CN102259233A - Intermediate-frequency inverter-resistance spot welding power-supply system - Google Patents

Intermediate-frequency inverter-resistance spot welding power-supply system Download PDF

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Publication number
CN102259233A
CN102259233A CN2011102145196A CN201110214519A CN102259233A CN 102259233 A CN102259233 A CN 102259233A CN 2011102145196 A CN2011102145196 A CN 2011102145196A CN 201110214519 A CN201110214519 A CN 201110214519A CN 102259233 A CN102259233 A CN 102259233A
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circuit
power
control
output
spot welding
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曾敏
曹彪
黄增好
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GUANGZHOU JINGYUAN ELECTRICAL EQUIPMENT CO Ltd
South China University of Technology SCUT
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GUANGZHOU JINGYUAN ELECTRICAL EQUIPMENT CO Ltd
South China University of Technology SCUT
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Abstract

The invention claims an intermediate-frequency inverter-resistance spot welding power-supply system, comprising a main circuit and a control system, wherein the main circuit comprises a power switch, an input rectifier filter circuit, a power inverter circuit, an intermediate-frequency transformer and an output rectifier filter circuit which are connected successively; the control system comprises a control transformer and a control circuit; the control transformer and the input rectifier filter circuit are respectively connected with an industrial frequency alternating current power grid through the power switch; the output rectifier filter circuit is connected with a load; the control circuit is respectively connected with the power inverter circuit, a keyboard and display equipment; the control circuit is also connected with an output end of the power inverter circuit. The power-supply system has advantages of simplicity, feasibility, high efficiency and high control accuracy and fast response speed; in addition, based on a 3-sectional heating mode, the power-supply system has constant current, constant voltage, constant power, set pulse width and other output functions; moreover the power-supply system has 15 items of adjustable welding parameters and 20 groups of storable welding parameters.

Description

A kind of medium frequency inverter resistance spot welding power supply system
Technical field
The present invention relates to the spot welding power of welding field, relate in particular to a kind of medium frequency inverter resistance spot welding power supply system.
Background technology
Resistance spot welding power supply mainly contains following several: single phase industrial frequence formula power supply, three phase low frequency formula power supply, controllable silicon secondary commutation formula power supply, capacitance energy storage type power supply, contravariant power etc., and mainly there is following problem in preceding four kinds of application of power in pinpoint welding procedure:
(1) energy output control and time control accuracy can not meet the demands.Its response speed of AC spot-welding power supply of main flow is 20ms at present, control response speed and adjusting lack of resolution;
(2) most of power supply adopts Industrial Frequency Transformer, and volume is big, heavy, low, the consumptive material of efficient;
(3) major part is an open cycle system, part belt current, voltage FEEDBACK CONTROL, and power supply stability is not enough.
From the employed electronic devices and components of control circuit, the resistance spot welding control system can be divided into: discrete component control system, integrated circuit control system, Control System of Microcomputer etc.Wherein the core devices of Control System of Microcomputer employing can be divided into single-chip microcomputer, digital signal processor and programmable logic controller (PLC) again.Preceding two kinds of control systems gradually go out market, and what widely adopt at present is Control System of Microcomputer, and the digital signal processor development rapidly.
From quality control method, the resistance spot welding quality control method comprises: constant current control, dynamic electric resistor monitoring, voltage across poles monitoring, the monitoring of thermal expansion electrode displacement, supercritical ultrasonics technology, surface temperature and infra-red method etc.Wherein, the research of preceding four kinds of methods is comparatively ripe, and constant current control is most widely used.Current signals is directly carried out on main circuit, and its output is pulsation or AC signal.In order directly to reflect the size of current in the pinpoint welding procedure, need effectively handle this sampled signal.
Advantages such as the inverse switch power supply has the efficient height, and is in light weight, and voltage can rise and can fall, and power output is big.But because circuit working is on off state, so noise ratio is bigger, conduction loss, the switching loss of switching tube also can not be ignored.Be head it off, traditional hard switching pattern is replaced by soft switch technique.Soft switch technique can further improve power-efficient, reduces the loss of switching device and improve power supply reliability on the basis of medium frequency inverter.
On the control implementation, at present resistance spot welding power supply extensively adopts the full-bridge inverting pulse duration modulation method, and its control mode can be divided into: three kinds of bipolarity controls, finite both control, phase shifting control.The full-bridge phase shifting converter has obtained extensive concern in recent years, in be widely used in powerful communication power supply and the electric power operation power supply.Yet this control method has following significant disadvantages:
(1) the lagging leg switching tube will lose the ZVT function under underloading;
(2) for realizing the ZVS of lagging leg, must be in circuit series inductance, this can cause duty-cycle loss, increases the primary current quota;
(3) there is big circulation in former limit, has increased system's on-state loss.
Summary of the invention
The objective of the invention is to overcome the shortcoming and defect of above-mentioned prior art, a kind of power supply control accuracy height, the fast medium frequency inverter resistance spot welding power supply system of response speed are provided.
The present invention is achieved through the following technical solutions:
A kind of medium frequency inverter resistance spot welding power supply system is characterized in that: comprise main circuit, control system, described main circuit comprises power switch, input rectifying filter circuit, power inversion circuit, intermediate-frequency transformer, the output rectifier and filter that connects successively; Described control system comprises control transformer, control circuit; Described control transformer, input rectifying filter circuit are connected with the industrial frequency AC electrical network by power switch respectively, output rectifier and filter is connected with load, control circuit is connected respectively with power inversion circuit, keyboard, display device, and this control circuit also is connected with the output of power inversion circuit.
The full-bridge type inversion change-over circuit that described power inversion circuit is made up of four IGBT pipes and inverse parallel diode, electric capacity and resistance.
Described control circuit comprises processor and connected reset circuit, voltage/current sample circuit, overload protecting circuit, power inverting drive circuit; Described power inverting drive circuit also is connected with a power inversion circuit; Described voltage/current sample circuit is connected with the output of output rectifier and filter respectively; Described processor also is connected with keyboard, display device.
Described processor comprises A/D modular converter, comparison module, PWM output module, driver module and keyboard interface, wherein the A/D modular converter is connected with the voltage/current sample circuit, the PWM output module is connected with the power inverting drive circuit, driver module is connected with display device, and keyboard interface is connected with keyboard.
Medium frequency inverter resistance spot welding power supply of the present invention system also comprises a virtual value treatment circuit, is used for directly calculating the real effective of the complexity input waveform of the AC compounent that comprises direct current, and converts thereof into direct-flow output signal.
Beneficial effect compared with prior art of the present invention is:
(1) gets rid of traditional Industrial Frequency Transformer, alleviated the volume and weight of power supply greatly;
(2) reverse frequency can be 1kHz, and 4kHz, 8kHz bring up to Millisecond with the control accuracy of power supply, improve the response speed of system greatly, significantly promotes the adjusting resolution ratio and the controllability of power supply;
(3) by virtual value treatment circuit and increment type PID control algolithm, can guarantee the accuracy of exporting;
(4) adopt finite both control, realized ZVZCS, greatly reduce the loss of power;
(5) have constant current, constant voltage, permanent power, decide multiple output characteristics such as pulsewidth, improve the Technological adaptability of equipment;
(6) 15 welding parameters are adjustable, and 20 bond pads parameters store, and have realized multi-parameterization;
(7) adopt LCD to show, be furnished with keyboard input and RS232 communication interface, realized human oriented design;
(8) adopt intelligent monitoring, but on-line monitoring welding current, voltage or power output guarantee the uniformity of its technical process, have simplified control circuit, have realized high efficiency, the intellectuality of power supply;
(9) the present invention is various high-frequency electronic components and parts, network element device, various SMT Inductor, SMD transformer, various induction type IC cards, various clock and watch coils, Microspeaker, news Chinese percussion instrument micromachine, the welding of various integrated packages, module, various metal wire, metal tape, sheet metal, and the repairing of printed substrate etc. provides a kind of novel low-cost, high reliability, high efficiency resistance spot welding equipment, can increase product technology content, make it to have characteristics efficient, energy-saving and environmental protection, have tangible economic benefit and social benefit.
Description of drawings
Fig. 1 is a medium frequency inverter resistance spot welding power supply system architecture diagram of the present invention;
Fig. 2 is the main circuit diagram of medium frequency inverter resistance spot welding power supply of the present invention system;
Fig. 3 is the control system block diagram of medium frequency inverter resistance spot welding power supply of the present invention system;
Fig. 4 is current-voltage correlation figure of the present invention;
Fig. 5 is a virtual value treatment circuit of the present invention;
Fig. 6 is a pid control algorithm flow chart of the present invention.
The specific embodiment
Below in conjunction with specific embodiment the present invention is done further concrete detailed description the in detail, but embodiments of the present invention are not limited thereto, the technological parameter for not indicating especially can carry out with reference to routine techniques.
Embodiment
As shown in Figure 1, medium frequency inverter resistance spot welding power supply of the present invention system comprises main circuit, control system, and described main circuit comprises power switch, input rectifying filter circuit, power inversion circuit, intermediate-frequency transformer, the output rectifier and filter that connects successively; Described control system comprises control transformer, control circuit; Described control transformer, input rectifying filter circuit are connected with the industrial frequency AC electrical network by power switch respectively, output rectifier and filter is connected with load, control circuit is connected respectively with power inversion circuit, keyboard, display device, and this control circuit also is connected with the output of power inversion circuit.
As shown in Figure 2.The full-bridge type inversion change-over circuit that described power inversion circuit is made up of four IGBT pipe Q1, Q2, Q3, Q4 and inverse parallel diode, electric capacity and resistance.
As shown in Figure 3.Described control circuit comprises processor and connected reset circuit, voltage/current sample circuit, overload protecting circuit, power inverting drive circuit; Described power inverting drive circuit also is connected with a power inversion circuit; Described voltage/current sample circuit is connected with the output of output rectifier and filter respectively; Described processor also is connected with keyboard, display device, RS232 communication interface.
Described processor comprises A/D modular converter, comparison module, PWM output module, driver module and keyboard interface, communication interface, the A/D modular converter is connected with the voltage/current sample circuit, the PWM output module is connected with described power inverting drive circuit, driver module is connected with display device by I/O mouth, the latch decoder of processor, keyboard interface is connected with keyboard by the I/O mouth of processor, and RS232 is connected with UART Universal Asynchronous Receiver Transmitter (UART) module of processor by max232.
Processor adopting digital signal processor DSP IC30F6010, it has 16 bit comparison PWM output functions, can export 8 road pwm signals simultaneously, and 4 the tunnel are used to control the driving power inverter circuit.Drive circuit converts pwm signal to the driving signal of the IGBT pipe switch that can drive described power inversion circuit.The output voltage size that power supply offers load can recently realize by the duty of regulating the control pwm signal.The voltage/current sample circuit comprises Hall element, voltage, current conversion circuit; In a single day have overcurrent, overvoltage, under-voltage, overheated, scarce cooling water phenomenon to produce in the power supply running, holding circuit will make the DSP control system produce interruption, reset, and guarantee whole power supply reliably working.
As shown in Figure 1, 2, the input rectifying filter circuit adopts the single-phase diode rectifier circuit.Described output rectifier and filter adopts diode rectification, electric capacity, inductor filter circuit; Described diode is a fast diode.
Power inversion circuit adopts the full-bridge type inversion change-over circuit that is suitable for high-power output, comprise four IGBT pipe Q1, Q2, Q3, Q4 and inverse parallel diode, electric capacity and resistance compositions, four IGBT pipes are formed four arms of bridge, and intermediate-frequency transformer is connected their centre.As shown in Figure 2, power inversion circuit adopts the control mode of finite both, and the driving signal pulsewidth of promptly leading arm IGBT pipe Q1, Q2 can be regulated; The driving signal pulsewidth of lagging leg IGBT pipe Q3, Q4 is non-adjustable, is fixed value (being maximum pulse width); IGBT pipe Q1 and Q3 be ON time ton simultaneously, and IGBT pipe Q2 and Q4 be while ON time ton also.Intermediate-frequency transformer primary voltage VAB is only relevant with IGBT tubulose attitude with output voltage, and is irrelevant with load characteristic and size, so just guaranteed the stability of this medium frequency inverter resistance spot welding power supply output voltage.For fear of same brachium pontis up and down two pipe conductings simultaneously cause short circuit, pipe must be provided with a fixing Dead Time up and down; Can realize the output voltage adjusting by regulating IGBT pipe Q1, Q2 driving signal pulsewidth.
Shown in Fig. 3,4, it is the power delivery stage that specific implementation process can be divided into four-stage: t1-t2; T2-t4 realizes the no-voltage shutoff of leading arm IGBT pipe Q1; T4-t5 realizes the no-voltage shutoff of lagging leg IGBT pipe Q4; T5-t6 realizes that no-voltage, zero current passing, the lagging leg IGBT of leading arm IGBT pipe Q2 manage the zero current passing of Q3; Again circulation after the t7.Wherein UQ1, UQ2 are the driving pulse of leading-bridge, and UQ3, UQ4 are the driving pulse of lagging leg, and turn-off time-delay Δ t time (t6-t5) back.Delay time Δ t (trailing edge) adjusts as required.More specifically, the t1 moment, IGBT pipe Q1 and Q3 conducting simultaneously, transformer primary current ip begins to rise, and electric current flows to IGBT from IGBT pipe Q1 through transformer and manages Q3, and power flows to secondary from former limit; T2 IGBT pipe Q1 constantly turn-offs, the shutoff of IGBT pipe Q1 is that ZVS turn-offs, primary current ip flows by former direction by the continuation that discharges and recharges that IGBT manages Q1, Q2 shunt capacitance, the electric capacity in parallel with Q2 is through after a while discharge, drop to zero at t3 moment voltage, the inverse parallel diode on the IGBT pipe Q2 begins the conducting afterflow; Because the voltage effect on the clamping capacitance, t4 circulation constantly decays to zero at t4～t5 constantly, and the energy on the clamping capacitance is by the shunt capacitance charging of transformer leakage inductance to IGBT pipe Q2, because time constant is very little, the very fast end of resonant process makes IGBT pipe Q2 both end voltage keep stable; T5 IGBT pipe Q3 constantly turn-offs, and at this moment the electric current and voltage on the IGBT pipe Q3 is zero, realizes that ZVZCS turn-offs.Behind a Dead Time of fixing, at t6 constantly, IGBT pipe Q2, Q4 conducting simultaneously, this moment, circulation decayed to zero concerning IGBT manages Q2, and voltage continues to keep, so be the ZVZCS conducting; Circuit working process and t1～t6 after the t6 are similar.
Intermediate-frequency transformer output of the present invention provides load behind output rectifier and filter.The output voltage of described intermediate-frequency transformer provides direct current output, supply load behind described output rectifier and filter.Described voltage/current sample circuit comprises Hall element, voltage, current conversion circuit.Current signals is directly carried out on main circuit, and its output is pulsation or AC signal.In order directly to reflect the size of current in the pinpoint welding procedure, need effectively handle this sampled signal.
As shown in Figure 5.Described virtual value treatment circuit adopts high-precision real effective converter AD536 as the virtual value scale unit.AD536A can directly calculate any complexity that comprises the AC compounent of direct current and import the real effective of waveform, and converts thereof into direct-flow output signal.Utilize AD536 to carry out the virtual value conversion and can obtain the welding current virtual value in real time, the software computing of when guaranteeing certainty of measurement, saving DSP greatly, the real-time of assurance system control.
The core devices of virtual value change-over circuit is AD536A, and signal is exported from pin 8 (Fig. 6) after treatment from pin 4 inputs.For improving the virtual value conversion accuracy, increased error in the periphery of AD536A and adjusted circuit.
As shown in Figure 6.Described increment type PID control algolithm can be derived by position pid algorithm (1) formula.
u ( k ) = K P [ ( k ) + T S T I Σ J = 0 k e ( j ) + T D T S ( e ( k ) - e ( k - 1 ) ) ] + u 0 - - - ( 1 )
The output valve of k-1 sampling instant that can controlled device by (1) is:
u ( k - 1 ) = K P [ ( k - 1 ) + T S T I Σ J = 0 k - 1 e ( j ) + T D T S ( e ( k - 1 ) - e ( k - 2 ) ) ] + u 0 - - - ( 2 )
(1) and (2) subtracted each other and put in order, just can obtain increment type PID control algolithm formula and be:
Δu ( k ) = u ( k ) - u ( k - 1 ) = K P { e ( k ) - e ( k - 1 ) + T S T I e ( k ) + T D T S [ e ( k ) - 2 e ( k - 1 ) + e ( k - 2 ) ] } = Ae ( k ) + Be ( k - 1 ) + Ce ( k - 2 ) Wherein, A = K P ( 1 + T S T I + T D T S ) B = - K P ( 1 + 2 T D T S ) C = K P T D T S - - - ( 3 )
T is the sampling period, T DBe derivative time, T IBe the time of integration.Find out that from formula (3) digital increments formula pid algorithm only needs to store nearest three error sampled value e (k), e (k-1), e (k-2).If computer control system adopts constant sampling period T, in case determine A, B, C, the deviate that three times are measured before and after using can be obtained controlled quentity controlled variable by formula (3).Here parameter is provided with the aritical ratio method that adopts in the engineering setting method.
Just can realize the present invention preferably as mentioned above.

Claims (5)

1. medium frequency inverter resistance spot welding power supply system, it is characterized in that: comprise main circuit, control system, described main circuit comprises power switch, input rectifying filter circuit, power inversion circuit, intermediate-frequency transformer, the output rectifier and filter that connects successively; Described control system comprises control transformer, control circuit; Described control transformer, input rectifying filter circuit are connected with the industrial frequency AC electrical network by power switch respectively, output rectifier and filter is connected with load, control circuit is connected respectively with power inversion circuit, keyboard, display device, and this control circuit also is connected with the output of power inversion circuit.
2. according to the described medium frequency inverter resistance spot welding power supply of claim 1 system, it is characterized in that: the full-bridge type inversion change-over circuit that described power inversion circuit is made up of four IGBT pipes and inverse parallel diode, electric capacity and resistance.
3. according to the described medium frequency inverter resistance spot welding power supply of claim 2 system, it is characterized in that: described control circuit comprises processor and connected reset circuit, voltage/current sample circuit, overload protecting circuit, power inverting drive circuit; Described power inverting drive circuit also is connected with a power inversion circuit; Described voltage/current sample circuit is connected with the output of output rectifier and filter respectively; Described processor also is connected with keyboard, display device.
4. according to the described medium frequency inverter resistance spot welding power supply of claim 3 system, it is characterized in that: described processor comprises A/D modular converter, comparison module, PWM output module, driver module and keyboard interface, wherein the A/D modular converter is connected with the voltage/current sample circuit, the PWM output module is connected with the power inverting drive circuit, driver module is connected with display device, and keyboard interface is connected with keyboard.
5. according to the described medium frequency inverter resistance spot welding power supply of claim 4 system, it is characterized in that: also comprise a virtual value treatment circuit, be used for directly calculating the real effective of the complexity input waveform of the AC compounent that comprises direct current, and convert thereof into direct-flow output signal.
CN2011102145196A 2011-07-29 2011-07-29 Intermediate-frequency inverter-resistance spot welding power-supply system Pending CN102259233A (en)

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Cited By (10)

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Publication number Priority date Publication date Assignee Title
CN102554441A (en) * 2011-12-02 2012-07-11 贵州黎阳航空动力有限公司 Constant-current control device for welding power source of medium-frequency inverter resistance electric welding machine and control method for welding power source
CN103187880A (en) * 2013-03-29 2013-07-03 无锡正一生源科技有限公司 Ultrasonic wave power source for driving magnetostrictive transducer
CN103264244A (en) * 2013-05-22 2013-08-28 广州市精源电子设备有限公司 Thermal compression bonding power source
CN105375748A (en) * 2015-11-25 2016-03-02 宋业贵 Driving power supply circuit for electric dehumidifier
CN106112245A (en) * 2016-08-11 2016-11-16 无锡洲翔成套焊接设备有限公司 Digital multi mash welder
CN108372354A (en) * 2018-02-05 2018-08-07 广州双穗电气设备有限公司 A kind of novel pulse direct current source of welding current
CN111010027A (en) * 2019-12-25 2020-04-14 广州市精源电子设备有限公司 Power factor correction circuit, method and device for resistance spot welding inverter power supply
CN111168217A (en) * 2020-01-20 2020-05-19 北京工业大学 Pulse type lossless energy storage resistance welding machine with intelligent control function
CN112548298A (en) * 2020-11-30 2021-03-26 华南理工大学 Micro-resistance spot welding power supply PID parameter self-tuning method based on pattern recognition
CN113608016A (en) * 2021-08-23 2021-11-05 天津津航计算技术研究所 AC115V current conditioning and collecting circuit based on effective value chip

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102554441A (en) * 2011-12-02 2012-07-11 贵州黎阳航空动力有限公司 Constant-current control device for welding power source of medium-frequency inverter resistance electric welding machine and control method for welding power source
CN102554441B (en) * 2011-12-02 2014-02-05 贵州黎阳航空动力有限公司 Constant-current control device for welding power source of medium-frequency inverter resistance electric welding machine and control method for welding power source
CN103187880A (en) * 2013-03-29 2013-07-03 无锡正一生源科技有限公司 Ultrasonic wave power source for driving magnetostrictive transducer
CN103264244A (en) * 2013-05-22 2013-08-28 广州市精源电子设备有限公司 Thermal compression bonding power source
CN105375748B (en) * 2015-11-25 2018-03-02 宋业贵 A kind of electric dehumidifier driving power circuit
CN105375748A (en) * 2015-11-25 2016-03-02 宋业贵 Driving power supply circuit for electric dehumidifier
CN106112245A (en) * 2016-08-11 2016-11-16 无锡洲翔成套焊接设备有限公司 Digital multi mash welder
CN108372354A (en) * 2018-02-05 2018-08-07 广州双穗电气设备有限公司 A kind of novel pulse direct current source of welding current
CN111010027A (en) * 2019-12-25 2020-04-14 广州市精源电子设备有限公司 Power factor correction circuit, method and device for resistance spot welding inverter power supply
CN111168217A (en) * 2020-01-20 2020-05-19 北京工业大学 Pulse type lossless energy storage resistance welding machine with intelligent control function
CN112548298A (en) * 2020-11-30 2021-03-26 华南理工大学 Micro-resistance spot welding power supply PID parameter self-tuning method based on pattern recognition
CN112548298B (en) * 2020-11-30 2022-01-28 华南理工大学 Micro-resistance spot welding power supply PID parameter self-tuning method based on pattern recognition
CN113608016A (en) * 2021-08-23 2021-11-05 天津津航计算技术研究所 AC115V current conditioning and collecting circuit based on effective value chip

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Application publication date: 20111130