CN103464359A - Self-adaption method of supersonic generator - Google Patents
Self-adaption method of supersonic generator Download PDFInfo
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- CN103464359A CN103464359A CN2013103684925A CN201310368492A CN103464359A CN 103464359 A CN103464359 A CN 103464359A CN 2013103684925 A CN2013103684925 A CN 2013103684925A CN 201310368492 A CN201310368492 A CN 201310368492A CN 103464359 A CN103464359 A CN 103464359A
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Abstract
The invention relates to a self-adaption method of a supersonic generator. The method includes presetting an optimal working voltage value of a system, and constantly maintaining output frequency of the supersonic generator to be a resonance point of the system; sampling a current signal of a resonance circuit through a current sampling unit, converting the current signal into a voltage value through an A/D (analog/digital) voltage conversion unit, and inputting the voltage value to a microprocessor; comparing the currently-sampled voltage value with the preset optimal working voltage value of the system, if the currently-sampled voltage value is larger than the preset optimal working voltage value, lowering output voltage of the supersonic generator by one gear, and resampling an output voltage value; if the former is smaller than the later, increasing the output voltage of the supersonic generator by one gear, and resampling an output voltage value; if the former is equal to the later, enabling the supersonic generator to work by taking a current output voltage gear as a stationery point. By the method, stability of output voltage of the supersonic generator is guaranteed, and welding quality is improved.
Description
Technical field
The present invention relates to the ultra-sonic welded technical field, be specifically related to a kind of adaptive approach of supersonic generator, be particularly useful for the supersonic generator of bonding machine.
Background technology
Supersonic generator is a kind of device in order to produce the supersonic frequency electric energy and to provide to ultrasonic transducer.When supersonic generator is used for bonding machine, can be applicable to the bonding machines such as ultrasonic plastic welding machine, ultrasonic metal bonding machine and ultrasonic wave cloth lace machine.Bonding machine and welded piece etc. form ultrasonic welding system, when welding system works in frequency resonance and impedance matching state, could normally weld.
Traditional analog ultrasonic wave generator adopts the analog form of self-oscillation to produce ultrasonic wave, and the ultrasonic wave frequency band of its generation is narrow, applies its applicable narrow range of welding system.The digitalized ultrasonic wave producer produces ultrasonic wave in separate excitation concussion mode, and it is wider that it produces hyperacoustic ultrasonic wave frequency band, applies the applicable scope of its welding system than the welding system money of application simulation supersonic generator.But the resonant frequency point of ultrasonic welding system is affected by the factors such as the material, surface pressing, face of weld temperature of welded piece easily, and the occurrence frequency drift, when ultrasonic welding system frequency drift scope exceeds hyperacoustic frequency range of supersonic generator generation, welding system can't be operated in the optimum resonant frequency point, easily cause that not prison welding, solder side corrugate etc., affect the quality of welded piece, when serious, also may cause ultrasonic welding system to stop shake, weld unsuccessfully.In addition, the power output of supersonic generator is subject to the impact of the factors such as drift degree of degree of roughness, the resonant frequency point of welded piece material difference, solder bond face.The power output of supersonic generator is unstable, and the voltage of output is also unstable, easily causes the welding of solder bond face inhomogeneous, affects the quality of welded piece.
All there is above-mentioned application bottleneck in existing supersonic generator.
Summary of the invention
The objective of the invention is to overcome shortcomings and deficiencies of the prior art, a kind of adaptive approach of supersonic generator is provided, the output voltage of supersonic generator can carry out self adaptation, guarantees the output voltage stabilization of supersonic generator.
The objective of the invention is to be achieved through the following technical solutions: a kind of adaptive approach of supersonic generator, comprise the adaptive approach of the output voltage of supersonic generator, specific as follows:
Step 1, preset system works optimum voltage value;
The resonance point that the output frequency of step 2, constant supersonic generator is system;
Step 3, by the current signal of current sampling unit sampling resonant tank, convert magnitude of voltage to by the A/D voltage conversion unit, and input to microprocessor;
Step 4, current sample voltage value and default system works optimum voltage value are compared, if current sample voltage value is greater than default system works optimum voltage value, the output voltage of supersonic generator reduces by one grade, and returns to step 3; If current sample voltage value is less than default system works optimum voltage value, the output voltage of supersonic generator improves one grade, and returns to step 3; If current sample voltage value equals default system works optimum voltage value, with current output voltage gear stationary point, work.
As preferably, repeatedly perform step 3 at same output voltage gear, obtain a plurality of sample voltage value, and remove the peculiar point in sample voltage value, by the method for moving average, sample voltage value is carried out smoothly the more corresponding current sample voltage value as this output voltage gear.
As preferably, also comprise the output frequency adaptive approach of supersonic generator, specific as follows:
Step 1, the inceptive direction that presets frequency change and current data initial value;
In step 2, the maximum operation frequency scope that allows in expected system, with certain frequency step, carry out frequency scanning, and the current data of this Frequency point of sampling resonant tank, and store this current data;
Step 3, current sample rate current data and last sample rate current data are compared, if current sample rate current data are larger than last sample rate current data, the frequency change direction is consistent with last frequency change direction, and returns to step 2; If current sample rate current data are less than last sample rate current data, frequency change direction and last frequency change opposite direction, and return to step 2; If front sample rate current data and last sample rate current data consistent, this Frequency point is resonance point, and in this resonance point stationary point work.
As preferably, also comprise the step of the threshold value that presets current data in described step 1;
Described step 2 comprises the step of frequency rough scanning and the step of frequency precise scanning, and the step of described frequency rough scanning is as follows:
In the maximum operation frequency scope allowed in expected system, with the first frequency step-length, carry out frequency rough scanning, and the current data of this Frequency point of sampling resonant tank, and store this current data;
Judge whether current sample rate current data are less than the threshold value of predetermined current data, if continue coarse scanning, otherwise carry out essence scanning;
The step of described frequency precise scanning is as follows:
The resonant frequency point that the frequency rough of take scanning obtains is reference, in expected system peak frequency range of drift, with the second frequency step-length, carries out frequency precise scanning, and the current data of this Frequency point of sampling resonant tank, and stores this current data.
As preferably, while carrying out frequency rough scanning, frequency change is not done time delay and is stopped, and while carrying out smart frequency scanning, frequency change is done certain time delay and stopped.
As preferably, the step of the current data of described this Frequency point of sampling resonant tank is specially: in same Frequency point sample rate current data repeatedly, and remove the peculiar point in the sample rate current data, by the method for moving average, the sample rate current data are carried out smoothly again, obtain the current sample rate current data of this Frequency point in resonant tank.
As preferably, described current data is magnitude of voltage, and the step of described sample rate current data is specially: the current signal of current sampling unit sampling resonant tank converts magnitude of voltage to by the A/D voltage conversion unit, and inputs to microprocessor.
As preferably, also comprise the step of the output voltage of constant supersonic generator between described step 1 and step 2.
The present invention has the following advantages and beneficial effect compared to existing technology:
(1) by the output voltage adaptive approach of supersonic generator, make the output voltage of supersonic generator can carry out self adaptation, guarantee the output voltage stabilization of supersonic generator, improve welding quality.
(2), by the output frequency adaptive approach of supersonic generator, the output frequency that makes supersonic generator carries out self adaptation with the resonant frequency point of welding system, makes welding system be operated in resonant frequency point, further improves welding quality.
(3) scan with frequency precise and be scanned into line frequency scanning by frequency rough, can fast, accurately find resonant frequency point, improve welding efficiency and welding quality.
(4) do not do time delay by frequency change when coarse frequency scans and stop, while carrying out smart frequency scanning, frequency change is done certain time delay stop, guarantees when welding system finds resonance point fast to guarantee the accuracy of resonance point.
(5) by repeatedly sampling, and remove repeatedly the peculiar point in sampled data, by four methods of moving average, sampled data is repeatedly carried out smoothly, improve the stability of welding system, the raising welding quality.
The accompanying drawing explanation
The flow chart of the output frequency adaptive approach that Fig. 1 is the present embodiment supersonic generator;
The flow chart of the output voltage adaptive approach that Fig. 2 is the present embodiment supersonic generator.
The specific embodiment
When supersonic generator is applied to welding field, the resonant frequency point of ultrasonic welding system is affected by the factor such as the material, surface pressing, face of weld temperature of welded piece easily, and the occurrence frequency drift; The power output of supersonic generator is subject to the impact of the factors such as drift degree of degree of roughness, the resonant frequency point of welded piece material difference, solder bond face.The invention provides a kind of adaptive approach of supersonic generator, make the output frequency of supersonic generator by the resonant frequency point of self adaptation automatic tracking system, and, by the self adaptation of output voltage, regulated output voltage, improve welding quality.
Below in conjunction with embodiment and accompanying drawing, the present invention is described in further detail, but embodiments of the present invention are not limited to this.
Embodiment
A kind of adaptive approach of supersonic generator, comprise the output frequency adaptive approach of supersonic generator and the output voltage adaptive approach of supersonic generator.This method is applicable to the digitalized ultrasonic wave producer, the digitalized ultrasonic wave producer produces ultrasonic wave in the separate excitation mode, and its ultrasonic wave frequency band range is wide, by adaptive approach provided by the invention, the bonding machine of applying this supersonic generator is applicable to various welded piece, and the scope of application is wide.
As shown in Figure 1 and Figure 2, a kind of adaptive approach of supersonic generator, specific as follows:
The threshold value of S101, the inceptive direction that presets frequency change, current data initial value, current data, system works optimum voltage value.The threshold value of the inceptive direction of described frequency change, current data initial value, current data can be set before supersonic generator or bonding machine dispatch from the factory, also can first when using or using at every turn the user be set.The threshold value of described current data, system works optimum voltage value are set according to welded piece, the parameter of system own when supersonic generator is specifically applied.
The output voltage of S102, constant supersonic generator;
The process that S103, system are carried out frequency rough scanning is as follows: in the maximum operation frequency scope allowed in expected system, with the first frequency step-length, carry out frequency rough scanning, and the current data of this Frequency point of sampling resonant tank, and store this current data;
Judge whether current sample rate current data are less than the threshold value of predetermined current data, if continue coarse scanning, otherwise carry out essence scanning.The step-length of first frequency described in the present embodiment is set to 5Hz, and frequency rough when scanning frequency change do not do time delay and stop, and system can complete the scanning of a Frequency point in 2ms, and described first frequency step-length is arranged between 5Hz-10Hz according to the frequency band range of system.
The process that S104, system are carried out frequency precise scanning is as follows: the resonant frequency point that the frequency rough of take scanning obtains is reference, in expected system peak frequency range of drift, carry out frequency precise scanning with the second frequency step-length, and the current data of this Frequency point of sampling resonant tank, and store this current data.The step-length of second frequency described in the present embodiment is set to 0.1Hz, and the time delay that frequency precise when scanning frequency change is 20ms stops, and described second frequency step-length can be arranged between 0.1Hz-0.5Hz according to the frequency band range of system.
S105, current sample rate current data and last sample rate current data are compared, if current sample rate current data are larger than last sample rate current data, the frequency change direction is consistent with last frequency change direction, and returns to S104; If current sample rate current data are less than last sample rate current data, frequency change direction and last frequency change opposite direction, and return to S104; If front sample rate current data and last sample rate current data consistent, this Frequency point is resonance point, and in this resonance point stationary point work.
The step of the current data of described this Frequency point of sampling resonant tank is specially: in same Frequency point sample rate current data repeatedly, and the method compared by actual samples curve and theoretical curve variation tendency (as, sampled point actual value on sampling curve is than the large twice of the desired value of theoretical curve, this sampled value is considered as peculiar point) remove the peculiar point in the sample rate current data, by four methods of moving average, the sample rate current data are carried out smoothly again, obtain the current sample rate current data of this Frequency point in resonant tank.Described current data is magnitude of voltage, and the current signal of current sampling unit sampling resonant tank, convert magnitude of voltage to by the A/D voltage conversion unit, and input to microprocessor.
The resonance point that the output frequency of S106, constant supersonic generator is system.
S107, at same output voltage gear, repeatedly carry out by the current signal of current sampling unit sampling resonant tank, convert magnitude of voltage to by the A/D voltage conversion unit, and input to the step of microprocessor, obtain a plurality of sample voltage value, and the method compared by actual samples curve and theoretical curve variation tendency (as, sampled point actual value on sampling curve is than the large twice of the desired value of theoretical curve, this sampled value is considered as peculiar point) remove the peculiar point in sample voltage value, by four methods of moving average, sample voltage value is carried out smoothly again, the corresponding current sample voltage value as this output voltage gear.
S108, current sample voltage value and default system works optimum voltage value are compared, if current sample voltage value is greater than default system works optimum voltage value, the output voltage of supersonic generator reduces by one grade, and returns to S107; If current sample voltage value is less than default system works optimum voltage value, the output voltage of supersonic generator improves one grade, and returns to S107; If current sample voltage value equals default system works optimum voltage value, with current output voltage gear stationary point, work.
Above-described embodiment is preferably embodiment of the present invention; but embodiments of the present invention are not restricted to the described embodiments; other any do not deviate from change, the modification done under Spirit Essence of the present invention and principle, substitutes, combination, simplify; all should be equivalent substitute mode, within being included in protection scope of the present invention.
Claims (8)
1. the adaptive approach of a supersonic generator, is characterized in that, comprises the adaptive approach of the output voltage of supersonic generator, specific as follows:
Step 1, preset system works optimum voltage value;
The resonance point that the output frequency of step 2, constant supersonic generator is system;
Step 3, by the current signal of current sampling unit sampling resonant tank, convert magnitude of voltage to by the A/D voltage conversion unit, and input to microprocessor;
Step 4, current sample voltage value and default system works optimum voltage value are compared, if current sample voltage value is greater than default system works optimum voltage value, the output voltage of supersonic generator reduces by one grade, and returns to step 3; If current sample voltage value is less than default system works optimum voltage value, the output voltage of supersonic generator improves one grade, and returns to step 3; If current sample voltage value equals default system works optimum voltage value, with current output voltage gear stationary point, work.
2. the adaptive approach of supersonic generator according to claim 1, it is characterized in that: at same output voltage gear, repeatedly perform step 3, obtain a plurality of sample voltage value, and remove the peculiar point in sample voltage value, by the method for moving average, sample voltage value is carried out smoothly the more corresponding current sample voltage value as this output voltage gear.
3. the adaptive approach of supersonic generator according to claim 1 and 2 is characterized in that: also comprise the output frequency adaptive approach of supersonic generator, specific as follows:
Step 1, the inceptive direction that presets frequency change and current data initial value;
In step 2, the maximum operation frequency scope that allows in expected system, with certain frequency step, carry out frequency scanning, and the current data of this Frequency point of sampling resonant tank, and store this current data;
Step 3, current sample rate current data and last sample rate current data are compared, if current sample rate current data are larger than last sample rate current data, the frequency change direction is consistent with last frequency change direction, and returns to step 2; If current sample rate current data are less than last sample rate current data, frequency change direction and last frequency change opposite direction, and return to step 2; If front sample rate current data and last sample rate current data consistent, this Frequency point is resonance point, and in this resonance point stationary point work.
4. the adaptive approach of supersonic generator according to claim 3, is characterized in that,
Also comprise the step of the threshold value that presets current data in described step 1;
Described step 2 comprises the step of frequency rough scanning and the step of frequency precise scanning, and the step of described frequency rough scanning is as follows:
In the maximum operation frequency scope allowed in expected system, with the first frequency step-length, carry out frequency rough scanning, and the current data of this Frequency point of sampling resonant tank, and store this current data;
Judge whether current sample rate current data are less than the threshold value of predetermined current data, if continue coarse scanning, otherwise carry out essence scanning;
The step of described frequency precise scanning is as follows:
The resonant frequency point that the frequency rough of take scanning obtains is reference, in expected system peak frequency range of drift, with the second frequency step-length, carries out frequency precise scanning, and the current data of this Frequency point of sampling resonant tank, and stores this current data.
5. the adaptive approach of supersonic generator according to claim 4 is characterized in that: while carrying out frequency rough scanning, frequency change is not done time delay and is stopped, and while carrying out smart frequency scanning, frequency change is done certain time delay and stopped.
6. the adaptive approach of supersonic generator according to claim 5, it is characterized in that, the step of the current data of described this Frequency point of sampling resonant tank is specially: in same Frequency point sample rate current data repeatedly, and remove the peculiar point in the sample rate current data, by the method for moving average, the sample rate current data are carried out smoothly again, obtain the current sample rate current data of this Frequency point in resonant tank.
7. the adaptive approach of supersonic generator according to claim 6, it is characterized in that, described current data is magnitude of voltage, the step of described sample rate current data is specially: the current signal of current sampling unit sampling resonant tank, convert magnitude of voltage to by the A/D voltage conversion unit, and input to microprocessor.
8. the adaptive approach of supersonic generator according to claim 7, is characterized in that, also comprises the step of the output voltage of constant supersonic generator between described step 1 and step 2.
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