数字化逆变电阻焊机研究与设计

发布时间：2018-06-22 06:01

本文选题：电阻焊机 + 全桥逆变　；参考：《山东大学》2017年硕士论文

【摘要】：随着人们对电阻焊机焊接控制精度和焊接质量的要求不断提高,以及计算机控制技术和大功率开关器件IGBT等电力电子器件的不断应用及发展,数字化逆变电阻焊机依靠其三相负载平衡、动态响应快、焊接质量高、易于控制、输出效率高等优点,受到国内外的广泛关注。本文对数字化逆变电阻焊机的工作过程、控制方式等进行深入分析,研究并设计出新型数字化逆变电阻焊机样机。首先,本文对数字化逆变电阻焊机工作原理、影响焊接因素进行分析,并对所设计样机主电路的拓扑结构和焊接工作模式进行详细的介绍。通过Matlab中Simulink工具箱建立拓扑结构模型,对数字化逆变电阻焊机的恒电压、恒电流和恒功率三种焊接模式进行仿真分析。其次,对所设计样机主电路工作过程和硬件设计过程、控制电路的信号检测和焊接控制过程进行介绍。数字化逆变电阻焊机完成能量传输过程的主电路,主要包括抗干扰及输入电压保护、三相输入整流滤波、浪涌电流抑制、全桥逆变(H桥)、IGBT缓冲保护、变压器电压电流变换以及次级整流电路等。文章详细分析了主电路中各部分电路的工作原理和工作过程,并通过对各部分功率电路中的电流、电压参数的计算,选择出参数合适的功率器件型号以及选择最佳的IGBT缓冲保护电路。作为数字化逆变电阻焊机的核心,控制电路主要实现对焊机整个工作系统的控制和电流电压信号检测。本文对控制系统各部分电路的功能进行详细介绍,根据其功能模块完成相应的电路设计,包括单片机最小系统及外围电路设计、人机交互界面设计、整流输出电流和焊接电流的检测电路设计、过电流故障保护电路设计、PWM信号互锁电路以及IGBT驱动电路设计等,并根据数字化逆变电阻焊机的恒电压、恒电流和恒功率三种工作模式的分析完成软件实现流程图的设计。最后,本文对所设计样机各部分功能电路分别测试,根据测试结果和输出波形做相应调试。并对测试过程中出现的问题进行分析,做出相关的电路改进和算法的改善,然后对所设计样机组装并进行稳定性和可靠性测试,实验结果基本符合系统设计要求。本文最后对文章内容总结,并在此基础上提出论文的不足之处和改进措施。
[Abstract]:With the increasing requirement of welding control precision and welding quality of resistance welding machine, and the application and development of power electronic devices such as computer control technology and IGBT, etc. Digital inverter resistance welding machine is widely concerned at home and abroad for its advantages of three-phase load balance, fast dynamic response, high welding quality, easy control and high output efficiency. In this paper, the working process and control mode of the digital inverter resistance welding machine are deeply analyzed, and the prototype of the new digital inverter resistance welding machine is studied and designed. Firstly, this paper analyzes the working principle of the digital inverter resistance welding machine and the factors affecting the welding, and introduces the topology structure and welding working mode of the main circuit of the designed prototype in detail. The topology model of digital inverter resistance welding machine is established by Simulink toolbox in Matlab. Three welding modes, constant voltage, constant current and constant power, are simulated and analyzed. Secondly, the main circuit working process and hardware design process of the prototype, the signal detection and welding control process of the control circuit are introduced. The main circuit of digital inverter resistance welding machine to complete the process of energy transmission mainly includes anti-interference and input voltage protection, three-phase input rectifier filter, surge current suppression, full-bridge inverter (H-bridge) IGBT buffer protection. Transformer voltage and current conversion and secondary rectifier circuit. The working principle and working process of each part of the main circuit are analyzed in detail, and the parameters of current and voltage in each part of power circuit are calculated. Select the appropriate parameters of the power device model and select the best IGBT buffer protection circuit. As the core of the digital inverter resistance welding machine, the control circuit mainly realizes the control of the whole working system of the welding machine and the detection of the current and voltage signals. In this paper, the functions of each part of the control system are introduced in detail. According to its function module, the corresponding circuit design is completed, including the design of the minimum system and peripheral circuit of the single chip microcomputer, the design of the man-machine interface. The detection circuit of rectifier output current and welding current, over-current fault protection circuit, PWM signal interlocking circuit and IGBT drive circuit are designed, and according to the constant voltage of digital inverter resistance welder, The analysis of three working modes of constant current and constant power completes the design of software flow chart. Finally, the functional circuits of the prototype are tested and debugged according to the test results and output waveforms. The problems in the testing process are analyzed and the circuit and algorithm are improved. Then the prototype is assembled and the stability and reliability are tested. The experimental results basically meet the requirements of the system design. Finally, this paper summarizes the content of the article, and on the basis of this, puts forward the deficiencies and improvement measures.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG438.2

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