小功率弧焊电流源设计及建模仿真

摘 要

随着焊接工艺研究的深入以及焊接生产自动化和柔性化的发展，对弧焊电源本身的精确控制和柔性化，提出了更为紧迫的需要。由于弧焊逆变电源的逆变频率一般在20K-100KHz的范围，在焊机体积和重量减小的同时，其输出电感明显减小，因此弧焊逆变电源在时间的精确控制上具备了良好的基础。但是，由于目前弧焊逆变电源多采用模拟电路进行控制，使得弧焊电源的输出信号的幅值控制精度并没有实质性的提高，同时焊接电源的柔性化更是无从谈起。因此，本文针对弧焊逆变电源的精确控制和柔性化，对弧焊逆变电源的数字化控制进行了研究。

数字化逆变弧焊电源具有能够柔性化控制、控制精度高、稳定性强、一致性好、通用性强等优点，近年来成为弧焊电源的主要发展方向。针对数字化逆变弧焊电源，性能良好的控制方案设计是弧焊电源稳定、可靠工作的关键。通过比较与改进传统控制策略，对弧焊电流源系统硬件和软件进行设计，通过仿真及实验证明了所提出控制方案的有效性。主要研究内容如下：

(1) 研究弧焊电流源的背景，以及国内外弧焊电流源的现状和发展趋势；总结弧焊电流源的优缺点及意义；研究控制系统仿真软件Matlab的发展现状。

(2) 弧焊电流源控制系统的硬件电路设计。硬件设计中主电路主要包括逆变电路拓扑选择、变压器设计、输出滤波电感设计。控制电路主要对信号采样调理电路、IGBT驱动电路、保护电路的硬件进行设计。

(3)在Matlab仿真环境下建立数字化逆变弧焊电流源的系统模型，通过仿真验证控制策略的有效性，本次控制方案能够及时调节变压器过电流、快速响应系统不同状态间的切换、对负载变化具有很强的适应性，并保证电源稳态工作时与给定无误差。通过Matlab仿真模型的结果进行了对比分析，功率负载的实验表明，仿真结果准确，本文研制的数字化弧焊逆变电源符合设计要求，满足焊接工艺的需要。

关键词：逆变弧焊电源，Matlab仿真，数字化控制，建模与仿真

Abstract

With the development of welding technology and welding production automation and flexibility, it is more urgent to accurately control and flexibility of arc welding power source itself. As the inverter frequency of arc welding inverter is generally in the range of 20K-100khz, the output inductance decreases obviously with the decrease of the volume and weight of the welding machine, so the arc welding inverter has a good foundation in the precise control of time. However, due to the current arc welding inverter power supply mostly adopts analog circuit to control, the amplitude control precision of output signal of arc welding power supply has not been substantially improved, and the flexibility of welding power supply is out of the question. Therefore, this paper studies the digital control of arc welding inverter power supply for precise control and flexibility.

Digital inverter arc welding power supply has the advantages of flexible control, high control precision, strong stability, good consistency and versatility, and has become the main development direction of arc welding power supply in recent years. For digital inverter arc welding power supply, the design of good performance control scheme is the key to stable and reliable operation of arc welding power supply. By comparing and improving the traditional control strategy, the hardware and software of arc welding current source system are designed, and the effectiveness of the proposed control scheme is proved by simulation and experiment. The main research contents are as follows:

(1) Study the background of arc welding current source, and the current situation and development trend of arc welding current source at home and abroad; The advantages and disadvantages and significance of arc welding current source are summarized. The development of control system simulation software Matlab is studied.

(2) Hardware circuit design of arc welding current source control system. The main circuit of hardware design mainly includes inverter topology selection, transformer design, output filter inductor design. The control circuit mainly designs the hardware of signal sampling and conditioning circuit, IGBT driving circuit and protection circuit. 

(3) in the Matlab simulation environment to establish system model of digital inverter arc welding current source, the effectiveness of the proposed control strategy is validated by computer simulation, the control scheme can timely adjust transformer overcurrent, rapid response system to switch between different states, has a strong adaptability to changes in load, and ensure the power supply steady work with a given no error. The results of Matlab simulation model are compared and analyzed. The power load experiment shows that the simulation results are accurate. The digital arc welding inverter developed in this paper meets the design requirements and the needs of welding process.

Key words: Inverter arc welding power supply, Matlab simulation, digital control, modeling and simulation

目录

摘    要....................................................................................................................... 1

第一章 绪论............................................................................................................ 6

1.1  概述............................................................................................................. 6

1.2  课题研究的现状........................................................................................ 7

1.2.1  国外现状............................................................................................ 7

1.2.2  国内现状............................................................................................ 8

1.3  课题研究的意义........................................................................................ 9

1.4  仿真工具MATLAB/Simulink简介.................................................... 10

1.5  课题的研究内容及章节安排............................................................... 12

第二章 弧焊电源的基本原理及特性............................................................. 13

2.1  弧焊电源的基本原理............................................................................ 13

2.2  弧焊电源的基本特性............................................................................ 14

2.2.1  弧焊电源的外特性........................................................................ 14

2.2.2  弧焊电源的调节特性.................................................................... 15

2.2.3  弧焊电源的动态特性.................................................................... 16

第三章 弧焊电流源的主电路设计.................................................................. 17

3.1  输入电路设计.......................................................................................... 17

3.2  逆变电路设计.......................................................................................... 17

3.3  输出电路设计.......................................................................................... 18

3.4  电路参数的选择..................................................................................... 19

3.4.1  确定变压器变比与占空比........................................................... 19

3.4.2  输入整流电路的设计与计算....................................................... 20

3.4.3  逆变电路的设计与计算................................................................ 22

3.4.4  输出整流电路的设计与计算....................................................... 23

第四章 弧焊电流源系统硬件设计.................................................................. 24

4.1      弧焊电流源系统组成......................................................................... 24

4.2      弧焊电流源主电路系统硬件设计................................................... 25

4.2.1  逆变电路的选择............................................................................. 25

4.2.2  大功率高频变压器........................................................................ 26

4.2.3  输出滤波电感设计........................................................................ 26

4.3      弧焊电流源控制电路系统硬件设计............................................... 27

4.3.1  采样调理电路设计........................................................................ 27

4.3.2  IGBT驱动电路设计....................................................................... 28

4.3.3  保护电路设计................................................................................. 29

第五章 弧焊电流源建模与仿真分析............................................................. 29

5.1      弧焊电流源系统仿真模型................................................................ 29

5.2      仿真输出波形及分析......................................................................... 30

5.3      本章小结............................................................................................ 32

第六章  结束语................................................................................................... 32

参考文献................................................................................................................ 34

致    谢................................................................................................................ 36

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