CN101386098A - Micro-controller control method of soft-switch invert welding source of electric welding machine - Google Patents

Micro-controller control method of soft-switch invert welding source of electric welding machine Download PDF

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Publication number
CN101386098A
CN101386098A CNA2008102018502A CN200810201850A CN101386098A CN 101386098 A CN101386098 A CN 101386098A CN A2008102018502 A CNA2008102018502 A CN A2008102018502A CN 200810201850 A CN200810201850 A CN 200810201850A CN 101386098 A CN101386098 A CN 101386098A
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welding
chip
current
soft switch
pwm
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聂先明
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Shanghai Hugong Electric Welding Machine Manufacturing Co Ltd
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Shanghai Hugong Electric Welding Machine Manufacturing Co Ltd
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Priority to CNA2008102018502A priority Critical patent/CN101386098A/en
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

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Abstract

The invention relates to a singlechip control method used for an electric welder soft switch inverter welding power; the singlechip control unit sets welding parameters and outputs the welding parameters to a given current; the welding parameters are converted into analog and feedback current by an A/D converter so as to carry out PI adjustment; the value after PI adjustment is sent to a PWM chip in current mode and a PWM driving pulse is output; the PWM driving pulse is separated and amplified by a driving transformer and used for driving the IGBT of the soft switch inverter welding power; during process of over-heat, over-voltage and empty-load, the singlechip control device outputs a locking signal to lock the PWM chip, thus locking the output; the singlechip control unit utilizes a general synchronous or asynchronous serial receiver and a transponder to communicate with a gauge head singlechip; therefore, welding data is sent to the gauge head singlechip in real time and long distance communication with a remote controller is realized through a serial external interface by virtue of a bus; the method can set the welding parameter and monitor the power, and has simple operation and high efficiency, and the controlled power has wide application scope.

Description

The Single-chip Controlling method of electric welding machine soft switch inverter welding power source
Technical field
The present invention relates to a kind of inversion welding source control method technical field, particularly soft switch inverter welding power source control method technical field, specifically be meant a kind of Single-chip Controlling method of electric welding machine soft switch inverter welding power source.
Background technology
Soft switch technique makes power switch pipe stagger at switching process immediate current track and tube voltage drop track, power switch pipe loss and the excessive problem of switch stress have been solved largely, reduce the du/dt of power device and the electromagnetic interference that di/dt causes, improved efficient.Therefore, the soft switching regulator source of welding current is a kind of novel source of welding current with bright prospects.
Along with the application of singlechip technology in the source of welding current, the flexibility of the source of welding current is designed to possibility, and source of welding current design time shortens greatly, just develops towards the modularization direction.Therefore, set soft switch technique and singlechip technology are built a source of welding current platform and are developed welding rod weldering, TIG weldering, CO 2The sources of welding current such as weldering, submerged-arc welding seem very meaningful.
Summary of the invention
The object of the present invention is to provide a kind of Single-chip Controlling method of electric welding machine soft switch inverter welding power source, this Single-chip Controlling method can set welding parameter and monitoring power supply work, simple to operate, efficient is high, wide by the power supply purposes scope of its control.
To achieve the above object, the invention provides a kind of Single-chip Controlling method of electric welding machine soft switch inverter welding power source, be characterized in, set welding parameter by the Single-chip Controlling unit, export given electric current, the process A/D converter converts analog quantity to and feedback current carries out the PI adjusting, and the value after PI regulates is sent into the PWM chip of current-mode, export the PWM driving pulse then, after driving transformer is isolated amplification, be used to drive the IGBT of soft switch inverter welding power source.
Preferably, also comprise: when overheated, under-voltage or when unloaded, monolithic processor control device output locking signal blocks the PWM chip, thereby blocks output.
Preferably, also comprise step: Single-chip Controlling unit by using universal synchronous is communicated by letter with the gauge outfit chip microcontroller with transponder with the asynchronous serial receiver, in real time welding data is sent to the gauge outfit single-chip microcomputer.
Preferably, also comprise step: Single-chip Controlling unit by using Serial Peripheral Interface (SPI) is by the telecommunication of bus realization with remote controller.
Adopted the Single-chip Controlling method of electric welding machine soft switch inverter welding power source of the present invention, because the power supply that the present invention is used to control adopts soft switch technique, so stable performance, the efficient height, power consumption is little, has good electric property; The present invention adopts 3 single-chip microcomputers, saved a large amount of analog circuits, simple for structure, can set welding parameter and monitoring power supply work, simple to operate, efficient is high, whole in addition SCM system adopts advanced Atmega single-chip microcomputer, system takes up room more than needed many, can online programming at any time butt welding machine carry out online upgrading; The power supply of the present invention's control can be used for welding rod weldering, TIG weldering, CO 2Weldering, submerged-arc welding etc.
Description of drawings
Fig. 1 is the main circuit schematic diagram that is subjected to the source of welding current that the present invention controls.
Fig. 2 is control signal of the present invention and main circuit waveform schematic diagram.
Fig. 3 is the structural representation of a specific embodiment of the present invention.
Fig. 4 is the main program flow chart of a specific embodiment of the present invention.
Fig. 5 is the peripheral circuit diagram of the PWM chip of a specific embodiment of the present invention.
The specific embodiment
Below will be described in further detail real-time recording method of welder performance of the present invention.
See also Fig. 1～shown in Figure 5, the Single-chip Controlling method of electric welding machine soft switch inverter welding power source of the present invention, set welding parameter by the Single-chip Controlling unit, export given electric current, the process A/D converter converts analog quantity to and feedback current carries out the PI adjusting, value after PI regulates is sent into the PWM chip of current-mode, exports the PWM driving pulse then, is used to drive the IGBT of soft switch inverter welding power source after driving transformer is isolated amplification.
Preferably, also comprise: when overheated, under-voltage or when unloaded, monolithic processor control device output locking signal blocks the PWM chip, thereby blocks output.
Preferably, also comprise step: Single-chip Controlling unit by using universal synchronous is communicated by letter with the gauge outfit chip microcontroller with transponder with the asynchronous serial receiver, in real time welding data is sent to the gauge outfit single-chip microcomputer.
Preferably, also comprise step: Single-chip Controlling unit by using Serial Peripheral Interface (SPI) is by the telecommunication of bus realization with remote controller.
The single-chip computer control system that is used for electric welding machine soft switch inverter welding power source of the present invention, comprise monolithic processor control device, A/D converter, PI regulon, PWM chip and be used for the driving transformer of the IGBT of driving switch inversion welding source, described monolithic processor control device comprises Single-chip Controlling unit, the electrification reset unit and the hour hands unit that are connected with described Single-chip Controlling unit respectively, described Single-chip Controlling unit connects described PI regulon by described A/D converter, and described PI regulon connects described driving transformer by described PWM chip.
Preferably, described monolithic processor control device also comprises the gauge outfit single-chip microcomputer, and described gauge outfit single-chip microcomputer connects described Single-chip Controlling unit.
Preferably, described monolithic processor control device also comprises the remote controller single-chip microcomputer, and described remote controller single-chip microcomputer connects described Single-chip Controlling unit.
Preferably, described Single-chip Controlling unit connects described PWM chip.
The power circuit principle of the soft switch inverter welding power source of above-mentioned single-chip computer control system as shown in Figure 1.Power circuit adopts pulsactor formula FB-ZVZCS-PWM converter topology, leading-bridge (IGBT 1And IGBT 2The brachium pontis of forming) realizes ZVT, lagging leg (IGBT 3And IGBT 4The brachium pontis of forming) realizes Zero Current Switch, thereby realized the zero-voltage and zero-current switch (ZVZCS) of soft-switching inversion welding machine.Blocking capacitor C bThe decay loop current, pulsactor L rThe blocking-up current reversal increases.U InBe input dc power potential source, VD 1～VD 4Be respectively and IGBT 1～IGBT 4The diode of (model is BSM75GB120DN2) reverse parallel connection, C 1, C 2Be respectively IGBT 1, IGBT 2Output capacitance and external capacitor sum, L kBe transformer T rLeakage inductance, VD R1And VD R2(model MUR200) is output commutation diode, L fBe output inductor, R is the electric arc equivalent resistance.Now with circuit topology shown in Figure 1 and adopt finite both to be controlled to be example, the realization principle of leading arm no-voltage, lagging leg zero current is described.
IGBT 1～IGBT 4Control signal, two brachium pontis mid-point voltage U AB, transformer primary current i pAnd capacitor C bBoth end voltage U CbWaveform as shown in Figure 2.
t 0Constantly turn-off IGBT 1, because IGBT 1Shunt capacitance C 1Both end voltage can not be suddenlyd change, so IGBT 1No-voltage is turn-offed.After this C 1, C 2Begin to discharge and recharge t 1Constantly discharge and recharge end, VD 2Conducting is IGBT 2Open and created the condition that no-voltage is opened, primary current circulation begins.At this moment, capacitor C bVoltage U CbBe added on the leakage inductance of transformer the very fast decay of primary current, t entirely 2Primary current decays to zero constantly, and pulsactor blocking-up current reversal increases, and makes primary current remain zero, thereby realizes IGBT 4Zero-current switching.The soft switching process of half period similarly in addition.
The single-chip computer control system principle of compositionality as shown in Figure 3.With Atmega16 is core, constitutes single-chip minimum system with electrify restoration circuit, clock circuit, and the given electric current of PD (0～7) output converts analog quantity and feedback current i to through D/A converter 7537 fCarry out PI and regulate, the PWM chip UC3846 that the value after PI regulates is sent into current-mode exports the PWM driving pulse then, isolates to amplify driving IGBT through driving transformer.When overheated, under-voltage or when unloaded, single-chip microcomputer output locking signal blocks UC3846, thereby blocks output.In addition, unit utilizes universal synchronous to communicate by letter with the chip microcontroller of gauge outfit with transponder (USART) with the asynchronous serial receiver, in real time welding data is sent to the gauge outfit single-chip microcomputer, utilize serial peripheral equipment interface SPI to pass through the telecommunication of realization of 485 buses and remote controller.
Single-chip computer control system has adopted 3 Atmega single-chip microcomputers altogether, and master control borad, gauge outfit and remote controller are used a slice single-chip microcomputer respectively, and main control singlechip is communicated by letter with the remote control chip microcontroller with the gauge outfit single-chip microcomputer.Be example with the SMAW welding machine below, introduce the function of 3 single-chip microcomputers.
(1) main control singlechip is responsible for the management function of whole welding machine, and communicates by letter with the remote controller chip microcontroller with the gauge outfit single-chip microcomputer in real time.It has parameter and sets and the switching value input function; setup parameter comprises welding current, push current, striking electric current, striking time, cable length; the switching value input comprises that temperature protection signal, arc voltage state Vinn, striking become function signal etc.; PD (0～7) mouthful of different welded conditions of output given electric current (striking electric current, push current promptly superpose) constantly, and the output of output protection signal blockade in time as required.
(2) gauge outfit single-chip microcomputer be responsible for sampling three-phase electricity input, arc voltage and feedback current, and and the welding parameter that sends over of main control singlechip show in the lump.Because of there being special single-chip microcomputer to be responsible for demonstration, so display parameters increase (5 of display parameters: welding current, push current, striking electric current, striking time, cable length greatly; 6 of welding parameters: electric current, A during welding, B, C three-phase input voltage, arc voltage, accumulative total weld interval).
(3) the remote controller single-chip microcomputer can be set welding current and push current when remote control mode, shows welding current and arc voltage parameter that main control singlechip sends in real time, and can in time light trouble light according to failure condition.
The ATmega16 single-chip microcomputer is based on 8 the CMOS microcontrollers of low-power consumption that strengthen the AVR risc architecture.Because its advanced instruction set and single clock cycle time for each instruction, the data throughput of ATmega16 is up to 1MIPS/MHz, thereby can the contradiction of relieving system between power consumption and processing speed.The In-System Programmable Flash that it has 16kB (has the ability of reading while write, be RWW), the EEPROM of 512B, the SRAM of 1kB, 32 universaling I/O port lines, 32 general purpose working registers, debugging and programming in the supporting pieces, 3 timer/counter flexibly, sheet inside/outsides with comparison pattern interrupt serial USART able to programme, 8 tunnel 10 ADC with optional differential input stage programmable-gain, the programmable watchdog timer of oscillator, 1 SPI serial port, and moderate, therefore have high performance price ratio.
With the SMAW welding machine is example, and the software of main control singlechip mainly is made up of following components: main program, initialize routine, A/D conversion program, striking program, cable compensation program, plus-minus thrust interrupt routine, signal procedure.Main program flow chart as shown in Figure 4.
After resetting after powering on, program brings into operation from 002AH.System carries out initialization subroutine earlier, and blocks welding machine output, finishes the initial value of each parameter then and sets.When selecting remote control mode for use, accept the setup parameter on the remote controller, otherwise this machine of acceptance parameter.Single-chip microcomputer calculates the output cable pressure drop according to the cable length and the welding current value of input, calculates stack push current arc voltage flex point value automatically.Welding machine detects arc voltage state V subsequently InnWhether, be 1 o'clock, welding machine is lifted a blockade if being 1 (being whether welding rod contacts with workpiece), open interruption, and begin to carry out the striking program, be i.e. the output welding current set-point behind the striking electric current that superposeed, when striking cancellation striking electric current after time is up, export normal welding current value.Welding machine detects arc voltage, utilizes external interrupt to enter interruption subroutine stack thrust when arc voltage is lower than flex point value after single-chip microcomputer calculates, the welding current set-point behind the output stack thrust magnitude.
Because system adopts the Atmega single-chip microcomputer, it is more than needed many to take up room, and can online programming be upgraded by the source of welding current.
The soft ON-OFF control circuit of ZVZCS-PWM is a core with the UC3846 chip of current-mode, and the UC3846 chip adopts the peak-current mode control method, and promptly switching device is open-minded in the set time, and when current instantaneous value reached the electric current set-point, switching device turn-offed.The UC3846 peripheral circuit is seen Fig. 5.
Set-point links to each other with 5 pin (error amplifier is input in the same way), 6 pin (error amplifier reverse input end) and 7 pin (compensation end) of the value input UC3846 of value of feedback after PI regulates, is connected into the follower form, forms outer voltage input feedback.
The primary current detected value is imported 4 pin (current sense amplifier positive input terminal), carries out the transient current feedback, forms the current inner loop feedback.
Because the current-mode converter be operated in dutycycle greater than 50% and continuous electric inducing current condition under can produce subharmonic oscillation, it is that working condition is caused simultaneously by the sampling of fixed frequency and peak point current.For this reason, utilize the sawtooth waveforms of 8 pin (oscillation output end) output that 4 pin are carried out slope-compensation.
11,14 pin are exported 2 road pwm signals, and sending U5 respectively is the pulse stretcher circuit of core, form 2 tunnel fixed pulse width triggering signals of lagging leg; The pulse of 10 pin (synchronous signal output end) output send the fixed pulse width widening circuit to form the dead band of 2 tunnel fixed pulse width; 16 pin connect guard signal, as long as the guard signal input of high level is arranged, 11,14 pin stop the output of pwm signal, thereby block leading-bridge.
At designed control circuit, utilize the four-way storage oscilloscope to detect, Fig. 6, Fig. 7 are respectively 4 IGBT drive control signal under 2 kinds of different loads situations that collect.As seen from the figure when welding current and arc voltage higher (welding current 400A, arc voltage 36V), leading-bridge IGBT 1, IGBT 2Pulsewidth is bigger, lagging leg IGBT 3, IGBT 4Fixed pulse width, IGBT 1～IGBT 44 groups of drive control signal realize the finite both control mode; As welding current 58A, during arc voltage 6V, leading-bridge IGBT 1, IGBT2Compression pulse width, lagging leg IGBT 3, IGBT 4Fixed pulse width.Through overtesting and on-line debugging, the result shows that the control circuit each several part is working properly.
In sum, the Single-chip Controlling method of electric welding machine soft switch inverter welding power source of the present invention can set welding parameter and monitoring power supply work, simple to operate, efficient is high, wide by the power supply purposes scope of its control.
In this specification, the present invention is described with reference to its certain embodiments.But, still can make various modifications and conversion obviously and not deviate from the spirit and scope of the present invention.Therefore, specification and accompanying drawing are regarded in an illustrative, rather than a restrictive.

Claims (4)

1. the Single-chip Controlling method of an electric welding machine soft switch inverter welding power source, it is characterized in that, set welding parameter by the Single-chip Controlling unit, export given electric current, the process A/D converter converts analog quantity to and feedback current carries out the PI adjusting, value after PI regulates is sent into the PWM chip of current-mode, exports the PWM driving pulse then, is used to drive the IGBT of soft switch inverter welding power source after driving transformer is isolated amplification.
2. the Single-chip Controlling method of electric welding machine soft switch inverter welding power source as claimed in claim 1 is characterized in that, also comprises: when overheated, under-voltage or when unloaded, monolithic processor control device output locking signal blocks the PWM chip, thereby blocks output.
3. the soft switch inverter welding power source numerical control method of electric welding machine as claimed in claim 1, it is characterized in that, also comprise step: Single-chip Controlling unit by using universal synchronous is communicated by letter with the gauge outfit chip microcontroller with transponder with the asynchronous serial receiver, in real time welding data is sent to the gauge outfit single-chip microcomputer.
4. the soft switch inverter welding power source numerical control method of electric welding machine as claimed in claim 1 is characterized in that, also comprises step: Single-chip Controlling unit by using Serial Peripheral Interface (SPI) is by the telecommunication of bus realization with remote controller.
CNA2008102018502A 2008-10-28 2008-10-28 Micro-controller control method of soft-switch invert welding source of electric welding machine Pending CN101386098A (en)

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102205476A (en) * 2011-05-26 2011-10-05 太原市星云焊接设备有限公司 High-frequency soft switching contravariant digital multifunctional welding machine
CN102248266A (en) * 2011-07-11 2011-11-23 江苏科技大学 Automatic voltage regulation (AVR) singlechip control-based thick wire electric-gas vertical welding machine and control method
CN102892542A (en) * 2011-05-17 2013-01-23 松下电器产业株式会社 Welding apparatus
CN102909459A (en) * 2012-10-12 2013-02-06 申巧言 Welding system without control line
CN103100785A (en) * 2013-02-28 2013-05-15 广州市长胜焊接设备实业有限公司 Digitization inversion arc welding machine output pole short circuit automatic protection system
CN105665883A (en) * 2016-01-12 2016-06-15 南通富力机电设备有限责任公司 Automatic ball grinding control device and method based on single chip microcomputer and used for alternate current argon arc welding tungsten electrode
CN107073629A (en) * 2014-11-11 2017-08-18 松下知识产权经营株式会社 Welder and welding method
CN111545882A (en) * 2020-05-19 2020-08-18 北京工业大学 Arc energy adjusting device and method
CN112475568A (en) * 2020-10-28 2021-03-12 上海沪工焊接集团股份有限公司 Arc guide control method and device for double-voltage plasma cutting machine

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102892542A (en) * 2011-05-17 2013-01-23 松下电器产业株式会社 Welding apparatus
CN102892542B (en) * 2011-05-17 2014-12-03 松下电器产业株式会社 Welding apparatus
CN102205476B (en) * 2011-05-26 2014-01-08 太原市星云焊接设备有限公司 High-frequency soft switching contravariant digital multifunctional welding machine
CN102205476A (en) * 2011-05-26 2011-10-05 太原市星云焊接设备有限公司 High-frequency soft switching contravariant digital multifunctional welding machine
CN102248266A (en) * 2011-07-11 2011-11-23 江苏科技大学 Automatic voltage regulation (AVR) singlechip control-based thick wire electric-gas vertical welding machine and control method
CN102248266B (en) * 2011-07-11 2013-06-05 江苏科技大学 Automatic voltage regulation (AVR) singlechip control-based thick wire electric-gas vertical welding machine and control method
CN102909459A (en) * 2012-10-12 2013-02-06 申巧言 Welding system without control line
CN102909459B (en) * 2012-10-12 2014-12-17 申巧言 Welding system without control line
CN103100785A (en) * 2013-02-28 2013-05-15 广州市长胜焊接设备实业有限公司 Digitization inversion arc welding machine output pole short circuit automatic protection system
CN103100785B (en) * 2013-02-28 2015-11-25 广州长胜机电有限公司 A kind of digitlization inverter arc welding machine output stage short circuit automatic protective system
CN107073629A (en) * 2014-11-11 2017-08-18 松下知识产权经营株式会社 Welder and welding method
CN105665883A (en) * 2016-01-12 2016-06-15 南通富力机电设备有限责任公司 Automatic ball grinding control device and method based on single chip microcomputer and used for alternate current argon arc welding tungsten electrode
CN111545882A (en) * 2020-05-19 2020-08-18 北京工业大学 Arc energy adjusting device and method
CN112475568A (en) * 2020-10-28 2021-03-12 上海沪工焊接集团股份有限公司 Arc guide control method and device for double-voltage plasma cutting machine
CN112475568B (en) * 2020-10-28 2024-02-20 上海沪工焊接集团股份有限公司 Arc guiding control method and device for double-voltage plasma cutting machine

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