CN105413902B - A kind of electrostatic powder coating controller and control method - Google Patents

A kind of electrostatic powder coating controller and control method Download PDF

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Publication number
CN105413902B
CN105413902B CN201510903906.9A CN201510903906A CN105413902B CN 105413902 B CN105413902 B CN 105413902B CN 201510903906 A CN201510903906 A CN 201510903906A CN 105413902 B CN105413902 B CN 105413902B
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circuit
powder coating
electrostatic
output
signal
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CN105413902A (en
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李向阳
哀薇
熊文元
熊春豆
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South China University of Technology SCUT
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South China University of Technology SCUT
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05BSPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B5/00Electrostatic spraying apparatus; Spraying apparatus with means for charging the spray electrically; Apparatus for spraying liquids or other fluent materials by other electric means
    • B05B5/025Discharge apparatus, e.g. electrostatic spray guns
    • B05B5/03Discharge apparatus, e.g. electrostatic spray guns characterised by the use of gas, e.g. electrostatically assisted pneumatic spraying
    • B05B5/032Discharge apparatus, e.g. electrostatic spray guns characterised by the use of gas, e.g. electrostatically assisted pneumatic spraying for spraying particulate materials

Abstract

A kind of electrostatic powder coating controller disclosed by the invention, including main control MCU circuit, and man-machine interface circuit, trigger signal process circuit, spray gun interface signal process circuit and the air pressure signal processing circuit being connected respectively with main control MCU circuit, in addition to the Switching Power Supply for foregoing circuit power supply.The controller and control method of the present invention, it can realize that multiple-working mode, electric parameter and pneumatic parameter automatically control and increase Learning control strategy on the basis of PI controls.

Description

A kind of electrostatic powder coating controller and control method
Technical field
The present invention relates to electrostatic powder coating field, more particularly to a kind of electrostatic powder coating controller and control method.
Background technology
Electrostatic powder coating is powered coating powder is firmly adsorbed in quilt the active force of charged particle using electrostatic field The workpiece surface of processing, powder bed are formed solid after high-temperature baking, fusing, levelling and low-temperature setting in workpiece surface Coating.Electrostatic powder coating controller is the key equipment for completing electrostatic powder coating, and existing controller is often only to electrostatic Voltage and electrostatic induced current, which realize, to be automatically controlled, and flow velocity air pressure and atomization air pressure is not implemented to automatically control, many state's outer controls Device also only has the manual regulatory function of atomization air pressure and flow velocity air pressure so as to the stable gas pressure of source of the gas in electrostatic spray process Property require it is very high;The control model that existing controller is supported often also only has electrostatic potential pattern and electrostatic induced current pattern, It is difficult to meet that high quality spraying requires;In addition, in the real time execution of control model, the control strategy of use is mainly PI controls Strategy, lack the Advanced Control Strategies of suitable complex part curved surface.The present invention realizes electrostatic potential, electrostatic induced current, flow velocity air pressure With the automatically controlling of four variables of atomization air pressure, various control pattern is provided, and Learning control strategy is introduced electrostatic spraying control In system, the high quality spraying to complex part curved surface is realized.
The content of the invention
The shortcomings that it is an object of the invention to overcome prior art and deficiency, there is provided a kind of electrostatic powder coating controller.
Another object of the present invention is to provide a kind of electrostatic powder coating control method, can realize multiple-working mode, Electric parameter and pneumatic parameter automatically control and increase Learning control strategy on the basis of PI controls.
The purpose of the present invention is realized by following technical scheme:
A kind of electrostatic powder coating controller, including main control MCU circuit, and the people being connected respectively with main control MCU circuit Machine interface circuit, trigger signal process circuit, spray gun interface signal process circuit and air pressure signal processing circuit, in addition to be upper State the Switching Power Supply of circuit power supply.
The man-machine interface circuit includes three end LDO voltage stabilizer SPX1117, LED, charactron LED driver, key-press input Scanning circuit;Wherein+5V is reduced to the MCU working powers of+3.3V as man-machine interface circuit by three end LDO voltage stabilizer SPX1117; Charactron LED driver, key-press input scanning circuit use 2 BC7277, and BC7277 passes through SPI interface and man-machine interface MCU communicates;The MCU of man-machine interface is used using USART1 interfaces and RS422 drivers SP3490 and main control MCU circuit communication USART3 interfaces and RS485 drivers SP485 are connected with outside RS485 buses, realize more electrostatic powder coating controller groups Net.
The MCU of the main control MCU circuit uses STM32F205VC.
The MCU of the man-machine interface circuit uses STM32F100C8.
The main control MCU circuit is communicated with man-machine interface circuit by RS422 interfaces (passing through SP3490 driving chips).
Another object of the present invention is realized by following technical scheme:
A kind of electrostatic powder coating control method, comprises the following steps:
Main control MCU circuit is connected by I/O interfaces with trigger signal process circuit, outer triggering signal is received, with reference to quiet The working condition output triggering permissive signal of electro-powder spray controller;Output is obtained by spray gun interface signal process circuit Voltage, electric current and electric output state feedback signal, the mode of operation and working condition with reference to electrostatic powder coating controller are defeated Go out control voltage, adjust the electrostatic potential or electrostatic induced current of output;By air pressure signal process circuit obtain flow velocity air pressure and Atomization air pressure feedback signal, with reference to mode of operation and working condition the output step motor control letter of electrostatic powder coating controller Number, adjust flow velocity air pressure and atomization air pressure output valve;
Trigger signal process circuit receives outer triggering signal and is changed into touching for main control MCU circuit after changing its logic level Send out input signal;Output air circuit breaker signal and electricity are determined according to the logical AND result of outer triggering signal and triggering permissive signal Path switching signal it is logically high and low, realize the on and off of gas circuit and circuit output;
Air pressure signal process circuit becomes air input pressure according to the adjusting position of baroswitch signal and stepper motor For required flow velocity air pressure and atomization air pressure pressure, while output pressure measured value is exported and gives main control MCU circuit, in master control The digital control of air pressure is realized inside MCU circuits, the external spray gun of spray gun interface signal process circuit, Switching Power Supply is provided 24V voltages are changed into the control voltage needed for external spray gun, receive the current feedback input value of spray gun, while output voltage, electricity Stream and state (normal, overload and short circuit) are transferred to main control MCU circuit, and electrostatic powder coating is realized together with main control MCU circuit The various control models of controller.
The control model of the electrostatic powder coating control method is electrostatic mode of operation, and electrostatic mode of operation includes conventional Constant voltage mode and constant current mode, in addition to constant power mode and constant current density pattern;Wherein constant power mode is quiet The product of electricity output voltage and current is constant, and constant current density pattern is on the basis of constant current mode, according to output pressure Change is finely adjusted to output current so that the charge number of output and the amount of powder exported are approximate directly proportional, and the electric current such as realization is close Degree.
The electrostatic powder coating control method, it is a repetition Workpiece painting process for automatically electrostatic spray process, draws Enter iterative learning control thought, in each Electrostatic Control voltage output, be used to correct this control according to preceding secondary control error Voltage output processed.Raising has complex curved surface part electrostatic powder coating control accuracy.
The present invention compared with prior art, has the following advantages that and beneficial effect:
(1) in addition to voltage and current output control automatically, also automatically controlled with flow velocity air pressure and atomization air pressure, reduction pair Input the requirement of source of the gas pressure stability.
(2) there is RS485 communication external interfaces, electrostatic powder coating controller both can form separate unit hand with electrostatic gun Dynamic powder spraying system, can also be by RS485 networkings into the large automatic paint finishing with more spray guns.
(3) there is the totally four kinds of electrostatic sprayings of constant voltage mode, constant current mode, constant power mode and constant current density pattern Mode of operation, adapt to higher spraying coating process requirement.
(4) iterative learning controlling mechanism is introduced, there is higher control accuracy than common PI control algolithms, improve Coating quality.
Brief description of the drawings
Fig. 1 is electrostatic powder coating controller architecture block diagram.
Fig. 2 is electrostatic powder coating controller man-machine interface.
Fig. 3 is electrostatic powder coating controller pressure control schematic diagram.
Fig. 4 is constant voltage mode control loop.
Fig. 5 is constant current mode control loop.
Fig. 6 is constant power mode control loop
Fig. 7 is permanent density mode schematic diagram.
Embodiment
With reference to embodiment and accompanying drawing, the present invention is described in further detail, but embodiments of the present invention are unlimited In this.
With reference to figure 1, electrostatic powder coating controller is believed by Switching Power Supply, man-machine interface circuit, main control MCU circuit, triggering Number process circuit, air pressure signal process circuit and spray gun interface signal process circuit composition.
Switching Power Supply uses bright latitude Switching Power Supply NED-100D, and alternating current 220V AC is changed into direct current 24V and 5V, wherein 24V Switch electromagnetic valve and stepper motor to electric output circuit and the air pressure signal processing circuit of spray gun interface signal process circuit Power supply, other circuits are powered using 5V.This electrostatic powder coating controller uses dual-MCU configuration, except main control MCU circuit contains Outside MCU, man-machine interface circuit also contains MCU, and main control MCU selects STM32F205VC, man-machine interface MCU to select STM32F100C8, both are communicated by RS422 interfaces (passing through SP3490 driving chips).Main control MCU circuit passes through I/O interfaces It is connected with trigger signal process circuit, receives outer triggering signal, (is stopped with reference to the working condition of electrostatic powder coating controller Or operation) output triggering permissive signal;By spray gun interface signal process circuit obtain output voltage, electric current and electrically it is defeated Do well feedback signal, defeated with reference to the mode of operation and working condition output control voltage of electrostatic powder coating controller, regulation The electrostatic potential or electrostatic induced current gone out;Flow velocity air pressure and atomization air pressure feedback signal are obtained by air pressure signal process circuit, With reference to electrostatic powder coating controller mode of operation and working condition export step motor control signal, regulation flow velocity air pressure and Atomization air pressure output valve.Trigger signal process circuit receives outer triggering signal and is changed into main control MCU after changing its logic level The triggering input signal of circuit;Output air circuit breaker is determined according to the logical AND result of outer triggering signal and triggering permissive signal Signal and contactor signal it is logically high and low, realize the on and off of gas circuit and circuit output.Air pressure signal process circuit root Certain air input pressure is changed into required flow velocity air pressure and atomization according to the adjusting position of baroswitch signal and stepper motor Atmospheric pressure, while output pressure measured value is exported and gives main control MCU circuit, the number of air pressure is realized inside main control MCU circuit Word controls.The external spray gun of spray gun interface signal process circuit, the 24V voltages that Switching Power Supply provides are changed into needed for external spray gun Control voltage, the current feedback input value of spray gun is received, while output voltage, electric current and state (normal, overload and short circuit) Main control MCU circuit is transferred to, the various control models of electrostatic powder coating controller are realized together with main control MCU circuit.
+ 5V is reduced to the working powers of+3.3V as MCU by man-machine interface circuit using three end LDO voltage stabilizer SPX1117. LED and charactron LED driver and key-press input scanning circuit use 2 BC7277, BC7277 to lead to by SPI interface and MCU Letter.Man-machine interface MCU is communicated using USART1 interfaces and RS422 drivers SP3490 with main MCU;Using USART3 interfaces and RS485 drivers SP485 is connected with outside RS485 buses, realizes more electrostatic powder coating controller networkings.With reference to figure 2, people Machine interface is made up of 4 LED lights, 11 Digital sum pipe, 12 Digital sum pipe, 43 Digital sum pipes and 12 buttons.4 LED light shows " default ", " RUN ", " triggering " and " communication " working condition respectively, wherein " default " LED is bright to refer to people Machine interface is in human configuration running parameter state;" RUN " LED is bright to refer to that electrostatic powder coating controller is currently running, Otherwise stop waiting;" triggering " LED is bright to refer to that spray controller receives extraneous trigger signal and exports triggering output electricity Gas and air pressure signal;" communication " LED equivalent refer to spray painting control with outside RS485 bus communications.The instruction spray of 1 Digital sum pipe The electrostatic mode of operation of controller is applied, can be constant voltage mode, constant current mode, constant power mode and constant current density pattern.2 Which group running parameter Digital sum pipe shows, spray controller can store from 00~99 100 groups of running parameters totally, wherein 00~ 09 group of parameter is to be solidificated in inside spray controller, it is impossible to changes, only may bring up use, can be adapted to current most of conventional sprays Painting process technological parameter, facilitates user directly to recall use, it is not necessary to each parameter is configured one by one, other parameters group is by user Voluntarily configure.43 Digital sum pipes realize electrostatic potential, electrostatic induced current, flow velocity air pressure and atomization air pressure numerical value respectively.12 are pressed Key has " parameter group ", " voltage ", " electric current ", " electrostatic mode " and " flow velocity air pressure " totally 6 option and installment type buttons respectively, " startup " and " stopping " 2 spray controllers are started working and the button that is stopped, " default ", " increase ", " reduction " and " true Recognize " 4 parameter modification operating knobs.Running parameter configuration process is as follows, first " default " button, and " default " LED is bright, can into parameter Configuration status, if 15 seconds press without key, " default " LED goes out, and is retracted into parameter and can configure state;When " default " LED is bright, press " parameter group " button, 2 " parameter group " charactron flickers, the parameter to be worked is selected by " reduction " and " increase " button Group, during parameter group code name is changed, other numeral methods preserve the relevant parameter in the parameter group, are pressed by " confirmation " Key, current parameter group code name is set to current operating parameters group.When needing to change the parameter in current operating parameters group, Parameter can configure state, after selection parameter group code, the parameter button changed on demand, modified as needed to voltage parameter, then by " electricity Pressure " button, then corresponding parameter display charactron flicker, by changing parameter value by " increase " and " reduction " button, really " finally Recognize " button completion parameter modification.
Electrostatic powder coating controller not only realizes automatically controlling for output voltage and electric current, also achieves air pressure signal Automatically control.With reference to figure 3, flow velocity air pressure is identical with the close loop control circuit structure of atomization air pressure, pressure sensing amplifying circuit 1 LM324, the connection of air pressure feedback signal are used using MPS20N1000D-S, amplifier with sensor in pressure sensing amplifying circuit 2 Main control singlechip STM32F205VC ADC;Actuator uses pressure-reducing valve and stepper motor, and stepper motor driver chip uses A4985SLPTR-T, main control singlechip STM32F205VC realize pressure-reducing valve aperture regulation by I/O connection motor drive ics, So that output pressure value is near setting value.The fast of output pressure can be realized using the input of switch electromagnetic valve control source of the gas Speed cut-out and unlatching, while pressure-reducing valve frequent movement is reduced, extend pressure-reducing valve working life.
Constant voltage mode, constant current mode, constant power pattern and isodensity pattern may be selected in electrostatic powder coating controller Four kinds of mode of operations, current operation mode is shown by one digit number code pipe.Constant voltage mode realized by voltage control loop, reference chart 4, the Vout that voltage control loop circuit is changed into 24V input voltage variable values is exported.T401 and T403 compositions reach woods Pause power adjustment pipe, and T401 selects high-power PNP transistor TIP147, T403 to select NPN transistor MMBT4401.A401 is put for error Big device, track to track amplifier OPA4188 is selected, it exports the base stage that T403 is driven by resistance R403 (3k Ω).Usv is voltage control The setting value in loop processed, exported by main MCU DAC, its work excursion is 0.85V~3.0V, and corresponding output voltage is about When 5.95V~21V, Usv are 0V, output is closed.Upv is output voltage measured value, passes through resistance R404 (3k Ω), resistance R405 (3k Ω) and resistance R406 (resistance is 1k Ω) series connection partial pressure measurement, intrinsic standoff ratio 1:7.Resistance R402 (100 Ω) is T403 The colelctor electrode current-limiting resistance of (PNP transistor MMBT4403);Resistance R401 (0.5 Ω) is T401 overcurrent protection resistance, works as stream When crossing T401 electric current and being more than 1.4A, T402 is begun to turn on, and improves T401 base voltages, so as to the collector current of restricted T 401 Continue to increase.
Constant current mode, constant power pattern and isodensity pattern are by main MCU internal firmwares and Fig. 4 voltage control loops and outside Enclose circuit realiration.Fig. 5 is constant current mode control loop, and the voltage output of linear voltage decreasing voltage control loop is to spray gun;Spray gun Spraying current translation circuit can be fed back to by spray gun interface with the spraying current of workpiece composition spraying process, spraying current becomes Change the ADC of circuit connection main control MCU circuit;Main control MCU circuit is according to spraying current setting value Isv and spraying current measured value Ipv difference, by spraying current controller output voltage setting value Usv, so as to be performed by linear voltage decreasing voltage control loop Regulation process, realizes constant current controlling pattern, and spraying current translation circuit is realized inside MCU using firmware.In general electrostatic The current-mode of powder spray control uses PI control algolithms, and invention increases learning functionality, employs iterative learning control Algorithm, to adapt to the fast spraying of complex part, coating quality is improved, shown in Iterative Learning Control Algorithm such as formula (1).
In order to ensure voltage setting value in spray gun requirement working range, amplitude limit output is employed, as shown in formula (2), is obtained Final desired voltage setting value.
In formula (1), k is processing times (relative to the number of workpiece to be machined), and k initial values are 0, voltage setting value Usv Initial value be 0, spraying operation every time, is extracted experience from from k-1 time later, the voltage setting value Usv of k times is changed, so as to improve Control accuracy, β1For current feedback gain, 35 are taken as;In formula (2), [USVMIN,USVMAX] it is voltage setting value working range [0.85V,3.0V]。
The control loop of constant power pattern is similar to constant current mode control loop, as shown in fig. 6, employing Power Control Device instead of current controller, add power calculator (being multiplier), other as constant current mode.Constant power mould Shown in the Iterative Learning Control Algorithm of formula such as formula (3).
In formula (3), WeFor power error, sgn, sqr and abs difference sign function, evolution function and ABS function, β2 For Feedback of Power gain, 5.9 are taken, with formula (1) unanimously, similarly voltage setting value is also required to by formula (2) its physical significance Could be as the setting value of voltage control loop after slicing algorithm.
In electrostatic spray process, air pressure change will cause powder density to change, and isodensity pattern is the change according to air pressure Change the change for the electric charge average for adjust the setting value of current control loop, reducing powder particle institute band, improve coating quality. With reference to figure 7, isodensity pattern is to be realized on the basis of constant current mode according to air pressure change correcting current setting value;First subtracts Musical instruments used in a Buddhist or Taoist mass asks flow velocity air pressure PF setting values and the difference of measured value, and the second subtracter asks atomization air pressure PA setting values and the difference of measured value; Permanent density conpensation obtains IMsv as electrostatic induced current control according to flow velocity draught head and atomization gas pressure difference correcting current setting value Isv The setting value in loop processed;Shown in permanent density conpensation backoff algorithm such as formula (4).
IMSV=ISV1·(PFSV-PFPV)+α2·(PASV-PAPV) (4)
α in formula (4)1And α2For correction factor, value is respectively 0.05 and 0.01, or is determined by testing.Although this hair Bright to have employed air pressure Automatic Control Strategy, the average undulating value of air pressure is little, but because the air pressure adjustment time (passes through stepping Motor) it is longer, transient swing phenomenon be present, by formula (4) transient state air pressure fluctuation can be overcome to influence coating quality, so as to enter One step improves coating quality.
Above-described embodiment is the preferable embodiment of the present invention, but embodiments of the present invention are not by above-described embodiment Limitation, other any Spirit Essences without departing from the present invention with made under principle change, modification, replacement, combine, simplification, Equivalent substitute mode is should be, is included within protection scope of the present invention.

Claims (7)

  1. A kind of 1. electrostatic powder coating controller, it is characterised in that:Including main control MCU circuit, and respectively with main control MCU circuit Connected man-machine interface circuit, trigger signal process circuit, spray gun interface signal process circuit and air pressure signal processing circuit, also Including the Switching Power Supply powered for foregoing circuit;
    The man-machine interface circuit includes three end LDO voltage stabilizer SPX1117, LED, charactron LED driver, key-press input scanning Circuit;Wherein+5V is reduced to the MCU working powers of+3.3V as man-machine interface circuit by three end LDO voltage stabilizer SPX1117;It is digital Pipe LED driver, key-press input scanning circuit use 2 BC7277, BC7277 to lead to by the MCU of SPI interface and man-machine interface Letter;The MCU of man-machine interface is using USART1 interfaces and RS422 drivers SP3490 and main control MCU circuit communication, using USART3 Interface and RS485 drivers SP485 are connected with outside RS485 buses, realize more electrostatic powder coating controller networkings.
  2. 2. electrostatic powder coating controller according to claim 1, it is characterised in that:The MCU of the main control MCU circuit is used STM32F205VC。
  3. 3. electrostatic powder coating controller according to claim 1, it is characterised in that:The MCU of the man-machine interface circuit is adopted Use STM32F100C8.
  4. 4. electrostatic powder coating controller according to claim 1, it is characterised in that:The main control MCU circuit and man-machine boundary Face circuit passes through RS422 interface communications.
  5. A kind of 5. electrostatic powder coating control method, using electrostatic powder coating control described in Claims 1-4 any claim Device processed, it is characterised in that comprise the following steps:
    Main control MCU circuit is connected by I/O interfaces with trigger signal process circuit, outer triggering signal is received, with reference to electrostatic powder The working condition output triggering permissive signal of last spray controller;The electricity of output is obtained by spray gun interface signal process circuit Pressure, electric current and electric output state feedback signal, exported with reference to the mode of operation and working condition of electrostatic powder coating controller Control voltage, adjust the electrostatic potential or electrostatic induced current of output;Flow velocity air pressure and mist are obtained by air pressure signal process circuit Change air pressure feedback signal, with reference to mode of operation and working condition the output step motor control letter of electrostatic powder coating controller Number, adjust flow velocity air pressure and atomization air pressure output valve;
    Trigger signal process circuit receive outer triggering signal and changing be changed into after its logic level main control MCU circuit triggering it is defeated Enter signal;Determine that output air circuit breaker signal and circuit are opened according to the logical AND result of outer triggering signal and triggering permissive signal OFF signal it is logically high and low, realize the on and off of gas circuit and circuit output;
    Air input pressure is changed into institute by air pressure signal process circuit according to the adjusting position of baroswitch signal and stepper motor The flow velocity air pressure and atomization air pressure pressure needed, while output pressure measured value is exported and gives main control MCU circuit, in main control MCU electricity The digital control of air pressure, the external spray gun of spray gun interface signal process circuit, the 24V voltages that Switching Power Supply is provided are realized inside road It is changed into the control voltage needed for external spray gun, receives the current feedback input value of spray gun, while output voltage, electric current and state Main control MCU circuit is transferred to, the various control models of electrostatic powder coating controller are realized together with main control MCU circuit.
  6. 6. electrostatic powder coating control method according to claim 5, it is characterised in that its control model works for electrostatic Pattern, electrostatic mode of operation include conventional constant voltage mode and constant current mode, in addition to constant power mode and constant current it is close Degree pattern;Wherein constant power mode is constant for the product of electrostatic output voltage and electric current, and constant current density pattern is in constant current On the basis of pattern, output current is finely adjusted according to the change of output pressure so that the charge number of output and the powder of output Measure directly proportional, realize uniform current density.
  7. 7. electrostatic powder coating control method according to claim 5, it is characterised in that the electrostatic powder coating control Method, it is a repetition Workpiece painting process for automatically electrostatic spray process, iterative learning control thought is introduced, in each electrostatic When control voltage exports, exported according to preceding secondary control error for correcting this control voltage.
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CN109453910B (en) * 2018-11-26 2020-12-01 青岛中邦科技发展有限公司 Voltage control method and system for electrostatic spraying spray gun
CN109433441A (en) * 2018-11-30 2019-03-08 青岛中邦科技发展有限公司 A kind of Multifunctional static electricity spray painting control method and system
CN112474150B (en) * 2020-11-13 2022-06-17 北京市劳动保护科学研究所 Dust removal system and method for powder coating
CN113019732B (en) * 2021-03-11 2022-09-23 深圳市德贝尔喷枪有限公司 High-precision spray gun spraying control system based on linear regulation

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