CN1438760A - Soft-switch hidden-arc welding contrarariant power supply with double closed-loop control - Google Patents
Soft-switch hidden-arc welding contrarariant power supply with double closed-loop control Download PDFInfo
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Abstract
With being connected to the slope compensation sector in parallel, the current and voltage detection sector is connected to the phase shift type pulse width modulation sector. The current and voltage detection sector through the error amlifier is also connected to the controller, which is connected to the driver sector. The output of the drive sector is connected to the inversion bridge. The above sectors constitute the peak current control circuit in the internal ring. Fuzzy intelligent control is adopted in average current control in the external ring. The magnetic switch is connected between the secondary of the high frequency power transformer and secondary high frequency rectification filtration sector. In the invention, the double closed loop controls raise the dynamic performances of the system; the open structure typed power transformer increases the thermal efficiency of power sources.
Description
(1) technical field
The present invention relates to electromechanical integration technology area, particularly high-frequency soft switch inversion transformation technique and two closed loop field of intelligent control technology specifically are meant a kind of soft switch submerged-arc welding inverter with two closed-loop controls.
(2) background technology
At present, in the submerged-arc welding field, because the needed big electric current of its technology, high power, so mainly based on silicon rectifier and thyristor rectifier formula, the rectifier type power supply is reliable for traditional submerged arc welding electric power, technical comparative maturity, but equipment volume is huge, heavy, energy consumption is high, efficient is low, and because its reasons in structure, the dynamic characteristic aspect is also not ideal enough.Advanced hard switching inverter, volume is little, efficient is high, and technology content is higher, added value is high, but the operational environment of device is more abominable, and switching loss is big, and high order harmonic component can cause electric network pollution, needs to absorb buffer circuit, and the raising of reverse frequency also is restricted.Specifically, mainly there is the problem of the following aspects in the high power contravariant Arc Welding Power:
(1) integrity problem is because the environment for use of welding machine is abominable, and is very high to the requirement of its reliability.At present, common inverter type welder is owing to reasons such as high frequency parasitic oscillation, the complicated variation of load frequent, electromagnetic interference, magnetic bias, and particularly under high-power situation, there is the not enough problem of reliability in power supply.
(2) Harmonic Interference is present, and the inverter type welder on the market is the hard switching working method substantially, and the harmonic wave meeting feedback grid that produces in switching process pollutes electrical network; Also can cause serious electromagnetic interference simultaneously.
(3) control cycle of the control performance inverter type welder of welding machine is short, and the dynamic response of complete machine is fast.But this advantage does not obtain enough attention and embodiment in existing product, still is being confined to traditional control model and mentality of designing aspect the electric arc control, and the performance advantage of inverter is not fully played.
(4) inverter type welder of power factor problem hard switching work, all there is distortion in its work wave, also has high order harmonic component, has reduced power factor.
(5) the high-frequency power transformer transmitted power is big, temperature rise is serious, be limited to magnetic materials production level and welding machine production cost, magnetic material window and effective magnetic conductive area can not be too big, increased the technical difficulty of transformer device structure design, thermal design and electrical design.
Adopting soft switch technique is the good method that addresses these problems, but the soft-switching inversion technology is with respect to the hard switching technology, there is technology starting point problem of higher, exploitation to soft switching inverter, need more deep understanding and research be arranged to soft switch mechanism, to the device parasitic parameter sufficient understanding to be arranged, and grasp the rule and the mechanism of the change of current of soft switch resonance.And, the soft-switching inversion welding machine that is grinding at present, the common full-bridge phase-shift soft switch topology of basic employing, though implementation is fairly simple, soft-switching range is narrow, change of current loss is big but exist, in the diode reverse recovery process,, had a strong impact on safe, stable, the reliably working of inverter because of wiping voltage overshoot and the ringing that shakes and cause.
Adopt the equipment of high-frequency inversion technology to be in laboratory stage substantially.Even the domestic high-frequency inversion submerged arc welding electric power of identifying by country also belongs to the hard switching working method.By retrieval, the submerged arc inverter of soft switching regulator does not have technological achievement at present, does not more introduce to the market.Particularly power supply is adopted fuzzy intelligence control, also belong to blank.The mentality of designing of welding system also rests on the basis of traditional electric arc control method, the adjusting function of control system does not have the control performance good binding with contravariant arc welding power source, the response speed and the degree of regulation that mainly are wire feed system are difficult to guarantee, obtained certain effect although adopt fuzzy control technology, but fuzzy control rests on manual setting design fuzzy control rule basically, the subjective degree of the selection of membership function is bigger, because the optimization to fuzzy control rule relates to huge search volume, adopt traditional optimization method, amount of calculation is quite big, and the performance evaluation function also had a lot of restrictive conditions, therefore, be difficult to obtain optimum control law.
(3) summary of the invention
The present invention is exactly in order to solve above-mentioned the deficiencies in the prior art part, and a kind of soft switch submerged-arc welding inverter with two closed-loop controls is provided.This power supply is by research, development and application to novel soft switch technique, is making full use of, is excavating on the Based Intelligent Control means basis, solves the subject matter of traditional submerged arc welding electric power, and provides development platform and interface for intelligent welding control system.
A kind of soft switch submerged-arc welding inverter of the present invention with two closed-loop controls; by the electromagnetic compatibility link; the rectifying and wave-filtering link; phase-shift type full-bridge inverting link; high-frequency power transformer; secondary filtering high-frequency rectifier link; current/voltage detects link; phase-shift type pulse-width modulation link; drive link; net is pressed and is detected link; electric current and voltage; the overtemperature protection link interconnects composition; it is characterized in that; after described current/voltage detects link and the slope-compensation link is in parallel; be connected with phase-shift type pulse-width modulation link; current/voltage detects link and also is connected with controller by error amplifier; controller also is connected with the driving link; the output that drives link is connected with inverter bridge; ring peak current control circuit was serially connected with magnetic switch between the secondary and secondary filtering high-frequency rectifier link of described high-frequency power transformer in above-mentioned link constituted.
In order to realize the present invention better, radiator in the described phase-shift type full-bridge inverting link and the high-frequency power transformer time utmost point is connected with temperature sensor; Described current/voltage detects link and is connected with electronic switch; Described elementary dc bus side adopts LC filtering; Described high-frequency power transformer adopts Open architecture, leaves the slit between the winding.
The present invention compared with prior art has following advantage and beneficial effect:
1. the present invention has realized the soft switch of gamut, has significantly reduced the switching loss and the electric stress of power tube, has improved condition of work, has reduced electromagnetic interference, has improved overall efficiency.
2. the present invention has increased interior ring power control circuit on the basis of power main circuit, by two closed-loop controls, has improved the dynamic property of system, has overcome bias phenomenon.
3. power transformer of the present invention adopts Open architecture, has saved resonant inductance, has improved the heat efficiency of power supply.
4. the present invention has improved power supply reliability and Technological adaptability by multiple effective protection measure.
(4) description of drawings
Fig. 1 is an entire system block diagram of the present invention;
Fig. 2 is a main circuit schematic diagram of the present invention;
Fig. 3 is error amplification of the present invention, phase shift, driving ring economize on electricity road schematic diagram;
Fig. 4 is fuzzy microcontroller control system circuit theory diagrams of the present invention;
Fig. 5 is an external characteristic commutation circuit schematic diagram of the present invention;
Fig. 6 is an overheated detection protective circuit schematic diagram of the present invention;
Fig. 7 is an entire system FB(flow block) of the present invention.
(5) embodiment
Below in conjunction with drawings and Examples, the present invention is described in further detail.
As shown in Figure 1, become the smooth direct current electricity behind the processing of three-phase main-frequency alternating current process electromagnetic compatibility, the rectifying and wave-filtering, as the busbar voltage (AC-DC) of phase-shift type no-voltage inverter; According to control law switching tube is turned on and off by control system under no-voltage, thereby obtain the high-frequency high-voltage (DC-AC) of 25KHz, again behind high frequency transformer transformation, magnetic switch and secondary filtering high-frequency rectifier, obtain to be fit to tens volts direct current (AC-DC) of submerged welding process needs, finish weld task together jointly with the wire feed walking mechanism.Control and drive circuit through adjuster, are controlled the operate as normal of power supply and wire feed walking mechanism according to detected weldingvoltage, electric current and interior circular current.
As shown in Figure 2, common frequency power network meets rectifying block B1, connect filtering link L1, C2, C3, C4, C5, R1, R2, connect inverter bridge VT1～VT4 again, C6～C8, it is elementary that output meets high-frequency power transformer T1, transformer time utmost point serial connection magnetic switch LS1, LS2, output DC behind high frequency full-wave rectifying circuit D1～D8, sustained diode 9～D12, filtering link L2, C12, C13, C14 again, above link constitutes the power main circuit.Interior circular current detect link HALL1 with the parallel connection of slope-compensation link after, producing link UC3879 with PWM links to each other, the same error amplifier of average current detection link HALL2, PI controller U1 or fuzzy controller 80C552 connect by the J1 interface, output links to each other with 3 pin that PWM produces link UC3879, output 7,8,12,13 pin of UC3879 link to each other with 4 14,15 pins that drive link EXB841 respectively, the output that drives link extremely links to each other with G, the E of 4 switching tubes of inverter bridge respectively, and above-mentioned link constitutes power control circuit.Temperature sensor RRZ is directly installed on the radiator and the transformer time utmost point, and output meets quadratic transformation circuit U 27, U28, U25, D15, and output connects diverter switch 4051.Over-current detection HALL2 connects 4051 and realizes overcurrent protection; Voltage detection signal also links to each other with 4051 and realizes that pulsewidth limits; Accessory power supply connects active elements such as amplifier, UC3879, EXB841 respectively.The three-phase main-frequency alternating current after electromagnetic compatibility is handled by three-phase commutation bridge B
1Rectification is again through L
1And C
2, C
3Be filtered into the smooth direct current electricity, by 4 IGBT power tube VT
1～VT
4Constitute full-bridge inverter, C
6～C
8Be resonant capacitance, assist the realization of soft switch.High frequency after the inversion (25KHz) square-wave signal is through transformer T
1Pass through magnetic switch (L after the step-down
S1, L
S2), high-frequency rectification is by fast diode parallel connection (D
1～D
4, D
5～D
8) full-wave rectifying circuit that constitutes finishes, again through outputting inductance L
2Export behind the flat ripple.
As shown in Figure 3, J
1Be outer shroud average current feedback signal, J
2For giving determining voltage signal, the two relatively after, through the output signal of adjuster (analog circuit or single-chip microcomputer, but wire jumper) input signal as phase shift chip UC3879; J
3Be interior ring peak current feedback signal, 19 pins with entering UC3879 after the compensating signal stack compare with error signal in UC3879 inside, make UC3879 export corresponding phase shift four road PWM waveforms.This four road complementary in twos phase shift signal enters integrated drive chips EXB841 respectively, output converter bridge switching parts pipe VT
1～VT
4Drive signal.
As shown in Figure 4, single-chip microcomputer PCB80C552 system is as the core of outer shroud electric current fuzzy control, the deviation of outer shroud sample rate current and given signal is carried out the calculating process of obfuscation, fuzzy reasoning and ambiguity solution in single-chip microcomputer inside, output signal compares with injection current as the 3 pin input signals of UC3879, determine the size of drive signal phase shift, thus the output of control power supply.Simultaneously, this system is also as the control core of whole welding system.
As shown in Figure 5, the output voltage U f to the submerged-arc welding inverter course of work detects in real time, judges and analyze that the minimum effectively mode of output pulse width of employing restriction is controlled the hangover size of current.Increased current foldback circuit in the circuit, when the current signal If that detects surpasses set-point, commutation circuit will be transformed into a lower output valve, and making the effective pulsewidth of output is zero, turn-offs inverter bridge.Adopt this outer control method of dragging, also have two extra benefits: the one, because the control of the peak value of interior ring is responsive especially to the variation of signal, take the minimum pulse width restriction, can avoid under narrow pulsewidth situation, interior ring peak value control produces unsettled situation; The 2nd, when little electric current welded, if arc length is shorter, welding machine can increase electric current automatically so, promoted the droplet transfer, was not easy blow-out.
As shown in Figure 6, heat protection mainly is to prevent that some devices in particular cases from crossing heat-induced damage and inverter failure.The present invention utilizes PTC type RRZ thermistor, and they are installed in respectively on transformer and the fin, and when temperature raise, drive signal was cut off in protective circuit work, and inverter bridge quits work.After temperature reduces, open drive signal, inverter bridge is started working.Closing protective has been taked two measures, and the one, bus bar side has adopted LC filtering in elementary tributary, the big filter inductance of connecting, one side limits the growth rate of electric current, improves the primary current waveform on the other hand, reduces high order harmonic component, improves power factor; Another measure is to adopt time-delay, guarantees the conducting of main circuit elder generation, and conducting behind the control circuit can also start moment, prevents false triggering and damages power device.
As shown in Figure 7, its core is a single-chip microcomputer PCB80C552 system.The given signal of keyboard scan and show after the initialization, with the outer shroud feedback current relatively after, through fuzzy algorithmic approach; output enters UC3879; control the phase-shift PWM signal, simultaneously according to feedback current, voltage signal protection power supply, and control wire feed walking mechanism is effectively worked.
High-frequency power transformer adopts Open architecture, leaves the slit between the winding.In high-power soft switching arc welding inverter, the function of high frequency transformer comprises: (1) electrical isolation; (2) step-down; (3) magnetic coupling transmits energy; (4) the soft switching process of participation power switch pipe.The first three items function is identical with traditional arc welding inverter.But last function is the distinctive what's new of soft-switching arc welding inverter.State variables such as the leakage inductance of power transformer and exciting curent, winding conducting electric current are irrelevant, and only depend on the structural parameters of winding.If elementary winding inner diameter r
0, thickness h
1, the secondary winding thickness h
2And two insulation distance δ between the winding become big, then the leakage inductance of transformer increases.Therefore, the winding of traditional high-frequency power transformer usually has to be designed to the closely-coupled as far as possible enclosed construction of every circle coil.In the Novel Soft Switching arc welding inverter, utilize transformer leakage inductance to cooperate magnetizing inductance to realize Zero-voltage soft switch, the leakage inductance of high frequency transformer has been transformed into an active factor.Therefore, the present invention proposes and has adopted the open type transformer that can be applicable to high-power soft switching arc welding inverter.The winding of this transformer and the structure of radiator are very similar, and its efficiently radiates heat area increases more than 10 times than the area of dissipation of traditional closed transformer, greatly reduces the thermal resistance of transformer.
The embodiment of the invention has following characteristics:
1. main power circuit of the present invention adopts the novel full-bridge phase shifting Zero-voltage soft switch topological structure (as shown in Figure 2) of band magnetic switch.This circuit topology has been connected in series two pulsactors (magnetic switch) at the inferior utmost point of transformer on the basis of traditional basic phase-shifting full-bridge no-voltage inverter, when the weber number that passes through low (electric current is little), be in the high resistant off state, after weber, number surpassed certain value, inductance was saturated, the low-resistance conducting.Like this can be in the time of the common conducting of inferior utmost point rectifier diode, in both transformer afterflows, the non operating state, the transformer time utmost point and rectification circuit are disconnected, make transformer remain the inductance state, by magnetizing inductance and exciting current rationally are set, obtain suitable magnetization energy, widen the soft-switching range of lagging leg switching tube, thereby reduce circulating loss and duty-cycle loss, make power-efficient that bigger improvement be arranged; The band magnetic switch phase-shift full bridge inverter circuit topology, can realize the gamut Zero-voltage soft switch.
2. the present invention adopts the control of outer shroud mean value fuzzy intelligence---two closed loop constant currents (band is outer to be dragged) control system (as shown in Figure 3) that interior ring peak current control combines.Submerged-arc welding is generally big electric current crin welding, electric arc is flat characteristic, for obtaining good electric arc elasticity and appearance of weld, guarantee that hot input variable is stable in the welding process, to obtain good welding quality, and for fear of when the short circuit, pulsewidth is narrow partially and influence steady operation, the external characteristic that the present invention adopts the constant current band to drag outward.The acquisition of tradition welding machine external characteristics of constant current is to adopt average current control mode.Under this pattern; current sampling signal is the mean value in a plurality of inversion cycles; so be difficult to accurately, the operating state of proper, transient response power device, can not realize to power device in real time, effectively monitor and protect, and the control effect has bigger sluggishness.The present invention organically combines current average control and current peak control model, utilize Hall current sensor, detect the inductive current (peak current) of primary and the average output current of power supply respectively, average current signal and given signal are relatively, construction system outer shroud average current control mode, error signal is through adjuster (single-chip microcomputer 80C552, with the wire feed system common platform, as shown in Figure 4) after the computing, deliver to the PWM comparator with peak current with the stack of slope compensation, obtain pwm pulse then and turn-off constantly,, thereby constitute ring in the peak current through the operating state of drive circuit control switch pipe.The adding of interior ring peak-current mode, system's transient state closed loop response is obviously improved, transient response to the variation of the variation of input voltage and output loading is all accelerated, and have simple magnetic flux equilibrium function (solution transformer bias) automatically and instantaneous peak current current-limiting function, intrinsic current-limiting function of pulse one by one and the automatic current equalizing parallel function in inherence, improved the dynamic characteristic and the whole aircraft reliability of system.The deviation of outer shroud sampling average electric current and given signal and rate of change thereof enter single-chip microcomputer (adjusting compensation tache as the input variable of fuzzy intelligence control, be fuzzy controller), through fuzzy quantization is after the fuzzy quantity, it is carried out fuzzy reasoning by the rule of determining, then with the The reasoning results defuzzification, become analog quantity, as the given signal of the control of interior ring.The introducing of outer shroud mean value fuzzy control, the constant current section of the external characteristic of assurance submerged-arc welding inverter; Blur the realization of peak value control, improved the Technological adaptability of submerged-arc welding inverter.
For solving the shortcoming that external characteristics of constant current power supply short circuit electric current is little, electric arc thrust is not enough, and when guaranteeing short circuit, IGBT is operated in suitable pulsewidth scope, and the present invention adopts the constant current band to drag characteristic (as shown in Figure 5) outward.Output voltage (Uf) to the submerged-arc welding inverter detects in real time, judges and analyzes, and adopts the minimum effectively mode of output pulse width of restriction to control the hangover size of current.Circuit has increased overcurrent protection, and when the current signal (If) that detects surpasses set-point, commutation circuit will be transformed into a lower output valve, and making output pulse width is zero, turn-offs inverter bridge.In addition, the introducing of dragging outward can be avoided under the burst pulse situation, the wild effect that interior ring peak value control produces; When little electric current welds, if arc length is shorter, can make welding machine increase electric current automatically, promote the droplet transfer, be difficult for blow-out.
3. the present invention has realized the real-time monitoring of device for power switching and protection (overheated, overcurrent, over-and under-voltage, closing protective and soft start; as shown in Figure 6); cooperate with Novel Soft Switching main circuit and above-mentioned control method, further improved the reliability of inversion submerged arc welding electric power and system.Heat protection mainly is to prevent that some devices in particular cases from crossing heat-induced damage and inverter failure.The present invention has adopted overheated detection protective circuit, utilizes PTC type RRZ thermistor, and they are installed in respectively on transformer and the fin, and drive signal is cut off in protective circuit work when temperature raises, and inverter bridge quits work; After temperature reduces, open drive signal, inverter bridge is started working.Closing protective has been taked two measures, and the one, adopted LC filtering in elementary dc bus side, the big filter inductance of connecting, one side limits the growth rate of electric current, improves the primary current waveform on the other hand, reduces high order harmonic component, improves power factor; Another measure is to adopt time-delay, guarantees the conducting of main circuit elder generation, conducting behind the control circuit.Can also start moment, prevent false triggering and damage power device.Single-chip microcomputer 80C552 system is the control core of total system, also is the common platform of fuzzy control of outer shroud mean value and wire feed fuzzy control.
4. the present invention has adopted novel open type structure high-frequency power transformer, utilizes self magnetizing inductance and leakage inductance realizes soft switch and make the heat radiation situation that obvious improvement arranged.
As mentioned above, can realize the present invention preferably.
Claims (5)
1. soft switch submerged-arc welding inverter with two closed-loop controls, by the electromagnetic compatibility link, the rectifying and wave-filtering link, phase-shift type full-bridge inverting link, high-frequency power transformer, secondary filtering high-frequency rectifier link, current/voltage detects link, phase-shift type pulse-width modulation link, drive link, net is pressed and is detected link, electric current and voltage, the overtemperature protection link interconnects composition, it is characterized in that, after described current/voltage detects link and the slope-compensation link is in parallel, be connected with phase-shift type pulse-width modulation link, current/voltage detects link and also is connected with controller by error amplifier, controller also is connected with the driving link, the output that drives link is connected with inverter bridge, ring peak current control circuit in above-mentioned link constitutes; Be serially connected with magnetic switch between the secondary and secondary filtering high-frequency rectifier link of described high-frequency power transformer.
2. a kind of soft switch submerged-arc welding inverter with two closed-loop controls according to claim 1 is characterized in that radiator in the described phase-shift type full-bridge inverting link and the secondary temperature sensor that is connected with of high-frequency power transformer.
3. a kind of soft switch submerged-arc welding inverter with two closed-loop controls according to claim 1 is characterized in that, described current/voltage detects link and is connected with electronic switch.
4. a kind of soft switch submerged-arc welding inverter with two closed-loop controls according to claim 1 is characterized in that, described elementary dc bus side adopts LC filtering.
5. a kind of soft switch submerged-arc welding inverter with two closed-loop controls according to claim 1 is characterized in that, described high-frequency power transformer adopts Open architecture, leaves the slit between the winding.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB031139264A CN1303750C (en) | 2003-03-17 | 2003-03-17 | Soft-switch hidden-arc welding contrarariant power supply with double closed-loop control |
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|---|---|---|---|
| CNB031139264A CN1303750C (en) | 2003-03-17 | 2003-03-17 | Soft-switch hidden-arc welding contrarariant power supply with double closed-loop control |
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| CN1303750C CN1303750C (en) | 2007-03-07 |
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Cited By (18)
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| CN1319694C (en) * | 2005-01-13 | 2007-06-06 | 上海交通大学 | Full-digital speed change control method for wire feeding for submerged arc welding |
| CN100343006C (en) * | 2004-01-15 | 2007-10-17 | 沈阳工业大学 | Multifunctional integrated welding and cutting equipment |
| CN100400214C (en) * | 2006-06-27 | 2008-07-09 | 华南理工大学 | Synergistic controlled soft switch contravariant type double-wire pulse MIG arc welding power supply |
| CN101147998B (en) * | 2007-11-01 | 2010-04-07 | 重庆润通动力有限公司 | Internal combustion direct current arc welding machine current regulator |
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| CN104280592A (en) * | 2014-09-30 | 2015-01-14 | 卧龙电气集团股份有限公司 | Passive lossless high-frequency magnetic isolation type direct voltage detection circuit |
| CN104393744A (en) * | 2014-12-05 | 2015-03-04 | 郭智峰 | Digitalized peak current control device |
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| JP3371962B2 (en) * | 2000-12-04 | 2003-01-27 | サンケン電気株式会社 | DC-DC converter |
| CN2518260Y (en) * | 2001-08-13 | 2002-10-23 | 周立峰 | High voltage and frequency pulse d.c. generator |
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