WO2018233202A1 - 反极性等离子弧机器人增材制造系统及其实现方法 - Google Patents

反极性等离子弧机器人增材制造系统及其实现方法 Download PDF

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Publication number
WO2018233202A1
WO2018233202A1 PCT/CN2017/112636 CN2017112636W WO2018233202A1 WO 2018233202 A1 WO2018233202 A1 WO 2018233202A1 CN 2017112636 W CN2017112636 W CN 2017112636W WO 2018233202 A1 WO2018233202 A1 WO 2018233202A1
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Prior art keywords
arc
circuit
power source
additive manufacturing
main
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PCT/CN2017/112636
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English (en)
French (fr)
Inventor
王振民
张福彪
韦俊好
王鹏飞
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South China University of Technology SCUT
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South China University of Technology SCUT
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Priority to SG11201912751SA priority Critical patent/SG11201912751SA/en
Priority to US16/625,746 priority patent/US20210146469A1/en
Publication of WO2018233202A1 publication Critical patent/WO2018233202A1/zh
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/22—Direct deposition of molten metal
    • 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
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • 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
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/006—Control circuits therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/32—Plasma torches using an arc
    • H05H1/34—Details, e.g. electrodes, nozzles
    • H05H1/341—Arrangements for providing coaxial protecting fluids
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/32—Plasma torches using an arc
    • H05H1/34—Details, e.g. electrodes, nozzles
    • H05H1/36—Circuit arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to the technical field of welding and additive manufacturing, in particular to a reverse polarity plasma arc robot additive manufacturing system and an implementation method thereof.
  • Additive manufacturing is a “bottom-up” manufacturing method that uses solid layers of materials to create solid parts.
  • Metal additive manufacturing technology mainly uses lasers and electron beams as heat sources to continuously process complex parts layer by layer by continuously melting or sintering metal powder.
  • lasers and electron beams as heat sources to continuously process complex parts layer by layer by continuously melting or sintering metal powder.
  • the reverse polarity plasma arc additive is manufactured by using a combined or transfer type plasma arc as a heat source, and an alloy powder or a wire material is used as a filler metal to effectively combine the weld overlay metal and the base metal to form a high density, a high degree of bonding, and a low Diluting the rate of the surfacing structure to achieve additive manufacturing.
  • Plasma arc additive manufacturing not only repairs damaged parts, but also creates complex metal parts that are small, uniform, and dense.
  • Reverse polarity plasma arc additive manufacturing is a highly integrated, intelligent, automated system.
  • the plasma power source provides energy for the additive manufacturing process and its performance is critical.
  • Universal welding power sources are commonly used to manufacture workpieces, and there are few dedicated reverse polarity, digital, high-performance dedicated plasma additive manufacturing power sources.
  • the stability, uniformity and synergy of the wire feeding system are also important when manufacturing wire-reinforced materials, which directly affects the stability of the additive process, the appearance of the additive and the processing flow.
  • the technical problem to be solved by the present invention is to provide a reverse polarity plasma arc robot additive manufacturing system and an implementation method thereof, the system has a simple topology and full digital control, and can adopt any required current according to the characteristics of the material and the workpiece.
  • the waveform is additively manufactured, and the process adaptability is good, which can improve the quality of the process of additive manufacturing.
  • a reverse polarity plasma arc robot additive manufacturing system including industrial robots, additive manufacturing power supplies, wire feeders, machine vision systems, industrial computers, plasma torches, refrigeration
  • the device, the gas device and the auxiliary fixture; the industrial robot, the additive manufacturing power source, the wire feeder, the refrigeration device, the gas device, and the auxiliary fixture are all connected to the industrial computer through the CAN BUS;
  • the machine vision system is via TCP/
  • the IP protocol is coupled to an industrial computer;
  • the plasma torch is coupled to the refrigeration device, the additive manufacturing power source, the wire feeder, the gas device, and the auxiliary fixture;
  • the refrigeration device is also coupled to the additive manufacturing power source;
  • the machine vision system is configured to detect workpiece information and position information of the additive additive and feed the information into the industrial computer; in the additive manufacturing process, the machine vision system is used to identify the path, monitor the state, and Tracking artifacts;
  • the industrial computer is used for selecting an additive manufacturing mode and its supporting basic process parameters, and performing a additive path planning; in the additive manufacturing process, the industrial computer supplies the industrial robot, the additive manufacturing power source, and the wire feeder , gas installation and auxiliary fixtures for data processing and remote monitoring;
  • the industrial robot is used as an actuator for controlling the plasma torch and the auxiliary fixture to complete corresponding operation operations;
  • the additive manufacturing power source is used to provide the energy required for the additive manufacturing process
  • the wire feeder is used for conveying the wire and adjusting the feed speed
  • the plasma torch is used to complete energy conversion, providing energy and power for wire deposition and transition of molten metal;
  • the refrigeration device is configured to provide a cooling effect for the additive manufacturing power source and the plasma torch;
  • the gas device is configured to supply an ion gas and a shielding gas to the plasma torch;
  • the auxiliary fixture is used to complete the clamping and displacement operation of the workpiece.
  • the additive manufacturing power source comprises a main arc power source and a dimension arc power source, wherein the main arc power source and the dimension arc power source are connected to a plasma torch;
  • the main arc power source comprises a main arc power main circuit and a main arc power control circuit.
  • the dimension arc power source comprises a main circuit of a dimension arc power source, a dimension arc power supply control circuit, and a high frequency high voltage arc ignition circuit;
  • the main circuit of the main arc power source is used for realizing conversion and transmission of main arc energy
  • the main arc power control circuit is used to control the normal operation of each task of the main arc power source
  • the main circuit of the dimensional arc power source is used for realizing conversion and transmission of the arc energy
  • the dimensional arc power control circuit is used to control the normal operation of each task of the arc voltage power supply
  • the high frequency high voltage arc striking circuit is used to break the air gap between the tungsten electrode of the plasma torch and the nozzle to establish a sustaining arc.
  • the main circuit of the main arc power supply adopts a dual inverter topology, including an input rectification filter module, an IGBT high frequency inverter circuit, an intermediate frequency transformer, a fast rectification filter module, an IGBT low frequency modulation circuit, and a high voltage stable arc circuit;
  • the input rectification filter module is configured to convert 380V three-phase alternating current into smooth direct current;
  • the IGBT high frequency inverter circuit is used for inverting the rectified direct current into high frequency alternating current;
  • the intermediate frequency transformer is used for energy conversion,
  • the additive manufacturing process provides the required high current, low voltage alternating current;
  • the fast rectification filtering module is configured to convert the alternating current through the intermediate frequency transformer into a large current, low voltage direct current;
  • the IGBT low frequency modulation circuit is used to pass
  • the direct current of the fast rectification and filtering module performs the commutation adjustment, the frequency modulation and the inductance filtering, and outputs the required current voltage
  • the main arc power control circuit includes a DSC controller, a high frequency inverter drive circuit, an overcurrent detection circuit, a current feedback circuit, a low frequency modulation drive circuit, a steady arc circuit drive circuit, a human-machine interaction system, and an overheat detection circuit. , an overvoltage detection circuit, an undervoltage detection circuit, and a CAN communication interface circuit;
  • the DSC controller generates three sets of all-digital PWM control signals, and respectively controls the low frequency modulation drive circuit, the high frequency inverter drive circuit, and the arc stabilization circuit drive circuit;
  • the high frequency inverter driving circuit is configured to convert a PWM control signal generated by the DSC controller into a driving signal required by the power switch tube IGBT in the IGBT high frequency inverter circuit;
  • the overcurrent detecting circuit is configured to prevent an excessive current from passing through the power switch IGBT;
  • the current feedback circuit is configured to implement closed loop adjustment of a power supply output current
  • the low frequency modulation driving circuit is configured to convert a PWM control signal generated by the DSC controller into a driving signal required by the power switching transistor IGBT in the IGBT low frequency modulation circuit;
  • the arc-stabilizing circuit driving circuit is configured to convert a PWM control signal generated by the DSC controller into a driving signal required for the power switching tube IGBT in the high-voltage arcing circuit;
  • the human-computer interaction system is used to implement a dialogue between a person and a power source
  • the overheat detection circuit is configured to prevent the IGBT temperature of the power switch tube from being too high
  • the overvoltage detection circuit is configured to detect whether a 380V three-phase alternating current voltage input by the power source is too high;
  • the undervoltage detection circuit is configured to detect whether a 380V three-phase alternating current voltage input by the power source is too low;
  • the CAN communication interface circuit is used to communicate with other systems to achieve digital coordination.
  • the DSC controller includes a DSC microcontroller, a power supply module, an external clock circuit, a reset circuit, and a JTAG debug download circuit.
  • the main circuit of the dimensional arc power supply comprises an input rectification filter module, a MOSFET inverter circuit, an intermediate frequency transformer and a fast rectification filter module;
  • the input rectification filter module is configured to convert 380V three-phase alternating current into smooth direct current;
  • the MOSFET inverter circuit is configured to invert the rectified DC power into a high frequency alternating current;
  • the intermediate frequency transformer is used for energy conversion to obtain a high current, low voltage alternating current;
  • the fast rectification filter module is used to pass the intermediate frequency transformer The alternating current is converted into a large current, low voltage direct current.
  • the wire feeder includes a wire feeding control system, a high frequency AC/DC inverter, a wire feeding driving circuit, a wire feeding motor, a pressing wheel and a fixing bracket, and the wire feeding control system includes a DSC controller, Optocoupler isolation module, voltage sampling module, transformer filter module, power supply module, fault detection module and CAN driver.
  • the wire feeding drive circuit comprises a high frequency half bridge chopper circuit, two diodes, a relay switch, an optocoupler and a motor load.
  • Another object of the present invention is to provide a method for implementing a reverse polarity plasma arc robot additive manufacturing system, comprising the following steps:
  • the industrial computer selects the corresponding additive manufacturing mode and its supporting basic process parameters according to the characteristics of the workpiece and its wire; the machine vision system detects the workpiece and its position information of the additive and feeds it into the industrial computer. And carry out the additive path planning to coordinate the movement of the industrial robot and the auxiliary fixture to the corresponding station;
  • the wire feeder performs stable wire feeding according to the preset process requirements of the industrial computer.
  • the plasma arc jet generated by the plasma torch melts the wire and deposits and forms according to the corresponding path.
  • the additive manufacturing is performed.
  • the vibrating arc power supply of the power supply works first, and the high-frequency high-voltage arc-ignition circuit is used to generate a high-frequency high-voltage signal, which breaks the tungsten gap of the plasma torch and the air gap of the nozzle, and uses a small current to establish and maintain the arc; after the successful arc-ignition, the dimension
  • the DSC controller of the arc power supply sends a successful arc signal to the DSC controller of the main arc power source, activates the main arc power source, and generates a transfer arc between the workpiece and the tungsten electrode; after the transfer arc succeeds, the additive manufacturing system is based on materials and processes. It is required to turn off the maintenance arc to perform the additive manufacturing process in the case of transfer arc; or to maintain the arc to continue working, thereby forming a mixed arc of the arc + transfer arc for additive manufacturing;
  • the output waveform of the main arc power source includes reverse polarity, variable polarity, and pulse; the speed of the wire feeding is constant speed or variable speed or pulsation change.
  • the present invention has at least the following beneficial effects:
  • the additive manufacturing power source of the invention not only realizes high-frequency and high-efficiency inverse change, but also realizes integration and digital integration of the arc-arc power source and the main arc power source; the digital relationship between the main arc power source and the maintenance power source through the CAN network Collaborative, compact, better compatibility, better adaptability of the field environment, and greater expansion capability;
  • the reverse polarity plasma arc robot additive manufacturing system of the invention realizes modularization and digital integration of all key components through DSC-based high-speed high-precision full digital control technology and CAN BUS bus network cooperation technology, and has better flexibility and precision. Higher, more precise control, and better quality;
  • the additive manufacturing power source of the invention can realize various working modes such as transfer arc, transfer + non-transfer arc mixing, and can realize accurate output of waveforms of various polarities and arbitrary shapes, and can be realized with a digital wire feeder. Quality control of heat transfer, mass transfer and mass transfer in additive manufacturing process, improving the quality of additive materials;
  • the invention adopts the high-frequency half-bridge chopper driving mode based on DSC precision control, which can realize various wire feeding modes such as forward rotation, reverse rotation and pulsation, and the wire feeding process is more stable and the anti-disturbance capability is stronger.
  • FIG. 1 is a schematic structural view of an additive manufacturing system of a reverse polarity plasma arc robot according to the present invention
  • FIG. 2 is a schematic structural view of an additive manufacturing power source in the additive manufacturing system of the reverse polarity plasma arc robot of the present invention
  • FIG. 3 is a circuit diagram of a main circuit of a main arc power supply in the additive manufacturing system of the reverse polarity plasma arc robot of the present invention
  • FIG. 4 is a main arc power supply control circuit of the reverse polarity plasma arc robot additive manufacturing system of the present invention. Schematic;
  • FIG. 5 is a schematic diagram showing the circuit structure of a DSC controller in the additive manufacturing system of the reverse polarity plasma arc robot of the present invention
  • FIG. 6 is a schematic diagram showing the circuit structure of a high frequency inverter driving circuit in the additive manufacturing system of the reverse polarity plasma arc robot of the present invention
  • FIG. 7 is a schematic diagram showing the circuit structure of a low frequency modulation driving circuit in the additive manufacturing system of the reverse polarity plasma arc robot of the present invention.
  • FIG. 8 is a schematic diagram of a main circuit of a virtual arc power supply in the additive manufacturing system of the reverse polarity plasma arc robot of the present invention.
  • FIG. 9 is a circuit schematic diagram of a wire feeder control system in a reverse polarity plasma arc robot additive manufacturing system of the present invention.
  • Fig. 10 is a circuit diagram showing the wire feeding drive circuit of the wire feeder of the reverse polarity plasma arc robot additive manufacturing system of the present invention.
  • the present invention provides a reverse polarity plasma arc robot additive manufacturing system, including an industrial robot, an additive manufacturing power source, a wire feeder, a machine vision system, an industrial computer, a plasma torch, a refrigeration device, and a gas.
  • the device, the auxiliary fixture, and the like; the industrial robot, the additive manufacturing power source, the wire feeder, the refrigeration device, the gas device, and the auxiliary fixture are all connected to the industrial computer through the CAN BUS;
  • the machine vision system passes the TCP/IP Connected to an industrial computer;
  • the refrigeration device is further connected to an additive manufacturing power source and a plasma torch;
  • the wire feeder is further connected to a plasma torch;
  • the gas device is connected to a plasma torch; and the auxiliary fixture is connected to a plasma torch .
  • the industrial robot as an actuator, mainly completes the adjustment of the position of the welding torch and the corresponding movement of the clamping welding gun.
  • the additive manufacturing power main circuit and the DSC control circuit the main circuit part of the welding power source realizes the conversion and transmission of the welding process energy, is the core part of the whole welding system; and the DSC control circuit mainly realizes the PWM switching signal of the power switching tube.
  • the occurrence, the PID adjustment of the sampling signal, the communication processing of the human-machine interaction system and the wire feeding system, and the related protection of the main circuit are responsible for the entire additive manufacturing.
  • the process control of the process is the "brain" of the entire welding power source.
  • the wire feeder is responsible for adjusting the feeding speed of the wire.
  • the wire feeding speed must be well matched with the current of the additive manufacturing and the welding additive speed to reduce the occurrence of welding defects, so the wire feeding speed must be A wide adjustment range ensures the anti-interference of the wire feeding system and the stability of the wire feed.
  • the machine vision system is mainly used for functions such as identification, state monitoring and tracking of the additive manufacturing process path; the industrial computer mainly performs functions such as coordinated control, hierarchical planning, and expert system of various parts of the system.
  • the plasma torch mainly performs energy conversion, and provides energy and power for wire deposition and transition of molten metal; the refrigeration device mainly provides cooling for the additive manufacturing power source and the plasma torch; the gas device mainly provides ion gas And protective gas; auxiliary fixtures mainly perform the functions of clamping and displacing the workpiece.
  • the additive manufacturing power source includes a main arc power source and a dimension arc power source; the main arc power source includes a main circuit and a control circuit; and the maintenance power source includes a main circuit, a control circuit, and a high frequency high voltage arc striking circuit. .
  • the main arc power source and the dimension arc power source are connected through a CAN BUS bus; the main arc power source and the dimension arc power source are directly connected to the plasma torch.
  • the control circuit of the main arc power supply and the synchronous arc power supply adopts a DSC controller with the same hardware structure, which differs only in the running software system, thereby reducing development cost and cycle, and improving compatibility and scalability.
  • the DSC controller 2 of the synchronous arc power supply first controls the operation of the high frequency and high voltage arc starting circuit, and generates a non-transfer arc between the tungsten electrode of the plasma torch and the nozzle, which is a radial arc arc; Frequency high voltage pilot circuit; then DSC controller 2 sends a successful arc signal to the DSC controller 1 of the main arc power supply via the CAN BUS bus, and then the main arc power supply works, causing the plasma torch to transfer between the tungsten electrode and the workpiece.
  • the arc becomes the main arc; then the plasma arc additive is fabricated according to predetermined parameters.
  • the arc arc and the main arc can coexist or exist separately.
  • the main circuit of the main arc power supply adopts a dual-inverter topology, and mainly includes input rectification and filtering modules BR1, C1-C2, L1, IGBT high-frequency inverter circuits Q1-Q4, C3-C7, R1- R4, intermediate frequency transformer T, fast rectification filter module D1-D4, R5-R8, YR1-YR4, C8-C11, L2-L3, IGBT low frequency modulation circuit Q5-Q8, high voltage arc stabilization circuit BR2, L4, C14-C15, Q9-Q12, C16-C19, R11-R14.
  • the working principle is that the 380V three-phase alternating current is converted into smooth direct current through the input rectification and filtering module, and then through the IGBT high-frequency inverter circuit, the constant current characteristic control and the dynamic characteristic adjustment are realized, and the energy conversion is performed through the intermediate frequency transformer, and the high frequency inverse is performed.
  • the changed alternating current is converted into an additive manufacturing process.
  • the high current and low voltage AC power required is converted into a large current and a low voltage DC through a fast rectification and filtering module.
  • the IGBT low frequency modulation circuit performs the commutation adjustment, the frequency modulation, and the inductance filtering at the output end, the output needs The current-voltage waveform;
  • the IGBT high-frequency inverter circuit adopts a full-bridge topology composed of four IGBTs, and filters the DC component of the primary side of the transformer through a series-connected DC capacitor C4 to prevent the core from entering saturation due to the volt-second imbalance;
  • the IGBT low-frequency modulation circuit uses two-way half-bridge parallel to form a double-half-bridge parallel topology.
  • the dotted frame is a high voltage arcing circuit whose main function is to ensure that the main arc power supply applies a higher voltage at the polarity switching moment of the output current, thereby ensuring reliable re-ignition of the arc when the current crosses zero.
  • the main arc power control circuit mainly comprises a DSC controller, a high frequency inverter drive circuit, an overcurrent detection circuit, a current feedback circuit, a low frequency modulation drive circuit, a steady arc circuit drive circuit, and a human-computer interaction system.
  • the DSC controller mainly includes a DSC microcontroller U1, a power supply module composed of a low dropout linear regulated power supply AMS1117 (U2), R6, D1, C14-C15, and a C2-C3, crystal oscillator.
  • An external clock circuit composed of Y1 and R3, a reset circuit composed of R7, S4, and C1, and a JTAG debug and download circuit composed of R2-R5, R8, and JTAG modules.
  • the high frequency inverter driving circuit of the main arc power control circuit is a high frequency pulse transformer isolated driving circuit, mainly composed of a plug port P1, R1-R4, and a P-channel power FET IRF9530M1.
  • And two-way push-pull output circuit composed of M3, N-channel power FET IRF530M2 and M4, high-frequency pulse voltage device T1-T2, IGBT composed of resistor R12, R16, diode D9, capacitor C7 "slow-open fast Off” network 1, IGBT "slow-on fast-off” network composed of resistors R13, R17, diode D10, capacitor C8 2.
  • IGBT "slow-on fast-off” network composed of resistors R14, R18, diode D11, capacitor C9
  • the IGBT consists of a resistor R15, R19, a diode D12, and a capacitor C10, a "slow-on-fast-off” network 4, a gate resistor R23-R-26, connectors P3-P4, and an auxiliary peripheral circuit.
  • the TTL type PWM drive signal generated by the DSC microprocessor is input to M1, M2, M3, and M4 after high-speed linear isolation, and the output signals are amplified and isolated by a high-frequency pulse transformer to generate four IGBT drivers. The signal drives the corresponding IGBT.
  • the “slow-on and fast-off” network can effectively reduce the IGBT switching losses.
  • the stable arc circuit drive circuit also adopts a similar structure.
  • the low-frequency modulation driving circuit of the main arc power control circuit has a high-speed optocoupler TLP250 as a core, and further includes a Zener diode D1-D2, a resistor R2-R6, and a capacitor C1-C4; wherein, the Zener diode D1 and D2 provide a negative bias when the IGBT is turned off to ensure fast and reliable turn-off of the IGBT.
  • Resistors R2 and R5 are gate resistors, and varistor R3 and R6 provide bypass channels for disturbing voltage spikes to reliably protect IGBTs.
  • an input rectification filter module composed of L1, C1, C2, C15, C16, R1, R2 and BR1 is connected.
  • the inverter bridges VT1 ⁇ VT4, C3 ⁇ C6, R3-R6, D1 ⁇ D4 of the MOSFET inverter circuit the inverter frequency is 100kHz
  • the output is connected to the intermediate frequency transformer T1 primary
  • the transformer secondary passes the fast rectification and filtering circuit D5 ⁇ D8, L2, C11 ⁇ C14, R11, R12 output DC power, the above link constitutes the main circuit of the dimensional arc power supply.
  • the high frequency signal generated by the high frequency and high voltage arc starting circuit is coupled into the output loop of the arc power supply through the transformer T2.
  • the wire feeder mainly comprises a control system, a high frequency AC/DC inverter, a wire feeding drive circuit, a wire feeding motor, a pressing wheel, a fixing bracket and the like.
  • the wire feeder control system comprises a DSC controller, an optocoupler isolation module, a voltage sampling module, a transformer filter module, a power supply module, a fault detection module, and a CAN driver.
  • the wire feeder driving circuit of the wire feeder is mainly composed of a MOSFET power tube Q1-Q2, a high frequency half bridge chopper circuit, a diode D1-D2, a relay switch KR1, an optocoupler PC817, and an equivalent
  • the motor load is configured to realize the working mode such as forward feed wire, reverse spinning and adjustable speed pulse feed.
  • the motor speed can be adjusted steplessly and can compensate for fluctuations in the motor speed caused by fluctuations in the supply voltage and changes in the internal resistance of the power supply.
  • the industrial computer selects the corresponding additive manufacturing mode and its supporting basic process parameters according to the characteristics of the workpiece and its wire; then uses the machine vision system to detect the workpiece and its position information of the additive and feed it into the industrial computer.
  • the additive path planning is carried out to coordinate the movement of the industrial robot and the auxiliary fixture to the corresponding station; the refrigeration unit and the gas unit are activated to prepare for the work of the plasma torch and the additive manufacturing power source.
  • the three-phase power supply supplies power to the additive manufacturing power supply and the wire feeder, and begins the additive manufacturing process.
  • the vibrating arc power supply for the additive manufacturing power supply works first, using the high-frequency high-voltage arc-ignition circuit to generate high-frequency high-voltage signals, breaking the tungsten gap of the plasma torch and the air gap of the nozzle, and establishing a sustaining arc with a small current; After that, the DSC controller of the synchronous arc power supply is sent to the main arc power controller.
  • the arc-arc success signal activates the main arc power source to generate a transfer arc between the workpiece and the tungsten electrode. After the transfer arc is successful, the additive manufacturing system can turn off the sustain arc according to the requirements of materials and processes, thereby increasing the transfer arc.
  • the wire feeder performs stable wire feeding according to predetermined process requirements, and the plasma arc jet generated by the plasma torch melts the wire and deposits and forms according to the corresponding path.
  • the output waveform of the main arc power source can have various shapes, including reverse polarity, variable polarity, pulse, etc.; the wire feed speed can also be constant speed, variable speed or pulsation change.
  • the status information of industrial robots, additive manufacturing power supplies, wire feeders, gas devices, auxiliary fixtures, etc. are fed into the industrial computer through the CAN BUS network for data processing and remote centralized monitoring, further improving the automation and intelligence of the additive manufacturing process. Level of development.

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Abstract

一种反极性等离子弧机器人增材制造系统及其实现方法，系统包括工业机器人、增材制造电源、送丝机、机器视觉系统、工业计算机、等离子焊枪、制冷装置、气体装置以及辅助工装夹具。所述工业机器人、增材制造电源、送丝机、制冷装置、气体装置、辅助工装夹具均通过CAN BUS总线与工业计算机相连；所述机器视觉系统通过TCP/IP协议与工业计算机相连；所述等离子焊枪连接所述制冷装置、增材制造电源、送丝机、气体装置以及辅助工装夹具；所述制冷装置还与增材制造电源相连。增材制造电源包括主弧电源和维弧电源，所述主弧电源与维弧电源均与等离子焊枪相连；所述主弧电源包括主弧电源主电路和主弧电源控制电路，所述维弧电源包括维弧电源主电路、维弧电源控制电路以及高频高压引弧电路。增材制造电源不仅实现了高频高效逆变化，而且实现了维弧电源和主弧电源的一体化和数字化集成；主弧电源和维弧电源两者之间通过CAN网络进行数字协同，体积紧凑，兼容性更好，现场环境的适应性更好，扩展能力更强。

Description

反极性等离子弧机器人增材制造系统及其实现方法 技术领域
本发明涉及焊接与增材制造技术领域，特别涉及一种反极性等离子弧机器人增材制造系统及其实现方法。
背景技术
增材制造是一种“自下而上”的制造方法，采用材料的逐层累加方式制造实体零件。金属类增材制造技术主要以激光、电子束为热源，通过不断熔化或烧结金属粉来连续逐层制备复杂零部件。近年来，由于激光热源成型速度慢、电子束可加工构件体积小等局限性，低成本、高效率的电弧类增材制造技术得到了高度重视。反极性等离子弧增材制造以联合型或转移型等离子弧为热源，采用合金粉末或丝材作为填充金属，有效地将堆焊金属和基体金属熔化结合，形成高密度、高结合度、低稀释率的堆焊组织结构，从而实现增材制造。等离子弧增材制造不仅可以修复损坏的部件，还可以制造组织细小、均匀、致密的复杂金属零件。
近年来，丝材类的反极性等离子弧增材制造已成为研究重点。反极性等离子弧增材制造是一种高度集成智能化、自动化的系统。在等离子弧增材制造系统中，等离子体电源为增材制造过程提供能量，它的性能至关重要。国内的等离子电源设备的工业化水平同发达国家之间还存在较大的差距，普遍采用通用焊接电源来制造工件，很少有专用的反极性、数字化、高性能的专用等离子增材制造电源。另一方面，采用丝材熔积增材制造时，送丝系统的稳定性、均匀性以及协同能力也非常重要，直接影响到增材过程的稳定性、增材形貌以及加工流程。
发明内容
本发明要解决的技术问题在于，提供一种反极性等离子弧机器人增材制造系统及其实现方法，系统的拓扑结构简单，全数字化控制，可以根据材料与工件的特性采用所需的任意电流波形进行增材制造，工艺适应性好，可提升增材制造的工艺质量。
为解决上述技术问题，本发明提供如下技术方案：一种反极性等离子弧机器人增材制造系统，包括工业机器人、增材制造电源、送丝机、机器视觉系统、工业计算机、等离子焊枪、制冷装置、气体装置以及辅助工装夹具；所述工业机器人、增材制造电源、送丝机、制冷装置、气体装置、辅助工装夹具均通过CAN BUS总线与工业计算机相连；所述机器视觉系统通过TCP/IP协议与工业计算机相连；所述等离子焊枪连接所述制冷装置、增材制造电源、送丝机、气体装置以及辅助工装夹具；所述制冷装置还与增材制造电源相连；其中
所述机器视觉系统用于对拟增材制造的工件信息及其位置信息进行检测，并将信息馈入所述工业计算机；在增材制造过程中，机器视觉系统用于识别路径、监控状态以及跟踪工件；
所述工业计算机用于选择增材制造模式及其配套的基本工艺参数、进行增材路径规划；在增材制造过程中，所述工业计算机对所述工业机器人、增材制造电源、送丝机、气体装置以及辅助工装夹具进行数据处理和远程监控；
所述工业机器人作为执行机构，用于控制所述等离子焊枪和辅助工装夹具完成相应的动作操作；
所述增材制造电源用于提供增材制造过程所需的能量；
所述送丝机用于输送丝材并调节送给速度；
所述等离子焊枪用于完成能量的转换，为丝材熔积以及熔化金属的过渡提供能源与动力；
所述制冷装置用于为所述增材制造电源以及所述等离子焊枪提供冷却作用；
所述气体装置用于给所述等离子焊枪提供离子气和保护气；
所述辅助的工装夹具用于完成工件的夹持以及变位操作。
进一步地，所述增材制造电源包括主弧电源和维弧电源，所述主弧电源与维弧电源均与等离子焊枪相连；所述主弧电源包括主弧电源主电路和主弧电源控制电路，所述维弧电源包括维弧电源主电路、维弧电源控制电路以及高频高压引弧电路；其中
所述主弧电源主电路用于实现主弧能量的转换与传输；
所述主弧电源控制电路用于控制主弧电源各个任务的正常工作；
所述维弧电源主电路用于实现维弧能量的转换与传输；
所述维弧电源控制电路用于控制维弧电源各个任务的正常工作；
所述高频高压引弧电路用于击穿等离子焊枪的钨极和喷嘴间的气隙，以建立维持电弧。
进一步地，所述主弧电源主电路采用双逆变拓扑结构，包括输入整流滤波模块、IGBT高频逆变电路、中频变压器、快速整流滤波模块、IGBT低频调制电路以及高压稳弧电路；所述输入整流滤波模块用于将380V三相交流电转化为平滑的直流电；所述IGBT高频逆变电路用于将整流后的直流电逆变成高频交流电；所述中频变压器用于进行能量转换，为增材制造过程提供所需的高电流、低电压的交流电；所述快速整流滤波模块用于将经过中频变压器的交流电转变成大电流、低电压的直流电；所述IGBT低频调制电路用于将经过快速整流滤波模块的直流电进行换相调节、频率调制及电感滤波后，输出所需的电流电压波形；所述高压稳弧电路用于保证在IGBT低频调制电路输出电流的极性转换时刻施加较高的电压，从而确保在电流过零时电弧的可靠再引燃。
进一步地，所述主弧电源控制电路包括DSC控制器、高频逆变驱动电路、过流检测电路、电流反馈电路、低频调制驱动电路、稳弧电路驱动电路、人机交互系统、过热检测电路、过压检测电路、欠压检测电路以及CAN通信接口电路；
所述DSC控制器产生三组全数字PWM控制信号，并分别控制低频调制驱动电路、高频逆变驱动电路以及稳弧电路驱动电路；
所述高频逆变驱动电路用于将DSC控制器产生的PWM控制信号转换成IGBT高频逆变电路中功率开关管IGBT所需的驱动信号；
所述过流检测电路用于防止通过功率开关管IGBT的电流过大；
所述电流反馈电路用于实现电源输出电流的闭环调节；
所述低频调制驱动电路用于将DSC控制器产生的PWM控制信号转换成IGBT低频调制电路中功率开关管IGBT所需的驱动信号；
所述稳弧电路驱动电路用于将DSC控制器产生的PWM控制信号转换成高压稳弧电路中功率开关管IGBT所需的驱动信号；
所述人机交互系统用于实现人与电源之间的对话；
所述过热检测电路用于防止功率开关管IGBT温度过高；
所述过压检测电路用于检测电源输入的380V三相交流电电压是否过高；
所述欠压检测电路用于检测电源输入的380V三相交流电电压是否过低；
所述CAN通信接口电路用于与其它系统通信，实现数字化协同。
进一步地，所述DSC控制器包括DSC微控制器、电源供电模块、外部时钟电路、复位电路以及JTAG调试下载电路。
进一步地，所述维弧电源主电路包括输入整流滤波模块、MOSFET逆变电路、中频变压器以及快速整流滤波模块；所述输入整流滤波模块用于将380V三相交流电转化为平滑的直流电；所述MOSFET逆变电路用于将整流后的直流电逆变成高频交流电；所述中频变压器用于进行能量转换，得到高电流、低电压的交流电；所述快速整流滤波模块用于将经过中频变压器的交流电转化成大电流、低电压的直流电。
进一步地，所述送丝机包括送丝控制系统、高频AC/DC逆变器、送丝驱动电路、送丝电机、压紧轮以及固定支架，所述送丝控制系统包括DSC控制器、光耦隔离模块、电压采样模块、变压滤波模块、供电模块、故障检测模块以及CAN驱动器。
进一步地，所述送丝驱动电路包括高频半桥斩波电路、两个二极管、继电开关、光耦以及电机负载。
本发明另一目的是提供一种反极性等离子弧机器人增材制造系统的实现方法，包括如下步骤：
S1、工业计算机根据工件及其丝材的特性，选择相应的增材制造模式及其配套的基本工艺参数；机器视觉系统对拟增材制造的工件及其位置信息进行检测，并馈入工业计算机并进行增材路径规划，协调工业机器人以及辅助工装夹具运动到相应的工位；
S2、启动制冷装置和气体装置，为等离子焊枪和增材制造电源的工作做好准备；
S3、开启三相电源给增材制造电源和送丝机供电，进行增材制造工作；
S4、送丝机根据工业计算机预设的工艺要求进行稳定送丝，等离子焊枪产生的等离子弧射流将丝材熔化并按照相应的路径进行堆积成形。
进一步地，所述步骤S3中，三相电源给增材制造电源供电后，增材制造 电源的维弧电源首先工作，利用高频高压引弧电路产生高频高压信号，击穿等离子焊枪的钨极和喷嘴的气隙，采用很小的电流建立维持电弧；在引弧成功之后，维弧电源的DSC控制器给主弧电源的DSC控制器发送维弧成功信号，启动主弧电源，在工件和钨极之间产生转移弧；转移弧成功之后，增材制造系统根据材料和工艺的要求，可以关闭维持电弧，从而进行转移弧情况下的增材制造工艺；也可以使维持电弧继续工作，从而形成维弧+转移弧的混合弧进行增材制造；
其中，为精细控制热输入量和熔化金属的量，所述主弧电源的输出波形包括反极性、变极性、脉冲；送丝的速度为匀速或者变速或者脉动变化。
采用上述技术方案后，本发明至少具有如下有益效果：
1、本发明的增材制造电源不仅实现了高频高效逆变化，而且实现了维弧电源和主弧电源的一体化和数字化集成；主弧电源和维护电源两者之间通过CAN网络进行数字协同，体积紧凑，兼容性更好，现场环境的适应性更好，扩展能力更强；
2、本发明的反极性等离子弧机器人增材制造系统通过基于DSC的高速高精度全数字控制技术和CAN BUS总线网络协同技术实现了所有关键部件的模块化和数字化集成，柔性更好，精度更高，控制更精确，质量更能得到保证；
3、本发明的增材制造电源能够实现转移弧、转移+非转移弧混合等多种工作模式，能够实现多种极性、任意形状波形的精确输出，配合数字化的送丝机，能够实现对增材制造过程传热传质传量的优质调控，改善增材质量；
4、本发明采用了基于DSC精密控制的高频半桥斩波驱动方式，可以实现正转、反转、脉动等多种送丝模式，送丝过程更为平稳，抗扰动能力更强。
附图说明
图1是本发明反极性等离子弧机器人增材制造系统的结构示意图；
图2是本发明反极性等离子弧机器人增材制造系统中增材制造电源的结构示意图；
图3是本发明反极性等离子弧机器人增材制造系统中主弧电源主电路的电路示意图；
图4是本发明反极性等离子弧机器人增材制造系统中主弧电源控制电路的 结构示意图；
图5是本发明反极性等离子弧机器人增材制造系统中DSC控制器的电路结构示意图；
图6是本发明反极性等离子弧机器人增材制造系统中高频逆变驱动电路的电路结构示意图；
图7是本发明反极性等离子弧机器人增材制造系统中低频调制驱动电路的电路结构示意图；
图8是本发明反极性等离子弧机器人增材制造系统中维弧电源主电路原理图；
图9是本发明反极性等离子弧机器人增材制造系统中送丝机控制系统的电路原理图；
图10是本发明反极性等离子弧机器人增材制造系统中送丝机送丝驱动电路的电路原理图。
具体实施方式
需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互结合，下面结合附图和具体实施例对本申请作进一步详细说明。
如图1所示，本发明提供了一种反极性等离子弧机器人增材制造系统，包括工业机器人、增材制造电源、送丝机、机器视觉系统、工业计算机、等离子焊枪、制冷装置、气体装置、以及辅助的工装夹具等；所述工业机器人、增材制造电源、送丝机、制冷装置、气体装置、辅助工装夹具均通过CAN BUS与工业计算机相连；所述机器视觉系统通过TCP/IP与工业计算机相连；所述制冷装置还分别与增材制造电源和等离子焊枪相连；所述送丝机还与等离子焊枪相连；所述气体装置与等离子焊枪相连；所述辅助工装夹具与等离子焊枪相连。
所述工业机器人作为执行机构，主要完成焊枪位姿调整以及夹持焊枪进行相应的运动。
所述增材制造电源主电路和DSC控制电路，焊接电源的主电路部分实现焊接过程能量的转换与传输，是整个焊接系统的核心部分；而其DSC控制电路主要实现功率开关管PWM驱动信号的发生、采样信号的PID调节、人机交互系统及送丝系统的通信处理、主电路的相关保护等功能，负责整个增材制造 过程的流程控制，是整个焊接电源的“大脑”。
所述送丝机负责调节丝材的送给速度，送丝速度的大小必须与增材制造的电流大小及熔积增材速度等参数良好配合才能减少焊接缺陷的发生，所以送丝速度必须有一个宽的调节范围，保证送丝系统的抗干扰性及送丝的稳定性。
所述机器视觉系统主要用于增材制造过程路径的识别、状态监控以及跟踪等功能；所述工业计算机主要完成系统各部分的协调控制、分层规划、专家系统等功能。
所述等离子焊枪主要完成能量的转换，为丝材熔积以及熔化金属的过渡提供能源与动力；所述制冷装置主要为增材制造电源以及等离子焊枪提供冷却作用；所述气体装置主要提供离子气和保护气；辅助的工装夹具主要完成工件的夹持以及变位等功能。
如图2所示，所述增材制造电源包括主弧电源和维弧电源；所述主弧电源包括主电路和控制电路；所述维护电源包括主电路、控制电路和高频高压引弧电路。所述主弧电源与维弧电源通过CAN BUS总线相连接；所述主弧电源与维弧电源均直接与等离子焊枪相连。所述主弧电源和维弧电源的控制电路采用硬件结构相同的DSC控制器，仅在运行的软件系统上有所差异，从而降低开发成本和周期，提高兼容性和可扩展性。在正常工作时，维弧电源的DSC控制器2首先控制高频高压引弧电路工作，在等离子焊枪的钨极与喷嘴之间产生非转移弧，这为维弧电弧；起弧成功之后关闭高频高压引弧电路；然后DSC控制器2通过CAN BUS总线给主弧电源的DSC控制器1发送一个维弧成功的信号，然后主弧电源工作，使等离子焊枪在钨极和工件之间产生转移弧，成为主弧；然后按照预定的参数进行等离子弧增材制造。维弧电弧和主弧可以并存，也可以单独存在。
如图3所示，所述主弧电源主电路采用双逆变拓扑结构，主要包含输入整流滤波模块BR1、C1-C2、L1，IGBT高频逆变电路Q1-Q4，C3-C7，R1-R4，中频变压器T，快速整流滤波模块D1-D4，R5-R8，YR1-YR4，C8-C11，L2-L3，IGBT低频调制电路Q5-Q8，高压稳弧电路BR2，L4，C14-C15，Q9-Q12，C16-C19，R11-R14。其工作原理为通过输入整流滤波模块将380V三相交流电转化为平滑的直流电，然后经过IGBT高频逆变电路，实现恒流特性控制和动特性调节，经过中频变压器进行能量转换，将高频逆变后的交流电转化成增材制造过程所 需的高电流、低电压的交流电，再经过快速整流滤波模块，转变成大电流、低电压的直流电，最后经过IGBT低频调制电路进行换相调节、频率调制及输出端的电感滤波后，输出所需要的电流电压波形；IGBT高频逆变电路采用四个IGBT构成的全桥拓扑结构，并通过串联隔直电容C4滤除变压器原边的直流分量，避免磁芯因为伏秒不平衡而进入饱和；综合考虑成本及安全性等因素，IGBT低频调制电路使用两路半桥并联构成双半桥并联拓扑。虚线框部分为高压稳弧电路，其主要作用是保证主弧电源在输出电流的极性转换时刻施加较高的电压，从而确保在电流过零时电弧的可靠再引燃。
如图4所示，所述主弧电源控制电路主要包括DSC控制器、高频逆变驱动电路、过流检测电路、电流反馈电路、低频调制驱动电路、稳弧电路驱动电路、人机交互系统、过热检测电路、过压检测电路、欠压检测电路以及CAN通信接口电路等构成；所述DSC控制器要直接产生三组全数字PWM控制信号，分别控制低频调制驱动电路、高频逆变驱动电路以及稳弧电路驱动电路。
如图5所示，所述DSC控制器主要包括DSC微控制器U1、由低压差线性稳压电源AMS1117(U2)、R6、D1、C14-C15构成的电源供电模块、由C2-C3、晶振Y1以及R3构成的外部时钟电路、由R7、S4以及C1构成的复位电路以及由R2-R5、R8、JTAG模块等构成的JTAG调试及下载电路等构成。
如图6所示，所述主弧电源控制电路的高频逆变驱动电路为高频脉冲变压器隔离型驱动电路，主要由接插端口P1、R1-R4、由P沟道功率场效应管IRF9530M1和M3、N沟道功率场效应管IRF530M2和M4分别构成的两路推挽输出电路、高频脉冲电压器T1-T2、由电阻R12、R16、二极管D9、电容C7构成的IGBT“慢开快关”网络1、由电阻R13、R17、二极管D10、电容C8构成的IGBT“慢开快关”网络2、由电阻R14、R18、二极管D11、电容C9构成的IGBT“慢开快关”网络3、由电阻R15、R19、二极管D12、电容C10构成的IGBT“慢开快关”网络4、栅极电阻R23-R-26、接插件P3-P4以及辅助的外围电路构成。由DSC微处理器产生的TTL型的PWM驱动信号，经过高速线性隔离后分别输入到M1、M2和M3、M4，其输出信号分别再经过高频脉冲变压器进行放大及隔离后产生四路IGBT驱动信号，对相应的IGBT进行驱动。“慢开快关”网络能够有效的降低IGBT开关损耗。稳弧电路驱动电路也采用类似的结构。
如图7所示，所述主弧电源控制电路的低频调制驱动电路以高速光耦TLP250为核心，还包括稳压二极管D1-D2，电阻R2-R6，电容C1-C4；其中，稳压二极管D1、D2在IGBT关断状态时提供负偏压，保证IGBT的快速、可靠关断。电阻R2、R5为栅极电阻，而压敏电阻R3、R6为干扰的电压尖峰提供旁路通道，对IGBT进行可靠保护。
如图8所示，所述维弧电源主电路中三相交流输入电源经过电网EMI滤波处理之后，接入由L1、C1、C2、C15、C16、R1、R2和BR1构成的输入整流滤波模块，再连接MOSFET逆变电路的逆变桥VT1～VT4，C3～C6，R3-R6，D1～D4,逆变频率为100kHz，输出接中频变压器T1初级，变压器次级经过快速整流滤波电路D5～D8、L2、C11～C14、R11、R12后输出直流电，以上环节构成维弧电源的主电路。所述的高频高压引弧电路产生的高频信号通过变压器T2耦合进入维弧电源的输出回路。
如图9所示，所述送丝机主要包括控制系统、高频AC/DC逆变器、送丝驱动电路、送丝电机以及压紧轮、固定支架等构成。所述送丝机控制系统包含DSC控制器、光耦隔离模块、电压采样模块、变压滤波模块、供电模块、故障检测模块以及CAN驱动器等构成。
如图10所示，所述送丝机送丝驱动电路主要由MOSFET功率管Q1-Q2构成的高频半桥斩波电路、二极管D1-D2、继电开关KR1、光耦PC817以及等效的电机负载构成，能够实现正转送丝、反转抽丝及速度可调的脉动送丝等工作模式，电机转速可无级调节并且能够补偿供电电压波动及电源内阻变化引起的电机转速波动。
本发明的工作原理如下：
首先工业计算机根据工件及其丝材的特性，选择相应的增材制造模式及其配套的基本工艺参数；然后利用机器视觉系统对拟增材制造的工件及其位置信息进行检测并馈入工业计算机并进行增材路径规划，协调工业机器人以及辅助工装夹具运动到相应的工位；启动制冷装置和气体装置，为等离子焊枪和增材制造电源的工作做好准备。三相电源给增材制造电源和送丝机供电，开始进行增材制造工作。增材制造电源的维弧电源首先工作，利用高频高压燃弧电路产生高频高压信号，击穿等离子焊枪的钨极和喷嘴的气隙，采用很小的电流建立维持电弧；在燃弧成功之后，维弧电源的DSC控制器给主弧电源控制器发送 维弧成功信号，启动主弧电源，在工件和钨极之间产生转移弧；转移弧成功之后，增材制造系统根据材料和工艺的要求，可以关闭维持电弧，从而进行转移弧情况下的增材制造工艺；维持电弧也可以继续工作，从而形成维弧+转移弧的混合弧进行增材制造。送丝机按照预定的工艺要求进行稳定送丝，等离子焊枪产生的等离子弧射流将丝材熔化并按照相应的路径进行堆积成形。为精细控制热输入量和熔化金属的量，主弧电源的输出波形可以有多种形状，包括反极性、变极性、脉冲等；送丝速度也可以是匀速、变速或者脉动变化等。工业机器人、增材制造电源、送丝机、气体装置、辅助工装夹具等的状态信息均通过CAN BUS网络馈入到工业计算机进行数据处理和远程集中监控，进一步提高增材制造过程的自动化和智能化水平。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解的是，在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种等效的变化、修改、替换和变型，本发明的范围由所附权利要求及其等同范围限定。

Claims (10)

  1. 一种反极性等离子弧机器人增材制造系统，其特征在于，包括工业机器人、增材制造电源、送丝机、机器视觉系统、工业计算机、等离子焊枪、制冷装置、气体装置以及辅助工装夹具；所述工业机器人、增材制造电源、送丝机、制冷装置、气体装置、辅助工装夹具均通过CAN BUS总线与工业计算机相连；所述机器视觉系统通过TCP/IP协议与工业计算机相连；所述等离子焊枪连接所述制冷装置、增材制造电源、送丝机、气体装置以及辅助工装夹具；所述制冷装置还与增材制造电源相连；其中
    所述机器视觉系统用于对拟增材制造的工件信息及其位置信息进行检测，并将信息馈入所述工业计算机；在增材制造过程中，机器视觉系统用于识别路径、监控状态以及跟踪工件；
    所述工业计算机用于选择增材制造模式及其配套的基本工艺参数、进行增材路径规划；在增材制造过程中，所述工业计算机对所述工业机器人、增材制造电源、送丝机、气体装置以及辅助工装夹具进行数据处理和远程监控；
    所述工业机器人作为执行机构，用于控制所述等离子焊枪和辅助工装夹具完成相应的动作操作；
    所述增材制造电源用于提供增材制造过程所需的能量；
    所述送丝机用于输送丝材并调节送给速度；
    所述等离子焊枪用于完成能量的转换，为丝材熔积以及熔化金属的过渡提供能源与动力；
    所述制冷装置用于为所述增材制造电源以及所述等离子焊枪提供冷却作用；
    所述气体装置用于给所述等离子焊枪提供离子气和保护气；
    所述辅助的工装夹具用于完成工件的夹持以及变位操作。
  2. 根据权利要求1所述的反极性等离子弧机器人增材制造系统，其特征在于，所述增材制造电源包括主弧电源和维弧电源，所述主弧电源与维弧电源均与等离子焊枪相连；所述主弧电源包括主弧电源主电路和主弧电源控制电路，所述维弧电源包括维弧电源主电路、维弧电源控制电路以及高频高压引弧电路；其中
    所述主弧电源主电路用于实现主弧能量的转换与传输；
    所述主弧电源控制电路用于控制主弧电源各个任务的正常工作；
    所述维弧电源主电路用于实现维弧能量的转换与传输；
    所述维弧电源控制电路用于控制维弧电源各个任务的正常工作；
    所述高频高压引弧电路用于击穿等离子焊枪的钨极和喷嘴间的气隙，以建立维持电弧。
  3. 根据权利要求2所述的反极性等离子弧机器人增材制造系统，其特征在于，所述主弧电源主电路采用双逆变拓扑结构，包括输入整流滤波模块、IGBT高频逆变电路、中频变压器、快速整流滤波模块、IGBT低频调制电路以及高压稳弧电路；所述输入整流滤波模块用于将380V三相交流电转化为平滑的直流电；所述IGBT高频逆变电路用于将整流后的直流电逆变成高频交流电；所述中频变压器用于进行能量转换，为增材制造过程提供所需的高电流、低电压的交流电；所述快速整流滤波模块用于将经过中频变压器的交流电转变成大电流、低电压的直流电；所述IGBT低频调制电路用于将经过快速整流滤波模块的直流电进行换相调节、频率调制及电感滤波后，输出所需的电流电压波形；所述高压稳弧电路用于保证在IGBT低频调制电路输出电流的极性转换时刻施加较高的电压，从而确保在电流过零时电弧的可靠再引燃。
  4. 根据权利要求2所述的反极性等离子弧机器人增材制造系统，其特征在于，所述主弧电源控制电路包括DSC控制器、高频逆变驱动电路、过流检测电路、电流反馈电路、低频调制驱动电路、稳弧电路驱动电路、人机交互系统、过热检测电路、过压检测电路、欠压检测电路以及CAN通信接口电路；
    所述DSC控制器产生三组全数字PWM控制信号，并分别控制低频调制驱动电路、高频逆变驱动电路以及稳弧电路驱动电路；
    所述高频逆变驱动电路用于将DSC控制器产生的PWM控制信号转换成IGBT高频逆变电路中功率开关管IGBT所需的驱动信号；
    所述过流检测电路用于防止通过功率开关管IGBT的电流过大；
    所述电流反馈电路用于实现电源输出电流的闭环调节；
    所述低频调制驱动电路用于将DSC控制器产生的PWM控制信号转换成IGBT低频调制电路中功率开关管IGBT所需的驱动信号；
    所述稳弧电路驱动电路用于将DSC控制器产生的PWM控制信号转换成高压稳弧电路中功率开关管IGBT所需的驱动信号；
    所述人机交互系统用于实现人与电源之间的对话；
    所述过热检测电路用于防止功率开关管IGBT温度过高；
    所述过压检测电路用于检测电源输入的380V三相交流电电压是否过高；
    所述欠压检测电路用于检测电源输入的380V三相交流电电压是否过低；
    所述CAN通信接口电路用于与其它系统通信，实现数字化协同。
  5. 根据权利要求4所述的反极性等离子弧机器人增材制造系统，其特征在于，所述DSC控制器包括DSC微控制器、电源供电模块、外部时钟电路、复位电路以及JTAG调试下载电路。
  6. 根据权利要求2所述的反极性等离子弧机器人增材制造系统，其特征在于，所述维弧电源主电路包括输入整流滤波模块、MOSFET逆变电路、中频变压器以及快速整流滤波模块；所述输入整流滤波模块用于将380V三相交流电转化为平滑的直流电；所述MOSFET逆变电路用于将整流后的直流电逆变成高频交流电；所述中频变压器用于进行能量转换，得到高电流、低电压的交流电；所述快速整流滤波模块用于将经过中频变压器的交流电转化成大电流、低电压的直流电。
  7. 根据权利要求1所述的反极性等离子弧机器人增材制造系统，其特征在于，所述送丝机包括送丝控制系统、高频AC/DC逆变器、送丝驱动电路、送丝电机、压紧轮以及固定支架，所述送丝控制系统包括DSC控制器、光耦隔离模块、电压采样模块、变压滤波模块、供电模块、故障检测模块以及CAN驱动器。
  8. 根据权利要求7所述的反极性等离子弧机器人增材制造系统，其特征在于，所述送丝驱动电路包括高频半桥斩波电路、两个二极管、继电开关、光耦以及电机负载。
  9. 一种反极性等离子弧机器人增材制造系统的实现方法，其特征在于，包括如下步骤：
    S1、工业计算机根据工件及其丝材的特性，选择相应的增材制造模式及其配套的基本工艺参数；机器视觉系统对拟增材制造的工件及其位置信息进行检测，并馈入工业计算机并进行增材路径规划，协调工业机器人以及辅助工装夹具运动到相应的工位；
    S2、启动制冷装置和气体装置，为等离子焊枪和增材制造电源的工作做 好准备；
    S3、开启三相电源给增材制造电源和送丝机供电，进行增材制造工作；
    S4、送丝机根据工业计算机预设的工艺要求进行稳定送丝，等离子焊枪产生的等离子弧射流将丝材熔化并按照相应的路径进行堆积成形。
  10. 根据权利要求9所述的反极性等离子弧机器人增材制造系统的实现方法，其特征在于，所述步骤S3中，三相电源给增材制造电源供电后，增材制造电源的维弧电源首先工作，利用高频高压引弧电路产生高频高压信号，击穿等离子焊枪的钨极和喷嘴的气隙，采用很小的电流建立维持电弧；在引弧成功之后，维弧电源的DSC控制器给主弧电源的DSC控制器发送维弧成功信号，启动主弧电源，在工件和钨极之间产生转移弧；转移弧成功之后，增材制造系统根据材料和工艺的要求，可以关闭维持电弧，从而进行转移弧情况下的增材制造工艺；也可以使维持电弧继续工作，从而形成维弧+转移弧的混合弧进行增材制造；
    其中，为精细控制热输入量和熔化金属的量，所述主弧电源的输出波形包括反极性、变极性、脉冲；送丝的速度为匀速或者变速或者脉动变化。
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