CN103071893A - Circuit architecture of all-digital controlled inverter welding machine - Google Patents
Circuit architecture of all-digital controlled inverter welding machine Download PDFInfo
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- CN103071893A CN103071893A CN201110346745XA CN201110346745A CN103071893A CN 103071893 A CN103071893 A CN 103071893A CN 201110346745X A CN201110346745X A CN 201110346745XA CN 201110346745 A CN201110346745 A CN 201110346745A CN 103071893 A CN103071893 A CN 103071893A
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Abstract
The invention relates to a circuit architecture of an all-digital controlled inverter welding machine. A single chip microcomputer with an A/D (Analog/Digital) conversion function is used as a main control device, and an FPGA (field programmable gate array) is used as a core computing device, so that the parallel computing can be carried out, and simultaneously, other logic control can be carried out. Compared with a welding device digital control using DSP (Digital Signal Processing) as the core computing device, the circuit architecture provided by the invention has the advantages that peripheral devices and the possibly used multi-chip association can be eliminated, the circuit structure is simplified, the cost is saved, the precision of control on the welding process of the welding is also improved, the welding quality is further improved, and the splashing situation is reduced.
Description
Technical field
The present invention relates to the control system of electric welding machine, relate in particular to a kind of circuit framework of digital control formula inversion welding machine.
Background technology
The basic circuit structure of contravariant arc welding machine as shown in Figure 1.Traditional electric welding machine adopts analog control system, and its control circuit mainly is made of discrete component and integrated transporting discharging.Such system hardware framework is comparatively complicated, and the electrical quantity of analog element can produce drift along with the variation of environment temperature, affects the performance of control system.Therefore, the stability of analog control system is not fine; In addition, because each element function singleness, the control function of analog control system is limited, particularly can't realize comparatively complicated welding current waveform.Like this, welding quality no matter, the control of still splashing all can not reach preferably effect.
Digital electric welding machine has appearred in the development along with Power Electronic Technique, and its control system adopts digital pattern or part figure pattern.Digital electric welding machine has overcome the shortcoming of analog electrical welding machine, and not only hardware configuration is simple, and can realize more accurately control to welding procedure, has improved welding quality, has reduced and has splashed.The digital welding machine product of domestic and international main electric welding machine producer all adopts the control circuit structure of Fig. 2 at present.
The control circuit structure of Fig. 2 is compared with traditional analog electrical welding machine, and hardware configuration is simple, and parameter consistency is strong, and can improve welding quality, and minimizing is splashed.But its its main operational device DSP is that order is carried out to a plurality of computings, and in order more accurately welding process to be controlled in real time, need to carry out simultaneously a plurality of computings (control of output voltage control PWM and welding wire feeding servomotor will be carried out simultaneously at least), this just needs to increase the quantity of DSP; And DSP is an arithmetic unit, and whole control also needs peripheral devices (CPLD or FPGA) to cooperate.In fact, the advantage of DSP is continuous complicated multiplying, and for used multiplying and uncomplicated proportional integral computing, DSP compares with FPGA, not advantage.If the function of a plurality of DSP and peripheral devices can substitute with a FPGA, the circuit structure of Fig. 2 will further be simplified, and cost performance also will improve.
Summary of the invention
The invention provides a kind of simple in structurely, cost performance is high, can realize more meticulous control, thereby improves welding quality, reduces the control circuit framework of the full digital inversion welding machine that splashes.
Core devices of the present invention is a FPGA (field programmable gate array) who is not less than 10,000 LE (logical block) with the single-chip microcomputer of A/D translation function and capacity.The Main Function of single-chip microcomputer is: a, by electric current and the voltage data (analog quantity) of bus with the welding terminal sampling feedback, and the relevant temperature data (analog quantity) that the welding machine internal sensor records is input to the I/O mouth that it has the A/D modular converter, and carry out A/D and change, numerical data after the conversion is given the I/O pin of FPGA again by another I/O mouth output; B, coordinate communicating by letter between control circuit and the production line automatic control system by its serial communication interface; C, by its I/O mouth output data to interface circuit, realize the control of parameter (such as the voltage set, electric current etc.) display circuit (with LED or liquid crystal).The Main Function of FPGA is: a, its I/O pin receive the data of having carried out the A/D conversion of single-chip processor i/o mouth output, and it is carried out digital filtering operation; B, filtered sampled data is carried out the proportional integral computing, purpose is final control welding with the size of DC voltage; C, its I/O mouth receive presetting of user's input and weld real-time technological parameter, are used for the output current of control welding process; The operation result of d, the relevant setting value of basis and b, produce the pwm signal of excitation full-bridge IGBT module, and by its I/O mouth output, the High-voltage PWM converter pulse that the IGBT module produces under its excitation is inputted as primary, after the pwm pulse rectification of transformer secondary output induction as the Voltage-output of electric welding machine; E, the desired fundamental current waveform of usefulness FPGA internal SRAM pre-stored welding procedure; F, according to the correlated current waveform of input parameter value and the E institute pre-stored of C, carry out related operation, the result is used for adjusting in real time welding wire feed length and speed in welding process, thereby reaches current waveform that welding procedure requires by its I/O mouth output; G, according to the parameter that presets, by relevant computing, produce short circuit, overcurrent, overvoltage, the holding circuit control signal such as overheated, by its I/O mouth output.User's parameters that FPGA receives is: (1), welding wire are to the wire speed of the soldered thing of contact; (2), the peak point current of beginning electric current; (3), the time to peak of beginning electric current; The fall time of electric current when (4), producing electric arc; (5), current rise time during short circuit; (6), downslope time during electric arc; (7), the line sending amount of welding wire during large electric current; (8), the line sending amount of welding wire during primary current.By the setting of these parameters, can for concrete welding object and welding wire specification, adjust relevant welding procedure.
The software that the invention has the advantages that FPGA and single-chip microcomputer matches with hardware, jointly finishes the real-time control to welding procedure.Because SRAM being arranged as internal memory among the FPGA, can be used for storing the basic waveform of the welding current that presets, can call relevant basic waveform and expand by computing in the real-time control procedure of welding, as the control inputs of welding wire feeding servo control system.Because the value of each sampled point of stored waveform participates in welding current control, participate in control with the only key value (such as peak point current, duration etc.) of classical circuit and compare, control more meticulous.
Description of drawings
Fig. 1 is the general basic circuit structure of contravariant arc welding machine;
Fig. 2 is present general contravariant arc welding machine digital control circuit structure;
Fig. 3 is contravariant arc welding machine control circuit structure of the present invention;
Fig. 4 is the software architecture of the single-chip microcomputer of contravariant arc welding machine control circuit of the present invention;
Fig. 5 is the software architecture of the FPGA of contravariant arc welding machine control circuit of the present invention.
The specific embodiment
Below in conjunction with the drawings and specific embodiments the present invention is described in further detail:
The present invention is based on the basic circuit structure of contravariant arc welding machine shown in Figure 1, power supply is for adopting the PWM control mode of IGBT module.The major loop of power supply can after the rectifier bridge module rectification, adopt phase whole-bridging circuit for single-phase or three-phase alternating current input, realizes PWM, and realizes inversion through the transformer transformation.The transformer adopting amorphous alloy transformer can effectively reduce the volume of electric welding machine.Transformer secondary through over commutation, output dc voltage.At welding terminal, then output voltage, electric current are sampled by the arc voltage sensor.The voltage and current value of sampling enters FEEDBACK CONTROL and holding circuit.Servo electrical machinery system is adopted in the welding wire feeding.
The present invention is based on shown in Figure 3 take the full-digital circuit of FPGA as its main operational device, and the Voltage-output of power supply is carried out the closed loop proportional integration control; Welding wire feeding servo control system is carried the relevant parameter (size of welding current is decided by the line sending amount of welding wire) of current waveform.The closed-loop control of servomotor is realized that by the control system of itself control circuit of electric welding machine then provides relevant parameter in real time for it.The FPGA also electric current by monitoring sampling and voltage and temperature comes circuit protection system is sent guard signal.
The parameter that FPGA inputs all is the key parameter of welding procedure, has influence on the quality of welding and the size of splashing, and inputs by relevant terminal by the user, and what FPGA received is digital parameters.
The electric current basic waveform that the built-in SRAM pre-stored of FPGA requires when welding.It is corresponding with the growth of time that access unit address increases, each memory cell is stored be waveform in its address the sampled value of corresponding time point.Waveform parameter to storage is carried out real-time operation, its result just can carry relevant controlling parameters in real time to welding wire feeding servo control system, make it export in real time the desired electrical flow valuve of requirement at corresponding each time point, thereby reach the in real time accurately control to electric current in the welding procedure.
The effect of FPGA control depends on its software.SCM﹠FPGA all has its software, and software is the core of control system, and hardware is the carrier of software, and software is realized by hardware.As seen, this digital control formula inversion welding machine is actually a kind of programme-control condenser discharge welder, and it is essentially different with simulation control condenser discharge welder.
The essence of control system of the present invention is to carry out programme-control with software, and SCM﹠FPGA is the carrier of control software.The framework of scm software as shown in Figure 4; The framework of FPGA software as shown in Figure 5.
Core devices of the present invention be one with the single-chip microcomputer of A/D translation function, such as PIC18F458, be not less than the FPGA (field programmable gate array) of 10,000 LE (logical block) with a capacity, such as the EP2C20 of the Cyclone II series of ALTERA company.The Main Function of single-chip microcomputer is: a, by electric current and the voltage data (analog quantity) of bus with the welding terminal sampling feedback, and the relevant temperature data (analog quantity) that the welding machine internal sensor records is input to the I/O mouth that it has the A/D modular converter, and carry out A/D and change, numerical data after the conversion is given the I/O pin of FPGA again by another I/O mouth output; B, coordinate communicating by letter between control circuit and the production line automatic control system by its serial communication interface; C, by its I/O mouth output data to interface circuit, realize the control of parameter (such as the voltage set, electric current etc.) display circuit (with LED or liquid crystal).The Main Function of FPGA is: a, its I/O pin receive the data of having carried out the A/D conversion of single-chip processor i/o mouth output, and it is carried out digital filtering operation; B, filtered sampled data is carried out the proportional integral computing, purpose is final control welding with the size of DC voltage; C, its I/O mouth receive presetting of user's input and weld real-time technological parameter, are used for the output current of control welding process; The operation result of d, the relevant setting value of basis and b, produce the pwm signal of excitation full-bridge IGBT module, and by its I/O mouth output, the High-voltage PWM converter pulse that the IGBT module produces under its excitation is inputted as primary, after the pwm pulse rectification of transformer secondary output induction as the Voltage-output of electric welding machine; E, the desired fundamental current waveform of usefulness FPGA internal SRAM pre-stored welding procedure; F, according to the correlated current waveform of input parameter value and the E institute pre-stored of C, carry out related operation, the result is used for adjusting in real time welding wire feed length and speed in welding process, thereby reaches current waveform that welding procedure requires by its I/O mouth output; G, according to the parameter that presets, by relevant computing, produce short circuit, overcurrent, overvoltage, the holding circuit control signal such as overheated, by its I/O mouth output.User's parameters that FPGA receives is: (1), welding wire are to the wire speed of the soldered thing of contact; (2), the peak point current of beginning electric current; (3), the time to peak of beginning electric current; The fall time of electric current when (4), producing electric arc; (5), current rise time during short circuit; (6), downslope time during electric arc; (7), the line sending amount of welding wire during large electric current; (8), the line sending amount of welding wire during primary current.By the setting of these parameters, can for concrete welding object and welding wire specification, adjust relevant welding procedure.
Claims (4)
1. the circuit framework of a digital control formula inversion welding machine includes one and is not less than the FPGA of 10,000 LE with the single-chip microcomputer of A/D translation function and capacity, it is characterized in that realizing by single-chip microcomputer:
A. by bus the relevant temperature data that the electric current of welding terminal sampling feedback and voltage data and welding machine internal sensor record is input to the I/O mouth that it has the A/D modular converter, and carry out A/D and change, numerical data after the conversion is given the I/O pin of FPGA again by another I/O mouth output;
B. coordinate communicating by letter between control circuit and the production line automatic control system by its serial communication interface;
C. arrive interface circuit by its I/O mouth output data, realize the control of parameter, display circuit; Realize by FPGA:
A. its I/O pin receives the data of having carried out the A/D conversion of single-chip processor i/o mouth output, and it is carried out digital filtering operation;
B. filtered sampled data is carried out the proportional integral computing, purpose is the size that DC voltage is used in final control welding;
C. its I/O pin receives presetting of user's input and welds real-time technological parameter, is used for the output current of control welding process;
D. according to the operation result about setting value and b, produce the pwm signal of excitation full-bridge IGBT module, and by its I/O pin output, the High-voltage PWM converter pulse that the IGBT module produces under its excitation is inputted as primary, is the Voltage-output of electric welding machine after the pwm pulse rectification of transformer secondary output induction;
E. use the fundamental current waveform of FPGA internal SRAM pre-stored welding process requirement;
F. according to the correlated current waveform of input parameter value and the e institute pre-stored of c, carry out related operation, the result by its I/O mouth output, is used for adjusting in real time welding wire feed length and speed in welding process, thereby reaches the desired current waveform of welding procedure; G. according to the parameter that presets, by relevant computing, produce short circuit, overcurrent, overvoltage, overheated and other holding circuit control signal, by its I/O mouth output.
2. the circuit framework of digital control formula inversion welding machine according to claim 1 is characterized in that every Welding parameter setting that presets that its I/O pin in the c process of described FPGA receives user's input comprises that (1), welding wire are to the wire speed of the soldered thing of contact; (2), the peak point current of beginning electric current; (3), the time to peak of beginning electric current; (4), produce the fall time of arc current; (5), connect current rise time during short circuit; (6), downslope time connects during electric arc; (7), the line sending amount of welding wire during large electric current; (8), the line sending amount of welding wire during primary current.
3. the circuit framework of digital control formula inversion welding machine according to claim 1 is characterized in that pre-stored fundamental current waveform in the SRAM of FPGA.
4. the circuit framework of digital control formula inversion welding machine according to claim 1 is characterized in that by single-chip microcomputer sampled value being carried out the A/D conversion, finishes related operation by FPGA.
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| CN103331506A (en) * | 2013-07-23 | 2013-10-02 | 唐山开元焊接自动化技术研究所有限公司 | Handheld terminal for detecting automatic welding equipment and detection method for handheld terminal |
| CN103722322A (en) * | 2014-01-06 | 2014-04-16 | 山东大学 | Digital realization circuit and method of primary current feedback mode |
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Application publication date: 20130501 |