CN109462906B - Induction heating power supply DSP intelligent control system - Google Patents
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Abstract
Induction heating power DSP intelligence control system: the system comprises a task calling core, an AD data processing module, a start-stop control module, a communication management module, a key processing and alarming module and an interruption module. Induction heating power DSP intelligence control system: the system comprises a task calling core, an AD data processing module, a start-stop control module, a communication management module, a key processing and alarming module and an interruption module. The output power of the power supply is controlled by automatically controlling the duty ratio of the chopped wave PWM signal through the control system, so that the power supply power of the induction heating equipment is ensured to be constant; the frequency of the inverted PWM signal is automatically controlled to control the output frequency of the power supply, so that the constant frequency of the power supply of the induction heating equipment is ensured. The production process level is improved by constant power supply power and power supply frequency.
Description
Technical Field
The invention relates to the field of induction heating control, in particular to an intelligent control system of an induction heating power supply DSP.
Background
Induction heating lets in alternating current in induction coil, utilizes the electromagnetic induction principle to make the inside of the material (the work piece) that is heated produce eddy current, relies on the energy of these eddy current to heat the work piece, and its essence is to lean on induction coil to transmit the electric energy for the work piece that will heat, and then the electric energy changes into heat energy inside the metal, and induction coil and heated work piece are not direct contact, and the energy is through electromagnetic induction transmission. It was discovered in the early 19 th century, and subsequently endeavours to suppress this effect as a result of the recognition of the various hazards that electromagnetic induction presents in power generation, power transmission and in the application of electrical equipment. Until the end of the 19 th century, people have purposefully applied the principle to the fields of metal smelting, heat treatment, diathermy before pressure processing and the like, and various induction heating devices have appeared. In China, most of traditional heating modes are coal, oil, gas or electricity for heating, and have the defects of high energy consumption, poor labor condition, serious environmental pollution, difficult control of process quality and the like, and induction heating has the advantages that the traditional modes do not have: the device has high working reliability, no pollution, high efficiency, easy control of heating and the like, is widely applied to industrial production processes of metal smelting, diathermy, heat treatment, welding and the like, and becomes an indispensable technical means for departments of metallurgy, national defense, machining and the like, casting, forging, ship, airplane, automobile manufacturing and the like.
The traditional induction heating power supply mostly adopts an analog control system or a control system combining analog and digital. Although the current analog control technology is mature, the analog control technology has the defects of zero drift, poor flexibility and the like. The digital intelligent control of the induction heating power supply has become a trend of research and development.
The modern induction heating power supply technology is a multidisciplinary edge crossing technology which applies power electronic semiconductor devices, integrates an automatic control theory, a computer (microprocessor) technology, an electromagnetic technology and the like. With the development of industry, the application of induction heating power supplies is increasingly wide, and currently, the induction heating power supplies as energy-saving and efficient heating heat treatment equipment are developing towards the directions of full solid state, high frequency and high power, green product performance and intelligent control mode.
The traditional induction heating power control system adopts an analog electronic circuit formed by discrete components, has the defects of complex circuit, difficult adjustment of control parameters, zero drift, aging, poor universality and the like, and the intelligent control of the induction heating equipment is made to be a trend along with the appearance of a digital integrated chip, a singlechip, a DSP and an FPGA. The digital control technology is applied to the induction heating equipment system, so that a good human-computer interaction interface can be provided for a user, and the operation is convenient; but also is beneficial to realizing the update of the induction heating power supply. With the development of intelligent control of the induction heating equipment, some control functions which are difficult to realize in analog control can be realized, and the possibility of application of an advanced control algorithm in a control system is provided, so that the research on the intelligent control of the induction heating equipment has certain significance.
Disclosure of Invention
In order to solve the problems, the invention provides an intelligent control system of an induction heating power supply DSP.
The technical scheme of the invention is as follows:
an induction heating power supply DSP intelligent control algorithm: the system comprises a task calling core, an AD data processing module, a start-stop control module, a communication management module, a key processing and alarming module and an interruption module; the task calling core carries out task scheduling on the AD data processing module, the start-stop control module, the communication management module and the key processing and alarming module, and the occupation level of each module on the main control chip is arranged; the interrupt module forcibly occupies the main control chip when triggering execution; the start-stop control module completes initialization of relevant control parameters, starts or stops output of the inverted PWM signals, and starts or stops output of chopping signals; the AD data processing module acquires analog signals needed by the system, converts the analog signals into digital signals and filters the digital signals; and finishing the output of the inverted PWM signal and the output of the chopping signal; the key processing and alarming module can detect whether the key is pressed down and complete the corresponding action when the key is pressed down, and the key processing and alarming module can complete the alarm signal processing; the communication management module completes the function of receiving and transmitting serial port data.
Further: and the task calling core adopts a circulating occupation method to control the AD data processing module, the start-stop control module, the communication management module and the key processing module to circularly occupy the main control chip.
Further: the specific process of the AD data processing module for carrying out filtering processing on the digital signal is as follows: simultaneously collecting a plurality of signals every 1 millisecond, and storing each signal in an array; each array can store 5 data; and processing the data once every 5 milliseconds, removing a minimum value and a maximum value, and averaging the remaining 3 data to obtain the received data.
Further: the AD data processing module completes constant power calculation control, and the specific process of the constant power calculation control is as follows:
step 1, acquiring set output power acquired by an AD data processing module and detecting actual output power by the AD data processing module;
step 2, calculating a difference value between the set output power and the actual output power;
step 3, multiplying the difference by a coefficient to obtain a proportional term;
step 4, multiplying the difference value by a coefficient and carrying out integral operation to obtain an integral term;
step 5, multiplying the difference by a coefficient and carrying out differential operation to obtain a differential term;
step 6, summing a proportional term, an integral term and a differential term to obtain a control value;
step 7, judging whether the control value is larger than a preset integral saturation value or not, setting the control value to be equal to the integral saturation value when the control value is larger than the preset integral saturation value, and executing step 8 when the control value is not larger than the preset integral saturation value;
and 8, outputting a control value.
Further: the specific working process of data transceiving of the communication management module is as follows:
step 1, serial port data receiving;
step 2, carrying out Modbus protocol analysis on the serial port received data;
and step 3, responding Modbus protocol data.
Step 4, preparing data according to a Modbus protocol by the data to be sent;
and 5, the serial port sends data after Modbus protocol manufacturing.
Further: the constant frequency calculation control can be completed, and the specific process of the constant frequency calculation control is as follows:
step 1, acquiring a set phase difference and an actual phase difference;
step 2, calculating a difference value between the set phase difference and the actual phase difference;
step 3, multiplying the difference by a coefficient to obtain a proportional term;
step 4, multiplying the difference value by a coefficient and carrying out integral operation to obtain an integral term;
step 5, multiplying the difference by a coefficient and carrying out differential operation to obtain a differential term;
step 6, summing a proportional term, an integral term and a differential term to obtain an inversion PWM signal control value;
step 7, judging whether the control value of the inversion PWM signal is larger than a preset integral saturation value or not, setting the control value of the inversion PWM signal to be equal to the integral saturation value when the control value of the inversion PWM signal is larger than the preset integral saturation value, and executing the step 8 when the control value of the inversion PWM signal is not larger than the preset integral saturation value;
and 8, outputting the control value of the inversion PWM signal.
Further: and (3) calculating a difference value between the set phase difference and the actual phase difference in the constant frequency calculation control step 2, triggering an interruption module, executing the step 2-8 in the interruption module, and returning the control value of the inverted PWM signal output in the step 8 as a return value to the AD data processing module.
A memory: the memory stores instructions that, when executed, perform the control algorithm described above.
Induction heating power DSP intelligent control device: the central control chip is connected with a memory, and the memory is the memory.
Further: the central control chip is a DSP chip.
Compared with the prior art, the invention has the technical effects that the output power of the power supply is controlled by automatically controlling the duty ratio of the chopped wave PWM signal through the control system, so that the power supply power of the induction heating equipment is ensured to be constant; the frequency of the inverted PWM signal is automatically controlled to control the output frequency of the power supply, so that the constant frequency of the power supply of the induction heating equipment is ensured. The production process level is improved by constant power supply power and power supply frequency.
Drawings
FIG. 1 is a schematic diagram of the present invention.
Fig. 2 is a schematic diagram of task call core control.
FIG. 3 is a flow diagram of a start-stop control module.
Fig. 4 is a schematic flow chart of the AD data processing module.
Fig. 5 is a schematic diagram of a constant power calculation control structure.
Fig. 6 is a flow chart of a constant power calculation control method.
FIG. 7 is a schematic view of a key processing and alarm module.
Fig. 8 is a flow chart of a communication management module.
Fig. 9 is a schematic diagram of a constant frequency calculation control structure.
Fig. 10 is a flowchart of a constant frequency calculation control method.
Detailed Description
The invention is applied to the existing induction heating equipment.
As shown in the attached figure 1, the induction heating power supply DSP intelligent control algorithm: the system comprises a task calling core, an AD data processing module, a start-stop control module, a communication management module, a key processing and alarming module and an interruption module; the task calling core carries out task scheduling on the AD data processing module, the start-stop control module, the communication management module and the key processing and alarming module, and the occupation level of each module on the main control chip is arranged; and the interruption module is triggered to forcibly occupy the main control chip during execution.
And a task calling core:
the task calling core adopts a circulation occupation method to control the AD data processing module, the start-stop control module, the communication management module and the key processing module to circularly occupy the main control chip, and the specific process is as shown in figure 2:
the start-stop control module, the AD data processing module, the communication management module and the key processing module are called sequentially through the main control chip, and the start-stop control module is called again after the key processing module is occupied.
Start and stop the control module:
after receiving a start signal, the start-stop control module initializes related control parameters in a working process shown in fig. 3, then starts output of an inverted PWM signal, starts output of a chopping signal, and controls output power of a main circuit by using the PWM signal of the chopping signal; and the start-stop module stops all the PWM signals when the system setting start signal is invalid.
An AD data processing module:
as shown in fig. 4, the AD data processing module acquires analog signals required by the induction heating power supply DSP intelligent control system, and converts the analog signals into digital signals; the acquired signals are subjected to analog-to-digital conversion of a DSP chip to obtain corresponding numerical values, and the numerical values are subjected to filtering processing; and finishing the output of the inverted PWM signal and the output of the chopping signal.
The acquired analog signals comprise output voltage, output current and power setting level of a main circuit of the induction heating equipment, power output voltage monitored by an intelligent control system of an induction heating power supply DSP, monitored power load current signals, voltage of a filter capacitor of the induction heating equipment and cooling water pressure of the induction heating equipment.
The specific process of the filtering treatment is as follows: multiple signals are acquired simultaneously every 1 millisecond, each signal being stored in an array. Each array can hold 5 data, i.e. can hold data within 5 milliseconds.
And processing the data once every 5 milliseconds, removing a minimum value and a maximum value, and averaging the remaining 3 data to obtain the received data.
The AD data processing module finishes power setting signal processing, namely, the power setting signal processing is to linearize the acquired power setting level signal of the external input into a usable signal, namely, the usable signal is multiplied by a proper coefficient to obtain the set output power; the coefficients are set by the staff according to the system specifications.
The AD data processing module completes constant power calculation control, the constant power calculation control structure is shown in figure 5, the AD data processing module detects monitored power supply output voltage and monitored power supply load current, the product of the monitored power supply output voltage and the monitored power supply load current is actual output power, the actual output power and the set output power are used as input quantity of a constant power calculation control method, calculation is performed through the constant power calculation control method, the return value of the constant power calculation control method is a chopper circuit control value, the output duty ratio of chopper PWM is changed, and the monitored power supply output voltage is controlled.
The specific process of the constant power calculation control method is as shown in fig. 6:
step 1, acquiring set output power acquired by an AD data processing module and detecting actual output power by the AD data processing module;
step 2, calculating a difference value between the set output power and the actual output power;
step 3, multiplying the difference by a coefficient to obtain a proportional term; the coefficient is set by the staff according to the system specification;
step 4, multiplying the difference value by a coefficient and carrying out integral operation to obtain an integral term;
step 5, multiplying the difference by a coefficient and carrying out differential operation to obtain a differential term;
step 6, summing a proportional term, an integral term and a differential term to obtain a control value;
step 7, judging whether the control value is larger than a preset integral saturation value or not, setting the control value to be equal to the integral saturation value when the control value is larger than the preset integral saturation value, and executing step 8 when the control value is not larger than the preset integral saturation value;
and 8, outputting a control value.
And the AD data processing module completes load impedance calculation, and the load impedance of the power supply is obtained by dividing the monitored power supply output voltage acquired by the AD data processing module by the monitored power supply load current acquired by the AD data processing module.
The key processing and alarming module:
as shown in fig. 7, the induction heating power source is used by an operator operating a key on the panel. The key processing and alarming module can detect whether the key is pressed down.
When the key is not pressed, the key processing and alarm module detects that the signal corresponding to the key is at a high level (namely, a number 1). When a certain key is pressed, the key processing and alarm module detects that the signal corresponding to the key is at a low level (namely, a digital 0).
The key processing and alarming module completes the processing of starting the key, stopping the key and scram key:
when the start button is pressed down, the button processing and alarming module detects that the start button is pressed down, the button processing and alarming module sets a start signal to be effective, the start-stop control module can start output of the inverted PWM signal and start output of the chopping signal according to the start signal, and after the start button is lifted up, the start signal is not changed, and the working state of the equipment is not changed.
When the stop key is pressed down, the key processing and alarming module detects that the stop key is pressed down, the key processing and alarming module sets the starting signal to be invalid, the start-stop control module stops all PWM signals, and the main circuit has no current. After the stop key is lifted, the starting signal is not changed, and the working state of the equipment is unchanged.
When the emergency stop key is pressed down, the key processing and alarming module sets the starting signal to be invalid, the start-stop control module immediately stops the PWM signal, and the main circuit stops outputting current. And other keys of the device are disabled and do not play a control role. After the emergency stop key is lifted, the emergency stop function is invalid, and other key functions of the equipment are normally used.
The key processing and alarm module completes alarm signal processing:
when the AD data processing module detects that the working state of the equipment is abnormal, a corresponding alarm signal is generated, for example, the output current exceeds a rated range, and an overcurrent signal is changed from a low level (digital 0) to a high level (digital 1); when the voltage of the filter capacitor of the induction heating equipment exceeds a rated range, the overvoltage signal is changed from a low level (digital 0) to a high level (digital 1); when the induction heating equipment works, cooling water is needed to cool electronic devices, if the cooling water pressure is insufficient, the output signal of the water pressure gauge is changed from a low level (digital 0) to a high level (digital 1), and the signal is a water shortage signal.
The alarm signal is divided into two stages. Important alarm signals are overcurrent and overvoltage in the first stage, and the first stage alarm needs to be stopped and alarm latch is carried out. The water shortage signal is of a second level, the second-level alarm needs to be stopped and not latched, namely, the equipment can continue to work after the alarm disappears. The alarm signal can be cancelled by a reset operation.
The key processing and alarm module completes the timing of the starting time:
after the equipment starting key is pressed down, the key processing and alarming module starts to time.
The system triggers the execution of the interrupt module once every 1 millisecond, and when the enable signal is active, the count will begin to accumulate in the interrupt module until the enable signal is inactive and the value no longer accumulates the count. For example, when the count value is 1000, it indicates that the apparatus is operating for 1 second.
The communication management module:
the specific working process of data transceiving of the communication management module is as shown in fig. 8:
step 1, serial port data receiving;
step 2, carrying out Modbus protocol analysis on the serial port received data;
and step 3, responding Modbus protocol data.
Step 4, preparing data according to a Modbus protocol by the data to be sent;
and 5, the serial port sends data after Modbus protocol manufacturing.
Constant frequency calculation control:
the constant frequency calculation control structure is shown in fig. 9, the difference between the inversion PWM signal phase and the current phase of the monitored power load detected by the AD data processing module is calculated as the actual phase difference, the actual phase difference is used as the input signal of the constant frequency calculation control method, the given phase difference is used as the other input signal of the constant frequency calculation control method, the return value of the constant frequency calculation control method is the inversion PWM signal control value, and the inversion PWM signal frequency is changed to control the frequency of the inversion load circuit.
The specific process of the constant frequency calculation control method is shown in fig. 10:
step 1, acquiring a set phase difference and an actual phase difference;
step 2, calculating a difference value between the set phase difference and the actual phase difference;
step 3, multiplying the difference by a coefficient to obtain a proportional term; the coefficient is set by the staff according to the system specification;
step 4, multiplying the difference value by a coefficient and carrying out integral operation to obtain an integral term;
step 5, multiplying the difference by a coefficient and carrying out differential operation to obtain a differential term;
step 6, summing a proportional term, an integral term and a differential term to obtain an inversion PWM signal control value;
step 7, judging whether the control value of the inversion PWM signal is larger than a preset integral saturation value or not, setting the control value of the inversion PWM signal to be equal to the integral saturation value when the control value of the inversion PWM signal is larger than the preset integral saturation value, and executing the step 8 when the control value of the inversion PWM signal is not larger than the preset integral saturation value;
and 8, outputting the control value of the inversion PWM signal.
And 2, calculating a difference value between the set phase difference and the actual phase difference in the step 2, triggering an interruption module, executing the step 2-8 in the interruption module, and returning the control value of the inversion PWM signal output in the step 8 as a return value to the AD data processing module.
All functions of the task calling core, the AD data processing module, the start-stop control module, the communication management module, the key processing and alarming module and the interruption module are stored in a memory as executable instructions.
The memory is connected with a central control chip, and the central control chip calls the instructions stored in the memory to execute all functions of the task calling core, the AD data processing module, the start-stop control module, the communication management module, the key processing and alarming module and the interruption module.
The central control chip is also connected with an LED lamp, and when the control system is in a standby state, the LED is controlled to intermittently flash at the frequency of 1Hz for indication; when the control system is in an operating state, namely when the output power of the main circuit is controlled, the LED intermittently flickers at the frequency of 3Hz for indication.
The main control chip adopts a DSP chip of American TI, the DSP chip of the TI has various models including TMS320F2407, TMS320F2808, TMS320F2812 and TMS320F28335, the DSP chip TMS320F2407 is most applied at present, but the chip is excluded because the chip is pushed out for a long time and resources are deficient relative to a higher chip, and the TMS320F2808 and TMS320F28335 have fewer people and unknown stability; therefore, TMS320F2812 is selected, the chip is widely popularized after mass production, the use amount is large, ordering is rapid, resources are rich, and the chip can be flexibly applied.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various changes and modifications can be made without departing from the overall concept of the present invention, and these should also be considered as the protection scope of the present invention.
Claims (8)
1. The induction heating power supply DSP intelligent control algorithm is characterized in that: the system comprises a task calling core, an AD data processing module, a start-stop control module, a communication management module, a key processing and alarming module and an interruption module; the task calling core carries out task scheduling on the AD data processing module, the start-stop control module, the communication management module and the key processing and alarming module, and the occupation level of each module on the main control chip is arranged; the interrupt module forcibly occupies the main control chip when triggering execution; the start-stop control module completes initialization of relevant control parameters, starts or stops output of the inverted PWM signals, and starts or stops output of chopping signals; the AD data processing module acquires analog signals needed by the system, converts the analog signals into digital signals and filters the digital signals; and finishing the output of the inverted PWM signal and the output of the chopping signal; the key processing and alarming module can detect whether the key is pressed down and complete the corresponding action when the key is pressed down, and the key processing and alarming module can complete the alarm signal processing; the communication management module completes the function of receiving and transmitting serial port data;
the task calling core adopts a cyclic occupation method to control the AD data processing module, the start-stop control module, the communication management module and the key processing module to circularly occupy the main control chip;
the specific process of the AD data processing module for carrying out filtering processing on the digital signal is as follows: simultaneously collecting a plurality of signals every 1 millisecond, and storing each signal in an array; each array can store 5 data; and processing the data once every 5 milliseconds, removing a minimum value and a maximum value, and averaging the remaining 3 data to obtain the received data.
2. The induction heating power supply DSP intelligent control algorithm of claim 1, characterized by: the AD data processing module completes constant power calculation control, and the specific process of the constant power calculation control is as follows:
step 1, acquiring set output power acquired by an AD data processing module and detecting actual output power by the AD data processing module;
step 2, calculating a difference value between the set output power and the actual output power;
step 3, multiplying the difference by a coefficient to obtain a proportional term;
step 4, multiplying the difference value by a coefficient and carrying out integral operation to obtain an integral term;
step 5, multiplying the difference by a coefficient and carrying out differential operation to obtain a differential term;
step 6, summing a proportional term, an integral term and a differential term to obtain a control value;
step 7, judging whether the control value is larger than a preset integral saturation value or not, setting the control value to be equal to the integral saturation value when the control value is larger than the preset integral saturation value, and executing step 8 when the control value is not larger than the preset integral saturation value;
and 8, outputting a control value.
3. The induction heating power supply DSP intelligent control algorithm of claim 1, characterized by: the specific working process of data transceiving of the communication management module is as follows:
step 1, serial port data receiving;
step 2, carrying out Modbus protocol analysis on the serial port received data;
step 3, responding Modbus protocol data;
step 4, preparing data according to a Modbus protocol by the data to be sent;
and 5, the serial port sends data after Modbus protocol manufacturing.
4. The induction heating power supply DSP intelligent control algorithm of claim 1, characterized by: the constant frequency calculation control can be completed, and the specific process of the constant frequency calculation control is as follows:
step 1, acquiring a set phase difference and an actual phase difference;
step 2, calculating a difference value between the set phase difference and the actual phase difference;
step 3, multiplying the difference by a coefficient to obtain a proportional term;
step 4, multiplying the difference value by a coefficient and carrying out integral operation to obtain an integral term;
step 5, multiplying the difference by a coefficient and carrying out differential operation to obtain a differential term;
step 6, summing a proportional term, an integral term and a differential term to obtain an inversion PWM signal control value;
step 7, judging whether the control value of the inversion PWM signal is larger than a preset integral saturation value or not, setting the control value of the inversion PWM signal to be equal to the integral saturation value when the control value of the inversion PWM signal is larger than the preset integral saturation value, and executing the step 8 when the control value of the inversion PWM signal is not larger than the preset integral saturation value;
and 8, outputting the control value of the inversion PWM signal.
5. The induction heating power supply DSP intelligent control algorithm of claim 4, characterized by: and (3) calculating a difference value between the set phase difference and the actual phase difference in the constant frequency calculation control step 2, triggering an interruption module, executing the step 2-8 in the interruption module, and returning the control value of the inverted PWM signal output in the step 8 as a return value to the AD data processing module.
6. A memory, characterized by: the memory stores instructions that, when executed, perform the control algorithm of any of claims 1-5.
7. Induction heating power DSP intelligent control device, its characterized in that: the central control chip is connected with a memory, and the memory is the memory in claim 6.
8. The intelligent control device of the induction heating power supply DSP according to claim 7, characterized in that: the central control chip is a DSP chip.
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| JP3799324B2 (en) * | 2002-12-02 | 2006-07-19 | 株式会社東芝 | Induction heating cooker |
| KR100622803B1 (en) * | 2005-03-16 | 2006-09-19 | 쿠쿠전자주식회사 | Input current stabilizer of induction heating cooking device |
| TWI394547B (en) * | 2009-03-18 | 2013-05-01 | Delta Electronics Inc | Heating apparatus |
| CN103997116A (en) * | 2014-02-18 | 2014-08-20 | 重庆荣凯川仪仪表有限公司 | Emergency power supply control system based on DSP (Digital Signal Processor), and control method |
| CN104825052A (en) * | 2014-08-20 | 2015-08-12 | 江丽 | Temperature-adjustable intelligent heater and control method therefor |
| CN204206518U (en) * | 2014-12-02 | 2015-03-11 | 保定四方三伊电气有限公司 | Digital rectifier controller for induction heating power supply |
| CN204741273U (en) * | 2015-06-10 | 2015-11-04 | 国网四川省电力公司宜宾供电公司 | Designing a system for electric power automation control based on digital signal processing technology |
| CN106060989A (en) * | 2016-06-08 | 2016-10-26 | 东营威玛石油钻具有限公司 | Induction heating power supply method |
| CN205864774U (en) * | 2016-07-19 | 2017-01-04 | 国核华清（北京）核电技术研发中心有限公司 | High frequency induction heating device |
| CN107949086A (en) * | 2017-12-15 | 2018-04-20 | 郑州科创电子有限公司 | A kind of induction heating power and its control method |
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