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CN106208745A - CUT output current ripple frequency multiplication and modulating system - Google Patents

CUT output current ripple frequency multiplication and modulating system Download PDF

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Publication number
CN106208745A
CN106208745A CN201610643772.6A CN201610643772A CN106208745A CN 106208745 A CN106208745 A CN 106208745A CN 201610643772 A CN201610643772 A CN 201610643772A CN 106208745 A CN106208745 A CN 106208745A
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output
igbt module
circuit
current
diode
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CN106208745B (en
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刘鑫
王天风
杨喜军
唐厚君
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Shanghai Jiao Tong University
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Shanghai Jiao Tong University
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/02Conversion of AC power input into DC power output without possibility of reversal
    • H02M7/04Conversion of AC power input into DC power output without possibility of reversal by static converters
    • H02M7/06Conversion of AC power input into DC power output without possibility of reversal by static converters using discharge tubes without control electrode or semiconductor devices without control electrode
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00Conversion of DC power input into DC power output
    • H02M3/02Conversion of DC power input into DC power output without intermediate conversion into AC
    • H02M3/04Conversion of DC power input into DC power output without intermediate conversion into AC by static converters
    • H02M3/10Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H02M3/1582Buck-boost converters

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Inverter Devices (AREA)

Abstract

The present invention provides a kind of CUT output current ripple frequency multiplication and modulating system, including reduction voltage circuit, chopper circuit and cutting torch circuit, described chopper circuit includes two groups of BUCK circuit, is connected with the workpiece to be processed of cutting torch circuit after two groups of BUCK circuit output end parallel connections.The present invention is by designing discontinuous sawtooth carrier wave, the break-make of respective four IGBT module of the PWM drive signal control two-way BUCK circuit of equal duty ratio is produced when stable state, the IGBT module trigger sequence of each of which road BUCK circuit differs 90 ° successively, make the DC current ripple quadruple on each road, two-way output differs certain angle 45 ° according to actual condition, complementing each other so that the DC current output ripple octonary of synthesis, ripple current amplitude reduces further.The present invention support output current ripple frequency multiplication, single tube IGBT stress little, can modularized design and support High-current output, and control principle is clear, control signal occurs simple.

Description

等离子切割机输出电流纹波倍频及调制系统Plasma cutting machine output current ripple frequency multiplication and modulation system

技术领域technical field

本发明涉及等离子切割领域与电力电子变换领域的一种输出电流纹波消减技术,具体地,涉及一种等离子切割机输出电流纹波倍频及调制系统。The present invention relates to an output current ripple reduction technology in the fields of plasma cutting and power electronic conversion, and in particular relates to a frequency multiplication and modulation system for output current ripple of a plasma cutting machine.

背景技术Background technique

“切割与焊接”素有“钢铁裁缝”之称,现代工业离不开金属板材的切割和焊接,切割是焊接的首道工序,其切割断面的质量(平整度、光滑度)、切割效率以及材料利用率的高低都直接影响着焊接质量(例如焊接强度)、生产效率和成本,因此,现代工业的发展,离不开现代化的金属型材切割加工设备。目前,完成金属型材切割的主要方法有三种:火焰、等离子、激光三大切割方式,而等离子切割高效、成本低,是型材切割加工最理想的选择,在工业生产的诸多领域都得到了广泛的应用。"Cutting and welding" is known as "steel tailoring". Modern industry is inseparable from the cutting and welding of sheet metal. Cutting is the first process of welding. The quality of the cut section (flatness, smoothness), cutting efficiency and The level of material utilization directly affects welding quality (such as welding strength), production efficiency and cost. Therefore, the development of modern industry is inseparable from modern metal profile cutting and processing equipment. At present, there are three main methods for cutting metal profiles: flame, plasma, and laser. Plasma cutting is efficient and low-cost, and it is the most ideal choice for profile cutting. It has been widely used in many fields of industrial production. application.

等离子切割电源是机用等离子切割装置的核心部件之一,鉴于整体成本较低和效率较高,在大功率等离子切割装置中,斩波式电源日益受到青睐,功率电路支持输出电流等级不断升高。另一方面,工业界对直流电源的品质(包括电压稳定度和纹波峰峰值以及纹波频率)的要求也越来越高,单纯依靠无源器件(增加电容和电感)已经不能满足工业的需求。因此,大功率设计和输出电流纹波高频化是等离子切割直流源亟待解决的问题。The plasma cutting power supply is one of the core components of the machine plasma cutting device. In view of the lower overall cost and higher efficiency, in the high-power plasma cutting device, the chopping power supply is increasingly favored, and the power circuit supports the continuous increase of the output current level. . On the other hand, the industry has higher and higher requirements for the quality of DC power supply (including voltage stability, peak-to-peak ripple frequency, and ripple frequency), and relying solely on passive components (increasing capacitance and inductance) can no longer meet the needs of the industry. . Therefore, high-power design and high-frequency output current ripple are problems to be solved urgently for the plasma cutting DC source.

经过对等离子切割机输出电流纹波倍频调制方法现有技术的检索,发现主要有以下代表性文献:After searching the existing technology of the output current ripple frequency modulation method of the plasma cutting machine, it is found that there are mainly the following representative documents:

《等离子切割机直流电流源的设计》一文提出了两路BUCK输出提高等离子电源功率等级的方案,但是该电路的直流输出纹波频率较高,不能满足更高等级的输出电流精度要求。《等离子切割高性能电源系统的研究》一文提出了一种缓冲BUCK变换器用以减少电压电流突变,但是该电路不太适合作为高功率等级、高精度要求等离子切割机的电源。The article "Design of DC Current Source for Plasma Cutting Machine" puts forward a scheme to increase the power level of plasma power supply with two BUCK outputs, but the DC output ripple frequency of this circuit is relatively high, which cannot meet the higher level of output current accuracy requirements. The article "Research on High-Performance Power Supply System for Plasma Cutting" proposes a buffered BUCK converter to reduce sudden changes in voltage and current, but this circuit is not suitable as a power supply for plasma cutting machines with high power levels and high precision requirements.

综合以上,对等离子切割机输出电流纹波倍频调制方法现有技术的检索后发现,现有的控制方法缺少能够有效提高纹波频率的控制策略。Based on the above, after searching the prior art of the frequency multiplication modulation method of the output current ripple of the plasma cutting machine, it is found that the existing control method lacks a control strategy that can effectively increase the ripple frequency.

发明内容Contents of the invention

针对现有技术中的缺陷,本发明的目的是提供一种等离子切割机输出电流纹波倍频及调制系统,能够有效提高纹波频率。In view of the defects in the prior art, the purpose of the present invention is to provide a plasma cutting machine output current ripple frequency multiplication and modulation system, which can effectively increase the ripple frequency.

根据本发明的第一方面,提供一种等离子切割机输出电流纹波倍频系统,包括降压电路、斩波电路和割炬电路,其中:所述降压电路用以完成三相交流电压的变换;所述斩波电路用以合成一路稳定的直流电流;所述割炬电路用以完成精细切割。According to the first aspect of the present invention, a plasma cutting machine output current ripple frequency multiplication system is provided, including a step-down circuit, a chopper circuit and a cutting torch circuit, wherein: the step-down circuit is used to complete the three-phase AC voltage transformation; the chopper circuit is used to synthesize a stable direct current; the cutting torch circuit is used to complete fine cutting.

优选地,所述降压电路包括一只工频变压器,其中:所述工频变压器三相初级绕组的输入端分别与三相交流电源380V相连,其次级包括两组相差30°的三相次级绕组220V,三相次级绕组的初相分别为Y接0°和Δ接30°。Preferably, the step-down circuit includes a power frequency transformer, wherein: the input ends of the three-phase primary windings of the power frequency transformer are respectively connected to a three-phase AC power supply of 380V, and its secondary includes two sets of three-phase secondary windings with a difference of 30° The primary winding is 220V, and the initial phases of the three-phase secondary winding are Y connected to 0° and Δ connected to 30° respectively.

优选地,所述斩波电路包括两组BUCK电路,分别是第一BUCK电路和第二BUCK电路,第一BUCK电路、第二BUCK电路输出端并联后与割炬电路的待加工的工件相连。Preferably, the chopping circuit includes two groups of BUCK circuits, namely a first BUCK circuit and a second BUCK circuit, the output ends of the first BUCK circuit and the second BUCK circuit are connected in parallel to the workpiece to be processed in the cutting torch circuit.

所述第一BUCK电路包括:第一二极管不控三相整流桥、第一电解电容、第一功率电阻、第一IGBT模块、第二IGBT模块、第三IGBT模块、第四IGBT模块、第一反向快恢复功率二极管、第二反向快恢复功率二极管、第三反向快恢复功率二极管、第四反向快恢复功率二极管和第一平波电感,其中:第一二极管不控三相整流桥的输入为降压电路中Y接0°三相次级绕组的输出Ua1、Ub1与Uc1,第一二极管不控三相整流桥的直流输出正极与第一电解电容的正极、第一功率电阻的一端、第一反向快恢复功率二极管阴极、第二反向快恢复功率二极管阴极、第三反向快恢复功率二极管阴极、第四反向快恢复功率二极管阴极、第一平波电感的一端相连,第一二极管不控三相整流桥的直流输出负极与第一电解电容的负极、第一功率电阻的另一端、第一IGBT模块的发射极、第二IGBT模块的发射极、第三IGBT模块的发射极、第四IGBT模块的发射极相连,第一IGBT模块的集电极、第二IGBT模块的集电极、第三IGBT模块的集电极、第四IGBT模块的集电极与第一反向快恢复功率二极管阳极、第二反向快恢复功率二极管阳极、第三反向快恢复功率二极管阳极、第四反向快恢复功率二极管阳极相连,形成直流电源的负极,第一平波电感的另一端形成直流电源的正极;The first BUCK circuit includes: a first diode uncontrolled three-phase rectifier bridge, a first electrolytic capacitor, a first power resistor, a first IGBT module, a second IGBT module, a third IGBT module, a fourth IGBT module, The first reverse fast recovery power diode, the second reverse fast recovery power diode, the third reverse fast recovery power diode, the fourth reverse fast recovery power diode and the first smoothing inductor, wherein: the first diode is not The input of the controlled three-phase rectifier bridge is the output Ua1, Ub1 and Uc1 of the Y-connected 0° three-phase secondary winding in the step-down circuit, the first diode does not control the DC output positive pole of the three-phase rectifier bridge and the first electrolytic capacitor positive pole, one end of the first power resistor, first reverse fast recovery power diode cathode, second reverse fast recovery power diode cathode, third reverse fast recovery power diode cathode, fourth reverse fast recovery power diode cathode, the first reverse fast recovery power diode cathode, One end of a smoothing inductor is connected, the first diode does not control the DC output negative pole of the three-phase rectifier bridge, the negative pole of the first electrolytic capacitor, the other end of the first power resistor, the emitter of the first IGBT module, the second IGBT The emitter of the module, the emitter of the third IGBT module, and the emitter of the fourth IGBT module are connected, the collector of the first IGBT module, the collector of the second IGBT module, the collector of the third IGBT module, and the fourth IGBT module The collector of the first reverse fast recovery power diode anode, the second reverse fast recovery power diode anode, the third reverse fast recovery power diode anode, and the fourth reverse fast recovery power diode anode are connected to form the negative pole of the DC power supply , the other end of the first smoothing inductor forms the positive pole of the DC power supply;

所述第二BUCK电路包括:第二二极管不控三相整流桥、第二电解电容、第二功率电阻、第五IGBT模块、第六IGBT模块、第七IGBT模块、第八IGBT模块、第五反向快恢复功率二极管、第六反向快恢复功率二极管、第七反向快恢复功率二极管、第八反向快恢复功率二极管和第二平波电抗器,其中:第二二极管不控三相整流桥的三相输入为降压电路中Δ接30°三相次级绕组的输出Ua2、Ub2与Uc2,第二二极管不控三相整流桥的直流输出正极与第二电解电容的正极、第二功率电阻的一端、第五反向快恢复功率二极管阴极、第六反向快恢复功率二极管阴极、第七反向快恢复功率二极管阴极、第八反向快恢复功率二极管阴极、第二平波电感的一端相连,第二二极管不控三相整流桥的直流输出负极与第二电解电容的负极、第二功率电阻的另一端、第五IGBT模块发射极、第六IGBT模块发射极、第七IGBT模块发射极、第八IGBT模块发射极,第五IGBT模块集电极、第六IGBT模块集电极、第七IGBT模块集电极、第八IGBT模块集电极与第五反向快恢复功率二极管阳极、第六反向快恢复功率二极管阳极、第七反向快恢复功率二极管阳极、第八反向快恢复功率二极管阳极相连,形成直流电源的负极,第二平波电感的另一端形成直流电源的正极;The second BUCK circuit includes: a second diode uncontrolled three-phase rectifier bridge, a second electrolytic capacitor, a second power resistor, a fifth IGBT module, a sixth IGBT module, a seventh IGBT module, an eighth IGBT module, The fifth reverse fast recovery power diode, the sixth reverse fast recovery power diode, the seventh reverse fast recovery power diode, the eighth reverse fast recovery power diode and the second smoothing reactor, wherein: the second diode The three-phase input of the uncontrolled three-phase rectifier bridge is the output Ua2, Ub2 and Uc2 of the 30° three-phase secondary winding in the step-down circuit, and the DC output positive pole of the second diode uncontrolled three-phase rectifier bridge is connected to the second The positive pole of the electrolytic capacitor, one end of the second power resistor, the fifth reverse fast recovery power diode cathode, the sixth reverse fast recovery power diode cathode, the seventh reverse fast recovery power diode cathode, the eighth reverse fast recovery power diode The cathode and one end of the second smoothing inductor are connected, the second diode does not control the DC output negative pole of the three-phase rectifier bridge, the negative pole of the second electrolytic capacitor, the other end of the second power resistor, the emitter pole of the fifth IGBT module, and the negative pole of the second electrolytic capacitor. The emitter of the sixth IGBT module, the emitter of the seventh IGBT module, the emitter of the eighth IGBT module, the collector of the fifth IGBT module, the collector of the sixth IGBT module, the collector of the seventh IGBT module, the collector of the eighth IGBT module and the fifth The anode of the reverse fast recovery power diode, the anode of the sixth reverse fast recovery power diode, the anode of the seventh reverse fast recovery power diode, and the anode of the eighth reverse fast recovery power diode are connected to form the negative pole of the DC power supply, and the second smoothing inductor The other end forms the positive pole of the DC power supply;

所述割炬电路与两路BUCK电路的两个输出端相连,其中:待加工的工件一端与斩波电路的正极相连,待加工的工件另一端与等离子弧柱一端相连,等离子弧柱另一端与割炬碰嘴及内部电极相连,割炬电路的负极与斩波电路的负极相连。The torch circuit is connected to two output terminals of two BUCK circuits, wherein: one end of the workpiece to be processed is connected to the positive pole of the chopper circuit, the other end of the workpiece to be processed is connected to one end of the plasma arc column, and the other end of the plasma arc column It is connected with the torch bumper and the internal electrode, and the negative pole of the cutting torch circuit is connected with the negative pole of the chopper circuit.

根据本发明的第二方面,提供一种上述等离子切割机输出电流纹波倍频系统的调制系统,包括滤波单元、期望电流比较单元、分数阶PID调节单元、限幅单元、载波比较单元和极性判断单元,其中:载波比较单元包括第一~第八载波比较单元;极性判断单元包括第一~第八极性判断单元;According to the second aspect of the present invention, there is provided a modulation system of the output current ripple frequency multiplication system of the plasma cutting machine, including a filter unit, a desired current comparison unit, a fractional PID adjustment unit, a limiting unit, a carrier comparison unit and a pole A polarity judgment unit, wherein: the carrier comparison unit includes first to eighth carrier comparison units; the polarity judgment unit includes first to eighth polarity judgment units;

采样所得的运行中切割机输出电流信号,即两路BUCK电路输出的总电流信号io,送入滤波单元,经滤波单元滤波后的输出电流输入期望电流比较单元,期望电流比较单元将该输出电流与对应希望实际输出电流的期望电流相减得到电流误差,该电流误差输入分数阶PID调节单元,分数阶PID调节单元对电流误差进行比例积分微分调节,分数阶PID调节单元的输出与限幅单元相连,限幅单元确保分数阶PID调节输出限制在指定上下限之间,防止出现上溢和下溢,限幅单元的输出作为第一载~第八载波比较单元的一个输入,其另一输入分别为第一~第八载波,分别进行比较,即分数阶PID调节输出与载波进行大小比较,比较后的8路结果分别输入第一~第八极性判断单元,第一~第八极性判断单元进行极性判断:比较后的8路结果为正时输出高电平,比较后的8路结果为负时输出低电平,第一~第八极性判断单元的输出产生第一~第八PWM驱动信号,八个PWM驱动信号分别驱动BUCK电路中第一~第八IGBT模块的通断,完成输出电压到输出电流的变换。The sampled output current signal of the cutting machine in operation, that is, the total current signal io output by the two BUCK circuits, is sent to the filter unit, and the output current filtered by the filter unit is input to the expected current comparison unit, and the expected current comparison unit converts the output current The current error is obtained by subtracting the expected current corresponding to the desired actual output current. The current error is input to the fractional-order PID adjustment unit, and the fractional-order PID adjustment unit performs proportional integral differential adjustment on the current error. The output of the fractional-order PID adjustment unit and the limiter unit Connected, the limiting unit ensures that the fractional-order PID adjustment output is limited between the specified upper and lower limits to prevent overflow and underflow. The output of the limiting unit is used as one input of the first carrier to the eighth carrier comparison unit, and the other input The first to eighth carrier waves are compared separately, that is, the fractional-order PID adjustment output is compared with the carrier wave, and the compared 8-way results are respectively input to the first to eighth polarity judgment units, and the first to eighth polarity Judgment unit for polarity judgment: output high level when the compared 8-way results are positive, output low level when the compared 8-way results are negative, the outputs of the first to eighth polarity judgment units generate the first to eighth polarity judgment units. The eighth PWM driving signal, the eight PWM driving signals respectively drive the on-off of the first to eighth IGBT modules in the BUCK circuit to complete the conversion from the output voltage to the output current.

本发明通过等占空比的PWM驱动信号控制两路BUCK电路的八个IGBT模块的通断,其中每一路IGBT模块触发顺序依次相差90°,使得每一路的直流电流纹波4倍频,两路输出根据实际工况相差一定角度45°,互相补充使得合成的直流电流输出电流纹波频率8倍频,电流纹波进一步减小。The present invention controls the on-off of the eight IGBT modules of the two BUCK circuits through PWM driving signals with equal duty ratios, wherein the trigger sequence of each IGBT module is sequentially different by 90°, so that the frequency of the DC current ripple of each path is multiplied by 4, and the two The two outputs differ by a certain angle of 45° according to the actual working conditions, and complement each other so that the synthesized DC current output current ripple frequency is 8 times the frequency, and the current ripple is further reduced.

与现有技术相比,本发明具有如下的有益效果:Compared with the prior art, the present invention has the following beneficial effects:

(1)每路BUCK电路的四个IGBT模块采用移相控制策略,移相90°,使得每路输出电流纹波4倍频;(1) The four IGBT modules of each BUCK circuit adopt a phase-shift control strategy, and the phase is shifted by 90°, so that the output current ripple of each channel is multiplied by 4;

(2)两路BUCK电路相互补充,移相45°,使得输出的输出电流纹波8倍频,输出电流纹波更低;(2) The two BUCK circuits complement each other and shift the phase by 45°, so that the output current ripple of the output is multiplied by 8, and the output current ripple is lower;

(3)八个IGBT模块分担功率输出,可支持大电流输出且单管功率应力小;(3) Eight IGBT modules share the power output, which can support large current output and the single-tube power stress is small;

(4)每路BUCK电路的四个IGBT模块共用一个平波电感,更节省元器件且能够降低电源体积;(4) The four IGBT modules of each BUCK circuit share one smoothing inductor, which saves components and reduces the volume of the power supply;

(5)IGBT模块的发射极接在整流器输出的负极上,使得驱动电路的设计更加方便。(5) The emitter of the IGBT module is connected to the negative pole of the rectifier output, which makes the design of the driving circuit more convenient.

本发明通过等占空比移相控制策略,使得每一路输出电流纹波倍频,并有效降低合成输出电流的纹波,电流纹波多倍频、单管IGBT应力小、可模块化设计和支持大电流输出,具有控制原理清晰明了、控制信号发生简单的优点。The invention adopts the equal duty cycle phase-shifting control strategy to make each output current ripple frequency multiplied, and effectively reduce the synthesized output current ripple, current ripple multiplied frequency, single-tube IGBT stress is small, modular design and support Large current output has the advantages of clear control principle and simple control signal generation.

附图说明Description of drawings

通过阅读参照以下附图对非限制性实施例所作的详细描述,本发明的其它特征、目的和优点将会变得更明显:Other characteristics, objects and advantages of the present invention will become more apparent by reading the detailed description of non-limiting embodiments made with reference to the following drawings:

图1为本发明一实施例的倍频系统电路图;Fig. 1 is a circuit diagram of a frequency multiplication system according to an embodiment of the present invention;

图2为本发明一实施例的调制系统原理图。FIG. 2 is a schematic diagram of a modulation system according to an embodiment of the present invention.

具体实施方式detailed description

下面结合具体实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明,但不以任何形式限制本发明。应当指出的是,对本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进。这些都属于本发明的保护范围。The present invention will be described in detail below in conjunction with specific embodiments. The following examples will help those skilled in the art to further understand the present invention, but do not limit the present invention in any form. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

如图1所示,本实施例提供一种等离子切割机输出电流纹波倍频调制系统,包括降压电路11、斩波电路和割炬电路14,其中:所述降压电路用以完成三相交流电压的变换;所述斩波电路用以合成一路稳定的直流电流;所述割炬电路用以完成精细切割。As shown in Figure 1, this embodiment provides a plasma cutting machine output current ripple frequency multiplication modulation system, including a step-down circuit 11, a chopper circuit and a cutting torch circuit 14, wherein: the step-down circuit is used to complete three Phase-to-phase alternating voltage conversion; the chopper circuit is used to synthesize a stable direct current; the cutting torch circuit is used to complete fine cutting.

如图1所示,所述降压电路11包括一只工频变压器,其中:所述工频变压器三相初级绕组的输入端分别与三相交流电源380V相连,其次级包括两组相差30°的三相次级绕组220V,三相次级绕组的初相分别为Y接0°和Δ接30°,用于实现380V-220V的电压转变。As shown in Figure 1, the step-down circuit 11 includes a power frequency transformer, wherein: the input ends of the three-phase primary windings of the power frequency transformer are respectively connected to the three-phase AC power supply 380V, and its secondary includes two groups with a phase difference of 30° The three-phase secondary winding of the three-phase secondary winding is 220V, and the initial phases of the three-phase secondary winding are Y connected to 0° and Δ connected to 30°, which are used to realize the voltage transformation of 380V-220V.

如图1所示,所述斩波电路包括两组BUCK电路,分别是第一BUCK电路12和第二BUCK电路13;As shown in FIG. 1, the chopper circuit includes two groups of BUCK circuits, which are respectively a first BUCK circuit 12 and a second BUCK circuit 13;

所述第一BUCK电路12包括:一只二极管不控三相整流桥B1、一只电解电容E1、一只功率电阻R1、四只IGBT模块S1-S4、四只反向快恢复功率二极管D1-D4和一只平波电抗器L1,其中:二极管不控三相整流桥B1的三相输入为降压电路11中Y接0°三相次级绕组的输出ua1、ub1与uc1,二极管不控三相整流桥B1的直流输出正极P1与电解电容E1的正极、功率电阻R1的一端、反向快恢复功率二极管D1-D4阴极、平波电感L1的一端相连,二极管不控三相整流桥B1的直流输出负极N1与电解电容E1的负极、功率电阻R1的另一端、IGBT模块S1-S4的发射极相连,IGBT模块S1-S4的集电极与反向快恢复功率二极管D1-D4阳极相连,形成直流电源的负极,平波电感L1的另一端形成直流电源的正极;The first BUCK circuit 12 includes: a diode uncontrolled three-phase rectifier bridge B1, an electrolytic capacitor E1, a power resistor R1, four IGBT modules S1-S4, and four reverse fast recovery power diodes D1- D4 and a smoothing reactor L1, wherein: the three-phase input of the diode uncontrolled three-phase rectifier bridge B1 is the output ua1, ub1 and uc1 of the 0° three-phase secondary winding in the step-down circuit 11, and the diode is uncontrolled The positive pole P1 of the DC output of the three-phase rectifier bridge B1 is connected to the positive pole of the electrolytic capacitor E1, one end of the power resistor R1, the cathodes of the reverse fast recovery power diodes D1-D4, and one end of the smoothing inductor L1, and the diode is not controlled by the three-phase rectifier bridge B1 The DC output negative electrode N1 of the DC output is connected to the negative electrode of the electrolytic capacitor E1, the other end of the power resistor R1, and the emitters of the IGBT modules S1-S4, and the collectors of the IGBT modules S1-S4 are connected to the anodes of the reverse fast recovery power diodes D1-D4. Form the negative pole of the DC power supply, and the other end of the smoothing inductor L1 forms the positive pole of the DC power supply;

所述第二BUCK电路13包括:一只二极管不控三相整流桥B2、一只电解电容E2、一只功率电阻R2、四只IGBT模块S5-S8、四只反向快恢复功率二极管D5-D8和一只平波电抗器L2,其中:二极管不控三相整流桥B2的三相输入为降压电路11中Δ接30°三相次级绕组的输出ua2、ub2与uc2,二极管不控三相整流桥B2的直流输出正极P2与电解电容E2的正极、功率电阻R2的一端、反向快恢复功率二极管D5-D8阴极、平波电感L2的一端相连,二极管不控三相整流桥B2的直流输出负极N2与电解电容E2的负极、功率电阻R2的另一端、IGBT模块S5-S8的发射极相连,IGBT模块S5-S8的集电极与反向快恢复功率二极管D5-D8阳极相连,形成直流电源的负极,平波电感L2的另一端形成直流电源的正极;The second BUCK circuit 13 includes: a diode uncontrolled three-phase rectifier bridge B2, an electrolytic capacitor E2, a power resistor R2, four IGBT modules S5-S8, and four reverse fast recovery power diodes D5- D8 and a smoothing reactor L2, wherein: the three-phase input of the diode uncontrolled three-phase rectifier bridge B2 is the output ua2, ub2 and uc2 of the 30° three-phase secondary winding in the step-down circuit 11, and the diode is uncontrolled The DC output positive pole P2 of the three-phase rectifier bridge B2 is connected to the positive pole of the electrolytic capacitor E2, one end of the power resistor R2, the cathodes of the reverse fast recovery power diodes D5-D8, and one end of the smoothing inductor L2, and the diode does not control the three-phase rectifier bridge B2 The DC output negative electrode N2 of the DC output is connected to the negative electrode of the electrolytic capacitor E2, the other end of the power resistor R2, and the emitter of the IGBT module S5-S8, and the collector of the IGBT module S5-S8 is connected to the anode of the reverse fast recovery power diode D5-D8. Form the negative pole of the DC power supply, and the other end of the smoothing inductor L2 forms the positive pole of the DC power supply;

第一BUCK电路、第二BUCK电路输出端并联后与割炬电路14的工件相连,其中,工件与斩波电路的正极相连,割炬电路的负极与斩波电路的负极相连。The output ends of the first BUCK circuit and the second BUCK circuit are connected in parallel to the workpiece of the cutting torch circuit 14, wherein the workpiece is connected to the positive pole of the chopping circuit, and the negative pole of the cutting torch circuit is connected to the negative pole of the chopping circuit.

如图2所示,一种上述倍频系统的调制系统,通过设计不连续的锯齿载波,在稳态时产生等占空比的PWM驱动信号控制两路BUCK电路的各自四个IGBT模块的通断,其中每一路BUCK电路的IGBT模块触发顺序依次相差90°,使得每一路的直流电流纹波四倍频,两路输出根据实际工况相差一定角度45°,互相补充使得合成的直流电流输出纹波八倍频,纹波电流幅值进一步减小。As shown in Figure 2, a modulation system of the above-mentioned frequency multiplication system, by designing a discontinuous sawtooth carrier, generates a PWM drive signal with an equal duty cycle in a steady state to control the communication of the four IGBT modules of the two BUCK circuits. The trigger sequence of the IGBT modules of each BUCK circuit differs by 90° in sequence, so that the DC current ripple of each path is quadrupled, and the two outputs differ by a certain angle of 45° according to the actual working conditions. The ripple frequency is eight times higher, and the ripple current amplitude is further reduced.

一种上述倍频系统的调制系统,包括滤波单元、期望电流比较单元、分数阶PID调节单元、限幅单元、载波比较单元(图2中载波比较单元的两个输入1、2和一个输出3)、极性判断单元和PWM发生单元,采样所得电流信号送入滤波单元,滤波单元的输出与期望电流相减,所得电流误差输入分数阶PID调节单元,分数阶PID调节单元的输出与限幅单元相连,限幅单元的输出分别与载波1-8做比较,比较后的结果分别与极性判断单元1-8相连,极性判断单元1-8的输出分别产生PWM1-8。第一BUCK电路12的PWM控制信号分别相差90°,具体地:PWM1超前PWM2 90°,PWM2超前PWM3 90°,PWM3超前PWM4 90°,该路的输出电流纹波四倍频;第二BUCK电路13的PWM控制信号分别相差90°,具体地:PWM5超前PWM6 90°,PWM6超前PWM790°,PWM7超前PWM8 90°,该路的输出电流纹波四倍频;PWM1和PWM5根据电路工作情况会相差一个角度,两路BUCK电路的输出电流相互补充,使得合成的输出电流io的纹波进一步减小,从而实现精细大电流输出,满足等离子切割机的直流电源要求。A modulation system of the above-mentioned frequency multiplication system, comprising a filter unit, a desired current comparison unit, a fractional-order PID adjustment unit, a limiting unit, and a carrier comparison unit (two inputs 1, 2 and an output 3 of the carrier comparison unit in Fig. 2 ), the polarity judgment unit and the PWM generation unit, the current signal obtained by sampling is sent to the filter unit, the output of the filter unit is subtracted from the expected current, and the obtained current error is input to the fractional-order PID adjustment unit, and the output of the fractional-order PID adjustment unit and the limiter The units are connected, and the output of the limiting unit is compared with the carrier 1-8 respectively, and the compared results are respectively connected with the polarity judging unit 1-8, and the output of the polarity judging unit 1-8 generates PWM1-8 respectively. The PWM control signals of the first BUCK circuit 12 differ by 90°, specifically: PWM1 leads PWM2 by 90°, PWM2 leads PWM3 by 90°, PWM3 leads PWM4 by 90°, and the output current ripple of this circuit is quadrupled in frequency; the second BUCK circuit The PWM control signals of 13 have a difference of 90°, specifically: PWM5 leads PWM6 by 90°, PWM6 leads PWM790°, PWM7 leads PWM8 by 90°, and the output current ripple frequency of this channel is quadruple; PWM1 and PWM5 will differ according to the working conditions of the circuit At one angle, the output currents of the two BUCK circuits complement each other, so that the ripple of the synthesized output current i o is further reduced, so as to realize fine and large current output and meet the DC power requirements of the plasma cutting machine.

某一实施例中,各器件的选型和参数为:In a certain embodiment, the selection and parameters of each device are:

交流输入电压宽范围,380V±15%,工频50Hz或60Hz,额定输入电压380VAC,额定输出直流电压平均值150V,额定输出电流270A,输入功率为45kW;AC input voltage wide range, 380V±15%, power frequency 50Hz or 60Hz, rated input voltage 380VAC, rated output DC voltage average 150V, rated output current 270A, input power 45kW;

IGBT斩波频率:20kHz;IGBT chopping frequency: 20kHz;

电解电容E1-E2:450V,6800μF,四只并联;Electrolytic capacitors E1-E2: 450V, 6800μF, four in parallel;

二极管不控三相整流桥B1-B2:600V,300A/100℃;Diode uncontrolled three-phase rectifier bridge B1-B2: 600V, 300A/100℃;

平波电抗器L1-L2:2.2mH,130A,0.35mm厚,硅钢;Smoothing reactor L1-L2: 2.2mH, 130A, 0.35mm thick, silicon steel;

IGBT模块与反向快恢复功率二极管S1与D1、S2与D2、S3与D3、S4与D4、S5与D5、S6与D6,S7与D7,S8与D8:600V,250A/100℃,单桥臂IGBT模块;IGBT module and reverse fast recovery power diode S1 and D1, S2 and D2, S3 and D3, S4 and D4, S5 and D5, S6 and D6, S7 and D7, S8 and D8: 600V, 250A/100℃, single bridge arm IGBT module;

功率电阻R1-R2:50kΩ,5W;Power resistor R1-R2: 50kΩ, 5W;

工频变压器TR1:380V/2x220V,75kVA。Power frequency transformer TR1: 380V/2x220V, 75kVA.

本发明的关键原理在于:Key principles of the present invention are:

(1)载波移相驱动技术,每路BUCK电路中4只IGBT模块的驱动信号交错90°,两路BUCK电路中8只IGBT模块的驱动信号交错45°,可以有效地降低每只平波电感的尺寸和降低电流纹波;(1) Carrier phase-shift driving technology, the driving signals of 4 IGBT modules in each BUCK circuit are staggered by 90°, and the driving signals of 8 IGBT modules in two BUCK circuits are staggered by 45°, which can effectively reduce the smoothing inductance of each size and reduce current ripple;

(2)特殊的载波设计,如图2所示,在稳态时,每只IGBT模块的驱动信号的产生是由不连续的锯齿载波和控制信号相比较产生的,在稳态时具有相同的占空比,比较后极性为正,产生高电平,驱动相应的IGBT模块导通,比较后极性为负,产生低电平,驱动相应的IGBT模块关断;在动态时,每只IGBT模块的驱动信号的产生是由不连续的锯齿载波和控制信号相比较产生的,占空比实时变化;(2) Special carrier design, as shown in Figure 2, in the steady state, the driving signal of each IGBT module is generated by comparing the discontinuous sawtooth carrier with the control signal, and has the same Duty cycle, after comparison, the polarity is positive, generates high level, drives the corresponding IGBT module to turn on, and after comparison, the polarity is negative, generates low level, drives the corresponding IGBT module to turn off; in dynamic state, each The driving signal of the IGBT module is generated by comparing the discontinuous sawtooth carrier with the control signal, and the duty cycle changes in real time;

(3)等占空比的载波移相驱动技术与传统的载波移相驱动技术不同,传统的载波移相驱动技术中的占空比不能等分,可大可小,当占空比大于等于1/4时,每路BUCK电路不能实现倍频功能,两路BUCK电路的最终输出电流纹波仅仅2倍频,只有当占空比小于1/4时,每路BUCK电路才能实现倍频功能,最终输出电流纹波8倍频。在输出电压较高时,尤其对于等离子气割机应用场合,占空比大于0.5但小于0.6,因此本发明在任何工况下能够实现输出电流的8倍频,才能在载波频率不变情况下提高直流电感电流纹波频率,进而提高电流精细度,改进工件切割质量,而且也能够提高输出功率等级;或者维持直流电感电流纹波频率不变,进而降低载波频率,降低IGBT模块的开关损耗,以此提高功率等级。(3) The carrier phase-shift driving technology with equal duty ratio is different from the traditional carrier phase-shift driving technology. 1/4, each BUCK circuit cannot realize the frequency multiplication function, the final output current ripple of the two BUCK circuits is only 2 times the frequency, only when the duty ratio is less than 1/4, each BUCK circuit can realize the frequency multiplication function , the final output current ripple is multiplied by 8. When the output voltage is high, especially for the application of plasma gas cutting machine, the duty cycle is greater than 0.5 but less than 0.6, so the present invention can achieve 8 times the frequency of the output current under any working conditions, and can improve the frequency of the output current without changing the carrier frequency DC inductor current ripple frequency, thereby improving the current fineness, improving the cutting quality of the workpiece, and can also increase the output power level; or maintain the DC inductor current ripple frequency unchanged, thereby reducing the carrier frequency, reducing the switching loss of the IGBT module, and This increases the power level.

以上对本发明的具体实施例进行了描述。需要理解的是,本发明并不局限于上述特定实施方式,本领域技术人员可以在权利要求的范围内做出各种变形或修改,这并不影响本发明的实质内容。Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art may make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention.

Claims (4)

1. a CUT output current ripple frequency doubling system, including reduction voltage circuit, chopper circuit and cutting torch circuit, its In: described reduction voltage circuit is in order to complete the conversion of three-phase alternating voltage;The direct current that described chopper circuit is stable in order to synthesize a road Electric current;Described cutting torch circuit is in order to complete fine cut;It is characterized in that:
Described reduction voltage circuit includes an Industrial Frequency Transformer, wherein: the input of described Industrial Frequency Transformer three-phase primary windings divides Not being connected with three-phase alternating-current supply, its secondary includes the three-phase secondary windings of two groups of differences 30 °, and the first phase of three-phase secondary windings is divided Do not connect 0 ° for Y and Δ connects 30 °;
Described chopper circuit includes two groups of BUCK circuit, is a BUCK circuit and the 2nd BUCK circuit respectively, a BUCK electricity It is connected with the workpiece to be processed of cutting torch circuit after road, the 2nd BUCK circuit output end parallel connection;
A described BUCK circuit includes: the first diode do not control three-phase commutation bridge, the first electrochemical capacitor, the first power resistor, First IGBT module, the second IGBT module, the 3rd IGBT module, the 4th IGBT module, first reversely recover soon power diode, Second reversely recover soon power diode, the 3rd reversely recover soon power diode, the 4th the fastest recover power diode and First flat ripple inductance, wherein: it is that in reduction voltage circuit, Y connects 0 ° of three-phase secondary windings that the first diode does not control the input of three-phase commutation bridge Output Ua1, Ub1 and Uc1, the first diode is not just controlling the direct current output cathode of three-phase commutation bridge and the first electrochemical capacitor Pole, one end of the first power resistor, the first reverse power diode negative electrode of recovery soon, second the fastest recovery power diode the moon Pole, the 3rd reversely fast recover power diode negative electrode, the 4th the fastest recover power diode negative electrode, the one of the first flat ripple inductance End is connected, and the first diode does not control direct current output negative pole and the negative pole of the first electrochemical capacitor, the first power electricity of three-phase commutation bridge The other end of resistance, the emitter stage of the first IGBT module, the emitter stage of the second IGBT module, the emitter stage of the 3rd IGBT module, the The emitter stage of four IGBT module is connected, the colelctor electrode of the first IGBT module, the colelctor electrode of the second IGBT module, the 3rd IGBT module Colelctor electrode, the colelctor electrode of the 4th IGBT module and first reversely fast recover power diode anode, second reversely recover merit soon Rate diode anode, the 3rd the fastest recovery power diode anode, the 4th the fastest power diode anode that recovers are connected, shape Becoming the negative pole of DC source, the other end of the first flat ripple inductance forms the positive pole of DC source;
Described 2nd BUCK circuit includes: the second diode do not control three-phase commutation bridge, the second electrochemical capacitor, the second power resistor, 5th IGBT module, the 6th IGBT module, the 7th IGBT module, the 8th IGBT module, the 5th reversely recover soon power diode, 6th reversely recover soon power diode, the 7th reversely recover soon power diode, the 8th the fastest recover power diode and Second smoothing reactor, wherein: the second diode is not controlled the three-phase input of three-phase commutation bridge and connect 30 ° of three-phases for Δ in reduction voltage circuit Output Ua2, Ub2 and Uc2 of secondary windings, the second diode does not control direct current output cathode and the second electrolysis electricity of three-phase commutation bridge The positive pole of appearance, one end of the second power resistor, the 5th reverse fast recovery power diode negative electrode, the 6th reverse recovery power two soon Pole tube cathode, the 7th reverse fast recovery power diode negative electrode, the 8th the fastest recovery power diode negative electrode, the second flat ripple electricity One end of sense is connected, the second diode do not control the direct current output negative pole of three-phase commutation bridge and the negative pole of the second electrochemical capacitor, second The other end of power resistor, the 5th IGBT module emitter stage, the 6th IGBT module emitter stage, the 7th IGBT module emitter stage, Eight IGBT module emitter stages, the 5th IGBT module colelctor electrode, the 6th IGBT module colelctor electrode, the 7th IGBT module colelctor electrode, Eight IGBT module colelctor electrodes and the 5th reversely fast recover power diode anode, the 6th the fastest recover power diode anode, 7th the fastest recovery power diode anode, the 8th the fastest power diode anode that recovers are connected, formation DC source Negative pole, the other end of the second flat ripple inductance forms the positive pole of DC source.
CUT output current ripple frequency doubling system the most according to claim 1, it is characterised in that described cutting torch Circuit is connected, wherein with two outfans of two-way BUCK circuit: workpiece one end to be processed is connected with the positive pole of chopper circuit, The workpiece other end to be processed is connected with plasma column one end, and the plasma column other end and cutting torch touch mouth and internal electrode phase Even, the negative pole of cutting torch circuit is connected with the negative pole of chopper circuit.
3. a modulating system for CUT output current ripple frequency doubling system described in claim 1 or 2, its feature exists In, including filter unit, expectation electric current comparing unit, Fractional Order PID regulation unit, clipping unit, carrier wave comparing unit and pole Property judging unit, wherein: carrier wave comparing unit includes first~the 8th carrier wave comparing unit;Polarity judging unit include first~ Ends of the earth property judging unit;
Cutting machine output current signal in the operation of sampling gained, i.e. the total current signal io of two-way BUCK circuit output, sends into Filter unit, the output electric current input expectation electric current comparing unit after filtered unit filtering, it is desirable to electric current comparing unit should Output electric current obtains current error with the corresponding expectation current subtraction wishing actual output current, this current error input fractional order PID regulates unit, and Fractional Order PID regulation unit carries out PID regulation, Fractional Order PID regulation unit to current error Output be connected with clipping unit, clipping unit guarantees that Fractional Order PID regulation export-restriction is being specified between bound, prevents out Existing overflow and underflow, the output of clipping unit carries~an input of the 8th carrier wave comparing unit as first, its another input Be respectively first~the 8th carrier wave, compare respectively, i.e. Fractional Order PID regulation output carries out size with carrier wave and compares, and compares After 8 tunnel results input respectively first~ends of the earth property judging unit, first~ends of the earth property judging unit carry out polarity judgement: 8 tunnel results after Bi compare are that timing exports high level, and 8 tunnel results after comparing are output low level, first~the ends of the earth time negative Property judging unit output produce first~the 8th PWM drive signal, eight PWM drive signal drive in BUCK circuit the respectively The break-make of the one~the 8th IGBT module, completes the output voltage conversion to output electric current.
Modulating system the most according to claim 3, it is characterised in that control two by the PWM drive signal of equal duty ratio The break-make of eight IGBT module of road BUCK circuit, each of which road IGBT module trigger sequence differs 90 ° successively so that each DC current ripple 4 frequency multiplication on road, two-way output differs certain angle 45 ° according to actual condition, complements each other so that synthesis DC current output current ripple frequency 8 frequency multiplication, current ripples reduces further.
CN201610643772.6A 2016-08-08 2016-08-08 Plasma cutting machine output current ripple frequency multiplication and modulating system Expired - Fee Related CN106208745B (en)

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