CN109822193A - Integrated Pulse MIG Welding Power Source system and its control method based on LLC - Google Patents
Integrated Pulse MIG Welding Power Source system and its control method based on LLC Download PDFInfo
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- CN109822193A CN109822193A CN201910234491.9A CN201910234491A CN109822193A CN 109822193 A CN109822193 A CN 109822193A CN 201910234491 A CN201910234491 A CN 201910234491A CN 109822193 A CN109822193 A CN 109822193A
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Abstract
The invention discloses integrated Pulse MIG Welding Power Source systems and its control method based on LLC, including three-phase alternating current to input power grid, human-computer interface module, main control module, peak value of pulse module, pulse base value module and arc load；The peak value of pulse submodule includes main circuit, drive module, failure protection module, measure voltage &；The main control module includes DSP Digital Control module; the DSP Digital Control module is connected with failure protection module, drive module and measure voltage & respectively; the main control module controls drive module according to pulse sequence; realize that the alternation switch to pulse base value module and the fully loaded output of peak value of pulse module switches, the configuration of the present invention is simple eliminates the disadvantage of split type system structure complexity；Strong antijamming capability solves subsystem in split type structure and is in communication with each other mode and is easy the problems such as being disturbed；Operating condition is improved, electromagnetic interference is reduced, improves overall efficiency.
Description
Technical field
The present invention relates to digital welding power source technical fields, and in particular to a kind of integrated pulse MIC welding based on LLC
Power-supply system and its control method.
Background technique
Pulse MIC (Metal Inert-Gas Welding, welding) welding technology is relatively chiefly used in height
The automatic welding occasion of performance, it integrates high-efficiency high-quality and automation, its outstanding advantages show themselves in that welding current adjusts model
Enclose wider, all galvanic areas including short circuiting transfer to spray transfer can weld slab, can also weld thin plate, weld
Penetration is good compared with short circuiting transfer when thin plate, deformation is small, welding efficiency is high；After pulse current, it can be used lesser flat
Equal electric current is welded, and the critical current of continuous current spray transfer when average current ratio MIG is welded is low, therefore the heat of base material is defeated
It is low to enter amount, welding deformation is small, is suitable for all-position welding；Droplet transfer process control is stronger；Without splashing (or base when welding
This without splash), arc length it is short, axial direction is good, deposition efficiency is high, appearance of weld is good, and face of weld is wide and flat, weld fumes is small.
Therefore pulse MIC welding paid attention in production, especially robot welding when welding quality and required precision it is relatively high
Occasion it is even more so.Within a period of time from now on, pulse MIC welding will further replace hand in the welding of major industrial country
Work arc welding and CO2Weldering, application range will be more and more extensive.
Recently as being growing more intense for market competition, welding production efficiency is improved, guarantees product quality, realize welding life
When the automation of production, the intelligent attention, especially robot welding increasingly by welding production enterprise welding quality and
The relatively high occasion of required precision is even more so.In addition modern artificial intelligence technology, digital information processing technique, computer regard
The involvement of the new and high technologies such as feel technology also promotes pulse MIC welding technology just towards welding high-speed and high-efficiency, welding control number
Change, the development of control system intelligent direction.
Pulse MIG Welding Power Source main circuit can be divided into hard switching and phase shifting full bridge soft switch form at present.Hard switching circuit function
Voltage and current understands some and overlaps during rate device turns on and off, and causes switching loss, leads to efficiency
It is low, electromagnetic pollution is brought, therefore each power device requires external snubber circuit, causes circuit many and diverse.Phase-shifting full-bridge
Soft switch circuit opens the stage using phase shifting control in switching tube, allows current lagging voltage, and zero electricity of power switch tube may be implemented
Press off it is logical, but exist at light load lagging leg be difficult to realize Sofe Switch；And secondary side rectifier diode can not achieve zero-current switching,
Switching loss is caused, there are reverse-recovery problems and ringing voltage spike is caused to be difficult to handle, deteriorates whole aircraft reliability, therefore secondary
Side rectifier diode needs external snubber circuit；When overloaded, secondary side duty-cycle loss caused by primary current is excessive is more
Add seriously, so that power supply energy is not fully utilized, and voltage ring is further exacerbated by.This greatly increases electric energy
Loss, do not catch up with more and require higher and higher energy-saving demand on Vehicles Collected from Market.
Compared with hard switching and phase shifting full bridge soft switch technology, LLC resonant converter not only has primary side MOSFET function
Rate switch tube zero voltage turn-on characteristics, while being able to achieve the zero-current switching and low resistance to pressure request of secondary side rectifier diode, secondary side
Rectifier diode zero-current switching overcomes reverse recovery loss, and the electromagnetic interference of generation is small, is easy to solve conduction and radiation problem,
And its power down Property comparison of holding time is good, is lost low, and transfer efficiency is higher.When LLC resonant converter work is in resonance frequency
When rate, gain and load unrelated, under this operating condition, the electric current of primary side is close to sinusoidal current, primary side MOSFET
(Metal-Oxide-Semiconductor Field-Effect Transistor, Metal-oxide-semicondutor field-effect are brilliant
Body pipe) power switch tube may be implemented that no-voltage is opened, zero-current switching may be implemented in secondary side rectifier diode, the function on former pair side
Rate device all obtains optimal utilization, and efficiency highest, electromagnetic interference is also minimum, and resonance frequency is the best work of LLC resonance circuit
Make a little.
Using the Pulse MIG Welding Power Source of LLC resonant converter topological structure, need using more estrade modules through Collaborative Control
For arc load power supply.More estrade modules will realize Collaborative Control, it is necessary to carry out data communication during the work time, generally use
The mode of CAN fieldbus Pulse by Pulse communication, but which design of hardware and software is complicated, it is at high cost, it is easy by external interference, no
Conducive to the stabilization of welding process.
It can be seen that the existing digital welding power source based on LLC resonant converter topological structure mainly have it is following several
The shortcomings that a aspect:
(1) structure is complicated.More estrade module control systems are mutually indepedent, between two control systems by communication protocol come
Carry out the Collaborative Control between data exchange realization submodule control system.Split type system structure is complicated, bulky, control
System hardware and software is complicated.
(2) system is not sufficiently stable.Split type control system is carried out data exchange by the way of communication protocol and realizes power supply
Between Collaborative Control, which be easy by external interference, be unfavorable for the stabilization of welding process.
Lack that a kind of structure is simple on the market at present, the Pulse MIG Welding Power Source system of system stability and high efficiency.Based on LLC's
Integrated Pulse MIG Welding Power Source system can realize the adjusting and current impulse of submodule control system by single control system
The Collaborative Control of phase, avoids drawbacks described above.
Summary of the invention
In order to overcome shortcoming and deficiency of the existing technology, the present invention provides a kind of integrated pulse MIC based on LLC
Weld power-supply system and its control method.
The purpose of the present invention is realized at least through following technical solution.
A kind of integrated Pulse MIG Welding Power Source system based on LLC, including three-phase alternating current input power grid, man-machine interface mould
Block, main control module, peak value of pulse module, pulse base value module and arc load；
The pulse base value module is made of a pulse base value submodule, and the peak value of pulse module is by several pulses
Peak value submodule composes in parallel, and the peak value of pulse submodule includes main circuit, drive module, failure protection module, voltage electricity
Flow detection module；The main control module includes DSP (Digital Signal Processor, digital signal processor) number
Change control module, the DSP Digital Control module respectively with failure protection module, drive module and measure voltage &
It is connected, the failure protection module and measure voltage & are connect with the input terminal of main circuit and output end respectively；
The main circuit include sequentially connected input rectifying filter module, LLC resonance modules, power transformer module and
Output rectification filter module, the input rectifying filter module are connect with three-phase alternating current input power grid, the output rectification filter
Module is connect with arc load；
The main control module is connected with pulse base value module and peak value of pulse module respectively, the main control module root
Drive module is controlled according to pulse sequence, to realize that the switch to pulse base value module and the fully loaded output of peak value of pulse module is cut
It changes, several submodules work at the same time output peak impulse voltage and pulse peak current, this rank in the peak value of pulse module
Section pulse base value module is without output；A submodule work output pulse base value voltage and pulse base in the pulse base value module
It is worth electric current, this stage pulse peak value module is without output, to guarantee that all submodule LLC resonance modules work in resonance frequency most
Good operating point.
DSP Digital Control module, the pulse base value module and peak value of pulse module are equipped in the main control module
In measure voltage & acquire the real-time voltage current signal of each submodule respectively, and by voltage and current sampled signal
It is sent into DSP Digital Control module by measure voltage &, each submodule is arranged in the DSP Digital Control module
Given value of current value, given value of current value generation departure compared with the real-time current value of feedback of each submodule, departure point
Output quantity, which is not obtained, after anti-integral is saturated PI algorithm adjusts pulse base value module and each submodule of peak value of pulse module respectively
PFM (Pulse Frequency Modulation, pulse frequency modulated).
The DSP Digital Control module uses TMS320F28335 digital signal processor, the Digital Signal Processing
Device embeds task manager, and the task manager has pulse frequency modulated unit, generates multichannel PFM letter by single DSP
It number realizes and the alternating of pulse base value module and peak value of pulse module is controlled.
The LLC resonance modules are made of inversion network and LLC resonant network, and the inversion network is by four power switch
Pipe and first capacitor are constituted；Four power switch tubes are MOSFET power switch tube, respectively the first power switch tube,
Second power switch tube, third power switch tube and the 4th power switch tube；The pole first power switch tube DS is respectively with
Two poles power switch tube D are connected with the pole third power switch tube D, the pole the second power switch tube DS respectively with the first power
The pole switching tube D is connected with the 4th pole power switch tube D, the pole third power switch tube DS respectively with the first power switch tube
The pole S is connected with the 4th power switch tube S pole, the pole the 4th power switch tube DS respectively with the second power switch tube S pole and
Third power switch tube S pole is connected.
The LLC resonant network includes resonant inductance, magnetizing inductance and resonant capacitance, the resonant inductance, magnetizing inductance,
Resonant capacitance and equivalent load are followed in series to form resonant cavity, and the equivalent load is by power transformer module, output rectification
Filter module and arc load are constituted.
The failure protection module include over-voltage detection circuit interconnected, undervoltage detection circuit, over-current detection circuit,
Excess temperature detection circuit and gate circuit.
The output rectification filter module includes the first rectifier diode, the second rectifier diode and the second capacitor.
The LLC resonance modules work in resonance frequency best operating point, work on four different operation modes:
The LLC resonance modules in the first operation mode, open by first power switch tube and the 4th power switch tube
Logical, the three-phase alternating current input power grid provides energy for resonant cavity, and resonance current flows through the first power switch tube and the 4th power
Switching tube, the electric current that transformer primary side is supplied to load are equal to resonance current and subtract exciting current, after exciting current is first negative just, change
Just lower negative on depressor secondary voltage, first rectifier diode is open-minded, the shutdown of the second rectifier diode, the magnetizing inductance quilt
Output voltage clamp, is not involved in resonant process, the exciting current linear rise；
The LLC resonance modules in the second operation mode, close by first power switch tube and the 4th power switch tube
Disconnected, the third power switch tube endobiosis output capacitance charge is zero by resonant cavity pumping, the 4th power switch tube body
Endoparasitism output capacitance charge is filled to supply voltage, and second power switch tube and third power switch by resonant cavity
Pipe parasitism anti-paralleled diode afterflow, the voltage between second power switch tube and the pole third power switch tube DS is zero,
Primary voltage of transformer dipole inversion, lower just upper negative, second rectifier diode starts open-minded, and magnetizing inductance is again by secondary side
Output voltage clamp, is not involved in resonant process；
The LLC resonance modules in third operation mode, open by second power switch tube and third power switch tube
Logical, voltage is zero between second power switch tube and the pole DS of third power switch tube, therefore second and third power is opened
Closing pipe is that no-voltage is open-minded, and exciting current is first just being born afterwards, and magnetizing inductance is not involved in resonance, exciting current linear decline, transformer
Under above bearing just, the shutdown of the first rectifier diode, the second rectifier diode are open-minded, and the second rectifier diode electric current declines after rising,
Condition is provided for subsequent work mode the first rectifier diode zero-current switching；
The LLC resonance modules in four operation modes, close by second power switch tube and third power switch tube
Disconnected, the 4th power switch tube endobiosis output capacitance charge is zero by resonant cavity pumping, the third power switch tube body
Endoparasitism output capacitance charge is filled to supply voltage, and first power switch tube and the 4th power switch by resonant cavity
Pipe parasitism anti-paralleled diode afterflow, the voltage between first power switch tube and the 4th pole power switch tube DS is zero,
The condition of offer is opened for first power switch tube and the 4th power switch tube no-voltage, is just born down on transformer, first is whole
Stream diode is opened, the second rectifier diode turns off, since the second rectifier diode electric current of a upper operation mode falls to zero,
So the second rectifier diode zero-current switching, the first rectifier diode electric current rises.
The output current phase of several submodules is adjusted in the pulse base value module and peak value of pulse module, increases
Mitigate power grid burden while high-power output.
Several submodules use parallel redundancy allocation plan in the pulse base value module and peak value of pulse module.
Power transformer module uses the transformation of different no-load voltage ratios in the pulse base value module and the peak value of pulse module
Device, the transformer of the difference no-load voltage ratio realize that the fully loaded output of pulse base value module low-voltage and peak value of pulse module high voltage are fully loaded
Output.
The main control module is communicated by CAN (Controller Area Network, CAN bus) and man-machine interface
Module is connected, and the human-computer interface module includes ARM (Advanced RISC Machines) chip and LCD screen.ARM chip
Human-computer interaction, real-time display and prison are realized as the control core of man-machine interface using 32 bit processor STM32F103ZET6
Control, improves the intelligence of system.
A kind of integrated Pulse MIG Welding Power Source control method based on LLC, the control method include the following steps:
1) after the source of welding current is communicated by initializing and with man-machine interface verifying, the source of welding current judges that arc welding gun switch is disconnected and closes,
It is performed the next step suddenly if arc welding gun switch closure, otherwise continues waiting for the instruction of human-computer interaction next time；
2) if arc welding gun switch is closed, advanced promoting the circulation of qi valve is supplied gas, then slow wire feed striking, and whether detection electric current is more than certain threshold
Value continues to repeat slow wire feed striking, and detect electric current if being less than threshold value, if being more than certain threshold value, enters pulse base value
Current constant control is flowed with the control of peak value switching sequence and pulse base value module constant current and peak value of pulse wired in parallel；
3) main control module is cut according to switch of the pulse sequence to pulse base value module and the fully loaded output of peak value of pulse module
It changes, when peak value of pulse output, several peak value of pulse submodules are worked at the same time, and export peak impulse voltage and peak value of pulse electricity
Stream, this stage pulse base value module is without output；When the output of pulse base value, a submodule job, defeated in pulse base value module
Pulse base value voltage and pulse background current out, this stage pulse peak value module is without output, to guarantee that all subsystem LLC are humorous
Vibration module work in resonance frequency best operating point, when working in resonance frequency best operating point, the gain of LLC resonance modules and
Load unrelated, primary current realizes that no-voltage is opened, secondary side rectifies two poles close to sinusoidal current, primary side MOSFET power switch tube
Pipe realizes zero-current switching.
Further, in the welding process, the source of welding current communicates with man-machine interface and constantly detects arc welding gun switch signal, when
After detecting welding gun cut-off signal, the source of welding current enters receipts arc and controls and send receipts arc signal, into the receipts arc stage.
Compared with the prior art, the invention has the following advantages:
(1) system structure is simple, and the present invention is by integrally realizing based on LLC resonant converter topological structure
Pulse MIG Welding Power Source system, eliminate that split type system structure is complicated, and bulky, control system software and hardware is complicated to be lacked
Point；
(2) strong antijamming capability, the unified pulse base value module to welding power source system of main control module in the present invention
It is controlled with peak value of pulse module, the configuration of the present invention is simple, meanwhile, control function is mainly realized by internal algorithm, is solved
Separated type pulse MIG weldering power control system subsystem, which is in communication with each other, is easy the problem of being disturbed；
(3) present invention uses LLC harmonic technology, realizes the Sofe Switch of gamut, greatly reduces the switch of power tube
Loss and electric stress, improve operating condition, reduce electromagnetic interference, improve overall efficiency.
Detailed description of the invention
Fig. 1 is electrical block diagram of the invention；
Fig. 2 is main circuit schematic diagram of the invention；
Fig. 3 is that peak value of pulse module of the present invention communicates with human-computer interface module with pulse base value module and main control module and shows
It is intended to；
Fig. 4 is drive module schematic diagram of the invention；
Fig. 5 is pulse period timing diagram of the invention；
Fig. 6 is DSP Digital Control module flow diagram of the invention.
Wherein: 1- peak value of pulse module, 2- pulse base value module, 10- peak value of pulse submodule, 20- pulse base value submodule
Block, 101- main control module, 102- failure protection module, 103- drive module, 104- input rectifying filter module, 105-LLC
Resonance modules, 106- power transformer module, 107- output rectification filter module, 108- measure voltage &, 110- tri-
Mutually exchange input power grid, 200- human-computer interface module, 300- arc load.
Specific embodiment
Below with reference to examples and drawings, the present invention is described in further detail, but embodiments of the present invention are not
It is limited to this.
As shown in Figure 1, a kind of integrated Pulse MIG Welding Power Source system based on LLC, including three-phase alternating current input power grid
110, human-computer interface module 200, main control module 101, peak value of pulse module 1, pulse base value module 2 and arc load 300；
The peak value of pulse module 1 includes several peak value of pulse submodules 10, and the pulse base value module 2 includes one
Pulse base value submodule 20, the peak value of pulse submodule 10 and pulse base value submodule 20 include main circuit, drive module
103, failure protection module 102, measure voltage & 108；The main control module 101 includes DSP Digital Control mould
Block, the DSP Digital Control module respectively with each sub-module fault protective module 102, drive module 103 and voltage and current
Detection module 108 is connected, and the failure protection module 102 is connect with the input terminal of main circuit；The measure voltage & current mould
Block 108 is connect with the output end of main circuit；
The main circuit includes sequentially connected input rectifying filter module 104, LLC resonance modules 105, power transformer
Module 106 and output rectification filter module 107, the input rectifying filter module 104 connect with three-phase alternating current input power grid 110
It connects, the output rectification filter module 107 is connect with arc load 300；
The main control module 101 is connected with pulse base value module 2 and peak value of pulse module 1 respectively, the main control
Module 101 controls drive module 103 according to pulse sequence, to realize fully loaded to pulse base value module 2 and peak value of pulse module 1
The switching of output, several submodules work at the same time output peak impulse voltage and pulse in the peak value of pulse module 1
Peak point current, this stage pulse base value module 2 is without output；Submodule work output pulse base in the pulse base value module 2
Threshold voltage and pulse background current, this stage pulse peak value module 1 is without output.
DSP Digital Control module, the pulse base value module 2 and peak value of pulse are equipped in the main control module 101
Measure voltage & 108 in module 1 acquires the real-time voltage current signal of respective submodule respectively, and by voltage and current
Sampled signal is sent into DSP Digital Control module, and the given value of current of each submodule is arranged in the DSP Digital Control module
Value, given value of current value generation departure compared with the real-time current value of feedback of each submodule, departure is respectively through anti-integral
The PFM that output quantity adjusts each submodule in pulse base value module 2 and peak value of pulse module 1 respectively is obtained after saturation PI algorithm.
The DSP Digital Control module uses TMS320F28335 digital signal processor, the Digital Signal Processing
Device embeds task manager, and the task manager has pulse frequency modulated unit, generates multichannel PFM letter by single DSP
It number realizes and the alternating of pulse base value module 2 and peak value of pulse module 1 is controlled.
As shown in Fig. 2, the LLC resonance modules 105 include inversion network and LLC resonant network, the inversion network packet
Include four power switch tubes and first capacitor；Four power switch tubes are MOSFET pipe, respectively the first power switch
Pipe, the second power switch tube, third power switch tube and the 4th power switch tube.
The LLC resonant network includes resonant inductance, magnetizing inductance and resonant capacitance, the resonant inductance, magnetizing inductance,
Resonant capacitance and equivalent load constitute resonant cavity together, and the resonant inductance, magnetizing inductance, resonant capacitance are connected by series system
It connects, the equivalent load includes power transformer module 106, output rectification filter module 107 and arc load 300.
The failure protection module 102 includes over-voltage detection circuit interconnected, undervoltage detection circuit, over-current detection electricity
Road, excess temperature detection circuit and gate circuit.
The output rectification filter module 107 includes the first rectifier diode D1, the second rectifier diode D2With the second capacitor
C2。
The LLC resonance modules 105 include inversion network and LLC resonant network, and the inversion network includes four power
Switching tube and first capacitor C1；Four power switch tubes are high-voltage MOSFET pipe, respectively the first power switch tube V1、
Second power switch tube V2, third power switch tube V3With the 4th power switch tube V4。
Four power switch tubes provide the alternating control of PFM frequency variation signal by drive module 103 and turn on and off, described
First power switch tube V1With the 4th power switch tube V4, while opening and simultaneously turning off, the second power switch tube V2And third
Power switch tube V3, while opening and simultaneously turning off, and V1With V4And V2With V3Alternating turns on and off, two power of same bridge arm
Switching tube V1With V3Between and V2With V4Between there are dead time, the LLC resonant network includes resonant inductance Lr, magnetizing inductance
LmWith resonant capacitance Cr, the resonant inductance Lr, magnetizing inductance Lm, resonant capacitance CrResonant cavity is formed together with equivalent load.
Transformer refers to power transformer module 106 in the present embodiment, wherein pulse base value module 2 and peak value of pulse mould
Transformer of the power transformer module 106 using different no-load voltage ratios, the transformer realization pulse base value mould of the difference no-load voltage ratio in block 1
The fully loaded output of 2 low-voltage of block and the fully loaded output of 1 high voltage of peak value of pulse module.
The LLC resonance modules 105 work in resonance frequency best operating point, work in four different operation modes
On.
The LLC resonance modules 105 are in the first operation mode, the first power switch tube V1With the 4th power switch
Pipe V4Open-minded, the three-phase alternating current input power grid provides energy for resonant cavity, and resonance current flows through the first power switch tube V1With
Four power switch tube V4, the electric current that transformer primary side is supplied to load is equal to resonance current and subtracts exciting current, and exciting current is first
After negative just, just lower negative, the first rectifier diode D on the transformer secondary voltage1It is open-minded, the second rectifier diode D2It closes
It is disconnected, the magnetizing inductance LmIt is clamped by output voltage, is not involved in resonant process, the exciting current linear rise.
The LLC resonance modules 105 are in the second operation mode, the first power switch tube V1With the 4th power switch
Pipe V4Shutdown, the third power switch tube V3Endobiosis output capacitance charge is zero by resonant cavity pumping, and the 4th power is opened
Close pipe V4Endobiosis output capacitance charge is filled to supply voltage, and the second power switch tube V by resonant cavity2With
Three power switch tube V3Parasitic anti-paralleled diode afterflow, the second power switch tube V2With third power switch tube V3DS
Voltage between pole is zero, to realize the second power switch tube V2With third power switch tube V3No-voltage, which is opened, to be created condition,
The primary voltage of transformer dipole inversion, lower just upper negative, the second rectifier diode D2Start open-minded, magnetizing inductance LmWeight
It is newly clamped by secondary side output voltage, is not involved in resonant process.
The LLC resonance modules 105 are in third operation mode, the second power switch tube V2With third power switch
Pipe V3Open-minded, voltage is zero between described second and the pole DS of third power switch tube, therefore the second power switch tube V2And third
Power switch tube V3It is that no-voltage is open-minded, exciting current is first just being born afterwards, and magnetizing inductance is not involved in resonance, under exciting current is linear
It drops, under being born on transformer just, the first rectifier diode D1Shutdown, the second rectifier diode D2It is open-minded, the second rectifier diode D2Electricity
Stream declines after rising, and is the second rectifier diode of subsequent work mode D2Zero-current switching provides condition.
The LLC resonance modules 105 are in four operation modes, the second power switch tube V2With third power switch
Pipe V3Shutdown, the 4th power switch tube V4Endobiosis output capacitance charge is zero by resonant cavity pumping, and the third power is opened
Close pipe V3Endobiosis output capacitance charge is filled to supply voltage, and the first power switch tube V by resonant cavity1With
Four power switch tube V4Parasitic anti-paralleled diode afterflow is the first power switch tube V1With the 4th power switch tube V4Zero
Voltage opens offer condition, just lower negative, the first rectifier diode D on transformer1It opens, the second rectifier diode D2Shutdown, due to
Second rectifier diode D of a upper operation mode2Electric current falls to zero, so the second rectifier diode D1Zero-current switching, first
Rectifier diode D1Electric current rises.
As shown in figure 3, several peak value of pulse submodules 10 and pulse base value submodule 20 with 101 phase of main control module
Even, the main control module 101 is connected by CAN fieldbus with human-computer interface module 200.101 basis of main control module
Pulse sequence realizes the switching to pulse base value submodule 20 and the fully loaded output of peak value of pulse submodule 10.The pulse peak
The sinusoidal current phase of 1 several submodules of value module is adjusted, and mitigates power grid burden while increasing power output.It is described
Human-computer interface module 200 includes ARM chip and LCD screen.ARM chip uses 32 bit processor STM32F103ZET6, as man-machine
The control core at interface realizes human-computer interaction, real-time display and monitoring, improves the intelligence of system.
Fig. 4 is the MOSFET full-bridge LLC drive module schematic diagram in the present invention.103 primary side of drive module uses high speed
MOSFET N1b~N4bThe totem pillar pushing structure of composition, can be to the driving pulse that DSP Digital Control module sends over
PFM_1 and PFM_2 realization is switched fast and increases driving power.The secondary side of drive module 103 uses voltage-stabiliser tube D9b~D10b、D16b
~D17b、D23b~D24b、D30b~D31bPressure stabilizing clamper is carried out to driving pulse, to prevent by driving transformer T1bAnd T2bConversion
The excessively high damage converter primary side translation circuit high-voltage MOSFET V of obtained driving pulse amplitude1~V4；Capacitor C7b~C10bTo height
Press MOSFET V1~V4Carry out acceleration driving, with eliminate as far as possible open moment MOSFET the Miller effect bring open delay it is unfavorable
It influences；D13bWith V1b、D20bWith V2b、D27bWith V3b、D34bWith V4bThe repid discharge circuit of composition can add in the driving pulse turn-off time
Fast pulse back edge shutdown is eliminated secondary open-minded caused by shutdown moment MOSFET the Miller effect.
It is pulse period timing diagram of the invention shown in Fig. 5.One pulse period includes 2 stages: peak value of pulse TpRank
Section and pulse base value TbStage.The main control module 101 is according to pulse sequence to pulse base value module 2 and peak value of pulse module
The switching of 1 fully loaded output.Peak value of pulse TpWhen stage exports, several submodules are worked at the same time in peak value of pulse module 1,
Peak impulse voltage and pulse peak current are exported, this stage pulse base value module 2 is without output；Pulse base value TbWhen stage exports
Only 2 one submodules 20 of pulse base value module work, and export pulse base value voltage and pulse background current, this stage pulse peak
It is worth module 1 without output, to guarantee that all submodule LLC resonance modules 105 work in resonance frequency best operating point.It works in
When resonance frequency best operating point, the gains of LLC resonance modules 105 and load unrelated, primary current is close to sinusoidal current, primary side
MOSFET power switch tube may be implemented that no-voltage is opened, zero-current switching may be implemented in secondary side rectifier diode, former pair side
Power device all obtains optimal utilization, efficiency highest, and electromagnetic interference is also minimum.
A kind of integrated Pulse MIG Welding Power Source system based on LLC, the control method includes step as shown in FIG. 6
It is rapid:
1) DSP and power-supply system are by initialization, and main control module with after man-machine interface CAN communication, weld by source of welding current judgement
Rifle switch is disconnected to be closed, and is performed the next step suddenly if arc welding gun switch closure, and the instruction of human-computer interaction next time is otherwise continued waiting for；
2) it carries out air valve to supply gas, into striking control process: slow wire feed striking, whether detection electric current I is more than certain threshold value
(60A) continues to repeat slow wire feed striking, and detect electric current if being less than threshold value, if being more than certain threshold value, enters pulse
Base value and the control of peak value switching sequence；And carry out 1 parallel current-sharing constant current control of 2 constant current of pulse base value module and peak value of pulse module
System；
3) main control module 101 is realized according to pulse sequence to pulse base value module 2 and the fully loaded output of peak value of pulse module 1
Switching, when peak value of pulse output, several submodules are worked at the same time in peak value of pulse module 1, export peak value of pulse
Voltage and pulse peak current, this stage pulse base value module 2 is without output；When the output of pulse base value, in pulse base value module 2
One submodule 20 works, and exports pulse base value voltage and pulse background current, this stage pulse peak value module 1 without output, from
And guarantee that all submodule LLC resonance modules 105 work in resonance frequency best operating point, work in resonance frequency best effort
When point, the gains of LLC resonance modules 105 and load unrelated, primary current is close to sinusoidal current, primary side MOSFET power switch tube
Realize that no-voltage is opened, secondary side rectifier diode realizes zero-current switching.
In the welding process, the source of welding current communicates with man-machine interface and constantly detects arc welding gun switch signal, welds when detecting
After rifle cut-off signal, the source of welding current enters receipts arc and controls and send receipts arc signal, controls the stage into arc is received, the A in Fig. 6 is indicated
The turnover of flow chart marks.
The above embodiment is a preferred embodiment of the present invention, but embodiments of the present invention are not by the embodiment
Limitation, other any changes, modifications, substitutions, combinations, simplifications made without departing from the spirit and principles of the present invention,
It should be equivalent substitute mode, be included within the scope of the present invention.
Claims (10)
1. the integrated Pulse MIG Welding Power Source system based on LLC, which is characterized in that input power grid, main control including three-phase alternating current
Module, peak value of pulse module, pulse base value module and arc load；
The peak value of pulse module includes several peak value of pulse submodules, and the pulse base value module includes a pulse base value
Submodule, the pulse base value submodule and peak value of pulse submodule include main circuit, drive module, failure protection module,
Measure voltage &；The main control module includes DSP Digital Control module, the DSP Digital Control module point
It is not connected with each sub-module fault protective module, drive module and measure voltage &, the failure protection module
It is connect with the input terminal of main circuit；The connection of the output end of the measure voltage & and main circuit；
The main circuit includes sequentially connected input rectifying filter module, LLC resonance modules, power transformer module and output
Rectification filtering module, the input rectifying filter module are connect with three-phase alternating current input power grid, the output rectification filter module
It is connect with arc load；
The main control module is connected with pulse base value module and peak value of pulse module respectively, and the main control module is according to arteries and veins
Timing control drive module is rushed, to realize the switching to pulse base value module and the fully loaded output of peak value of pulse module, institute
It states several submodules in peak value of pulse module and works at the same time output peak impulse voltage and pulse peak current, this stage pulse
Base value module is without output；Submodule work output pulse base value voltage and pulse background current in the pulse base value module,
This stage pulse peak value module is without output；
DSP Digital Control module is equipped in the main control module, in the pulse base value module and peak value of pulse module
Measure voltage & acquires the real-time voltage current signal of respective submodule respectively, and voltage and current sampled signal is sent into
The given value of current value of each submodule, the given value of current is arranged in DSP Digital Control module, the DSP Digital Control module
Value generation departure compared with the real-time current value of feedback of each submodule, departure obtain after anti-integral is saturated PI algorithm respectively
Adjust the PFM of each submodule in pulse base value module and peak value of pulse module respectively to output quantity.
2. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1, which is characterized in that described
DSP Digital Control module uses TMS320F28335 digital signal processor, and the digital signal processor embeds event pipe
Device is managed, the task manager has pulse frequency modulated unit, generates multichannel PFM signal by single DSP and realizes to pulse
The control of the alternating of base value module and peak value of pulse module.
3. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1, which is characterized in that described
LLC resonance modules include inversion network and LLC resonant network, and the inversion network includes four power switch tubes and the first electricity
Hold；Four power switch tubes are MOSFET pipe, respectively the first power switch tube, the second power switch tube, third function
Rate switching tube and the 4th power switch tube；The pole first power switch tube DS respectively with the second pole power switch tube D and third
The pole power switch tube D is connected, and the pole the second power switch tube DS is opened with the first pole power switch tube D and the 4th power respectively
Close the pole pipe D be connected, the pole third power switch tube DS respectively with the first power switch tube S pole and the 4th power switch tube S
Pole is connected, the pole the 4th power switch tube DS respectively with the second power switch tube S pole and third power switch tube S pole phase；
The LLC resonant network includes resonant inductance, magnetizing inductance and resonant capacitance, the resonant inductance, magnetizing inductance, resonance
Capacitor and equivalent load are followed in series to form resonant cavity, and the equivalent load includes power transformer module, output rectification filter
Module and arc load.
4. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1, which is characterized in that described
Failure protection module includes over-voltage detection circuit interconnected, undervoltage detection circuit, over-current detection circuit, excess temperature detection circuit
And gate circuit；The output rectification filter module includes the first rectifier diode, the second rectifier diode and the second capacitor.
5. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1 or 3, which is characterized in that
The LLC resonance modules work in resonance frequency best operating point, work on four different operation modes:
For the LLC resonance modules in the first operation mode, first power switch tube and the 4th power switch tube are open-minded, institute
It states three-phase alternating current input power grid and provides energy for resonant cavity, resonance current flows through the first power switch tube and the 4th power switch
Pipe, the electric current that transformer primary side is supplied to load are equal to resonance current and subtract exciting current, after exciting current is first negative just, transformer
Just lower negative on secondary voltage, first rectifier diode is open-minded, and the second rectifier diode shutdown, the magnetizing inductance is exported
Voltage clamp is not involved in resonant process, the exciting current linear rise；
The LLC resonance modules are in the second operation mode, first power switch tube and the shutdown of the 4th power switch tube, institute
It is zero that third power switch tube endobiosis output capacitance charge, which is stated, by resonant cavity pumping, the 4th power switch tube endobiosis
Output capacitance charge is filled to supply voltage by resonant cavity, and second power switch tube and third power switch tube are parasitic
Anti-paralleled diode afterflow, the voltage between second power switch tube and the pole third power switch tube DS is zero, transformer
Original edge voltage dipole inversion, lower just upper negative, second rectifier diode starts open-minded, and magnetizing inductance exports electricity by secondary side again
Pressure clamp, is not involved in resonant process；
For the LLC resonance modules in third operation mode, second power switch tube and third power switch tube are open-minded, institute
Stating voltage between the second power switch tube and the pole DS of third power switch tube is zero, therefore second and third power switch tube is
No-voltage is open-minded, and exciting current is first just being born afterwards, and magnetizing inductance is not involved in resonance, exciting current linear decline, under bearing on transformer
Just, the shutdown of the first rectifier diode, the second rectifier diode are open-minded, and the second rectifier diode electric current declines after rising, and are next
Operation mode the first rectifier diode zero-current switching provides condition；
The LLC resonance modules are in four operation modes, second power switch tube and the shutdown of third power switch tube, institute
It is zero that the 4th power switch tube endobiosis output capacitance charge, which is stated, by resonant cavity pumping, the third power switch tube endobiosis
Output capacitance charge is filled to supply voltage by resonant cavity, and first power switch tube and the 4th power switch tube are parasitic
Anti-paralleled diode afterflow, it is described that the voltage between first power switch tube and the 4th pole power switch tube DS, which is zero,
First power switch tube and the 4th power switch tube no-voltage open offer condition, just lower negative, the first two poles of rectification on transformer
Pipe is opened, the second rectifier diode turns off, since the second rectifier diode electric current of a upper operation mode falls to zero, so the
Two rectifier diode zero-current switchings, the first rectifier diode electric current rise.
6. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1, which is characterized in that described
Several submodules and pulse base value module output current phase in peak value of pulse module are adjusted, and increase power output
Mitigate power grid burden simultaneously.
7. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1, which is characterized in that described
Several submodules and pulse base value module in peak value of pulse module are configured using parallel redundancy, the pulse base value module and
Power transformer module in the peak value of pulse module uses the transformer of different no-load voltage ratios, and the transformer of the difference no-load voltage ratio is real
The existing fully loaded output of pulse base value module low-voltage and the fully loaded output of peak value of pulse module high voltage.
8. a kind of integrated Pulse MIG Welding Power Source system based on LLC according to claim 1, which is characterized in that also wrap
Human-computer interface module is included, the main control module is connected by CAN communication with human-computer interface module, the human-computer interface module
Including ARM chip and LCD screen；The ARM chip uses 32 bit processor STM32F103ZET6.
9. a kind of integrated Pulse MIG Welding Power Source control method based on LLC, which is characterized in that the control method includes
Following steps:
1) after the source of welding current is communicated by initializing and with man-machine interface verifying, the source of welding current judges that arc welding gun switch is disconnected and closes, if weldering
Rifle closes the switch, and performs the next step suddenly, otherwise continues waiting for the instruction of human-computer interaction next time；
2) if arc welding gun switch is closed, advanced promoting the circulation of qi valve is supplied gas, then slow wire feed striking, and whether detection electric current is more than certain threshold value,
If being less than threshold value, continue to repeat slow wire feed striking, and detect electric current, if being more than certain threshold value, enter pulse base value and
The control of peak value switching sequence and pulse base value module constant current and peak value of pulse wired in parallel flow current constant control；
3) main control module is fully loaded with the switching of output according to pulse sequence to pulse base value module and peak value of pulse module, when
When peak value of pulse exports, several peak value of pulse submodules are worked at the same time, and export peak impulse voltage and pulse peak current, this
Stage pulse base value module is without output；When the output of pulse base value, a submodule job, exports pulse in pulse base value module
Base value voltage and pulse background current, this stage pulse peak value module is without output, to guarantee all subsystem LLC resonance modules
Resonance frequency best operating point is worked in, when working in resonance frequency best operating point, the gain and load nothing of LLC resonance modules
It closes, primary current realizes that no-voltage is opened, secondary side rectifier diode is realized close to sinusoidal current, primary side MOSFET power switch tube
Zero-current switching.
10. a kind of integrated Pulse MIG Welding Power Source control method based on LLC according to claim 9, feature exist
In, in the welding process, the source of welding current communicated with man-machine interface and constantly detection arc welding gun switch signal, when detect welding gun disconnect
After signal, the source of welding current enters receipts arc and controls and send receipts arc signal, into the receipts arc stage.
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