CN112894095A - Digital underwater welding power supply capable of outputting multiple external characteristics and working method thereof - Google Patents

Digital underwater welding power supply capable of outputting multiple external characteristics and working method thereof Download PDF

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Publication number
CN112894095A
CN112894095A CN202110028990.XA CN202110028990A CN112894095A CN 112894095 A CN112894095 A CN 112894095A CN 202110028990 A CN202110028990 A CN 202110028990A CN 112894095 A CN112894095 A CN 112894095A
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module
voltage
output
current
constant
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CN112894095B (en
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江平
石永华
詹家通
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South China University of Technology SCUT
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South China University of Technology SCUT
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/24—Features related to electrodes
    • B23K9/28—Supporting devices for electrodes
    • B23K9/287—Supporting devices for electrode holders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/32—Accessories
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/02—Conversion of ac power input into dc power output without possibility of reversal
    • H02M7/04—Conversion of ac power input into dc power output without possibility of reversal by static converters
    • H02M7/06—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes without control electrode or semiconductor devices without control electrode
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • H02M7/5387—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration
    • H02M7/53871—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration with automatic control of output voltage or current
    • H02M7/53873—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration with automatic control of output voltage or current with digital control
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • H02M7/539—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters with automatic control of output wave form or frequency
    • H02M7/5395—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters with automatic control of output wave form or frequency by pulse-width modulation

Abstract

The invention provides a digital underwater welding power supply capable of outputting multiple external characteristics and a working method thereof. According to the invention, by detecting the real-time working condition of underwater welding, the ARM microcontroller is triggered to switch in real time among different external characteristics such as constant-current external characteristics, constant-voltage external characteristics and constant-power external characteristics, so that the welding quality is ensured to achieve the best effect. The invention adopts a single ARM microcontroller to replace complex analog control, simplifies the structure of a control system, can effectively reduce the volume of the welding power supply, has higher software programming flexibility, and can increase the versatility of the welding power supply.

Description

Digital underwater welding power supply capable of outputting multiple external characteristics and working method thereof
Technical Field
The invention relates to the technical field of welding, in particular to a digital underwater welding power supply capable of outputting multiple external characteristics and a working method thereof.
Background
The environment for underwater welding is more demanding than land and therefore the requirements for welding power are also higher. Because arc striking and welding are carried out in water, even if a large amount of gas-making agent and arc stabilizer are added into the welding rod, arc striking is still difficult, so that higher welding current is needed in an arc striking stage, and the output of a power supply needs to keep constant current external characteristics. During underwater welding, the welding power supply needs to maintain the external characteristic of constant power in the welding stage because the pressure of water and the growth-rupture of bubbles have influence on the stability of electric arcs, so as to ensure the stability of the welding process.
At present, a common land welding power supply is adopted for underwater welding, the external characteristics of the land welding power supply are single, a control system is composed of analog devices, real-time conversion control of the external characteristics of power output cannot be realized through a software algorithm, and the land welding power supply cannot be flexibly converted according to actual requirements. In addition, for the control of the external characteristics of the existing welding power supply, a feedback system of the existing welding power supply is mostly controlled by adopting an analog device, when welding underwater, the performance of the existing welding power supply can be changed according to different underwater working environments (temperature, humidity, depth and the like), the response speed is low, the precision is low, and the analog device can be aged along with the time.
Disclosure of Invention
In order to solve the above technical problems, a first object of the present invention is to provide a digital underwater welding power source capable of outputting multiple external characteristics, which solves the problem of single external characteristic output of the conventional underwater welding power source.
The second purpose of the invention is to provide a working method of the digital underwater welding power supply capable of outputting multiple external characteristics.
The first purpose of the invention is realized by the following technical scheme: a digitized underwater welding power supply capable of outputting multiple external characteristics, comprising: the power supply comprises an EMC module, an input rectifier bridge module, an inversion module, a step-down transformer module, an output rectifier filter module, a current and voltage feedback module, an ARM microcontroller module, a PAC module, a driving module and an auxiliary power supply module;
the EMC module, the input rectifier bridge module, the inversion module, the step-down transformer module and the output rectifier filter module are sequentially connected and used as a forward path of a main circuit of the welding power supply, and the output end of the output rectifier filter module is connected to a load; the input end of the EMC module is connected with alternating current on the side of a power grid, the rectifier bridge module is used for rectifying the alternating current on the side of the power grid passing through the EMC module into high-voltage direct current, the inversion module is used for converting the high-voltage direct current into square wave alternating current, the step-down transformer is used for stepping down the square wave alternating current, and the output rectifier filter module is used for converting the stepped-down square wave alternating current into low-voltage direct current and transmitting the low-voltage;
the output end of the output rectifying and filtering module is also connected to the input end of the current-voltage feedback module, the output end of the current-voltage feedback module, the ARM microcontroller module, the PAC module and the driving module are sequentially connected, and the output end of the driving module is connected with the inversion module; the current and voltage feedback module is used for collecting the current and voltage of the load and feeding the current and voltage back to the ARM microcontroller module; the ARM microcontroller module is used for generating PWM pulse waves for realizing different external characteristic outputs according to the current and the voltage of a load; the PAC module is used for generating corresponding voltage signals to the driving module according to the PWM pulse waves for realizing different external characteristic outputs; the driving module is used for generating corresponding PWM pulses according to the voltage signals sent by the PAC module and sending the PWM pulses to the inversion module;
the output end of the EMC module is connected with the auxiliary power supply module, and the auxiliary power supply module is connected with the input rectifier bridge module, the inversion module, the step-down transformer module, the output rectifier filter module, the current and voltage feedback module, the ARM microcontroller module, the PAC module and the drive module and supplies power to the modules.
Preferably, the ARM microcontroller compares the current and voltage values of the load with set values, and operates an external characteristic closed-loop program control algorithm after obtaining the deviation, so as to obtain PWM pulse waves for realizing different external characteristic outputs, wherein the external characteristic outputs comprise constant-current external characteristic outputs, constant-voltage external characteristic outputs and constant-power external characteristic outputs, and the duty ratios of the PWM pulse waves for realizing different external characteristic outputs are different; the external characteristic closed-loop program control algorithm comprises a constant current PI algorithm, a constant voltage PI algorithm and a constant power PI algorithm.
Preferably, the ARM microcontroller module generates PWM pulse waves with adjustable duty ratios of 0-100%, the PAC module correspondingly outputs voltage signals of 0-10V, and the driving module correspondingly outputs the PWM pulse waves with adjustable duty ratios of 0-50%.
Furthermore, the inversion module is provided with two pairs of IGBT bridge switches, the driving module outputs PWM pulse waves with adjustable duty ratio of 0-50% and respectively sends the PWM pulse waves to the corresponding IGBT switch tubes, and the voltage and the current output by the digital underwater welding power supply are determined by the PWM duty ratio of the IGBT switch tubes.
Preferably, the PAC module includes an optocoupler and a PAC chip, the optocoupler is connected with the ARM microcontroller module through a light emitting diode inside the optocoupler, the optocoupler is connected with the PAC chip through a light detector inside the optocoupler, and the PAC chip is connected with the driving module.
Preferably, the auxiliary power module comprises a transformer and a voltage stabilizing chip, the input end of the transformer is connected with the EMC module, the output end of the transformer is connected with the voltage stabilizing chip, and the voltage stabilizing chip is connected with the input rectifier bridge module, the inversion module, the step-down transformer module, the output rectifier filter module, the current and voltage feedback module, the ARM microcontroller module, the PAC module and the driving module.
The second purpose of the invention is realized by the following technical scheme: the invention relates to a working method of a digitalized underwater welding power supply capable of outputting multiple external characteristics, which comprises the following steps:
s1, connecting the welding gun to the output end of the output rectifying and filtering module, connecting the EMC module to the alternating current on the side of the power grid, and supplying power to other modules by the auxiliary power supply module after the digitalized underwater welding power supply is powered on;
s2, initializing the ARM microcontroller module, continuously and circularly judging whether a welding gun switch is closed, and continuously and circularly detecting the on-off state of the welding gun if the welding gun switch is not closed; if the welding gun switch is closed, the step S3 is carried out;
s3, after the welding gun switch is closed, the ARM microcontroller module starts to execute arc striking control, so that the output rectifying and filtering module starts to output constant current external characteristics;
then, the ARM microcontroller module takes the load current collected by the current and voltage feedback module as a current sampling feedback value, calculates the PWM output duty ratio according to the current sampling feedback value and a given value, and then judges whether the arc striking is successful, wherein the arc striking success standard is that the current duration time of the power supply outputting more than 400A is as long as 5S, and if the power supply cannot continuously output the current of 400A for 5S, the arc striking failure is represented; if the arc striking is not successful, continuing to execute arc striking control; if the arc striking is successful, the step S4 is entered;
s4, after arc striking is successful, the ARM microcontroller module detects the welding condition in real time through the current and voltage feedback module, selects an external characteristic mode suitable for the current welding condition to output, and if the constant current external characteristic output is selected, the ARM microcontroller module performs constant current output control; if the constant voltage external characteristic output is selected, the ARM microcontroller module performs constant voltage output control; if the constant power external characteristic output is selected, the ARM microcontroller module performs constant power output control;
s5, after the ARM microcontroller module executes constant current, constant voltage or constant power output control, the on-off state of the welding gun is judged in real time, if the welding gun is continuously closed, the step S4 is returned to continuously detect the welding condition, and which external characteristic is selected for output is judged; if the welding gun switch is disconnected, arc-closing control is executed, so that the output rectifying and filtering module outputs the constant-voltage external characteristic;
then, the ARM microcontroller module judges whether arc-off is finished or not, and if the arc-off is finished, the current and voltage output of the output rectifying and filtering module is closed; and if the arc-closing is not finished, continuing to execute arc-closing control.
Preferably, in step S3, the ARM microcontroller module calls a constant current PI algorithm subroutine to perform arc ignition control, so that the output rectifying and filtering module starts constant current external characteristic output;
in step S4, if the constant current external characteristic output is selected, the ARM microcontroller module calls the constant current PI algorithm subroutine and performs constant current output control;
the process of calling the constant current PI algorithm subprogram by the ARM microcontroller module to carry out constant current output control is as follows:
firstly, reading a current sampling feedback value and assigning the current sampling feedback valueValue to variable IfThen calculating the feedback value and the given value IgThe deviation between the two is amplified by a certain multiple to obtain an amplified deviation eC；
Subsequently using the deviation eCPerforming PI operation to obtain a duty ratio U-KP*eC+RC，KPProportionality factor, R, set for ARM microcontroller moduleCThe integral compensation quantity calculated for the ARM microcontroller module; to prevent overflow of the calculated duty cycle U, U is compared with the minimum duty cycle UminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen get the voltage uCCorresponding to the value U for the minimum duty ratiominOtherwise, executing the next step and judging U>＝UmaxWhether the result is true or not; if U is present>＝UmaxIf it is true, take uCIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switching tube in the reverse transformation prevention module is prevented from being directly communicated; if U is present>＝UmaxIf not, execute uC＝U；
And then updating the integral compensation R for calculating the duty ratio next timeCThen, according to the original magnification factor, uCAnd reducing to restore the calculation result so as to obtain an actual voltage value, and assigning the actual voltage value to a comparison register for updating the PWM duty ratio.
Preferably, in step S4, if the constant voltage external characteristic output is selected, the ARM microcontroller module calls the constant voltage PI algorithm subroutine and performs constant voltage output control;
in step S5, the ARM microcontroller module invokes a constant voltage PI algorithm subroutine to perform arc extinguishing control, so that the output rectifying and filtering module outputs the constant voltage external characteristic;
the process of calling the constant voltage PI algorithm subprogram by the ARM microcontroller module to carry out constant voltage output control is as follows:
firstly, reading a voltage sampling feedback value and assigning the value to a variable UfThen calculating the feedback value and the given value UgThe deviation between the two is amplified by a certain multiple to obtain an amplified deviation eV；
Subsequently using the deviation eVPerforming PI operation to obtain a duty ratio U-KP*eV+RV，KPProportionality factor, R, set for ARM microcontroller moduleVThe integral compensation quantity calculated for the ARM microcontroller module; to prevent overflow of the calculated duty cycle U, U is compared with the minimum duty cycle UminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen get the voltage uVCorresponding to the value U for the minimum duty ratiominOtherwise, executing the next step and judging U>＝UmaxWhether the result is true or not; if U is present>＝UmaxIf it is true, take uVIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switching tube in the reverse transformation prevention module is prevented from being directly communicated; if U is present>＝UmaxIf not, execute uV＝U；
And then updating the integral compensation R for calculating the duty ratio next timeVThen, according to the original magnification factor, uVAnd reducing to restore the calculation result so as to obtain an actual voltage value, and assigning the actual voltage value to a comparison register for updating the PWM duty ratio.
Preferably, in step S4, if the constant power external characteristic output is selected, the ARM microcontroller module calls the constant power PI algorithm subroutine and performs constant power output control;
the process of calling the constant power PI algorithm subprogram by the ARM microcontroller module to carry out constant power output control is as follows:
firstly, reading a current sampling feedback value and a voltage sampling feedback value and respectively assigning the values to a variable IfAnd UfJudgment of UfAnd constant UdIf U is the size off>UdIf yes, calculating a voltage given value according to a constant power formula, and executing constant voltage external characteristic output under the condition of keeping the output power constant;
if U is presentf>UdIf the output power is not the same, the current given value is calculated according to a constant power formula, and constant current external characteristic output is executed under the condition that the output power is kept constant.
Compared with the prior art, the invention has the following advantages and beneficial effects:
(1) compared with the traditional welding power supply, the digital underwater welding power supply provided by the invention is provided with the feedback control system taking the ARM as the control core, and the output of different external characteristics of the welding power supply under different working conditions, including a constant-current external characteristic, a constant-voltage external characteristic and a constant-power external characteristic, is realized in a software programming mode, so that the digital underwater welding power supply has the advantages of flexibility in control, high response speed and high adjustment precision.
(2) The digital underwater welding power supply adopts a single ARM microcontroller to replace complex analog control, simplifies the structure of a control system and can effectively reduce the volume of the welding power supply. The flexibility of software programming is higher, and the versatility of the welding power supply can be increased.
Drawings
FIG. 1 is a schematic diagram of a digitized underwater welding power supply of the present invention.
Fig. 2 is an overall topology circuit diagram of the welding power supply of fig. 1.
Fig. 3 is a circuit diagram of a PAC module.
Fig. 4 is a graph of the constant current arc ignition external characteristic of the welding power supply of fig. 1.
Fig. 5 is a graph of the external constant power welding characteristic of the welding power supply of fig. 1.
Fig. 6 is a graph of the constant voltage, out-of-arc characteristic of the welding power supply of fig. 1.
Fig. 7 is a flow chart of a method of operating the welding power supply of fig. 1.
Fig. 8 is a control flowchart of the constant-current PI algorithm subroutine.
Fig. 9 is a control flowchart of the constant-pressure PI algorithm subroutine.
Fig. 10 is a control flow diagram of the constant power PI algorithm subroutine.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the following embodiments and accompanying drawings.
Examples
The embodiment discloses a digital underwater welding power supply capable of outputting multiple external characteristics, wherein the external characteristic output specifically comprises constant-current external characteristic output, constant-voltage external characteristic output and constant-power external characteristic output. As shown in fig. 1, the welding power supply includes an EMC module 10, an input rectifier bridge module 20, an inverter module 30, a step-down transformer module 40, an output rectifier filter module 50, a current-voltage feedback module 60, an ARM microcontroller module 70, a PAC module 80, a driver module 90, and an auxiliary power module 100.
The EMC module, the input rectifier bridge module, the inversion module, the step-down transformer module and the output rectifier filter module are sequentially connected and serve as a forward path of a main circuit of the welding power supply, and the output rectifier filter module is connected to a load.
The 220V alternating current on the power grid side is connected into the EMC module, the influence of electromagnetic interference on the welding power supply on the power grid side is reduced through the EMC module 10, and the alternating current on the power grid side passing through the EMC module is rectified by the input rectifier bridge module 20 and converted into high-voltage direct current. The high-voltage direct current is converted into square-wave alternating current through the inverter module 30, and the square-wave alternating current is converted into low-voltage direct current through the step-down transformer 40 and the output rectifying and filtering module 50.
As shown in fig. 2, the auxiliary power supply module includes a transformer and a voltage stabilization chip. The input end of the transformer is connected with the output end of the EMC module, the output end of the transformer is connected with the voltage stabilizing chip, and the voltage stabilizing chip is connected with the input rectifier bridge module, the inversion module, the step-down transformer module, the output rectifier filter module, the current and voltage feedback module, the ARM microcontroller module, the PAC module and the driving module. The auxiliary power supply module can convert the alternating current on the side of the power grid into corresponding direct current and supply power to the connected modules.
The output end of the output rectifying and filtering module is also connected to the input end of the current-voltage feedback module, the output end of the current-voltage feedback module, the ARM microcontroller module, the PAC module and the driving module are sequentially connected, and the output end of the driving module is connected with the inversion module.
The ARM microcontroller module adopts an ARM chip, and the current and voltage feedback module can adopt a Hall sensor. The current and voltage feedback module 60 collects the current and voltage signals (i.e. the current and voltage values of the low voltage dc) at the load end and feeds them back to the a/D interface of the ARM microcontroller module 70. The ARM microcontroller module 70 compares the collected voltage and current values with corresponding set values, operates a set external characteristic closed-loop program control algorithm after obtaining deviation, outputs a PWM pulse wave with adjustable duty ratio of 0-100% to control the PAC module 80 to output a voltage signal of 0-10V to the driving module 90, and the driving module 90 can adopt the existing driving module to output the PWM pulse wave with adjustable duty ratio of 0-50% to the inverter module 30 according to the voltage signal of 0-10V.
As shown in fig. 2, the EMC module may employ an EMC chip. The input rectifier bridge module is formed by connecting a rectifier bridge, a capacitor C1 and a resistor R1 in parallel, the input end of the rectifier bridge is connected with an EMC chip, the output end of the rectifier bridge is connected with the capacitor C1 and the resistor R1 which are connected in parallel, and the capacitor C1 and the resistor R1 are connected with the inverter module.
The inverter module 30 has two pairs of IGBT bridge switches, and the gates of the IGBT switching tubes V1, V2, V3, and V4 are all connected to the driving module. The ARM microcontroller module 70 runs an external characteristic closed-loop program control algorithm to control the driving module 90 to output the PWM pulse wave with adjustable duty ratio of 0-50% to the two pairs of IGBT switching tubes in the inverter module 30. The PWM duty ratio of the IGBT switching tube determines the voltage and the current output by the welding power supply. Here, the external characteristic closed-loop program control algorithm includes a constant current PI algorithm, a constant voltage PI algorithm, and a constant power PI algorithm.
The step-down transformer module adopts a transformer, a primary winding is connected with two pairs of IGBT switching tubes of the inversion module, and a secondary winding is connected with the output rectifying and filtering module.
The output rectifying and filtering module comprises two diodes D5 and D6, an inductor L1 and a capacitor C2, one of terminals of a secondary winding is sequentially connected with the diode D5 and the inductor L1 to serve as the anode output of the output rectifying and filtering module, and the inductor L1 is connected with the current and voltage feedback module; the center tap of the secondary winding is connected to an inductor L1 through a capacitor C2; the center tap is used as the negative output of the output rectifying and filtering module and is connected with the current and voltage feedback module; the other terminal of the secondary winding is connected to the cathode of diode D5 through diode D6.
Fig. 3 is a circuit diagram of PAC module 80, which includes an optocoupler and a PAC chip, the optocoupler being connected to the ARM microcontroller module through its internal light emitting diode, the optocoupler being connected to the PAC chip through its internal light detector, the PAC chip being connected to the drive module. The ARM microcontroller module outputs PWM pulse waves with adjustable duty ratios of 0-100%, the PWM pulse waves are isolated by an optical coupler and then input into the PAC chip, the PAC chip outputs voltage signals corresponding to 0-10V according to the PWM pulse waves with adjustable duty ratios of 0-100%, and the voltage signals are input into the driving module 90.
As shown in fig. 4, the arc striking stage of the underwater welding employs constant current arc striking, and the curve in fig. 4 is an external characteristic curve of the welding power supply in this embodiment at the constant current arc striking stage, which is measured through experiments. For the arc striking stage of underwater welding, a higher no-load voltage is maintained at the beginning, the value of the no-load voltage can be 60V, and the higher no-load voltage can puncture an insulating layer at the welding position to conduct electricity. Meanwhile, the no-load section is matched with thrust current (the increased current can be called thrust current), the current is continuously increased, the current is finally controlled to be near 400A, the arc striking can be easier due to the large current, and if the 400A current can be output for continuously 5S, the arc striking success can be judged.
Fig. 5 is a graph showing the external characteristics of constant power measured when the output power of the welding power supply of this embodiment is set at 7.2 KW. In the underwater welding process, the power output keeps the external characteristic of constant power. During the manual arc welding process, the arc length fluctuation caused by hand vibration is inevitable, and the power is required to be kept unchanged, so that certain penetration, fusion width and fusion speed in the welding process are ensured, and a better welding seam is formed.
As shown in fig. 6, the arc-closing stage of the underwater welding adopts constant-voltage arc-closing, and the curve of fig. 6 is the external characteristic curve of the welding power supply of this embodiment at the constant-voltage arc-closing stage measured through experiments. The arc-closing voltage is too high, so that the arc-closing is difficult, the cooling and solidification of a molten pool are not facilitated, and the voltage of about 20V can be selected as the arc-closing voltage. As can be seen from fig. 6, the voltage corresponding to each current value is around 20V.
As shown in fig. 7, this embodiment also discloses a working method of the above-mentioned digital underwater welding power supply, which comprises the following steps:
s1, connecting the welding gun to the output end of the output rectifying and filtering module, connecting the EMC module to the alternating current on the side of the power grid, and supplying power to other modules by the auxiliary power supply module after the digitalized underwater welding power supply is powered on;
s2, initializing the ARM microcontroller module, continuously and circularly judging whether a welding gun switch is closed, and continuously and circularly detecting the on-off state of the welding gun if the welding gun switch is not closed; if the welding gun switch is closed, the step S3 is carried out;
s3, after a welding gun switch is closed (at the moment, a welding gun is connected to a welding power supply, and the welding gun contacts a workpiece to generate an electric arc), the ARM microcontroller module starts to call a constant current PI algorithm subprogram to execute arc striking control, so that the output rectifying and filtering module starts constant current external characteristic output;
then, the ARM microcontroller module takes the load current collected by the current and voltage feedback module as a current sampling feedback value, calculates the PWM output duty ratio according to the current sampling feedback value and a given value, and then judges whether the arc striking is successful, wherein the arc striking success standard is that the current duration time of the power supply outputting more than 400A is as long as 5S, and if the power supply cannot continuously output the current of 400A for 5S, the arc striking failure is represented;
if the arc striking is not successful, continuing to call the constant current PI algorithm subprogram to execute arc striking control; if the arc striking is successful, the step S4 is entered;
s4, after arc striking is successful, the ARM microcontroller module detects the welding condition in real time through the current and voltage feedback module, selects an external characteristic mode suitable for the current welding condition to output, and calls a constant current PI algorithm subprogram to perform constant current output control if the constant current external characteristic output is selected; if the constant voltage external characteristic output is selected, the ARM microcontroller module calls a constant voltage PI algorithm subprogram to perform constant voltage output control; if the constant power external characteristic output is selected, the ARM microcontroller module calls a constant power PI algorithm subprogram to carry out constant power output control;
s5, after the ARM microcontroller module executes external constant current, constant voltage or constant power output control, the on-off state of the welding gun is judged in real time, if the welding gun is continuously closed, the step S4 is returned to continuously detect the welding condition, and which external characteristic is selected for output is judged; if the welding gun switch is disconnected, calling a constant voltage PI algorithm subprogram to execute arc extinction control, and enabling the output rectifying and filtering module to output constant voltage external characteristics;
then, the ARM microcontroller module judges whether arc-off is finished or not, and if the arc-off is finished, the current and voltage output of the output rectifying and filtering module is closed; and if the arc-closing is not finished, continuing to call the constant-voltage PI algorithm subprogram to execute arc-closing control.
Fig. 8 is a control flow chart of a constant current PI algorithm subroutine in the constant current external characteristic, which specifically includes:
firstly, reading a current sampling feedback value and assigning the current sampling feedback value to a variable IfThen calculating the feedback value and the given value IgDeviation e betweenCAnd amplifying a certain multiple to prevent ARM from being caused by deviation e in the operation processCToo small to mistakenly treat it as 0. The magnification is 1000 times, and the deviation e after the magnification is obtainedC。
And PI operation is carried out to obtain the duty ratio U-KP*eC+RC，KPProportionality factor, R, set for ARM microcontroller moduleCThe integral compensation calculated for the ARM microcontroller module is compared with the minimum duty ratio U to prevent the calculated duty ratio U from overflowingminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen take uCCorresponding to the value U for the minimum duty ratiominOtherwise, executing the next step to judge U>＝UmaxWhether the result is true or not;
if U is present>＝UmaxIf it is true, take uCIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switch tube is prevented from being directly connected;
if U is present>＝UmaxIf not, execute uC＝U。
The integral compensation R is calculated next stepC＝RC+KI*eC+KC*(uC-U), R on the left side of the equationCR on the right side of the equation for the updated integral compensation amount for the next calculation of duty cycleCFor the current integral compensation, KIIs the integral coefficient, KCTo prevent saturation of the integral coefficient, u is then added to the result of the calculationCReducing by 1000 times to obtain actual value, and assigning to comparison registers CMPA and CMPB in ARM microcontroller module, wherein the CMPA is uC，CMPB＝uCAnd is used for updating the PWM duty ratio.
Fig. 9 is a control flow chart of the constant voltage PI algorithm subroutine in the case of the constant voltage external characteristic, specifically:
firstly, reading a voltage sampling feedback value and assigning the value to a variable UfThen calculating the feedback value and the given value UgDeviation e betweenVAnd amplifying a certain multiple to prevent ARM from being caused by deviation e in the operation processCToo small to mistakenly treat it as 0. The magnification is 1000 times, and the deviation e after the magnification is obtainedV。
And PI operation is carried out to obtain the duty ratio U-KP*eV+RV，KPProportionality factor, R, set for ARM microcontroller moduleVThe integral compensation calculated for the ARM microcontroller module is compared with the minimum duty ratio U to prevent the calculated duty ratio U from overflowingminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen take uVCorresponding to the value U for the minimum duty ratiominOtherwise, executing the next step to judge U>＝UmaxWhether the result is true or not;
if U is present>＝UmaxIf it is true, take uVIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switch tube is prevented from being directly connected;
if U is present>＝UmaxIf not, execute uV＝U。
The integral compensation R is calculated next stepV＝RV+KI*eC+KC*(uV-U), R on the left side of the equationVR on the right side of the equation for the updated integral compensation amount for the next calculation of duty cycleVFor the current integral compensation, KIIs the integral coefficient, KCTo prevent saturation of the integral coefficient, u is then added to the result of the calculationVAnd reducing by 1000 times to obtain an actual value, and assigning the actual value to a comparison register for updating the PWM duty ratio.
Fig. 10 is a control flow chart of a constant power PI algorithm subroutine in the case of constant power external characteristics, specifically:
firstly, reading current and voltage sampling feedback values and assigning the values to a variable IfAnd UfJudgment of UfAnd constant UdIf U is the size off>UdIf yes, calculating a voltage given value according to a constant power formula, and executing constant voltage external characteristic output under the condition of keeping the output power constant;
if U is presentf>UdIf the output power is not the same, the current given value is calculated according to a constant power formula, and constant current external characteristic output is executed under the condition that the output power is kept constant.
Here with Uf>UdThe judgment is mainly performed to ensure that the arc is not broken, if the feedback voltage is too large, the arc is too long and easy to break, so that constant voltage control is required, and if the feedback voltage meets the condition, constant current control is performed.
The subsequent constant pressure/out-of-flow characteristic output execution process is the same as before, and the deviation e between the feedback value and the given value is calculated firstC(eV) And amplifying the voltage by 1000 times to prevent the ARM from being caused by deviation e in the operation processCToo small to mistakenly treat it as 0.
And then PI operation is carried out to obtain a duty ratio U, and the duty ratio U is compared with the minimum duty ratio U in order to prevent the calculated duty ratio U from overflowingminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen take uC(uV) Corresponding to the value U for the minimum duty ratiominOtherwise, executing the next step to judge U>＝UmaxWhether the result is true or not;
if U is present>＝UmaxIf it is true, take uVIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switch tube is prevented from being directly connected;
if U is present>＝UmaxIf not, execute uC(uV)＝U。
The integral compensation R is calculated next stepC(RV) Upon recovery of the calculation result, u is addedC(uV) And reducing by 1000 times to obtain an actual value, and assigning the actual value to a comparison register for updating the PWM duty ratio.
The above embodiments are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.

Claims (10)

1. A digital underwater welding power supply capable of outputting multiple external characteristics is characterized by comprising: the power supply comprises an EMC module, an input rectifier bridge module, an inversion module, a step-down transformer module, an output rectifier filter module, a current and voltage feedback module, an ARM microcontroller module, a PAC module, a driving module and an auxiliary power supply module;
the EMC module, the input rectifier bridge module, the inversion module, the step-down transformer module and the output rectifier filter module are sequentially connected and used as a forward path of a main circuit of the welding power supply, and the output end of the output rectifier filter module is connected to a load; the input end of the EMC module is connected with alternating current on the side of a power grid, the rectifier bridge module is used for rectifying the alternating current on the side of the power grid passing through the EMC module into high-voltage direct current, the inversion module is used for converting the high-voltage direct current into square wave alternating current, the step-down transformer is used for stepping down the square wave alternating current, and the output rectifier filter module is used for converting the stepped-down square wave alternating current into low-voltage direct current and transmitting the low-voltage;
the output end of the output rectifying and filtering module is also connected to the input end of the current-voltage feedback module, the output end of the current-voltage feedback module, the ARM microcontroller module, the PAC module and the driving module are sequentially connected, and the output end of the driving module is connected with the inversion module; the current and voltage feedback module is used for collecting the current and voltage of the load and feeding the current and voltage back to the ARM microcontroller module; the ARM microcontroller module is used for generating PWM pulse waves for realizing different external characteristic outputs according to the current and the voltage of a load; the PAC module is used for generating corresponding voltage signals to the driving module according to the PWM pulse waves for realizing different external characteristic outputs; the driving module is used for generating corresponding PWM pulses according to the voltage signals sent by the PAC module and sending the PWM pulses to the inversion module;
the output end of the EMC module is connected with the auxiliary power supply module, and the auxiliary power supply module is connected with the input rectifier bridge module, the inversion module, the step-down transformer module, the output rectifier filter module, the current and voltage feedback module, the ARM microcontroller module, the PAC module and the drive module and supplies power to the modules.
2. The digital underwater welding power supply capable of outputting multiple external characteristics according to claim 1, wherein an ARM microcontroller compares the current and voltage values of a load with a set value, and operates an external characteristic closed-loop program control algorithm after obtaining a deviation, so as to obtain PWM pulse waves for realizing different external characteristic outputs, wherein the external characteristic outputs comprise a constant-current external characteristic output, a constant-voltage external characteristic output and a constant-power external characteristic output, and the duty ratios of the PWM pulse waves for realizing different external characteristic outputs are different; the external characteristic closed-loop program control algorithm comprises a constant current PI algorithm, a constant voltage PI algorithm and a constant power PI algorithm.
3. The digital underwater welding power supply capable of outputting multiple external characteristics according to claim 1, wherein the ARM microcontroller module generates PWM pulse waves with adjustable duty ratios of 0-100%, the PAC module correspondingly outputs voltage signals of 0-10V, and the driving module correspondingly outputs the PWM pulse waves with adjustable duty ratios of 0-50%.
4. The digital underwater welding power supply capable of outputting multiple external characteristics according to claim 3, wherein the inverter module is provided with two pairs of IGBT bridge switches, the driving module outputs PWM pulse waves with adjustable duty ratio of 0-50% and respectively sends the PWM pulse waves to corresponding IGBT switch tubes, and the voltage and the current output by the digital underwater welding power supply are determined by the PWM duty ratio of the IGBT switch tubes.
5. The digital underwater welding power supply capable of outputting multiple external characteristics according to claim 1, wherein the PAC module comprises an optical coupler and a PAC chip, the optical coupler is connected with the ARM microcontroller module through a light emitting diode inside the optical coupler, the optical coupler is connected with the PAC chip through a light detector inside the optical coupler, and the PAC chip is connected with the driving module.
6. The digital underwater welding power supply capable of outputting multiple external characteristics according to claim 1, wherein the auxiliary power supply module comprises a transformer and a voltage stabilizing chip, the input end of the transformer is connected with the EMC module, the output end of the transformer is connected with the voltage stabilizing chip, and the voltage stabilizing chip is further connected with the input rectifier bridge module, the inversion module, the step-down transformer module, the output rectifier filter module, the current and voltage feedback module, the ARM microcontroller module, the PAC module and the driving module.
7. The working method of the digital underwater welding power supply capable of outputting the multi-external-characteristic as claimed in any one of claims 1 to 6 is characterized by comprising the following steps:
s1, connecting the welding gun to the output end of the output rectifying and filtering module, connecting the EMC module to the alternating current on the side of the power grid, and supplying power to other modules by the auxiliary power supply module after the digitalized underwater welding power supply is powered on;
s2, initializing the ARM microcontroller module, continuously and circularly judging whether a welding gun switch is closed, and continuously and circularly detecting the on-off state of the welding gun if the welding gun switch is not closed; if the welding gun switch is closed, the step S3 is carried out;
s3, after the welding gun switch is closed, the ARM microcontroller module starts to execute arc striking control, so that the output rectifying and filtering module starts to output constant current external characteristics;
then, the ARM microcontroller module takes the load current collected by the current and voltage feedback module as a current sampling feedback value, calculates the PWM output duty ratio according to the current sampling feedback value and a given value, and then judges whether the arc striking is successful, wherein the arc striking success standard is that the current duration time of the power supply outputting more than 400A is as long as 5S, and if the power supply cannot continuously output the current of 400A for 5S, the arc striking failure is represented; if the arc striking is not successful, continuing to execute arc striking control; if the arc striking is successful, the step S4 is entered;
s4, after arc striking is successful, the ARM microcontroller module detects the welding condition in real time through the current and voltage feedback module, selects an external characteristic mode suitable for the current welding condition to output, and if the constant current external characteristic output is selected, the ARM microcontroller module performs constant current output control; if the constant voltage external characteristic output is selected, the ARM microcontroller module performs constant voltage output control; if the constant power external characteristic output is selected, the ARM microcontroller module performs constant power output control;
s5, after the ARM microcontroller module executes constant current, constant voltage or constant power output control, the on-off state of the welding gun is judged in real time, if the welding gun is continuously closed, the step S4 is returned to continuously detect the welding condition, and which external characteristic is selected for output is judged; if the welding gun switch is disconnected, arc-closing control is executed, so that the output rectifying and filtering module outputs the constant-voltage external characteristic;
then, the ARM microcontroller module judges whether arc-off is finished or not, and if the arc-off is finished, the current and voltage output of the output rectifying and filtering module is closed; and if the arc-closing is not finished, continuing to execute arc-closing control.
8. The operating method of a digital underwater welding power supply capable of outputting multiple external characteristics according to claim 7, wherein in step S3, the ARM microcontroller module calls a constant current PI algorithm subroutine to execute arc striking control, so that the output rectifying and filtering module starts outputting the constant current external characteristics;
in step S4, if the constant current external characteristic output is selected, the ARM microcontroller module calls the constant current PI algorithm subroutine and performs constant current output control;
the process of calling the constant current PI algorithm subprogram by the ARM microcontroller module to carry out constant current output control is as follows:
firstly, reading a current sampling feedback value and assigning the current sampling feedback value to a variable IfThen calculating the feedback value and the given value IgThe deviation between the two is amplified by a certain multiple to obtain an amplified deviation eC；
Subsequently using the deviation eCPerforming PI operation to obtain a duty ratio U-KP*eC+RC，KPProportionality factor, R, set for ARM microcontroller moduleCThe integral compensation quantity calculated for the ARM microcontroller module; to prevent overflow of the calculated duty cycle U, U is compared with the minimum duty cycle UminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen get the voltage uCCorresponding to the value U for the minimum duty ratiominOtherwise, executing the next step and judging U>＝UmaxWhether the result is true or not; if U is present>＝UmaxIf it is true, take uCIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switching tube in the reverse transformation prevention module is prevented from being directly communicated; if U is present>＝UmaxIf not, execute uC＝U；
And then updating the integral compensation R for calculating the duty ratio next timeCThen, according to the original magnification factor, uCAnd reducing to restore the calculation result so as to obtain an actual voltage value, and assigning the actual voltage value to a comparison register for updating the PWM duty ratio.
9. The operating method of a digital underwater welding power supply capable of outputting multiple external characteristics according to claim 7, wherein in step S4, if the constant voltage external characteristic output is selected, the ARM microcontroller module calls the constant voltage PI algorithm subroutine and performs the constant voltage output control;
in step S5, the ARM microcontroller module invokes a constant voltage PI algorithm subroutine to perform arc extinguishing control, so that the output rectifying and filtering module outputs the constant voltage external characteristic;
the process of calling the constant voltage PI algorithm subprogram by the ARM microcontroller module to carry out constant voltage output control is as follows:
firstly, reading a voltage sampling feedback value and assigning the value to a variable UfThen calculating the feedback value and the given value UgThe deviation between the two is amplified by a certain multiple to obtain an amplified deviation eV；
Subsequently beneficial toBy deviation eVPerforming PI operation to obtain a duty ratio U-KP*eV+RV，KPProportionality factor, R, set for ARM microcontroller moduleVThe integral compensation quantity calculated for the ARM microcontroller module; to prevent overflow of the calculated duty cycle U, U is compared with the minimum duty cycle UminAnd maximum duty cycle UmaxAnd (3) comparison:
if U is present<＝UminThen get the voltage uVCorresponding to the value U for the minimum duty ratiominOtherwise, executing the next step and judging U>＝UmaxWhether the result is true or not; if U is present>＝UmaxIf it is true, take uVIs the maximum duty ratio corresponding value UmaxLimit it to UmaxThe switching tube in the reverse transformation prevention module is prevented from being directly communicated; if U is present>＝UmaxIf not, execute uV＝U；
And then updating the integral compensation R for calculating the duty ratio next timeVThen, according to the original magnification factor, uVAnd reducing to restore the calculation result so as to obtain an actual voltage value, and assigning the actual voltage value to a comparison register for updating the PWM duty ratio.
10. The operating method of a digital underwater welding power supply capable of outputting multiple external characteristics according to claim 7, wherein in step S4, if the constant power external characteristic output is selected, the ARM microcontroller module calls a constant power PI algorithm subroutine and performs constant power output control;
the process of calling the constant power PI algorithm subprogram by the ARM microcontroller module to carry out constant power output control is as follows:
firstly, reading a current sampling feedback value and a voltage sampling feedback value and respectively assigning the values to a variable IfAnd UfJudgment of UfAnd constant UdIf U is the size off>UdIf yes, calculating a voltage given value according to a constant power formula, and executing constant voltage external characteristic output under the condition of keeping the output power constant;
if U is presentf>UdIf not, according to the constant workThe rate formula calculates a current set value, and constant current external characteristic output is performed while keeping the output power constant.
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