CN201231371Y - Novel slant pulse CO2 welding inverter - Google Patents
Novel slant pulse CO2 welding inverter Download PDFInfo
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Abstract
一种新型的斜特性式脉冲CO2焊逆变电源,对恒流控制电流波形的CO2焊逆变电源进行改造,以提高稳弧性能。本实用新型的主要在普通CO2焊逆变电源中引入斜特性式弧长自动调节系统,该系统主要由单片机弧长自动调节模块、波控参数转换电路、恒流负反馈控制电路、PWM控制电路等部分组成。单片机弧长自动调节模块采用独创的斜特性式弧长自动调节算法,可实时求出脉冲CO2焊峰值电流脉宽调节量,以自动调节CO2焊弧长,从而使本实用新型具有自适应调节弧长功能的脉冲CO2焊逆变电源的优点。
A new type of oblique characteristic pulse CO2 welding inverter power supply, the CO2 welding inverter power supply with constant current control current waveform is modified to improve the arc stability performance. The utility model mainly introduces an oblique characteristic type arc length automatic adjustment system into the ordinary CO2 welding inverter power supply. components such as circuits. The single-chip arc length automatic adjustment module adopts the original oblique characteristic arc length automatic adjustment algorithm, which can calculate the pulse width adjustment amount of the pulse CO2 welding peak current in real time, so as to automatically adjust the CO2 welding arc length, so that the utility model has self-adaptive Advantages of pulse CO2 welding inverter power supply with arc length adjustment function.
Description
技术领域 technical field
本实用新型涉及一种逆变电源,更具体的说涉及一种脉冲CO2气体保护焊逆变电源。The utility model relates to an inverter power supply, in particular to a pulse CO2 gas shielded welding inverter power supply.
背景技术 Background technique
目前,CO2气体保护焊设备已广泛采用逆变式直流焊接电源,CO2逆变电源不仅具有体积小、重量轻、效率高等优点,而且开拓了发展各种脉冲式或波控式CO2焊机的新局面。基于IGBT逆变电源的工作频率高达20KHz,逆变式CO2焊电源的控制周期仅为50us,具有非常优良的动态响应特性,能以0.1ms的响应速度控制CO2焊燃弧过程及短路过程的电流波形,在焊接过程中,CO2焊燃弧阶段的电流峰值与基值被精确控制在设定值,实现了理想的电流波形控制使每个熔滴的能量得到定量控制,从而大幅度提高了设备的焊接性能。At present, CO2 gas shielded welding equipment has widely used inverter DC welding power supply. CO2 inverter power supply not only has the advantages of small size, light weight and high efficiency, but also develops various pulse or wave-controlled CO2 welding. The new situation of the machine. Based on the operating frequency of the IGBT inverter power supply up to 20KHz, the control period of the inverter CO2 welding power supply is only 50us, which has very good dynamic response characteristics, and can control the arcing process and short circuit process of CO2 welding with a response speed of 0.1ms During the welding process, the current peak value and the base value of the CO2 welding arc stage are precisely controlled at the set value, which realizes the ideal current waveform control and quantitatively controls the energy of each droplet, thereby greatly Improve the welding performance of the equipment.
但是,脉冲CO2焊逆变电源是通过对电流峰值与基值进行恒流闭环控制而实现电流波形控制的。也就是说,脉冲CO2焊逆变电源必须采用恒流控制模式来控制电流波形。However, the pulse CO2 welding inverter power supply realizes the current waveform control by performing constant current closed-loop control on the current peak value and the base value. That is to say, the pulse CO2 welding inverter power supply must adopt the constant current control mode to control the current waveform.
众所周知,在等速送丝式CO2焊设备中,传统是采用平特性CO2焊整流电源来解决电弧电压自动调节问题。否则电弧就不能稳定,则焊接过程也无法稳定。即,在CO2焊接过程中当弧长变长或变短时,平特性CO2电源就会产生自调节作用使输出电流反向变化,则焊丝熔化速度相应减小或增加,相应使焊丝端部与熔池表面的距离变小或变大,从而自动恢复弧长。As we all know, in constant-speed wire-feeding CO2 welding equipment, traditionally, the flat characteristic CO2 welding rectifier power supply is used to solve the problem of automatic adjustment of arc voltage. Otherwise, the arc will not be stable, and the welding process will not be stable either. That is, when the arc length becomes longer or shorter during the CO2 welding process, the flat characteristic CO2 power supply will produce a self-regulating effect to reverse the output current, and the melting speed of the welding wire will decrease or increase accordingly, and the welding wire end will be correspondingly The distance between the bottom and the surface of the molten pool becomes smaller or larger, thereby automatically restoring the arc length.
然而脉冲CO2焊设备采用恒流控制时,其外特性也就变为恒流特性,不能满足电弧电压自动调节性能,不能满足生产需要,因此需要改进。However, when pulsed CO2 welding equipment adopts constant current control, its external characteristics will become constant current characteristics, which cannot meet the automatic adjustment performance of arc voltage and production needs, so it needs to be improved.
发明内容 Contents of the invention
本实用新型的目的是克服现有技术的缺点,提供一种新型的斜特性式脉冲CO2焊逆变电源,对恒流控制电流波形的CO2焊逆变电源进行改造,以提高稳弧性能。本实用新型从电弧能量控制的角度研究了通过控制CO2焊燃弧过程峰值电流脉宽tp的途径来闭环控制CO2焊电弧电压的方法,建立以脉冲CO2焊逆变电源外特性斜率为判据,以峰值电流脉宽为控制量的自动控制模型。在此基础上提出了一种新型的斜特性式脉冲CO2焊电源。此电源以脉冲CO2焊逆变电源峰值电流脉宽为控制量,通过电弧电压反馈控制峰值电流脉宽使电源获得可调的斜降伏安特性,从而在保持恒流控制峰值与基值电流特性的同时,还使脉冲CO2气体保护焊逆变电源具有足够强烈的电弧电压自动调节特性。The purpose of this utility model is to overcome the shortcomings of the prior art, provide a new type of oblique characteristic pulse CO2 welding inverter power supply, and transform the CO2 welding inverter power supply with constant current control current waveform to improve arc stability performance . From the perspective of arc energy control, the utility model studies the method of closed-loop control of CO2 welding arc voltage by controlling the peak current pulse width tp of CO2 welding arc burning process, and establishes the external characteristic slope of pulse CO2 welding inverter power supply As the criterion, the automatic control model takes the peak current pulse width as the control quantity. On this basis, a new type of oblique characteristic pulse CO 2 welding power source is proposed. This power supply takes the peak current pulse width of the pulse CO2 welding inverter power supply as the control quantity, and controls the peak current pulse width through the arc voltage feedback so that the power supply can obtain adjustable slope volt-ampere characteristics, so as to maintain the constant current control peak and base value current characteristics At the same time, it also makes the pulse CO 2 gas shielded welding inverter power supply have sufficiently strong arc voltage automatic adjustment characteristics.
本实用新型的技术方案是这样实现的:The technical scheme of the utility model is achieved in that:
一种新型的斜特性式脉冲CO2焊逆变电源,是对恒流控制电流波形的CO2焊逆变电源的改造和性能提高,它包括逆变电源,其特殊之处在在于,它还包括斜特性式弧长自动调节系统,该系统是以脉冲CO2焊逆变电源峰值电流脉宽为控制量,以电源外特性斜率为判据,对电源电压进行负反馈控制,使脉冲CO2焊电源输出电流平均值随电弧电压下降而线性增加,从而将基于恒流控制电流波形的脉冲CO2焊逆变电源转变为斜特性式脉冲CO2焊逆变电源;所述的斜特性式弧长自动调节系统,该系统以单片机与弧长自动调节模块为核心,与基本电路连接而成,其电路包括控制面板、AD转换电路、波控参数转换电路、电源负反馈电路、恒流负反馈控制电路、PWM控制电路、焊接电流传感电路、焊接电压传感电路;通过电流与电压传感电路实时检测焊接电流Ih值与焊接电压Uh值,并将传感电路处理得的焊接电压模拟量Uv经过AD转换电路送入单片机CPU,再送入弧长自动调节模块;同时用户在控制面板设定的脉冲峰值电流Ip、基值电流Ib与外特性斜率K也送入单片机;弧长自动调节模块根据电弧电压变化量ΔUh与外特性斜率K实时计算出峰值电流脉宽tp的调节量Δtp;波控参数转换电路则根据峰值电流脉宽的调节量Δtp实时切换对恒流负反馈电路输出的电流设定值,使恒流负反馈电路实时切换对PWM控制电路的控制信号uk,继而使CO2焊逆变主电路改变脉冲电流波形宽度,从而使脉冲CO2焊逆变电源自动调节焊接电流平均值来调节焊丝熔化速度,稳定电弧长度。A new type of oblique characteristic pulse CO2 welding inverter power supply is the transformation and performance improvement of the CO2 welding inverter power supply with constant current control current waveform. It includes the inverter power supply. Its special feature is that it also Including the inclined characteristic type arc length automatic adjustment system, the system takes the peak current pulse width of the pulse CO 2 welding inverter power supply as the control quantity, and uses the slope of the external characteristic of the power supply as the criterion to carry out negative feedback control on the power supply voltage, so that the pulse CO 2 The average value of the output current of the welding power source increases linearly as the arc voltage drops, thereby converting the pulse CO2 welding inverter power source based on the constant current control current waveform into a ramp characteristic pulse CO2 welding inverter power source; the ramp characteristic arc Length automatic adjustment system, the system is based on single-chip microcomputer and arc length automatic adjustment module, connected with the basic circuit, its circuit includes control panel, AD conversion circuit, wave control parameter conversion circuit, power supply negative feedback circuit, constant current negative feedback Control circuit, PWM control circuit, welding current sensing circuit, welding voltage sensing circuit; real-time detection of welding current I h value and welding voltage U h value through the current and voltage sensing circuit, and the welding voltage processed by the sensing circuit The analog quantity U v is sent to the single-chip CPU through the AD conversion circuit, and then sent to the arc length automatic adjustment module; at the same time, the pulse peak current Ip , the base value current Ib and the external characteristic slope K set by the user on the control panel are also sent to the single-chip computer; The arc length automatic adjustment module calculates the adjustment amount Δt p of the peak current pulse width t p in real time according to the arc voltage variation ΔU h and the external characteristic slope K; the wave control parameter conversion circuit switches in real time according to the adjustment amount Δt p of the peak current pulse width For the current setting value output by the constant current negative feedback circuit, the constant current negative feedback circuit switches the control signal u k to the PWM control circuit in real time, and then the CO2 welding inverter main circuit changes the pulse current waveform width, so that the pulse CO 2. The welding inverter power supply automatically adjusts the average value of the welding current to adjust the melting speed of the welding wire and stabilize the arc length.
所述的斜特性式弧长自动调节系统基本电路为:(A)由单片机系统实现弧长自动调节算法与信号A/D、D/A转换;(B)由电子电路实现波控参数(电流波形峰值和基值)转换,焊接电流负反馈控制与逆变主电路脉宽调制(PWM)控制;其中:The basic circuit of the described oblique characteristic type arc length automatic adjustment system is: (A) the arc length automatic adjustment algorithm and signal A/D, D/A conversion are realized by the single-chip microcomputer system; (B) the wave control parameter (current) is realized by the electronic circuit Waveform peak value and base value) conversion, welding current negative feedback control and inverter main circuit pulse width modulation (PWM) control; where:
(1)所述的焊接电流波控参数转换电路,是由多路开关u1与运算放大器u2组成;多路开关u1的输入端x0,x1分别接单片机系统D/A模块的电流峰值Ip、模拟量up输出端与电流基值Ib模拟量ub输出端,其控制信号输入端A接单片机系统I/O接口电路的电流峰值时间tp开关脉冲信号ut输出端,ut脉冲信号为高电平时,多路开关u1的输入端x。与输出端x1选通,电路输出焊接电流波形峰值的设定值模拟量up,ut脉冲信号为低电平时,电路输出焊接电流波形基值的设定值模拟量ub。运算放大器U2电路用以调整从多路开关输出的电流设定值模拟信号至Us值,使之符号焊接电源负反馈控制电路输入要求,其放大倍数由WR1调节;(1) The welding current wave control parameter conversion circuit is composed of a multi-way switch u1 and an operational amplifier u2 ; the input terminals x0 and x1 of the multi-way switch u1 are respectively connected to the D/A module of the single-chip microcomputer system The current peak value I p , the output terminal of the analog quantity u p and the output terminal of the current base value I b analog quantity u b , the control signal input terminal A is connected to the current peak time t p switch pulse signal u t output of the I/O interface circuit of the microcontroller system Terminal, when the u t pulse signal is high level, the input terminal x of the multiplexer u 1 . Strobe with the output terminal x1 , the circuit outputs the set value analog u p of the welding current waveform peak value, when the u t pulse signal is low level, the circuit outputs the set value analog u b of the welding current waveform base value. Operational amplifier U 2 circuit is used to adjust the current setting value analog signal output from the multi-way switch to U s value to make it meet the input requirements of the negative feedback control circuit of the welding power supply, and its magnification is adjusted by WR 1 ;
(2)所述的焊接电源负反馈电路由运算放大器U3与U4同相放大电器组成;其中运算放大器U3用以调理焊接电流传感的模拟量信号Ui使之与焊接电流波控参数转换电路输出值相匹配,其放大倍数由WR2调节,其输出值Uif送入运算放大器U4的反相端;运算放大器U4的同相端入焊接电流波形参数模拟量Us,使之与焊接电流模拟量Uif进行负反馈处理并输出控制信号Uk,其负反馈强度由WR3调节;(2) The negative feedback circuit of the welding power supply is composed of operational amplifiers U 3 and U 4 in-phase amplifiers; wherein the operational amplifier U 3 is used to adjust the analog signal U i of the welding current sensor to make it consistent with the welding current wave control parameters The output values of the conversion circuit are matched, and its magnification is adjusted by WR 2. The output value U if is sent to the inverting terminal of the operational amplifier U4 ; Perform negative feedback processing with welding current analog U if and output control signal U k , whose negative feedback intensity is regulated by WR 3 ;
(3)脉宽调制电路PWM采用SG3525芯片组成,其输入端1接焊接电流负反馈电路输出端,其输出端产生对逆变器主电路IGBT元件的开关脉冲信号。(3) The pulse width modulation circuit PWM is composed of SG3525 chip. Its input terminal 1 is connected to the output terminal of the welding current negative feedback circuit, and its output terminal generates the switching pulse signal for the inverter main circuit IGBT component.
本实用新型的单片机弧长自动调节模块采用独创的斜特性式弧长自动调节算法,可实现求出峰值电流脉宽调节量。The single-chip arc length automatic adjustment module of the utility model adopts an original oblique characteristic type arc length automatic adjustment algorithm, which can realize the calculation of the peak current pulse width adjustment amount.
Δtp=-K*T0/Ip*ΔUhpΔtp=-K*T0/Ip*ΔUhp
式中:ΔUhp为弧长变化引起的脉冲CO2焊电弧电压平均值变化量;In the formula: ΔUhp is the change in the average value of pulsed CO2 welding arc voltage caused by the change of arc length;
T0为脉冲CO2焊熔滴过渡平均时间;T 0 is the average time of droplet transfer in pulse CO2 welding;
Tp为脉冲CO2焊峰值电流设定值;T p is the set value of pulse CO2 welding peak current;
K为斜特性脉冲CO2焊电源外特性斜率设定值其功能是当脉冲CO2焊弧长发生变化时,单片机弧长自动调节模块可根据弧长变化引起的电弧电压变化量ΔUhp,通过改变峰值电流脉宽来产生相应的电流自动调节量ΔIhp,有ΔIhp=T0/Tp*Δtp。K is the setting value of the external characteristic slope of the slope characteristic pulse CO2 welding power source. Its function is that when the pulse CO2 welding arc length changes, the single-chip arc length automatic adjustment module can change the arc voltage variation ΔUhp caused by the arc length change by changing The peak current pulse width is used to generate the corresponding current automatic adjustment value ΔIhp, ΔIhp=T0/Tp*Δtp.
由于Δtp与ΔIhp相对ΔUhp为负值,其作用是使弧长变化减少的负反馈作用。Since Δtp and ΔIhp are negative relative to ΔUhp, their function is a negative feedback function to reduce the change of arc length.
单片机弧长自动调节模块的自动调节作用:The automatic adjustment function of the single-chip arc length automatic adjustment module:
(1)当弧长增加,使ΔUhp增加超过参考值Uh0时,弧长自动调节模块输出的峰值电流脉宽脉冲Ut的脉宽就由设定值tp0降为(tp0-Δtp),使焊接电流减小;(1) When the arc length increases, so that ΔUhp increases beyond the reference value Uh0, the pulse width of the peak current pulse width pulse Ut output by the arc length automatic adjustment module is reduced from the set value tp0 to (tp0-Δtp), so that the welding current decrease;
(2)当弧长减小,使ΔUh降低时,此模块就使Ut脉宽增加为(tp0-Δtp),自动增加焊接电流平均值,以恢复弧长。(2) When the arc length decreases to reduce ΔUh, this module increases the Ut pulse width to (tp0-Δtp), and automatically increases the average value of the welding current to restore the arc length.
此系统实现了以脉冲CO2焊逆变电源峰值电流脉宽为控制量,以电源外特性斜率为判据,对电源电压进行负反馈控制,使脉冲CO2焊电源输出电流平均值随电弧电压下降而线性增加,将基于恒流控制电流波形的脉冲CO2焊逆变电源转变为斜特性式脉冲CO2焊逆变电源,从而使本实用新型具有自适应调节弧长功能的脉冲CO2焊逆变电源。This system realizes the negative feedback control of the power supply voltage with the peak current pulse width of the pulse CO2 welding inverter power supply as the control amount and the external characteristic slope of the power supply as the criterion, so that the average output current of the pulse CO2 welding power supply follows the arc voltage. Decrease and increase linearly, transform the pulse CO2 welding inverter power supply based on the constant current control current waveform into a slope characteristic pulse CO2 welding inverter power supply, so that the utility model has the pulse CO2 welding with the function of self-adaptive adjustment of arc length inverter power supply.
由于采用了上述技术方案,本实用新型具有如下优点与效果:Due to the above-mentioned technical scheme, the utility model has the following advantages and effects:
(1)本实用新型斜特性式脉冲CO2焊逆变电源具有自适应的弧长自动调节功能,在焊接过程中,当弧长变化时,此电源就能自动调节焊接电流平均值,以此改变焊丝熔化速度而恢复电弧长度。(1) The oblique characteristic pulse CO2 welding inverter power supply of this utility model has an adaptive arc length automatic adjustment function. During the welding process, when the arc length changes, the power supply can automatically adjust the welding current average value, so that Change the wire melting speed to restore the arc length.
(2)本实用新型斜特性式脉冲CO2焊逆变电源对弧长自动调节强度可由其外特性斜率定量调整,通过控制面板减小外特性斜率K值,就可以增加脉冲CO2焊逆变电源的自动调节弧长强度。(2) The arc length automatic adjustment intensity of the oblique characteristic pulse CO2 welding inverter power supply of the utility model can be quantitatively adjusted by its external characteristic slope, and the pulse CO2 welding inverter can be increased by reducing the external characteristic slope K value through the control panel The power supply automatically adjusts the arc length intensity.
(3)本实用新型提出的斜特性式脉冲CO2焊逆变电源具有自适应确定焊接稳定工作点的功能。在焊丝送进速度一定改变焊接电流峰值或焊接电流峰值一定改变焊丝送进速度时,本实用新型均能使焊接平均电流与平均电压稳定在新的工作点,即电源斜特性曲线与焊机等速送丝特性曲线的交点,从而解决了电弧电压自寻优问题。(3) The oblique characteristic pulse CO2 welding inverter power supply proposed by the utility model has the function of self-adaptively determining the stable working point of welding. When the welding wire feeding speed must change the welding current peak value or the welding current peak value must change the welding wire feeding speed, the utility model can stabilize the welding average current and average voltage at the new working point, that is, the slope characteristic curve of the power supply and the welding machine, etc. The intersection point of the characteristic curve of fast wire feeding solves the problem of arc voltage self-optimization.
(4)本实用新型提出的斜特性式脉冲CO2焊逆变电源能够既保持恒流控制特性以精确控制脉冲电流峰值与基值,又使电源具有足够强烈的弧长自动调节特性与电弧电压自寻优功能,较好地改进了波控式CO2焊逆变电源的性能。(4) The oblique characteristic pulse CO2 welding inverter power source proposed by the utility model can not only maintain the constant current control characteristic to accurately control the peak value and base value of the pulse current, but also make the power source have a sufficiently strong arc length automatic adjustment characteristic and arc voltage The self-optimizing function improves the performance of the wave-controlled CO2 welding inverter power supply.
附图说明 Description of drawings
图1为新型的斜特性式脉冲CO2焊逆变电源弧长自动调节系统框图Figure 1 is a block diagram of a new type of oblique characteristic pulse CO2 welding inverter arc length automatic adjustment system
图2为新型的斜特性式脉冲CO2焊逆变电源控制系统电路原理图Figure 2 is a schematic diagram of a new type of slope characteristic pulse CO2 welding inverter power supply control system circuit diagram
图3为新型的斜特性式脉冲CO2焊逆变电源自动调节弧长工作原理图Figure 3 is a working principle diagram of the new type of oblique characteristic pulse CO2 welding inverter power supply to automatically adjust the arc length
图4为微机弧长自动调节模块工作原理图Figure 4 is the working principle diagram of the microcomputer arc length automatic adjustment module
图5为斜特性式脉冲CO2焊逆变电源控制系统单片机控制流程图Figure 5 is the control flow chart of the single-chip microcomputer for the control system of the inverter power supply control system of the oblique characteristic pulse CO2 welding
图6为斜特性式脉冲CO2焊逆变电源实测电压与电流波形图Figure 6 is the measured voltage and current waveform diagram of the slope characteristic pulse CO2 welding inverter power supply
具体实施方式 Detailed ways
现结合附图详细描述本实用新型最佳实施例:Now describe in detail the preferred embodiment of the utility model in conjunction with the accompanying drawings:
一种斜特性式脉冲CO2焊逆变电源,其技术特征为:A slope characteristic pulse CO2 welding inverter power supply, its technical characteristics are:
1、采用斜特性式弧长自动调节系统。如图1所示,该系统包括单片机弧长自动调节模块、波控参数转换电路、电源负反馈电路、恒流负反馈控制电路、PWM控制电路、焊接电流传感电路、焊接电压传感电路、AD转换电路以及控制面板。此系统在焊接过程中,通过电流与电压传感电路实时检测焊接电流Ih值与焊接电压Uh值,并将传感电路处理得的焊接电压模拟量Uv经过AD转换电路送入单片机CPU,再送入弧长自动调节模块;同时用户在控制面板设定的脉冲峰值电流Ip、基值电流Ib与外特性斜率K也送入单片机;弧长自动调节模块根据电弧电压变化量ΔUh与外特性斜率K实时计算出峰值电流脉宽tp的调节量Δtp;波控参数转换电路则根据峰值电流脉宽的调节量Δtp实时切换对恒流负反馈电路输出的电流设定值,使恒流负反馈电路实时切换对PWM控制电路的控制信号uk,继而使CO2焊逆变主电路改变脉冲电流波形宽度,从而使脉冲CO2焊逆变电源自动调节焊接电流平均值来调节焊丝熔化速度,稳定电弧长度。1. Adopt oblique characteristic arc length automatic adjustment system. As shown in Figure 1, the system includes a single-chip microcomputer arc length automatic adjustment module, wave control parameter conversion circuit, power supply negative feedback circuit, constant current negative feedback control circuit, PWM control circuit, welding current sensing circuit, welding voltage sensing circuit, AD conversion circuit and control panel. During the welding process, the system detects the value of welding current I h and welding voltage U h in real time through the current and voltage sensing circuit, and sends the analog value U v of welding voltage processed by the sensing circuit to the single-chip CPU through the AD conversion circuit , and then sent to the arc length automatic adjustment module; at the same time, the pulse peak current I p , base value current I b and external characteristic slope K set by the user on the control panel are also sent to the microcontroller; the arc length automatic adjustment module according to the arc voltage variation ΔU h Calculate the adjustment amount Δt p of the peak current pulse width t p in real time with the external characteristic slope K; the wave control parameter conversion circuit switches the current setting value output by the constant current negative feedback circuit in real time according to the adjustment amount Δt p of the peak current pulse width , so that the constant current negative feedback circuit switches the control signal u k to the PWM control circuit in real time, and then the CO2 welding inverter main circuit changes the pulse current waveform width, so that the pulse CO2 welding inverter power supply automatically adjusts the average value of the welding current to Adjust the melting speed of welding wire to stabilize the arc length.
2、采用斜特性式弧长自动调节系统电路。如图2所示。此电路的基本特征为:由单片机系统实现弧长自动调节算法与信号A/D、D/A转换;由电子电路实现波控参数(电流波形峰值和基值)转换,焊接电流负反馈控制与逆变主电路脉宽调制(PWM)控制。其具体情况为:2. Adopt the inclined characteristic type arc length automatic adjustment system circuit. as shown in
(1)多路开关u1与运算放大器u2组成焊接电流波控参数转换电路。多路开关u1的输入端x0,x1分别接单片机系统D/A模块的电流峰值Ip、模拟量up输出端与电流基值Ib模拟量ub输出端,其控制信号输入端A接单片机系统I/O接口电路的电流峰值时间tp开关脉冲信号ut输出端,ut脉冲信号为高电平时,多路开关u1的输入端x。与输出端x1选通,电路输出焊接电流波形峰值的设定值模拟量up,ut脉冲信号为低电平时,电路输出焊接电流波形基值的设定值模拟量ub。运算放大器U2电路用以调整从多路开关输出的电流设定值模拟信号至Us值,使之符号焊接电源负反馈控制电路输入要求,其放大倍数由WR1调节;(1) The multi-way switch u 1 and the operational amplifier u 2 form a welding current wave control parameter conversion circuit. The input terminals x 0 and x 1 of the multi-way switch u 1 are respectively connected to the current peak value I p of the D/A module of the single-chip system, the output terminal of the analog quantity up and the output terminal of the current base value I b analog quantity u b , and its control signal input Terminal A is connected to the current peak time t p switch pulse signal u t output terminal of the single-chip system I/O interface circuit, when the u t pulse signal is high level, the input terminal x of the multi-way switch u 1 . Strobe with the output terminal x1 , the circuit outputs the set value analog u p of the welding current waveform peak value, when the u t pulse signal is low level, the circuit outputs the set value analog u b of the welding current waveform base value. Operational amplifier U 2 circuit is used to adjust the current setting value analog signal output from the multi-way switch to U s value to make it meet the input requirements of the negative feedback control circuit of the welding power supply, and its magnification is adjusted by WR 1 ;
(2)运算放大器U3与U4同相放大电器组成焊接电源负反馈电路。其中运算放大器U3用以调理焊接电流传感的模拟量信号Ui使之与焊接电流波控参数转换电路输出值相匹配,其放大倍数由WR2调节,其输出值Uif送入运算放大器U4的反相端;运算放大器U4的同相端入焊接电流波形参数模拟量Us,使之与焊接电流模拟量Uif进行负反馈处理并输出控制信号Uk,其负反馈强度由WR3调节;(2) Operational amplifier U 3 and U 4 in-phase amplifying electrical appliances form a welding power supply negative feedback circuit. The operational amplifier U 3 is used to adjust the analog signal U i of the welding current sensor to match the output value of the welding current wave control parameter conversion circuit, its magnification is adjusted by WR 2 , and its output value U if is sent to the operational amplifier The inverting terminal of U 4 ; the non-inverting terminal of the operational amplifier U 4 enters the analog quantity U s of the welding current waveform parameter, so that it can perform negative feedback processing with the analog quantity U if of the welding current and output a control signal U k , and its negative feedback intensity is determined by WR 3 regulation;
(3)脉宽调制电路PWM采用SG3525芯片组成,其输入端1接焊接电流负反馈电路输出端,其输出端产生对逆变器主电路IGBT元件的开关脉冲信号。(3) The pulse width modulation circuit PWM is composed of SG3525 chip. Its input terminal 1 is connected to the output terminal of the welding current negative feedback circuit, and its output terminal generates the switching pulse signal for the inverter main circuit IGBT component.
3、单片机弧长自动调节模块采用独创的斜特性式弧长自动调节算法,可实现求出峰值电流脉宽调节量3. The single-chip microcomputer arc length automatic adjustment module adopts the original oblique characteristic arc length automatic adjustment algorithm, which can realize the peak current pulse width adjustment amount
Δtp=-K*T0/Ip*ΔUhpΔtp=-K*T0/Ip*ΔUhp
式中:ΔUhp为弧长变化引起的脉冲CO2焊电弧电压平均值变化量;In the formula: ΔUhp is the change in the average value of pulsed CO2 welding arc voltage caused by the change of arc length;
T0为脉冲CO2焊熔滴过渡平均时间;T 0 is the average time of droplet transfer in pulse CO2 welding;
Tp为脉冲CO2焊峰值电流设定值;T p is the set value of pulse CO2 welding peak current;
K为斜特性脉冲CO2焊电源外特性斜率设定值其功能是当脉冲CO2焊弧长发生变化时,单片机弧长自动调节模块可根据弧长变化引起的电弧电压变化量ΔUhp,通过改变峰值电流脉宽来产生相应的电流自动调节量ΔIhp,有ΔIhp=T0/Tp*Δtp由于Δtp与ΔIhp相对ΔUhp为负值,其作用是使弧长变化减少的负反馈作用。K is the setting value of the external characteristic slope of the slope characteristic pulse CO2 welding power source. Its function is that when the pulse CO2 welding arc length changes, the single-chip arc length automatic adjustment module can change the arc voltage variation ΔUhp caused by the arc length change by changing The peak current pulse width is used to generate the corresponding current automatic adjustment value ΔIhp, ΔIhp=T0/Tp*Δtp Since Δtp and ΔIhp are negative relative to ΔUhp, its function is to reduce the arc length change. Negative feedback function.
4、单片机弧长自动调节模块使基于恒流控制电流波形的脉冲CO2焊逆变电源转变为斜特性式脉冲CO2焊逆变电源。如图3示;4. The single-chip microcomputer arc length automatic adjustment module converts the pulse CO 2 welding inverter power supply based on the constant current control current waveform into a slope characteristic pulse CO 2 welding inverter power supply. As shown in Figure 3;
(1)当弧长增加,使ΔUhp增加超过参考值Uh0时,弧长自动调节模块输出的峰值电流脉宽脉冲Ut的脉宽就由设定值tp0降为(tp0-Δtp),使焊接电流减小,使脉冲CO2焊电源输出的峰值电流脉宽随电弧电压增加而线性减小,则电源输出电流平均值也随电弧电压增加而线性下降;(1) When the arc length increases, so that ΔUhp increases beyond the reference value Uh0, the pulse width of the peak current pulse width pulse Ut output by the arc length automatic adjustment module is reduced from the set value tp0 to (tp0-Δtp), so that the welding current Decrease, so that the pulse width of the peak current output by the pulse CO2 welding power source decreases linearly with the increase of the arc voltage, and the average value of the output current of the power source also decreases linearly with the increase of the arc voltage;
(2)当弧长减小,使ΔUh降低时,此模块就使Ut脉宽增加为(tp0-Δtp),自动增加焊接电流平均值,使脉冲CO2焊电源输出的峰值电流脉宽随电弧电压下降而线性增加,则电源输出电流平均值也随电弧电压下降而线性增加,由此,本实用新型的单片机弧长自动调节模块将基于恒流控制电流波形的脉冲CO2焊逆变电源转变为斜特性式脉冲CO2焊逆变电源。(2) When the arc length decreases and ΔUh decreases, this module increases the Ut pulse width to (tp0-Δtp), automatically increases the average value of the welding current, and makes the peak current pulse width output by the pulse CO2 welding power supply follow the arc When the voltage decreases and increases linearly, the average value of the output current of the power supply also increases linearly with the decrease of the arc voltage. Therefore, the single-chip microcomputer arc length automatic adjustment module of the utility model converts the pulse CO2 welding inverter power supply based on the constant current control current waveform It is an inverter power supply for slope characteristic pulse CO 2 welding.
5、斜特性脉冲CO2焊逆变电源自动调节弧长的机理是:以峰值电流脉宽为控制量,以电源外特性斜率为判据,对电源电压进行负反馈控制。5. The mechanism of the inclined characteristic pulse CO 2 welding inverter power supply to automatically adjust the arc length is: take the peak current pulse width as the control amount, and use the slope of the external characteristic of the power supply as the criterion to carry out negative feedback control on the power supply voltage.
如图4所示,图中斜外特性与等速送丝特性曲线交点O为稳定工作点,在焊接过程中,当弧长从λ1增到λ2时,斜外特性与电弧静特性交点变为O’点,其电流值比稳定工作点减少ΔIh量,即,电源自动产生电弧电流调节量ΔIh来减小焊丝熔化速度,使之低于焊丝送进速度,焊丝末端向熔池移动,焊接工作点从波动点O’逐渐恢复至稳定工作点O,保持弧长稳定。As shown in Figure 4 , the intersection point O of the oblique outer characteristic and the constant -speed wire-feeding characteristic curve in the figure is the stable operating point. It becomes the O' point, and its current value is reduced by ΔI h compared with the stable operating point, that is, the power supply automatically generates an arc current adjustment value ΔI h to reduce the melting speed of the welding wire, making it lower than the feeding speed of the welding wire, and the end of the welding wire moves toward the molten pool Moving, the welding working point gradually recovers from the fluctuation point O' to the stable working point O, keeping the arc length stable.
6、本实用新型的自动调节强烈性弧长可由脉冲CO2焊逆变电源外特性斜率值K进行调节。6. The arc length of the automatic adjustment intensity of the utility model can be adjusted by the external characteristic slope value K of the pulse CO2 welding inverter power supply.
随斜率K值调大,电源的外特性曲线趋于平缓,即单位电弧电压变化引起的电源输出电流调节量变大,则斜特性脉冲CO2焊电源的弧长自动调节作用变强。As the slope K value increases, the external characteristic curve of the power source tends to be gentle, that is, the output current adjustment amount of the power source caused by the change of the unit arc voltage becomes larger, and the arc length automatic adjustment function of the slope characteristic pulse CO2 welding power source becomes stronger.
7、采用了电弧电流与电弧电压双闭环负反馈控制。本实用新型通过弧长自动调节系统后使电源既保持了脉冲CO2焊机能按设定值精确控制电流波形的特性,包括控制燃弧时的电流峰值与基值以及短路过渡的电流波形;同时使电源获得斜率可调的斜外特性,从而具备与平特性电源相当的弧长自动调节功能。7. Double closed-loop negative feedback control of arc current and arc voltage is adopted. The utility model not only keeps the power source through the arc length automatic adjustment system, but also maintains the characteristics that the pulse CO2 welding machine can accurately control the current waveform according to the set value, including controlling the current peak value and base value during arc burning and the current waveform of short-circuit transition; At the same time, the power supply can obtain the slope-outside characteristic with adjustable slope, so as to have the arc length automatic adjustment function equivalent to the flat characteristic power supply.
8、本实用新型采用单片机控制程序对燃弧过程与短路过程电流波形进行实时闭环控制。8. The utility model uses a single-chip microcomputer control program to perform real-time closed-loop control on the current waveforms of the arcing process and the short-circuit process.
如图5示,单片机系统实时控制焊接过程中的燃弧电流峰值时间与短路过渡过程中的短路电流波形设定值。在CO2焊燃弧阶段,单片机对焊接电压与电流进行闭环控制,根据焊接电压Uh的采样值来确定对峰值电流脉宽tp的调节量,即通过实时调节tp值控制燃弧电流峰值波形,使电源具有自动调节弧长功能。在CO2焊短路阶段,采用单片机对恒流负反馈控制电路输出短路电流设定波形来精确控制短路电流波形,使之按照单片机设定值进行变化。As shown in Figure 5, the single-chip microcomputer system controls the peak time of the arcing current during the welding process and the set value of the short-circuit current waveform during the short-circuit transition process in real time. In the CO 2 welding arcing stage, the single-chip microcomputer performs closed-loop control on the welding voltage and current, and determines the adjustment value of the peak current pulse width t p according to the sampling value of the welding voltage U h , that is, controls the arcing current by adjusting the value of t p in real time The peak waveform enables the power supply to have the function of automatically adjusting the arc length. In the short-circuit stage of CO 2 welding, the single-chip microcomputer is used to output the short-circuit current setting waveform to the constant current negative feedback control circuit to precisely control the short-circuit current waveform, so that it changes according to the setting value of the single-chip microcomputer.
图6为本实用新型一个实例的实测结果。此实例的脉冲CO2焊逆变电源外特性斜率为4A/V,脉冲CO2焊的峰值电流设定值为400A,基值电流设定值为50A。由图可见,脉冲CO2焊过程稳定,脉冲电源外特性斜率电流峰值和基值与设定值一致。Fig. 6 is the measured result of an example of the utility model. In this example, the external characteristic slope of the pulse CO 2 welding inverter power supply is 4A/V, the peak current setting value of pulse CO 2 welding is 400A, and the base value current setting value is 50A. It can be seen from the figure that the pulse CO2 welding process is stable, and the peak value and base value of the slope current of the external characteristic of the pulse power supply are consistent with the set value.
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| CN104393744B (en) * | 2014-12-05 | 2017-09-29 | 郭智峰 | Digitize peak current control device |
| CN105234528A (en) * | 2015-09-23 | 2016-01-13 | 唐山松下产业机器有限公司 | Welding power source with dropping characteristic and control method thereof |
| CN119347042A (en) * | 2024-11-01 | 2025-01-24 | 上海锅炉厂有限公司 | A pulse interface circuit and control method thereof |
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