CN104128680A - Electrochemical machining high frequency pulse power source based on SOPC technology - Google Patents
Electrochemical machining high frequency pulse power source based on SOPC technology Download PDFInfo
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Abstract
The invention relates to an electrochemical machining high frequency pulse power source based on an SOPC technology. The electrochemical machining high frequency pulse power source comprises an AC input end, a primary rectifying filter circuit, a full-bridge inverter circuit, a high-frequency variable voltage circuit, a secondary rectifying filter circuit, a chopper filter circuit and a pulse output end, and further comprises an energy release device, a load current detection circuit and a control system. The control system is connected with the full-bridge inverter circuit, the chopper filter circuit, the energy release device and the load current detection circuit. When the rise rate of currents detected by the load current detection circuit is continuously larger than a set value by four sampling periods, the control system controls the full-bridge inverter circuit and the chopper circuit to be turned off, and pulse signals are output to trigger the energy release device. According to the electrochemical machining high frequency pulse power source based on the SOPC technology, the energy release device is arranged, when an abnormal phenomenon happens to processing, the control system can timely trigger the energy release device to protect a processing electrode, the stability of the power source is improved, and full-digital control of the power source is achieved.
Description
Technical field
The present invention relates to the pulse power, particularly a kind of Electrolyzed Processing high frequency pulse power supply based on SOPC technology.
Background technology
Electrolyzed Processing (Electrochemical Machining, ECM), is a kind of method of removing material of dissolving with " ion " form based on anode metal, and workpiece anode and tool cathode connect direct current or the pulse power (being generally 10V ~ 25V).The advantage such as restriction that electrolytic processing process has that working (machining) efficiency is high, instrument is lossless, surface of the work, internal stress free smooth without heat affected layer, body structure surface, flawless, processing are not subject to material hardness after processing has been given play to significant advantage in small-sized, miniature, slim, overall structure, special type part manufacture field.
Pulse ECM Process (Pulse Electrochemicial Machining, PECM), can be divided into the types such as low frequency (tens of Hz) or high frequency (kHz ~ tens of kHz), wide pulse width (ms ~ tens of ms), narrow pulsewidth (tens of us ~ hundreds of us) by the wave character of electric current.Substitute DC electrolysis by Pulse ECM Process and process the physics, the chemical characteristic that have changed its process, can reach higher machining accuracy and stability.This is because method of electrochemical machining has been improved the uniformity in flow field, makes electrochemical reaction concentrate on electrode around in very little region, realizes localization ablation, is conducive to improve Electrolyzed Processing precision.
In the outer electrolysis processing of Present Domestic, the overwhelming majority still adopts dc source.The early stage DC generation unit that adopts, with the development during high-power thyristor, the dc source of thyristor voltage regulation, voltage stabilizing has progressively replaced again silicon rectifier power supply.
The electrolysis power of the power supply topologies of inversion rectification, taking the integrated pwm chip of monolithic as master controller, realizes voltage stabilizing or the current stabilization output of power supply, and output pulse frequency is in 15KHz left and right, power supply capacity Da Wananpei rank.
HeFei University of Technology has developed a set of full-bridge inverting high-frequency impulse electrolysis processing power source using IGBT (insulated gate bipolar transistor) as copped wave element.Taking SG3525 as PWM(pulse width modulation) pulse signal generation circuit and the regulating circuit of control chip.Its major parameter is: output frequency be up to 40kHz, output peak point current can reach 2000A, output average voltage reach between 24V and dutycycle 0.1 ~ 0.9 adjustable; fast short-circuit protective system adopts turn-offs inversion full-bridge and interpolar the capacity IGBT of the United Nations General Assembly in conjunction with realizing shutoff fast, effectively protection power source and tool-electrode and workpiece.
South China Science & Engineering University has developed SCR(IGCT) the quick change of current of DC current source of pressure regulation, voltage-stabilized power supply output becomes the pulse electrolysis power supply of high frequency, burst pulse.Maximum output voltage 20V (peak value); Frequency adjustable extent: 100Hz ~ 20kHz, adjustable continuously.Rated frequency: 1000A is 10kHz; 2000A is 1kHz.
[1] Chen Yuanlong, Yang Sheng. the development [J] of high-frequency impulse electrolysis processing power source. electromechanical engineering technology, 2012.
[2] Yu Yanqing, Wang Jianye, champion Han. MOSFET high-frequency narrow-pulse Electrolyzed Processing through engineering approaches power supply development [J]. electric machining and mould, 2005.
The major advantage of thyristor voltage regulation dc source is reliability, good economy performance, and the subject matter of existence is that volume of transformer is large, and major loop parallel branch is still many, and therefore floor space is large.Although DC electrolysis working (machining) efficiency is high, machining accuracy is not high, applicable not high to requirement on machining accuracy, and working (machining) efficiency is required to high processing occasion.
Inversion rectifier type pulse electrolysis power supply, although it is larger that power supply capacity can do, circuit is simple, machining accuracy is compared dc source Electrolyzed Processing precision and is improved, but be also not suitable for the occasion that requirement on machining accuracy is high, and output crest voltage is fixed, and waveform frequency and pulse width are non-adjustable, the parameter that is not easy to electrolytic processing process regulates.
Taking SG3525 as PWM(pulse width modulation) control chip, its simple and reliable and easy to use and flexible, output drives as push-and-pull output form, has increased driving force; Undervoltage lockout circuit, SS (soft start) control circuit, PWM latch are contained in inside, have overcurrent protection function, and frequency is adjustable, can limit maximum duty cycle simultaneously.But for the electrolysis power of chopped mode again of rectifying and wave-filtering after inversion, because the electrolysis power of this topological structure needs the pwm control signal of chopper and the pwm control signal of inverter to have certain concertedness.And SG3525 is mainly by regulating the pulse width of inverter to realize voltage stabilizing or the current stabilization control of power supply, thus for rectifying and wave-filtering after inversion again the electrolysis power of copped wave be not just well suited for.
There is the shortcoming that machining accuracy is not high in DC electrolysis power supply and inversion rectification electrolysis power, so be difficult to meet the requirement of high accuracy electrolysis processing, can not give play to the advantage of electrolytic processing process.
Summary of the invention
Main purpose of the present invention is, for above-mentioned deficiency of the prior art, provides a kind of Electrolyzed Processing high frequency pulse power supply based on SOPC technology.
The present invention solves the technical scheme that prior art problem adopts: a kind of Electrolyzed Processing high frequency pulse power supply based on SOPC technology, comprising:
Ac input end,
Elementary current rectifying and wave filtering circuit, is connected with described ac input end, for the alternating current of described ac input end input being carried out to rectification and filtering to form direct current;
Full bridge inverter, is connected with described elementary current rectifying and wave filtering circuit, for converting described direct current to high frequency pulse AC electricity;
High frequency transforming circuit, is connected with described full bridge inverter, for high frequency pulse AC electricity is converted to low-frequency pulse alternating current;
Secondary commutation filter circuit, is connected with described high frequency transforming circuit, forms pulse direct current for described low-frequency pulse alternating current being carried out to rectifying and wave-filtering;
Chopper circuit, is connected with described secondary commutation filter circuit, carries out frequency modulation to form the high impulse direct current of Electrolyzed Processing for paired pulses direct current;
Pulse output end, is connected with described chopper circuit, comprises cathode output end and cathode output end;
Energy releasing device, is connected in parallel between described cathode output end and cathode output end;
Load current detection circuit, is connected with described cathode output end, for detection of the electric current by load under machining state;
Control system, be connected with described full bridge inverter, chopper circuit, energy releasing device and load current detection circuit, when the climbing of the electric current detecting when described load current detection circuit is greater than continuous 4 sampling periods of setting value, described in described control system control, full bridge inverter and chopper circuit are closed, and output pulse signal triggers described energy releasing device.
Preferably, also comprise:
Primary current testing circuit, is connected with described full bridge inverter, and for the magnitude of voltage of described detection full bridge inverter, when described magnitude of voltage is greater than setting threshold values, the short circuit of described control system output short-circuit triggering signal control ac input end is with powered-down.
Preferably, described control system is the SOPC control system taking the soft core of NIOSII as processor.
Preferably, described chopper circuit comprises the High-frequency MOSFET power switch pipe of multiple parallel connections, and each High-frequency MOSFET power switch pipe drives by a power tube drive circuit.
Preferably, described energy releasing device comprises energy release and energy release drive circuit, energy release is connected in parallel between described cathode output end and cathode output end, and described energy release drive circuit is connected in described energy release and control system.
Preferably, in described control system, be connected with human-computer interaction interface and serial communication interface.
The invention has the beneficial effects as follows: the present invention has configured energy releasing device; in the time that load current detection circuit detects that the climbing of the electric current of detection is greater than continuous 4 sampling periods of setting value; i.e. now processing occurs abnormal; control system trigger energy releasing device protection in time machined electrode; improve the stability of electrolysis power, realized the full digital control of power supply, in addition; configured primary current testing circuit, one realizes full digital short-circuit protection.Further, the integrated SOPC power control system taking 32 NIOSii soft-core processors as core, the building of control system that has completed high-frequency impulse electrolysis power supply.Realize electrolysis power and electrolysis machine tool kinetic control system real-time, interactive by man-machine Fabric Interface and serial communication interface simultaneously, effectively improve machining accuracy and the scope of application of Electrolyzed Processing.
Brief description of the drawings
Fig. 1 is the schematic diagram of the Electrolyzed Processing high frequency pulse power supply of the embodiment of the present invention based on SOPC technology;
Fig. 2 is the power protection schematic diagram of high-frequency electrolysis power supply of the present invention;
Fig. 3 is digital pulse width modulation schematic diagram of the present invention;
Realization, functional characteristics and the advantage of the object of the invention, in connection with embodiment, are described further with reference to accompanying drawing.
Detailed description of the invention
Describe technical scheme of the present invention in detail below with reference to drawings and the specific embodiments, so as clearer, understand invention essence of the present invention intuitively.
Shown in Fig. 1, the invention provides a kind of Electrolyzed Processing high frequency pulse power supply based on SOPC technology, comprise ac input end, elementary current rectifying and wave filtering circuit, full bridge inverter, high frequency transforming circuit, secondary commutation filter circuit, chopper circuit, pulse output end, energy releasing device, load current detection circuit and control system.
Wherein, ac input end connects 220V single-phase alternating current.
Elementary current rectifying and wave filtering circuit is connected with described ac input end, for the alternating current of described ac input end input being carried out to rectification and filtering to form direct current.This elementary current rectifying and wave filtering circuit comprises rectifier bridge BR1 and filter capacitor C1, and the alternating current of ac input end input passes through rectifier bridge BR1 rectification, and by becoming straight high voltage direct current after filter capacitor C1 filtering.
Full bridge inverter is connected with described elementary current rectifying and wave filtering circuit, for converting described direct current to high frequency pulse AC electricity; This full bridge inverter is made up of four power switch pipes (T1-T4) and full bridge driving circuit 2, and full bridge driving circuit 2 is for driving four power switch pipes (T1-T4).
High frequency transforming circuit is connected with described full bridge inverter, for high frequency pulse AC electricity is converted to low-frequency pulse alternating current; This high frequency transforming circuit comprises high frequency transformer CT1 and is connected in the capacitor C 2 on high frequency transformer CT1 primary coil, high frequency transformer CT1 is low-frequency pulse alternating current by high frequency pulse AC electricity through a rated transformation ratio step-down, and capacitor C 2 is for isolating the DC component of high frequency transformer CT1 primary coil.
Secondary commutation filter circuit is connected with described high frequency transforming circuit, forms pulse direct current for described low-frequency pulse alternating current being carried out to rectifying and wave-filtering.This secondary commutation filter circuit comprises the rectification circuit being made up of fast recovery diode D1 and D2 and the filter circuit being made up of filter inductance L1 and filter capacitor C3, and low-frequency pulse alternating current forms low-frequency pulse direct current after by fast recovery diode D1 and D2 rectification and filter inductance L1 and filter capacitor C3 filtering.
Chopper circuit is connected with described secondary commutation filter circuit, carries out frequency modulation to form the high impulse direct current of Electrolyzed Processing for paired pulses direct current; This comprises that chopper Z1(is made up of the High-frequency MOSFET power switch pipe of multiple parallel connections), each High-frequency MOSFET power switch pipe drives by a power tube drive circuit 5.For reaching desirable current-sharing effect, choose the High-frequency MOSFET power switch pipe that characteristic is consistent as far as possible and carry out parallel connection, each High-frequency MOSFET power switch pipe correspondence independently resistance is eliminated unwanted oscillation, choose same power tube drive circuit 5, High-frequency MOSFET power switch pipe layout is symmetrical as far as possible and circuit loop is the shortest.
Pulse output end is connected with described chopper circuit, comprises cathode output end and cathode output end, and cathode output end is used for connecting processing work, and cathode output end is for fastening means negative electrode, provides high impulse direct current by output for Electrolyzed Processing.
Energy releasing device is connected in parallel between described cathode output end and cathode output end.This energy releasing device specifically comprises energy release Z2 and energy release drive circuit 6, energy release Z2 is connected in parallel between described cathode output end and cathode output end, and described energy release drive circuit 6 is connected in described energy release Z2 and control system 7.
Load current detection circuit is connected with described cathode output end, for detection of the electric current by load under machining state.This load current detection circuit specifically comprises the second current sensor HS2 and the load current detection and filter circuit 3, the second current sensor HS2 that are connected with described the second current sensor are connected in series on cathode output end.
Control system 7 is connected with described full bridge inverter, chopper circuit, energy releasing device and load current detection circuit; when the climbing of the electric current detecting when described load current detection circuit is greater than continuous 4 sampling periods of setting value; described control system 7 controls described full bridge inverter and chopper circuit cuts out; and output pulse signal triggers described energy releasing device, to protect the workpiece of tool cathode and processing.Concrete, control system 7 is controlled the High-frequency MOSFET power switch pipe of four power switch pipes (T1-T4) of full bridge inverter and multiple parallel connections of chopper circuit and is closed, and then sends a series of pulse signal trigger energy release.
Further, also comprise voltage isolation circuit, this voltage isolation circuit specifically comprises resistance R 1, R2, R3, voltage isolation feedback and filter circuit 4.
Load current detection and filter circuit 3, voltage isolation feedback and filter circuit 4 parts, after the output voltage of power supply and electric current are the sampling by 12 high-speed AD chips (TLV2541), after 32 rank FIR digital filterings, export to adjust pulsewidth size by PI computing.
Digital filtering is vital for digital power, and the present invention adopts 32 rank FIR low-pass digital filters, effectively filtering the interference causing when full bridge inverter and the chopper circuit change of current, improved stability and the control accuracy of power supply.
In a preferred embodiment of the invention, the present invention also comprises primary current testing circuit, be connected with described full bridge inverter, for the magnitude of voltage of described detection full bridge inverter, when described magnitude of voltage is greater than setting threshold values, the short circuit of described control system output short-circuit triggering signal control ac input end is with powered-down.
Specifically with reference to shown in Fig. 2, Fig. 2 is the power protection schematic diagram of high-frequency electrolysis power supply, primary current detection and filter circuit 1 that primary current testing circuit comprises the first current sensor HS1 and is connected with described the first current sensor HS1, the first current sensor HS1 is mainly for detection of the duty of full bridge inverter, set a threshold voltage A, when the magnitude of voltage that feeds back to control system 7 as the first current sensor HS1 is greater than threshold voltage A, short circuit triggering signal produces, control power-off, for more stable protection power source, after producing, short-circuit signal have the blind area time of T0 to determine whether genuine short circuit, in order to ensure the safety of power supply, after short circuit triggering signal disappears, there is the short-circuit signal of T1 time to keep, then recover the normal work of power supply.The second current sensor HS2 is mainly for detection of Electrolyzed Processing duty, when being greater than setting value, Current rise angle α just represents that processing is in electric discharge or short-circuit condition, control system 7 is closed power switch pipe (T1 ~ T4) and the chopper circuit of full bridge inverter, then trigger energy release Z2 immediately.
Current electrolysis processing electric current climbing is all to detect by hardware differential circuit, but when the change of current of high-power high-frequency switch power supply, disturb very large, can cause very large interference to testing circuit, and it is high to reliability requirement for Electrolyzed Processing power supply, otherwise can often there is improper damage and frequent power cutoff, cause the unstable of Electrolyzed Processing, the present invention adopts the current changing rate in 4 sampling periods of repeated sampling after digital filtering to judge the climbing of electric current.
Shown in Fig. 3, Fig. 3 is digital pulse width modulation schematic diagram, the operating frequency of full bridge inverter is given by period register, counter register Value adopts continuous increasing/reset mode, controlled the Sequential Activation of PWM1/PWM4 and PWM2/PWM3 by status register Sign, avoid upper underarm straight-through by dead band control register control Dead Time.
Control system of the present invention is the SOPC control system 7 taking the soft core of NIOSII as processor, is connected with human-computer interaction interface and serial communication interface 8 in this SOPC control system 7.Namely the present invention has built 32 SOPC control systems 7 that the soft core of NIOSII is processor, and energy supply control module, human-computer interaction module and serial communication function are integrated in one, and at utmost reduces discrete component quantity.
In sum; the present invention has configured energy releasing device; in the time that load current detection circuit detects that the climbing of the electric current of detection is greater than continuous 4 sampling periods of setting value; i.e. now processing occurs abnormal, and control system in time trigger energy releasing device is protected machined electrode, has improved the stability of electrolysis power; realize the full digital control of power supply; in addition, configured primary current testing circuit, one realizes full digital short-circuit protection.Further, the integrated SOPC power control system taking 32 NIOSii soft-core processors as core, the building of control system that has completed high-frequency impulse electrolysis power supply.Realize electrolysis power and electrolysis machine tool kinetic control system real-time, interactive by man-machine Fabric Interface and serial communication interface simultaneously, effectively improve machining accuracy and the scope of application of Electrolyzed Processing.
The foregoing is only the preferred embodiments of the present invention; not thereby limit its scope of the claims; every equivalent structure or conversion of equivalent flow process that utilizes description of the present invention and accompanying drawing content to do; directly or indirectly be used in other relevant technical fields, be all in like manner included in scope of patent protection of the present invention.
Claims (6)
1. the Electrolyzed Processing high frequency pulse power supply based on SOPC technology, is characterized in that, comprising:
Ac input end,
Elementary current rectifying and wave filtering circuit, is connected with described ac input end, for the alternating current of described ac input end input being carried out to rectification and filtering to form direct current;
Full bridge inverter, is connected with described elementary current rectifying and wave filtering circuit, for converting described direct current to high frequency pulse AC electricity;
High frequency transforming circuit, is connected with described full bridge inverter, for high frequency pulse AC electricity is converted to low-frequency pulse alternating current;
Secondary commutation filter circuit, is connected with described high frequency transforming circuit, forms pulse direct current for described low-frequency pulse alternating current being carried out to rectifying and wave-filtering;
Chopper circuit, is connected with described secondary commutation filter circuit, carries out frequency modulation to form the high impulse direct current of Electrolyzed Processing for paired pulses direct current;
Pulse output end, is connected with described chopper circuit, comprises cathode output end and cathode output end;
Energy releasing device, is connected in parallel between described cathode output end and cathode output end;
Load current detection circuit, is connected with described cathode output end, for detection of the electric current by load under machining state;
Control system, be connected with described full bridge inverter, chopper circuit, energy releasing device and load current detection circuit, when the climbing of the electric current detecting when described load current detection circuit is greater than continuous 4 sampling periods of setting value, described in described control system control, full bridge inverter and chopper circuit are closed, and output pulse signal triggers described energy releasing device.
2. the Electrolyzed Processing high frequency pulse power supply based on SOPC technology according to claim 1, is characterized in that, also comprises:
Primary current testing circuit, is connected with described full bridge inverter, and for the magnitude of voltage of described detection full bridge inverter, when described magnitude of voltage is greater than setting threshold values, the short circuit of described control system output short-circuit triggering signal control ac input end is with powered-down.
3. the Electrolyzed Processing high frequency pulse power supply based on SOPC technology according to claim 1, is characterized in that: described control system is the SOPC control system taking the soft core of NIOSII as processor.
4. the Electrolyzed Processing high frequency pulse power supply based on SOPC technology according to claim 1, it is characterized in that: described chopper circuit comprises the High-frequency MOSFET power switch pipe of multiple parallel connections, each High-frequency MOSFET power switch pipe drives by a power tube drive circuit.
5. the Electrolyzed Processing high frequency pulse power supply based on SOPC technology according to claim 1, it is characterized in that: described energy releasing device comprises energy release and energy release drive circuit, energy release is connected in parallel between described cathode output end and cathode output end, and described energy release drive circuit is connected in described energy release and control system.
6. the Electrolyzed Processing high frequency pulse power supply based on SOPC technology according to claim 1, is characterized in that: in described control system, be connected with human-computer interaction interface and serial communication interface.
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| CN107171588A (en) * | 2017-06-26 | 2017-09-15 | 北京无线电测量研究所 | A kind of modulator approach and system of the low energy storage broad pulse based on high voltage power supply |
| CN110814448A (en) * | 2019-11-25 | 2020-02-21 | 合肥工业大学 | Centralized rectification and voltage transformation distributed chopping pulse power supply |
| CN110977066A (en) * | 2019-11-25 | 2020-04-10 | 合肥工业大学 | Multichannel parallel trigger type high-frequency pulse power supply |
| CN112388079A (en) * | 2020-11-19 | 2021-02-23 | 西安理工大学 | Composite pulse working method of wire cut electrical discharge machining pulse power supply |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107171588A (en) * | 2017-06-26 | 2017-09-15 | 北京无线电测量研究所 | A kind of modulator approach and system of the low energy storage broad pulse based on high voltage power supply |
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| CN110977066A (en) * | 2019-11-25 | 2020-04-10 | 合肥工业大学 | Multichannel parallel trigger type high-frequency pulse power supply |
| CN112388079A (en) * | 2020-11-19 | 2021-02-23 | 西安理工大学 | Composite pulse working method of wire cut electrical discharge machining pulse power supply |
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