摘要
本文以汽车装配点焊车间生产线为背景,研制出了具有以太网通信功能的新型点焊控制器。为了解决控制时序和通讯时序的冲突,该控制器采用双单片机结构,一个单片机完成点焊过程的控制;另一个单片机负责点焊过程信息、质量信息与上位管理机的通信。两个单片机之间采用共用存储器方式实现数据的交换。
在点焊控制软件设计方面,不但保留了保证点焊质量的以往的网压补偿和恒流控制算法,还针对动态电阻明显的点焊材料基于热量百分数模型设计了动态电阻的反馈控制算法;接着,在正常的TCP网络状态变迁图基础上,建立了针对单片机和PC机特有的TCP状态变迁图,并利用该变迁图理论设计了通讯程序,用于实时远程监控焊机工作情况和焊接参数给定。
最后,对三种控制算法用数值计算的方法进行了验证,数据表明它们能很好的控制焊接质量;而对于通讯程序,利用专业网络监控软件进行了模拟调试,通过对底层数据的分析表明,该设计思想不但使传输中网络负荷小、数据传输速度快,而且能够排除实际点焊数据传输过程中的各种异常情况。
该网络化电阻点焊控制器的设计,能很好的实现对点焊过程的控制,能实现对焊接参数的远程给定和监视,从而保证点焊生产的质量,满足点焊工业化发展的需求。
A kind of spot welding controller that can communicate by Ethernet has been developed on the background of automobiles production line, in order to solve the collision of control and communication time sequence, this controller has two SCMs, one charges for controlling spot welding process, the other is in charge of the communication spot welding process information and spot welding quality information between spot-welder and PC.The two SCMs implement data exchange by shared memory.
On the side of spot welding software, not only the past voltage compensation and constant current algorithm which ensures spot welding quality are reserved, aiming at spot welding material with obvious dynamic resistance, but also the feedback control algorithm of dynamic resistance is designed on the basis of mode of heat percentage, and then the specific TCP state transition chart is established aiming at SCM and PC on the basis of normal TCP state transition chart, which is used to monitor soldering machine working situation in the real-time and long-distance way.
Finally the three kind of control algorithms are verified by numerical method, the data show that they can control welding quality perfectly, the communication programmer is tested by professional monitoring software, the analysis of rock-bottom data indicates that the design thought not only makes the burden of network small and data transfer quick, but also can eliminate kinds of abnormal situation in the process of practical spot welding data transfer.
The development of network based resistance spot welding controller can control the process of spot welding and realize the long-distance sending and monitoring of welding parameter, thereby the quality of spot welding is ensured and the demand of spot welding industrial development is satisfied.
引文
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