CN102350569B - Setting method of multifunctional digitized welding machine - Google Patents
Setting method of multifunctional digitized welding machine Download PDFInfo
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Abstract
The invention relates to a multifunctional digitized welding machine, which comprises a full-bridge type inversion main circuit, a control circuit and a soft switch PWM (Pulse-Width Modulation) driving circuit, wherein the full-bridge type inversion main circuit is composed of an IGBT (Insulated Gate Bipolar Translator); the soft switch PWM driving circuit of a symmetric carrier is based on a CPLD (Complex Programmable Logic Device) or FPGA (Field Programmable Gate Array); the inversion main circuit comprises a rectifying filtering module, an IGBT full-bridge inversion module, a main transformer and a secondary rectifying filtering module; the control circuit comprises a DSP (Digital Signal Processor) control processor, a manual idle-dropping circuit, a regulating, detecting and sampling circuit for a feedback current and voltage signal outputted by the welding machine, a collecting and setting circuit for a feeding speed and given voltage of the welding machine, a display circuit for an interface and parameter of an external keyboard and a communication circuit connected to a PC (Personal Computer); the regulating, detecting and sampling circuit for the feedback current and voltage signal outputted by the welding machine comprises a Hall voltage sensor for detecting a feedback arc voltage outputted by the welding machine and a Hall current sensor for detecting an output current of the welding machine; and the collecting and setting circuit for the feeding speed and given voltage of the welding machine comprises a collecting circuit for a given voltage and given current, namely the feeding speed, on a panel of a feeder.
Description
One, technical field
The invention belongs to multifunctional digital inverter type welder, be specifically related to a kind of multifunctional digital soft-switching inversion welding machine based on digital signal processor DSP and programmable logic controller (PLC) CPLD or FPGA.
Two, background technology
Because traditional welding machine volume is large, efficiency is low, and static and dynamic performance is not very desirable, causes welder performance poor; The existing welding machine mode that still logic circuit is controlled on arranging, does not have the design of Multifunctional digitized welding machine.But Multifunctional digitized welding machine is collection manual welding, DC argon arc welding, pulsed argon arc welding, gas is protected weldering, the new welder of the multiple welding procedure such as pulse GMAW and one, its feature richness, stable and reliable for performance.Multifunctional digital inverter type welder is mainly by DSP, the embedded microprocessors such as single-chip microcomputer are controlled, digital inverse welder is because adopt the controller of embedded microprocessor structure arc welding inverter, utilize the Intelligent Fuzzy Control algorithm of computer to adopt software to realize two closed-loop controls of butt welding machine system, and replaced the analog controller being formed by numerous discrete components, well realized the Digital Control of the source of welding current, and adjustment that can be real-time and technological parameter and duty that welding is set, improved to a great extent the operating efficiency of welding machine, and its control method is more flexible, response speed is faster.
Three, summary of the invention
The object of this invention is to provide a kind of function-stable reliable, method to set up and the device of the multifunctional digital inverter type welder that welding performance is good, it is core that this Study of digital welding machine be take digital signal processor DSP and programmable logic controller (PLC) CPLD or FPGA, the high speed processing capability in real time of DSP is dissolved in welder system, and in conjunction with CPLD or FPGA and soft switch phase shift inversion transformation technique, the two closed-loop controls of realization to welding power source integral system, the employing energy that becomes more meticulous is controlled, the external characteristics of control change device coordinates arc load, solve little electric current, the arc length stability of low arc length welding.
Technical scheme of the present invention is as follows: the method to set up of multifunctional digital inverter type welder, its operating circuit comprises the full-bridge inverter main circuit being comprised of IGBT, control circuit, the soft-switch PWM drive circuit of the symmetrical carrier wave based on CPLD or FPGA.Described inverter main circuit comprises rectification filtering module b, IGBT full-bridge inverting module c, main transformer d, and secondary rectification filtering module e.
Described control circuit mainly comprises: DSP control processor; Control panel power supply circuit; Idler circuit falls by hand; The feedback current of welding machine output, voltage signal conditioning detects and sample circuit; The collection of welding machine wire feed rate and given voltage and initialization circuit; Interface and parameter display circuit with external keyboard; (RS485) telecommunication circuit with PC;
Described craft is fallen idler circuit and first will be exchanged the direct current 17V voltage of 12V power supply after the rectification of B1 rectifier bridge as operating voltage Ud, Ud after filtering and after voltage stabilizing, be sent to optocoupler U6 again, to produce control signal dv_IN, be input to the capture function pin of DSP, when DSP starts operation detection after the level of this leg signal, according to real work mode, judge that selecting is the weldingvoltage UF-of actual feedback or operating voltage Ud when normal; Output control signal dV_SEL control triode V3 and relay K 1 by DSP form, the colelctor electrode of relay K 1 series connection and triode V3, welding is not under no-load condition, when DSP detects dv_IN and is low level, DSP output dV_SEL is high level, control relay inhale and, DSP output pwm signal not now, the unloaded output voltage of welding machine is Ud, and after welding rod and workpiece touching, Ud is for approaching 0V; When DSP detects dv_IN, be high level, now DSP output dV_SEL is low level, and control relay disconnects, DSP output pwm signal now, and at this moment welding machine output voltage is actual output voltage.
Described current and voltage signals conditioning comprises with sample circuit: for detection of Hall voltage sensor and the Hall current sensor that detects electric current of output voltage; Take corresponding current/voltage modulate circuit to carry out amplitude limit; For feedback arc voltage signal, after overvoltage sensor SEN1 carries out isolation detection, after resistance capacitance filtering, through operational amplifier U1, follow after amplification, sampled voltage UFO amplitude limit is sent within the scope of 0-3.3V again to the analog input port ADCIN0 of DSP; The feedback current signal detecting for Hall current sensor, after first passing through rc filter circuit, by amplifier, carry out signal condition again, first by the add circuit being formed by amplifier U4, through amplifying and following, sample rate current IFO is limited within the scope of 0-3.3V again, is then sent to the analog input pin ADCIN1 of DSP;
Sample circuit also comprises that given voltage and the given electric current on wire-feed motor panel is the collection of wire feed rate, and given current/voltage value is being delivered to too analog input port ADCIN3 and the ADCIN4 of DSP after amplifier regulates amplification;
For the current/voltage in the wire-feed motor after gathering, by the task manager module generation two-way pwm signal of DSP, through R56, C42, R58, after the resistance capacitance filtering of C43, by U12, carry out homophase amplification, just obtain corresponding wire feed rate given with voltage given signal.
Described CPLD or FPGA phase-shift soft switch control circuit are comprised of DSP U1 and CPLD or FPGA: feedback current IFO, feedback voltage UFO and given electric current I G, given voltage U G Fen Si road is sent to the interior AD of sheet of DSP, data after AD gathers, in DSP, realize electric current and voltage closed-loop control, adopt digital PID regulation, and welding process is carried out to accurate Waveform Control, calculate the pwm signal of being exported effective pulsewidth after switch time by the incident management register of DSP, again pwm signal is given to CPLD or FPGA to determine the size of phase shifting angle, CPLD or FPGA make after phase shift is processed and obtain four road PWM ripples, as output driving signal to realize the soft switch circuit of IGBT.The data-interface of DSP and CPLD or FPGA is realized by external memory interface, and the IS pin by DSP is expanded to exterior I O mouth space, and its address bus is connected with the IO mouth of CPLD or FPGA.
DSP realizes outside the collection calculating and PID fuzzy algorithmic approach of current/voltage as master controller, real the external characteristics of the source of welding current is controlled and the accurate control of welding machine technique sequential, comprised in advance and supplying gas, striking, lag behind and close gas, the control to air valve, the braking of motor, rifle switching signal completes the external control signal of wire feeder by real-time generation, by outside input key, for the selection of welding machine different working modes and the numeral of welding current voltage, shows control;
Overheated, overvoltage, the interruption protection of the signals such as overcurrent is controlled and is realized by DSP.
Sample rate current voltage four tunnel analog signals, before delivering to DSP, are passed through again diode DD1, DD2, and DD3, DD4 carries out amplitude limit, in order to avoid analog input voltage is too high or too low, enters DSP port and defective chip.
Multifunctional digitized welding machine of the present invention, comprises the full-bridge inverter main circuit being comprised of IGBT, control circuit, the soft-switch PWM drive circuit of the symmetrical carrier wave based on CPLD or FPGA.Described inverter main circuit comprises rectification filtering module b, IGBT full-bridge inverting module c, main transformer d, and secondary rectification filtering module e;
Described control circuit comprises: DSP control processor; Idler circuit, falls in control panel power supply circuit by hand; The feedback current of welding machine output, voltage signal conditioning detects and sample circuit; The collection of welding machine wire feed rate and given voltage and initialization circuit; Interface and parameter display circuit with external keyboard; Be connected (RS485) telecommunication circuit with PC;
Described craft is fallen idler circuit and is comprised that rectifier circuit, filtering, voltage stabilizing and optocoupler are input to the capture function pin of DSP, and the signal circuit of the unloaded output voltage of welding machine or the relay of fully loaded output voltage is controlled in DSP output;
Described current and voltage signals conditioning comprises with sample circuit: for detection of the Hall voltage sensor and the Hall current sensor that detects welding machine output current of welding machine output feedback arc voltage; Take corresponding current/voltage modulate circuit to carry out amplitude limit; After overvoltage sensor SEN1 carries out isolation detection, after resistance capacitance filtering, through operational amplifier U1, carry out follow-up amplifier, sampled voltage UFO amplitude limit is received within the scope of 0-3.3V again to the analog input port ADCIN0 of DSP; The feedback current signal detecting for Hall current sensor, the add circuit that process rc filter circuit and amplifier are carried out signal condition and be comprised of amplifier U4, then through amplifying and following, sample rate current IFO is limited in to the analog input pin ADCIN1 that receives again DSP within the scope of 0-3.3V;
Sample circuit comprises that given voltage and the given electric current on wire-feed motor panel is the Acquisition Circuit of wire feed rate, and given current/voltage value is meeting too analog input port ADCIN3 and the ADCIN4 of DSP after amplifier regulates amplification; According to the current/voltage gathering in wire-feed motor, the task manager module by DSP produces two-way pwm signal, through amplifying after resistance capacitance filtering and through homophase, export corresponding wire feed rate given with voltage given signal.
Described CPLD or FPGA phase-shift soft switch control circuit are comprised of DSP1 and CPLD or FPGA: feedback current IFO, feedback voltage UFO and given electric current I G, given voltage U G Fen Si road is sent to the interior AD of sheet of DSP, data after AD gathers, in DSP, realize electric current and voltage closed-loop control, the incident management register of DSP is exported the pwm signal of effective pulsewidth, again pwm signal is met to CPLD or FPGA, CPLD or FPGA output Si road PWM ripple, as the driving signal of output to realize the soft switch circuit of IGBT; The data-interface of DSP and CPLD or FPGA connects external memory interface.
The invention has the beneficial effects as follows: adopt advanced digital signal processor DSP and programmable logic controller (PLC) CPLD or FPGA as the core of Study of digital welding machine, gather accurately in real time feedback voltage and the magnitude of current of the source of welding current, and realize pulse width modulation and phase shifting control by Digital PID Algorithm, by phase shifting control, realize the soft switch technique of the ZVZCS of the leading arm of IGBT and lagging leg, on the most multiple welding manner collection and a welding machine, realized pulse GMAW, pulsed argon arc welding, the multiple welding procedure mode such as manual welding, and utilize sequential and the control of the JTAG mouth butt welding machine of DSP to carry out on-line debugging, software upgrading and renewal speed are fast, control mode is more versatile and flexible.Study of digital welding machine of the present invention can reduce and splashes, moulding is attractive in appearance, realize high-quality welding, the real-time selection of man machine communication interface and welding condition and state of the art and demonstration etc., realized craft, direct current argon arc, pulse argon arc, gas is protected, five kinds of welding manners such as pulse air guarantor, improve the dynamic response capability of welding machine, guaranteed the welding quality of welding machine and the stability of electric arc.
Four, accompanying drawing explanation
Fig. 1 is the overall structure figure of Multifunctional digitized welding machine.
Fig. 2 is the functional block diagram of the Multifunctional digitized welding machine based on DSP.
Fig. 3 is the main control connecting circuit figure that the present invention is based on DSP.
Fig. 4 is that unloaded partial circuit figure falls in the craft of control circuit.
Fig. 5 is signal condition and the sample circuit figure of feedback current voltage and wire feed rate setting section.
Fig. 6 is the partial circuit figure that CPLD or FPGA phase-shift PWM signal produce.
Fig. 7 is RS485 telecommunication circuit figure.
Five, the specific embodiment
Multifunctional digitized welding machine of the present invention is the soft-switching inversion formula Study of digital welding machine based on digital signal processor DSP and programmable logic controller (PLC) CPLD or FPGA.Its operating circuit comprises the full-bridge inverter main circuit being comprised of IGBT, DSP control circuit, the soft-switch PWM drive circuit of the symmetrical carrier wave based on CPLD or FPGA.
The main rectification filtering module b as shown in Figure 1 of described main circuit, IGBT full-bridge inverting module c, main transformer d, and the composition such as secondary rectification filtering module e.
Described control circuit mainly comprises: DSP control processor; Control panel power supply circuit; Idler circuit falls in the craft that contains rectifying part; The feedback current of welding machine output, voltage signal conditioning detects and sample circuit; The collection of welding machine wire feed rate and given voltage and initialization circuit; Interface and parameter display circuit with external keyboard; With RS485 telecommunication circuit of PC etc.
Described craft is fallen idler circuit and first will be exchanged the direct current 17V voltage of 12V power supply after the rectification of B1 rectifier bridge as operating voltage Ud, Ud is through C23, after E5 filtering and diode Z1 voltage stabilizing, be sent to again optocoupler U6, to produce control signal dv_IN, be input to the capture function pin of DSP, when DSP starts operation detection after the level of this leg signal, according to real work mode, judge that selecting is the weldingvoltage UF-of actual feedback or operating voltage Ud when normal, the realization of this function is comprised of output control signal dV_SEL control triode V3 and the relay K 1 of DSP, the colelctor electrode of relay K 1 series connection and triode V3, welding is not under no-load condition, when DSP detects dv_IN and is low level, DSP output dV_SEL is high level, control relay inhale and, DSP output pwm signal not now, the unloaded output voltage of welding machine is Ud, after welding rod and workpiece touching, Ud is for approaching 0V, when DSP detects dv_IN, be high level, now DSP output dV_SEL is low level, and control relay disconnects, DSP output pwm signal now, and at this moment welding machine output voltage is actual output voltage.
Described current and voltage signals conditioning comprises with sample circuit: for detection of Hall voltage sensor and the Hall current sensor that detects electric current of output voltage, to guarantee the isolation completely of sampled input signal and sampled output signal; Because the signal after voltage-current sensor exceeds the analog signal voltage scope (0-3.3V) of DSP, take corresponding current/voltage modulate circuit to carry out amplitude limit; For feedback arc voltage signal, after overvoltage sensor SEN1 carries out isolation detection, after R7 and the filtering of C31 resistance capacitance, through operational amplifier, U1 follows, after amplifying by the two-stage of amplifier U1 again, voltage U FO amplitude limit is sent within the scope of 0-3.3V again to the analog input port ADCIN0 of DSP; For feedback current signal, first to pass through R3 equally, C29, R4, after the rc filter circuit that C30 forms, then carry out signal condition by amplifier, specifically first by the add circuit being formed by amplifier U4, pass through again U4 amplification and follow that IFO is limited within the scope of 0-3.3V, be then sent to the analog input pin ADCIN1 of DSP; Sample circuit also comprises that given voltage and the given electric current on wire-feed motor panel is the collection of wire feed rate, and given current/voltage value is being delivered to too analog input port ADCIN3 and the ADCIN4 of DSP after amplifier U12 regulates amplification.Four tunnel analog signals, before delivering to DSP, are passed through again diode DD1, DD2, and DD3, DD4 carries out amplitude limit, in order to avoid analog input voltage is too high or too low, enters DSP port and defective chip.For the current/voltage in the wire-feed motor after gathering, by the task manager module generation two-way pwm signal of DSP, through R56, C42, R58, after the resistance capacitance filtering of C43, by U12, carry out homophase amplification, just obtain corresponding wire feed rate given with voltage given signal.
Described telecommunication circuit consists of the telecommunication circuit of the SN75176 that comprises 485 communication letter chips, realizes the serial communication between remote controller and host computer.DSP carries asynchronous communication interface, by external chip U8 (SN75176), convert RS485 bus to, it in circuit, is the isolation that realizes bus and DSP, between DSP communication interface place and chip U8, adopt optocoupler to isolate, optocoupler U9, U10, U11 passes through resistance R 38 with the asynchronous serial port pin of DSP respectively, R39, R30 is connected, after optocoupler output San road signal of communication is connected with U8, the output signal two ends voltage-stabiliser tube Z2 that connects respectively, Z3 composition absorption circuit is to prevent the interference in bus.
Described CPLD or FPGA phase-shift soft switch control circuit are comprised of DSP U1 and CPLD or FPGA U3: feedback current IFO, feedback voltage UFO and given electric current I G, given voltage U G Fen Si road is sent to the interior AD of sheet of DSP, data after AD gathers, in DSP, realize electric current and voltage closed-loop control, adopt fuzzy control method, realize digital PID regulation, and welding process is carried out to accurate Waveform Control, calculate the pwm signal of being exported effective pulsewidth after switch time by the incident management register of DSP, again pwm signal is given to CPLD or FPGA to determine the size of phase shifting angle, CPLD or FPGA make after phase shift is processed and obtain four road PWM ripples, as output driving signal to realize the soft switch circuit of IGBT.The data-interface of DSP and CPLD or FPGA is realized by external memory interface, and the IS pin by DSP is expanded to exterior I O mouth space, and its address bus is connected with the IO mouth of CPLD or FPGA.
During concrete enforcement, DSP, also will realize the external characteristics of the source of welding current is controlled except realizing the collection calculating and PID fuzzy algorithmic approach of current/voltage as master controller, and the accurate control as welding machine technique sequential, comprises in advance and supplying gas, and striking lags behind and closes gas etc.; Also can produce in real time the external control signal to wire feeder, comprise the control to air valve, the braking of motor, rifle switching signal etc.; Outside input key shows control for the selection of welding machine different working modes and the numeral of welding current voltage; To overheated, overvoltage, the interruption protection control of the signals such as overcurrent etc., are all realized by DSP.
Claims (2)
1. the method to set up of multifunctional digital inverter type welder, the operating circuit of digital inverse welder comprises the soft-switch PWM drive circuit of the full-bridge inverter main circuit, control circuit and the symmetrical carrier wave based on CPLD or FPGA that are comprised of IGBT; Described inverter main circuit comprises rectification filtering module, IGBT full-bridge inverting module, main transformer d and secondary rectification filtering module; The collection that described control circuit comprises DSP control processor, control panel power supply circuit, manual feedback current voltage signal conditioning of falling idler circuit, welding machine output and sample circuit, welding machine wire feed rate and given voltage and initialization circuit, the keystroke interface being connected with outside and parameter display circuit, the telecommunication circuit of communicating by letter with upper PC;
It is characterized in that described craft falls idler circuit and first will exchange the direct current 17V voltage of 12V power supply after the rectification of B1 rectifier bridge as operating voltage Ud, Ud after filtering and after voltage stabilizing, be sent to optocoupler U6 again, to produce control signal dv_IN, be input to the capture function pin of DSP, when DSP starts operation detection after the level of this leg signal, according to real work mode, judge that selecting is the weldingvoltage UF-of actual feedback or operating voltage Ud when normal; Output control signal dV_SEL by DSP controls triode V3 and relay K 1, the colelctor electrode of relay K 1 series connection triode V3, welding is not under no-load condition, when DSP detects dv_IN and is low level, DSP output dV_SEL is high level, control relay inhale and, DSP output pwm signal not now, the operating voltage of the zero load output of welding machine is Ud, and after welding rod and workpiece touching, Ud is for approaching 0V; When DSP detects dv_IN, be high level, now DSP output dV_SEL is low level, and control relay disconnects, DSP output pwm signal now, and at this moment welding machine output voltage is actual output voltage;
Described current and voltage signals conditioning comprises with sample circuit: for detection of Hall voltage sensor and the Hall current sensor that detects electric current of output voltage; Take corresponding current/voltage modulate circuit to carry out amplitude limit; For feedback arc voltage signal, after overvoltage sensor SEN1 carries out isolation detection, after resistance capacitance filtering, through operational amplifier U1, follow after amplification, sampled voltage UFO amplitude limit is sent within the scope of 0-3.3V again to the analog input port ADCIN0 of DSP; The feedback current signal detecting for Hall current sensor, after first passing through rc filter circuit, by amplifier, carry out signal condition again, first by the add circuit being formed by amplifier U4, through amplifying and following, sample rate current IFO is limited within the scope of 0-3.3V again, is then sent to the analog input pin ADCIN1 of DSP;
Sample circuit also comprises that given voltage and the given electric current on wire-feed motor panel is the collection of wire feed rate, and given current/voltage value is being delivered to too analog input port ADCIN3 and the ADCIN4 of DSP after amplifier regulates amplification;
For the current/voltage in the wire-feed motor after gathering, task manager module by DSP produces two-way pwm signal, through resistance R 56, capacitor C 42, resistance C42, resistance R 58, after the resistance capacitance filtering of capacitor C 43, by amplifier U12, carry out homophase amplification, just obtain corresponding wire feed rate given with voltage given signal;
CPLD or FPGA phase-shift soft switch control circuit are comprised of DSP and CPLD or FPGA, feedback current IFO, feedback voltage UFO and given electric current I G, given voltage U G Fen Si road is sent to the interior AD of sheet of DSP, data after AD gathers, in DSP, realize electric current and voltage closed-loop control, adopt digital PID regulation, and welding process is carried out to accurate Waveform Control, calculate the pwm signal of being exported effective pulsewidth after switch time by the incident management register of DSP, again pwm signal is given to CPLD or FPGA to determine the size of phase shifting angle, CPLD or FPGA make after phase shift is processed and obtain four road PWM ripples, as output driving signal to realize the soft switch circuit of IGBT,
DSP realizes outside the collection calculating and PID fuzzy algorithmic approach of current/voltage as master controller, realization is controlled the external characteristics of the source of welding current and the accurate control of welding machine technique sequential, welding machine technique sequential comprise in advance supply gas, striking, hysteresis pass gas, the braking to the control of air valve and motor; Arc welding gun switch signal completes the external control signal of wire feeder by real-time generation, by outside input key, for the selection of welding machine different working modes and the numeral of welding current voltage, shows control; Overheated, overvoltage, the interruption protection of over-current signal is controlled and is realized by DSP.
2. the method to set up of multifunctional digital inverter type welder according to claim 1, is characterized in that sample rate current voltage four tunnel analog signals, before delivering to DSP, carry out amplitude limit by diode again.
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| CN101249582A (en) * | 2008-03-28 | 2008-08-27 | 北京工业大学 | Complete digital PWM controlled AC pulse MIG welding system |
| CN101362245A (en) * | 2008-09-12 | 2009-02-11 | 叶玲平 | Full digit numerical control inversion welding machine |
| CN102091850A (en) * | 2010-12-31 | 2011-06-15 | 广东易事特电源股份有限公司 | Aluminum alloy digital welding machine with smooth transition double-pulse parameters |
| CN202344104U (en) * | 2011-09-29 | 2012-07-25 | 熊猫电子集团有限公司 | Multifunctional digital welding machine |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US7064290B2 (en) * | 2003-09-08 | 2006-06-20 | Lincoln Global, Inc. | Electric arc welder and method for controlling the welding process of the welder |
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Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1348845A (en) * | 2001-11-29 | 2002-05-15 | 上海交通大学 | Digital signal processor control method of gas metal-arc welder |
| CN101013874A (en) * | 2006-12-21 | 2007-08-08 | 中国科学院电工研究所 | System for controlling auto-disturbance rejection of stator voltage of variable speed constant frequency double-fed generator |
| CN101249582A (en) * | 2008-03-28 | 2008-08-27 | 北京工业大学 | Complete digital PWM controlled AC pulse MIG welding system |
| CN101362245A (en) * | 2008-09-12 | 2009-02-11 | 叶玲平 | Full digit numerical control inversion welding machine |
| CN102091850A (en) * | 2010-12-31 | 2011-06-15 | 广东易事特电源股份有限公司 | Aluminum alloy digital welding machine with smooth transition double-pulse parameters |
| CN202344104U (en) * | 2011-09-29 | 2012-07-25 | 熊猫电子集团有限公司 | Multifunctional digital welding machine |
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