软开关脉冲GMAW焊接电源及弧长稳定性研究
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摘要
脉冲熔化极气体保护焊（GMAW）工艺具有电流调节范围宽、适于全位置焊、焊缝成型优良等特点，在制造工业生产中逐渐获得广泛应用，然而其对弧焊电源性能提出了更高的要求。软开关弧焊电源正好符合脉冲GMAW焊的需求，当前对全桥软开关弧焊逆变器的建模研究还不系统，为了更好地在设计中优化弧焊电源参数，对软开关弧焊电源系统模型进行分析研究十分必要。通过对全桥移相软开关弧焊逆变电源的模型进行简化，建立了其等效小信号模型，并将峰值电流控制技术与移相软开关技术相互融合，研究了峰值电流控制模式下移相软开关逆变器稳定性问题，分析表明在脉宽调制占空比大于50%的情况下，斜坡补偿是逆变器稳定的必要条件。在此基础上分析了电源的动特性影响因素，并对弧焊电源的外特性边界形成因素进行了分析研究，为电源的研制和控制参数的优化设计提供了理论指导。
针对脉冲GMAW焊机设计中所存在的问题进行了分析研究，提出了基于DSP+ARM架构的控制电路设计方案，采用模块化的方式对相关电路进行功能设计，并对控制部分的软件功能实现进行了详细分析，建立了可靠的脉冲GMAW焊接电源平台，为进行弧焊过程工艺分析研究奠定了硬件基础。电源性能的测试结果表明所设计的脉冲GMAW焊接电源平台满足实际需求。
通过对脉冲GMAW焊接系统中各模块的模型分析，基于Matlab/Simulink仿真环境及其扩展工具S函数建立了脉冲GMAW焊接弧焊逆变电源主回路和控制系统的混合仿真模型，仿真模型能够有效地模拟实际弧焊逆变电源-动态电弧负载系统的动态过程特征。基于S函数所建立的脉冲GMAW焊接弧焊逆变电源-电弧系统仿真模型的控制策略能够仿真实际焊接弧长过程动态调节过程。通过引入干扰条件，仿真系统能定量分析脉冲GMAW焊接过程中各物理参数变化机理及影响因素，为实际脉冲GMAW焊逆变电源控制参数设计优化、验证新的弧长控制算法及策略提供了新途径。
脉冲GMAW焊接熔滴过渡方式对焊接工艺性能、焊缝成形和焊接质量有重要影响，为实现有效、精确控制熔滴过渡的行为，采用一脉一滴熔滴过渡方式是目前最佳的选择。在脉冲GMAW焊接特征参数选择分析的基础上，得出实现脉冲GMAW焊接一脉一滴熔滴过渡的最佳实现是I/I控制方法，即脉冲峰值和脉冲基值期间都采用恒流外特性电源。但由于恒流外特性下，电弧无自身调节作用，无法进行弧焊过程中弧长的调节，为此，提出了基于脉冲周期内环恒流控制外环弧压控制的双闭环控制策略。通过对单个脉冲周期的平均电流电压的模型计算研究发现，基于脉冲周期的双闭环弧长控制策略实现机理是周期平均值外特性自身调节作用，并通过周期平均值外特性上下台阶调节试验验证了理论分析的正确性，为脉冲GMAW焊接方式机器人自动化实现提供了理论基础。
Pulsed gas metal arc welding (GMAW) process has a wide range of current adjustment,suitable for all position welding, weld forming excellent characteristics. It is widely applied inthe manufacture of industrial production. However the performance of arc welding powersupply has put forward higher requirements. Soft switching arc welding power source is inaccord with the demand of pulsed GMAW welding. Now, the full-bridge soft switching arcwelding inverter modeling research is not system. In order to obtain optimal parameters ofsoft switch arc welding power supply in the design process, so it is very necessary to researchthe mode of arc welding power supply system. Based on full bridge soft-switching inverterarc welding power source model simplification, the equivalent small signal model is set up.The peak current control technology and phase-shifted full-bridge soft switching technologyis mutual integration, stability problem of phase inverter with soft switching is researched onthe peak current controlled mode. The analysis shows that slope compensation is necessaryconditions for inverter stability in the case of PWM duty ratio greater than50%. Above all,influence factors of dynamic characteristics for power supply are analyzed, and the boundarycurves of output characteristics for arc welding power supply is analyzed. This provides atheoretical guidance for welding supply development and optimization design of the controlparameters.
The existing design problems of pulsed GMAW welding machine are analyzed, controlcircuit based on the DSP+ARM topology architecture is proposed. It realized functionanalysis and design of circuit by using modular methods, and the realization of software forcontroller is designed in detail. So a reliable platform for pulsed GMAW welding powersupply is established. It provides a basic hardware foundation for welding process research.Test results of power characteristic performances show that the designed pulsed GMAWwelding power supply can meet the practical needs.
Through the model analysis of the pulsed GMAW welding system, main circuit andcontrol system simulation model are established based on the Matlab/simulink simulationenvironment and its extension S function establishes for pulsed GMAW welding power supply.The simulation model can effectively simulate the dynamic characteristics of special process for the actual arc welding inverter-dynamic arc load system. Control strategy can simulatethe real process of arc length dynamic adjustment based on simulation model of pulsedGMAW welding inverter and arc load system using S function. By introducing interferencecondition, simulation system can quantitative analysis the physical parameters variationmechanism and influence factors in pulsed GMAW welding process. It provides a new way tooptimize parameters of controller for pulsed GMAW welding inverter, verify new arc lengthcontrol algorithm and strategy.
It has an important effect for welding technological properties, weld forming andwelding quality with different droplet transfer mode of pulsed GMAW welding. Droplettransition of 'One drop per pulse' is the best choice to achieve effective, precise control ofdroplet transfer behavior. It comes to realize that I/I control method is best method to get 'onedrop per pulse' based on analysis parameters selection of pulsed GMAW welding. Outputcharacteristics of constant current power supply are used during both peak period and baseperiod. Arc has not self regulation with output characteristics of constant current, so arc lengthmust be controlled in the process of arc welding. Double loop control strategy of cycle loopconstant current control and outer loop arc voltage control in one pulse period is proposed.Through average current-voltage model of a single pulse period, it is found that the controlstrategy based on double closed-loop arc length of the pulse period of the cycle average of theoutput characteristics has self-regulation role. Step up and down tests of arc length regulationshow that the theoretical analysis is correct through periodic average output characteristics.This provides a theoretical basis for pulsed GMAW welding robotic automation.
针对脉冲GMAW焊机设计中所存在的问题进行了分析研究，提出了基于DSP+ARM架构的控制电路设计方案，采用模块化的方式对相关电路进行功能设计，并对控制部分的软件功能实现进行了详细分析，建立了可靠的脉冲GMAW焊接电源平台，为进行弧焊过程工艺分析研究奠定了硬件基础。电源性能的测试结果表明所设计的脉冲GMAW焊接电源平台满足实际需求。
通过对脉冲GMAW焊接系统中各模块的模型分析，基于Matlab/Simulink仿真环境及其扩展工具S函数建立了脉冲GMAW焊接弧焊逆变电源主回路和控制系统的混合仿真模型，仿真模型能够有效地模拟实际弧焊逆变电源-动态电弧负载系统的动态过程特征。基于S函数所建立的脉冲GMAW焊接弧焊逆变电源-电弧系统仿真模型的控制策略能够仿真实际焊接弧长过程动态调节过程。通过引入干扰条件，仿真系统能定量分析脉冲GMAW焊接过程中各物理参数变化机理及影响因素，为实际脉冲GMAW焊逆变电源控制参数设计优化、验证新的弧长控制算法及策略提供了新途径。
脉冲GMAW焊接熔滴过渡方式对焊接工艺性能、焊缝成形和焊接质量有重要影响，为实现有效、精确控制熔滴过渡的行为，采用一脉一滴熔滴过渡方式是目前最佳的选择。在脉冲GMAW焊接特征参数选择分析的基础上，得出实现脉冲GMAW焊接一脉一滴熔滴过渡的最佳实现是I/I控制方法，即脉冲峰值和脉冲基值期间都采用恒流外特性电源。但由于恒流外特性下，电弧无自身调节作用，无法进行弧焊过程中弧长的调节，为此，提出了基于脉冲周期内环恒流控制外环弧压控制的双闭环控制策略。通过对单个脉冲周期的平均电流电压的模型计算研究发现，基于脉冲周期的双闭环弧长控制策略实现机理是周期平均值外特性自身调节作用，并通过周期平均值外特性上下台阶调节试验验证了理论分析的正确性，为脉冲GMAW焊接方式机器人自动化实现提供了理论基础。
Pulsed gas metal arc welding (GMAW) process has a wide range of current adjustment,suitable for all position welding, weld forming excellent characteristics. It is widely applied inthe manufacture of industrial production. However the performance of arc welding powersupply has put forward higher requirements. Soft switching arc welding power source is inaccord with the demand of pulsed GMAW welding. Now, the full-bridge soft switching arcwelding inverter modeling research is not system. In order to obtain optimal parameters ofsoft switch arc welding power supply in the design process, so it is very necessary to researchthe mode of arc welding power supply system. Based on full bridge soft-switching inverterarc welding power source model simplification, the equivalent small signal model is set up.The peak current control technology and phase-shifted full-bridge soft switching technologyis mutual integration, stability problem of phase inverter with soft switching is researched onthe peak current controlled mode. The analysis shows that slope compensation is necessaryconditions for inverter stability in the case of PWM duty ratio greater than50%. Above all,influence factors of dynamic characteristics for power supply are analyzed, and the boundarycurves of output characteristics for arc welding power supply is analyzed. This provides atheoretical guidance for welding supply development and optimization design of the controlparameters.
The existing design problems of pulsed GMAW welding machine are analyzed, controlcircuit based on the DSP+ARM topology architecture is proposed. It realized functionanalysis and design of circuit by using modular methods, and the realization of software forcontroller is designed in detail. So a reliable platform for pulsed GMAW welding powersupply is established. It provides a basic hardware foundation for welding process research.Test results of power characteristic performances show that the designed pulsed GMAWwelding power supply can meet the practical needs.
Through the model analysis of the pulsed GMAW welding system, main circuit andcontrol system simulation model are established based on the Matlab/simulink simulationenvironment and its extension S function establishes for pulsed GMAW welding power supply.The simulation model can effectively simulate the dynamic characteristics of special process for the actual arc welding inverter-dynamic arc load system. Control strategy can simulatethe real process of arc length dynamic adjustment based on simulation model of pulsedGMAW welding inverter and arc load system using S function. By introducing interferencecondition, simulation system can quantitative analysis the physical parameters variationmechanism and influence factors in pulsed GMAW welding process. It provides a new way tooptimize parameters of controller for pulsed GMAW welding inverter, verify new arc lengthcontrol algorithm and strategy.
It has an important effect for welding technological properties, weld forming andwelding quality with different droplet transfer mode of pulsed GMAW welding. Droplettransition of 'One drop per pulse' is the best choice to achieve effective, precise control ofdroplet transfer behavior. It comes to realize that I/I control method is best method to get 'onedrop per pulse' based on analysis parameters selection of pulsed GMAW welding. Outputcharacteristics of constant current power supply are used during both peak period and baseperiod. Arc has not self regulation with output characteristics of constant current, so arc lengthmust be controlled in the process of arc welding. Double loop control strategy of cycle loopconstant current control and outer loop arc voltage control in one pulse period is proposed.Through average current-voltage model of a single pulse period, it is found that the controlstrategy based on double closed-loop arc length of the pulse period of the cycle average of theoutput characteristics has self-regulation role. Step up and down tests of arc length regulationshow that the theoretical analysis is correct through periodic average output characteristics.This provides a theoretical basis for pulsed GMAW welding robotic automation.
引文
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