group, n2 is pulse number in weak pulse group, f represents double pulse modulation frequency, I is average current, in impulse train cycle T weak=T is strong=T/2=500/f,
First set n1, n2 initial value, the unit pulse time is t ms, has;
Obtain average current
When flash group peak point current, weak pulse punching group peak point current, flash group background current, weak impulse train background current are fixedly time, there is relation one to one in n1, n2 and t1, t2, establishes n1, and n2 strengthens gradually, t1, t2 reduce gradually, the subfunction of obtaining current
as follows:
Along with x reduces gradually,
slope steepening tends towards stability when a certain position, according to certain rule, progressively strengthen n1, n2, corresponding t1, t2 progressively reduce, thereby cause electric current progressively to increase, and electric current is pushed the speed and accelerated gradually, can regulate continuously thereby realize welding current, and along with its increase of progressively increasing of electric current is faster.
6. according to the aluminum alloy digital welding machine with smooth transition double-pulse parameters described in claim 1-5 any one, it is characterized in that: ARM controls man-machine interactive system and comprises ARM module, CPLD module, button, encoder, LED and charactron display module, LED and charactron display module, encoder are connected with CPLD module, button, CPLD module are connected with ARM module, and ARM module is connected with the SCI interface of main control MCU.
7. the aluminum alloy digital welding machine with smooth transition double-pulse parameters according to claim 6, is characterized in that: main control MCU model is STC89C58RD+.
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