CN102500874A - Intelligent magnetic biasing detection and processing device for inversion welding power supply - Google Patents
Intelligent magnetic biasing detection and processing device for inversion welding power supply Download PDFInfo
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- CN102500874A CN102500874A CN2011103526458A CN201110352645A CN102500874A CN 102500874 A CN102500874 A CN 102500874A CN 2011103526458 A CN2011103526458 A CN 2011103526458A CN 201110352645 A CN201110352645 A CN 201110352645A CN 102500874 A CN102500874 A CN 102500874A
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Abstract
The invention discloses an intelligent magnetic biasing detection and processing device for an inversion welding power supply. The intelligent magnetic biasing detection and processing device comprises a sensor and signal conditioning module, an adder/subtracter module, a proportion adjuster, a comparator, a controller input signal conditioning module, a digital controller and an adjustment voltage input module, wherein the sensor and signal conditioning module for acquiring welding current sends a signal to the adder/subtracter module; the adjustment voltage input module sends a signal into the adder/subtracter module; the signals are processed by the adder/subtracter module and then sent to the comparator; current on the primary side of a main transformer is processed by the sensor and signal conditioning module and then sent to the proportion adjuster; the proportion adjuster sends the signals to the comparator; the comparator compares the signals sent by the adder/subtracter module and the proportion adjuster, and sends the signals to the controller input signal conditioning module; and the controller input signal conditioning module sends the signals to the digital controller. The intelligent magnetic biasing detection and processing device has high stability and reliability and high generality.
Description
Technical field
The present invention relates to welding technology field, relate in particular to a kind of inversion welding source intelligence magnetic bias and detect and treating apparatus.
Background technology
From the beginning eighties in 20th century, the advantages such as meticulous control that through the development in twenty or thirty year, inversion welding source is energy-efficient with it, dynamic response is fast, control is flexible, be convenient to waveform have become the main developing direction in the international welding equipment market.But the problem that reliability is low is the fast-developing bottleneck of the restriction source of welding current, and wherein the existence of bias phenomenon is the most key problem.Because multiple factor causes two PWM in the half period; The impulse amplitude or the width that are applied on the main transformer are unequal; To in main transformer, produce DC component, exciting current takes place sharply to change, and magnetization curve seriously distorts; Cause the main transformer magnetic bias, thereby make main transformer primary side current skyrocket (being generally several microseconds).Overcurrent in short time will make the power device thermal losses strengthen, and permanent lesions such as explosion take place.
The measure of the anti-magnetic bias of main circuit is mainly by following several method at present: (1) adds certain air gap in transformer magnetic circuit, improve the linearity of its magnetic conductivity, but can influence the power output of transformer, increases its volume and weight.(2) a simple practical again method on the engineering is the primary side increase block capacitor at transformer, the blocking-up DC component.This method can be bigger inhibition do not wait the magnetic bias that causes by positive and negative direction voltage amplitude, but because the working condition of main transformer also will receive the influence of secondary side output current, magnetic bias can't be eliminated fully.(3) application number is in 200910215161.1 the invention application " a kind of inverting welding power supply magnetic bias resisting device ", through at main transformer primary side series connection linear inductance, comes the anti-magnetic bias ability of increase system.Yet this method has suppressed current-rising-rate, has reduced the dynamic response performance of system, in the process that real-time is had relatively high expectations bigger limitation is arranged.(4) application number is that 99235012.3 patent " the control circuit device of the anti-magnetic bias of Switching Power Supply " has designed a kind of anti-magnetic bias control circuit to Switching Power Supply; This method is carried out slope compensation circuit with transformer primary side feedback current; Then with given the comparing of presetting; The output signal is delivered in the simulation PWM chip, cuts off the electric current that distortion takes place.Improvement along with welding procedure; Welding current waveform is also varied; Like pulse MIC welding, cold metal transition weldering etc., given comparison that this method is single and conventional analogue PWM chip controls have been difficult to satisfy at present the demand of welding procedure and the high performance digital source of welding current efficiently.
The defective of above-mentioned prior art is: only can suppress magnetic bias to a certain extent, and reduce the dynamic response performance of system, be difficult to satisfy welding procedure, particularly meticulous droplet control and the needs of problems of high performance digital welding power source system efficiently.
Summary of the invention
The object of the invention only can suppress magnetic bias in order to solve prior art exactly to a certain extent; And can reduce the dynamic response performance of system; Be difficult to satisfy welding procedure efficiently, like the problem of the demand of meticulous droplet control etc. and high performance digital welding power source system; Provide a kind of inversion welding source intelligence magnetic bias to detect and treating apparatus; When the main transformer magnetic bias, when causing primary side current sharply to increase; When passing through main transformer primary side current and welding current, gathers the magnetic bias testing circuit in the native system; Detect bias magnetic signal and width thereof immediately by testing circuit; And give digitial controller with feedback information, by corresponding control strategies adjustment PWM output pulse, realize that magnetic bias suppresses quickly and efficiently; Have high conformity, stability, reliability is high, and highly versatile, pervasive degree are high, flexible and changeable, the intelligent good advantage of control strategy.
To achieve these goals, the present invention adopts following technical scheme:
A kind of inversion welding source intelligence magnetic bias detects and treating apparatus, comprises sensor and signal condition module, adds/subtracter block proportional controller, comparator, controller input signal conditioning module, digitial controller, regulation voltage input module; Gather the sensor and the signal condition module of welding current; To be delivered to through the welding current signal of sensor and signal condition resume module and add/subtracter block; The regulation voltage input module with signal conveys to adding/subtracter block, signal through add/subtracter block is delivered to comparator after handling; The main transformer primary side current is delivered to proportional controller after sensor and signal condition resume module; Proportional controller carries signal to comparator; Comparator will add/subtracter block; And the signal that proportional controller is carried compares, and the signal of comparator output is delivered to digitial controller through the controller input signal conditioning module.
Add/subtracter mainly comprises resistance R 3, R4, R5, R6 and operational amplifier U
1_1AResistance R 5 two ends connect current Hall sensor and U respectively
1_1AIn-phase input end; Resistance R 6 one disconnections meet U
1_1AIn-phase input end, an end ground connection; Resistance R 3 one ends connect U
1_1AInverting input, an end connects the output of regulation voltage input module; Resistance R 4 one ends connect U
1_1AInverting input, an end is connected U
1_1AOutput.
Proportional controller mainly comprises resistance R 7, R8 and operational amplifier U
1_1BResistance R 7 one end ground connection, an end is connected operational amplifier U
1_1BInverting input; Potentiometer R8 one end connects U
1_1BInverting input, an end connects U
1_1BOutput.
Digitial controller adopts single-chip microcomputer, DSP or FPGA.
Operation principle of the present invention is: gather main transformer primary side current and welding current simultaneously; And carry out signal condition, and the transformer primary side current is adjusted into the in-phase pulse signal, carry out amplitude modulation by adder/subtracter and proportional controller respectively with the welding feedback current; Export by comparator then; Obtain position and width that bias magnetic signal produces, after the signal condition link, send to digitial controller.Position and power according to the bias magnetic signal appearance; By corresponding control strategy quick adjustment PWM dutycycle, change the voltagesecond product of current direction, produce suitable substance P WM and drive signal; Positive and negative direction voltagesecond product is tended to balance; Main transformer hightails saturated, recovers normal hysteresis curve workspace, reaches the purpose of eliminating magnetic bias.Simultaneously also can be through the maximum output current of the monitoring source of welding current.Concrete scheme and workflow are: obtain welding current by the current Hall sensor in real time, and convert voltage signal U to
I1, with the U that produces by resistance R 1 and potentiometer R2 dividing potential drop
mTogether, via resistance R 3, R4, R5, R6 and operational amplifier U
1_1AThe subtracter that constitutes adds up, the current feedback signal that output amplitude is adjustable, and wherein the effect of potentiometer R2 is to regulate the feedback current amplitude, confirms the critical point that bias phenomenon occurs; Simultaneously, obtain main transformer primary side current signal, and convert the in-phase pulse current signal to, via resistance R 7, R8 and operational amplifier U by current transformer
1_1BThe proportional controller that constitutes, the feedback signal that output amplitude is adjustable; With obtaining and the main transformer primary side current of conversion and the welding current signal of output,, can in time obtain bias magnetic signal and deliver to digitial controller and handle through comparator U2_1A comparison.Pull-up resistor R9 is used for guaranteeing that controller can receive bias magnetic signal accurately.Controller then can be adjusted the dutycycle of follow-up PWM driving pulse after detecting bias magnetic signal, make main transformer recover normal hysteresis curve workspace, reaches the purpose of eliminating magnetic bias, improves the stability of a system and reliability.
Digitial controller can adopt single-chip microcomputer, DSP or FPGA, and which kind of mode no matter all will guarantee the limit priority of this program.In a single day magnetic bias takes place in the source of welding current, and testing circuit is exported triggering signal at once and given digitial controller, makes the counter timing of starting working, when the magnetic bias duration less than m, think that then system itself can regulate this bias phenomenon automatically, needn't disturb; (value of m is very little when the magnetic bias duration surpasses m; Be generally several microseconds), then close each road PWM output immediately, finish this cycle pwm pulse in advance; And increase PWM dutycycle (PWM of the following cycle dutycycle=this cycle PWM dutycycle * N in next cycle; N＞1), impels main transformer magnetic core working curve to return normal condition, thereby eliminate bias phenomenon.Because the magnetic bias testing circuit all adopted analog device to build, thus can be timely, correct detect bias magnetic signal; And detected bias magnetic signal is sent to digitial controller, realization various control strategy able to programme, and the bias phenomenon that adapts under different process, different occasion and the application background is handled.In addition, during the main transformer magnetic bias, exciting current will take place sharply to change; Make main transformer saturated, main transformer primary side current waveform distorts, yet can not produce the obvious characteristics signal this moment in welding current; And during system's magnetic bias; The transformer primary side current skyrockets the time generally within several microseconds, thus the time that bias magnetic signal detects and control is handled can not surpass several microseconds, and The faster the better.Therefore, utilize this characteristics, introduce transformer primary side current feedback closed loop and can effectively suppress overcurrent, correct transformer bias, real-time guard IGBT remedies the deficiency of bridge circuit itself, the raising stability of a system.
Beneficial effect of the present invention: this method makes full use of the no-load voltage ratio relation and advanced digital control technology of inversion welding source major loop input and output, gathers simultaneously and handles main transformer primary side current and welding current, has the advantage that measure does not in the past have:
(1) high conformity, stability is high.Build the design concept that detection platform and digital technology are constructed the control system by analog circuit, with the processing requirements that can satisfy quick bias phenomenon fully, and improve system's disturbance rejection property greatly, high conformity is convenient to realize and commercial application.
(2) highly versatile, pervasive degree is high.Because of the method that this method has adopted transformer primary side current and welding current to gather simultaneously and handle,, all can continue to use this scheme so no matter be welding procedures such as direct current weldering, impulse welding, cold metal transition weldering.
(3) control strategy is flexible and changeable, and is intelligent good.Compare the control platform that the conventional analogue circuit is built, this method can be according to the diversity and the particularity of practical engineering application, and design Different control strategy (what provide in this example is the typical control method) is realized the automatic processing of bias phenomenon.
Description of drawings
Fig. 1 is that magnetic bias of the present invention detects and the control system functional block diagram;
Fig. 2 magnetic bias of the present invention detects and the processing scheme circuit diagram;
Fig. 3 magnetic bias Intelligent Control Strategy flow chart.
The specific embodiment
Below in conjunction with accompanying drawing and case study on implementation the present invention is further specified.
Inversion welding source intelligence magnetic bias detects and treating apparatus, shown in Fig. 1～3, comprises sensor and signal condition module, adds/subtracter block proportional controller, comparator, controller input signal conditioning module, digitial controller, regulation voltage input module.Gather the sensor and the signal condition module of welding current; To be delivered to through the welding current signal of sensor and signal condition resume module and add/subtracter block; The regulation voltage input module with signal conveys to adding/subtracter block, signal through add/subtracter block is delivered to comparator after handling; The main transformer primary side current is delivered to proportional controller after sensor and signal condition resume module; Proportional controller carries signal to comparator; Comparator will add/subtracter block; And the signal that proportional controller is carried compares, and comparator is signal conveys to controller input signal conditioning module, the signal condition module with signal conveys to digitial controller.Add/subtracter mainly comprises resistance R 3, R4, R5, R6 and operational amplifier U
1_1AResistance R 5 two ends connect current Hall sensor and U respectively
1_1AIn-phase input end; Resistance R 6 one disconnections meet U
1_1AIn-phase input end, an end ground connection; Resistance R 3 one ends connect U
1_1AInverting input, an end connects the output of regulation voltage input module; Resistance R 4 one ends connect U
1_1AInverting input, an end is connected U
1_1AOutput.Proportional controller mainly comprises resistance R 7, R8 and operational amplifier U
1_1BResistance R 7 one end ground connection, an end is connected operational amplifier U
1_1BInverting input; Potentiometer R8 one end connects U
1_1BInverting input, an end connects U
1_1BOutput.Digitial controller adopts single-chip microcomputer, DSP or FPGA.The control method of inversion welding source intelligence magnetic bias real-time detection circuit is, in a single day magnetic bias takes place the source of welding current, and testing circuit is exported triggering signal at once and given digitial controller, after digitial controller receives bias magnetic signal, and the timing of starting working of the counter in it.According to different welding conditions,, think that then system itself can regulate this bias phenomenon automatically, needn't disturb when magnetic bias duration during less than 3 microseconds; When the magnetic bias duration surpasses 3 microseconds, then close each road PWM output immediately, finish this cycle pwm pulse in advance, and increase the PWM dutycycle (N＞1) in next cycle, impel main transformer magnetic core working curve to return normal condition, thereby eliminate bias phenomenon.
Though the above-mentioned accompanying drawing that combines is described the specific embodiment of invention; But be not restriction to protection domain of the present invention; One of ordinary skill in the art should be understood that; On the basis of technical scheme of the present invention, those skilled in the art need not pay various modifications that creative work can make or distortion still in protection scope of the present invention.
Claims (4)
1. an inversion welding source intelligence magnetic bias detects and treating apparatus, it is characterized in that, comprises sensor and signal condition module, adds/subtracter block proportional controller, comparator, controller input signal conditioning module, digitial controller, regulation voltage input module.Gather the sensor and the signal condition module of welding current; To be delivered to through the welding current signal of sensor and signal condition resume module and add/subtracter block; The regulation voltage input module with signal conveys to adding/subtracter block, signal through add/subtracter block is delivered to comparator after handling; The main transformer primary side current is delivered to proportional controller after sensor and signal condition resume module; Proportional controller carries signal to comparator; Comparator will add/subtracter block; And the signal that proportional controller is carried compares, and comparator is signal conveys to controller input signal conditioning module, the signal condition module with signal conveys to digitial controller.
2. inversion welding source intelligence magnetic bias as claimed in claim 1 detects and treating apparatus, it is characterized in that said adding/subtracter mainly comprises resistance R 3, R4, R5, R6 and operational amplifier U
1_1AResistance R 5 two ends connect current Hall sensor and U respectively
1_1AIn-phase input end; Resistance R 6 one disconnections meet U
1_1AIn-phase input end, an end ground connection; Resistance R 3 one ends connect U
1_1AInverting input, an end connects the output of regulation voltage input module; Resistance R 4 one ends connect U
1_1AInverting input, an end is connected U
1_1AOutput.
3. inversion welding source intelligence magnetic bias as claimed in claim 1 detects and treating apparatus, it is characterized in that said proportional controller mainly comprises resistance R 7, R8 and operational amplifier U
1_1BResistance R 7 one end ground connection, an end is connected operational amplifier U
1_1BInverting input; Potentiometer R8 one end connects U
1_1BInverting input, an end connects U
1_1BOutput.
4. inversion welding source intelligence magnetic bias as claimed in claim 1 detects and treating apparatus, it is characterized in that said digitial controller adopts single-chip microcomputer, DSP or FPGA.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103722322A (en) * | 2014-01-06 | 2014-04-16 | 山东大学 | Digital realization circuit and method of primary current feedback mode |
| CN103737155A (en) * | 2014-01-06 | 2014-04-23 | 山东大学 | Single-phase full-bridge inversion topological magnetic biasing staged processing circuit and method |
| CN115420450A (en) * | 2022-08-21 | 2022-12-02 | 哈尔滨工业大学 | Electromagnetic vibration table system based on drive current feedback control |
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| CN201590774U (en) * | 2009-12-10 | 2010-09-22 | 厦门科华恒盛股份有限公司 | Autobalance control device for output of inverter |
| CN202317371U (en) * | 2011-11-10 | 2012-07-11 | 山东大学 | Intelligent magnetic biasing detecting and processing device for inverter welding power source |
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2011
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| EP0879665B1 (en) * | 1997-05-19 | 2003-02-12 | Illinois Tool Works Inc. | Welding power supply |
| JP4271293B2 (en) * | 1999-04-09 | 2009-06-03 | 中央精機株式会社 | Optimal control method and apparatus for arc welding |
| JP2003071564A (en) * | 2001-08-31 | 2003-03-11 | Sakaguchi Kogyo Kk | Simple welding heat input measuring device and welding machine using the welding heat input measuring device |
| CN1645731A (en) * | 2004-01-19 | 2005-07-27 | 厦门科华恒盛股份有限公司 | Regulating method and device for sine wave dc-to-ac converter bias magnet |
| CN201590774U (en) * | 2009-12-10 | 2010-09-22 | 厦门科华恒盛股份有限公司 | Autobalance control device for output of inverter |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103722322A (en) * | 2014-01-06 | 2014-04-16 | 山东大学 | Digital realization circuit and method of primary current feedback mode |
| CN103737155A (en) * | 2014-01-06 | 2014-04-23 | 山东大学 | Single-phase full-bridge inversion topological magnetic biasing staged processing circuit and method |
| CN103737155B (en) * | 2014-01-06 | 2015-04-29 | 山东大学 | Single-phase full-bridge inversion topological magnetic biasing staged processing circuit and method |
| CN115420450A (en) * | 2022-08-21 | 2022-12-02 | 哈尔滨工业大学 | Electromagnetic vibration table system based on drive current feedback control |
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