CN101856764A - Singlechip control method of soft switch fuzzy PID (Proportion Integration Differentiation) control welding power supply of electric welding machine - Google Patents
Singlechip control method of soft switch fuzzy PID (Proportion Integration Differentiation) control welding power supply of electric welding machine Download PDFInfo
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- CN101856764A CN101856764A CN200910048941A CN200910048941A CN101856764A CN 101856764 A CN101856764 A CN 101856764A CN 200910048941 A CN200910048941 A CN 200910048941A CN 200910048941 A CN200910048941 A CN 200910048941A CN 101856764 A CN101856764 A CN 101856764A
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- 230000001360 synchronised effect Effects 0.000 claims abstract description 6
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- 238000007778 shielded metal arc welding Methods 0.000 description 2
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Abstract
The invention relates to a singlechip control method of a soft switch fuzzy PID (Proportion Integration Differentiation) control welding power supply of an electric welding machine. The method comprises the following steps of: setting welding parameters and outputting given current by a singlechip control unit; converting the given current into analog quantity and feedback current through an A/D converter for PI (Pressure Index) adjustment; feeding a value subjected to PI adjustment into a current mode PWM (Pulse-Width Modulation) chip; outputting PWM drive pulse; using the drive pulse which is isolated and amplified by a drive transformer for driving Fuzzy-PID of the soft switch fuzzy PID control welding power supply; outputting a block signal for blocking the PWM chip by a singlechip control device so as to block the output in the overheat, undervoltage or no-load state; realizing the communication between a singlechip control unit and a header singlechip by using general synchronous and asynchronous serial receiver and forwarder; transmitting welding data to the header singlechip by the singlechip control unit in real time; and realizing long-distance communication between the singlechip control unit and a remote controller through a bus by using a serial external interface. The invention can be used for setting the welding parameters and monitoring the work of the power supply and has simple operation and high efficiency and wide range of the controlled power supply.
Description
Technical field
The present invention relates to a kind of the fuzzy control source of welding current control method technical field, particularly soft switch fuzzy PID control source of welding current control method technical field, specifically be meant a kind of Single-chip Controlling method of the electric welding machine soft switch fuzzy PID control source of welding current.
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 the Single-chip Controlling method of a kind of electric welding machine soft switch fuzzy PID control source of welding current, 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 the electric welding machine soft switch fuzzy PID control source of welding current, 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, 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 Fuzzy-PID of the soft switch fuzzy PID control source of welding current.
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 the electric welding machine soft switch fuzzy PID control source of welding current 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 the electric welding machine soft switch fuzzy PID control source of welding current 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 Fuzzy-PID of the soft switch fuzzy PID control source of welding current 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 the electric welding machine soft switch fuzzy PID control source of welding current of the present invention, comprise monolithic processor control device, the A/D converter, the PI regulon, the PWM chip, and be used for the driving transformer of the Fuzzy-PID of the driving switch fuzzy control source of welding current, described monolithic processor control device comprises the Single-chip Controlling unit, electrification reset unit and the hour hands unit that is 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 fuzzy PID control source of welding current 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 (Fuzzy-PID
1And Fuzzy-PID
2The brachium pontis of forming) realizes ZVT, lagging leg (Fuzzy-PID
3And Fuzzy-PID
4The brachium pontis of forming) realizes Zero Current Switch, thereby realized the zero-voltage and zero-current switch (ZVZCS) of soft switch Fuzzy-PID 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 Fuzzy-PID
1～Fuzzy-PID
4The diode of (model is BSM75GB120DN2) reverse parallel connection, C
1, C
2Be respectively Fuzzy-PID
1, Fuzzy-PID
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.
Fuzzy-PID
1～Fuzzy-PID
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 Fuzzy-PID
1, because Fuzzy-PID
1Shunt capacitance C
1Both end voltage can not be suddenlyd change, so Fuzzy-PID
1No-voltage is turn-offed.After this C
1, C
2Begin to discharge and recharge t
1Constantly discharge and recharge end, VD
2Conducting is Fuzzy-PID
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 Fuzzy-PID
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 Fuzzy-PID 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 Fuzzy-PID 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 Fuzzy-PID
1, Fuzzy-PID
2Pulsewidth is bigger, lagging leg Fuzzy-PID
3, Fuzzy-PID
4Fixed pulse width, Fuzzy-PID
1～Fuzzy-PID
44 groups of drive control signal realize the finite both control mode; As welding current 58A, during arc voltage 6V, leading-bridge Fuzzy-PID
1, Fuzzy-PID2Compression pulse width, lagging leg Fuzzy-PID
3, Fuzzy-PID
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 the electric welding machine soft switch fuzzy PID of the present invention control source of welding current 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 the electric welding machine soft switch fuzzy PID control source of welding current, 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 Fuzzy-PID of the soft switch fuzzy PID control source of welding current after driving transformer is isolated amplification.
2. the Single-chip Controlling method of the electric welding machine soft switch fuzzy PID control source of welding current as claimed in claim 1, it is characterized in that, also comprise: 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 fuzzy PID of electric welding machine as claimed in claim 1 controls source of welding current numerical control method, 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 fuzzy PID of electric welding machine as claimed in claim 1 control source of welding current numerical control method 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.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109597331A (en) * | 2018-11-28 | 2019-04-09 | 南京晨光集团有限责任公司 | A kind of pilot-operated type double electromagnet proportional valve controller based on current automatic adaptation |
| CN110262220A (en) * | 2019-06-24 | 2019-09-20 | 华南理工大学 | One kind welding pulse current pid parameter control method based on ant group algorithm MIG |
| CN110382152A (en) * | 2017-03-09 | 2019-10-25 | 伊利诺斯工具制品有限公司 | For measuring the solder type electric supply and welding equipment of welding circuit resistance via the communication on welding circuit |
| CN112506041A (en) * | 2020-11-19 | 2021-03-16 | 合肥工业大学 | PI controller and DC/DC converter |
| US11660695B2 (en) | 2017-03-09 | 2023-05-30 | Illinois Tool Works Inc. | Welding power supplies, wire feeders, and systems to measure a weld cable voltage drop |
-
2009
- 2009-04-07 CN CN200910048941A patent/CN101856764A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110382152A (en) * | 2017-03-09 | 2019-10-25 | 伊利诺斯工具制品有限公司 | For measuring the solder type electric supply and welding equipment of welding circuit resistance via the communication on welding circuit |
| US11027355B2 (en) | 2017-03-09 | 2021-06-08 | Illinois Tool Works | Welding power supplies, wire feeders, and systems to measure a weld circuit resistance via communications over the weld circuit |
| CN110382152B (en) * | 2017-03-09 | 2021-11-26 | 伊利诺斯工具制品有限公司 | Welding-type power supply and welding device for measuring welding circuit resistance via communication over the welding circuit |
| US11660695B2 (en) | 2017-03-09 | 2023-05-30 | Illinois Tool Works Inc. | Welding power supplies, wire feeders, and systems to measure a weld cable voltage drop |
| CN109597331A (en) * | 2018-11-28 | 2019-04-09 | 南京晨光集团有限责任公司 | A kind of pilot-operated type double electromagnet proportional valve controller based on current automatic adaptation |
| CN110262220A (en) * | 2019-06-24 | 2019-09-20 | 华南理工大学 | One kind welding pulse current pid parameter control method based on ant group algorithm MIG |
| CN110262220B (en) * | 2019-06-24 | 2021-09-21 | 华南理工大学 | Method for controlling PID (proportion integration differentiation) parameters of MIG (metal-inert gas) welding pulse current based on ant colony algorithm |
| CN112506041A (en) * | 2020-11-19 | 2021-03-16 | 合肥工业大学 | PI controller and DC/DC converter |
| CN112506041B (en) * | 2020-11-19 | 2022-07-08 | 合肥工业大学 | DC/DC converter |
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Application publication date: 20101013 |