焊接机器人专用MAG逆变焊接电源设计及工艺试验

发布时间：2018-02-28 02:48

本文关键词： 机器人焊接焊接电源 MAG焊接 MC56F8323 焊接专家系统　出处：《北京建筑大学》2015年硕士论文　论文类型：学位论文

【摘要】：随着工业机器人技术的发展,机器人焊接系统被广泛应用于工业生产中,焊接机器人对配套焊接电源的实时性和稳定性要求越来越高。为实现焊接机器人的全位置焊接,焊接电源必须有快速响应的能力,能够保证焊接特性跟随给定。本文介绍了基于DSP+MCU双控制构架的焊接电源系统,对电源内部结构和工作原理进行分析,提出包括主电路,主控电路,送丝机构,人机交互系统和通讯模块在内的多个模块设计方案,从硬件和软件两方面进行研究。主电路选择软开关全桥逆变形式,采用相移控制谐振的软开关技术,消除了开关损耗。新式的拓扑结构,解决了软开关电路应用于逆变电源时全负载区的换流问题,使电源功率提高到89%;分析移相PWM控制技术的原理,选择UCC3859芯片来实现PWM控制,确保主电路工作过程稳定、高效。分析MAG焊接的熔滴过渡过程,并对国内外目前应用广泛的几种电弧控制方法进行研究和比较,提出了一种基于模型参考自适应控制的电弧控制方法,采集电弧电压和焊接电流的反馈,通过基于超稳定性理论设计的模型参考自适应方法获得控制参数矩阵,对电流的波形进行调节,保证焊接电源的恒压特定和弧长稳定。详细介绍了MC56F8323型DSP芯片的工作特性和最小系统,围绕该芯片设计了主控系统。硬件方面,设计了开关电源电路、采样调理电路和欠压,过流等保护电路;软件方面,介绍了MC56F8323的编程环境,绘制了主程序和引弧、收弧、波形控制子程序的流程图,并进行程序编写。在设计过程中,充分考虑了硬件和软件的抗干扰性能。对焊接电源进行了性能测试,通过对5mm厚的12号碳钢板进行焊接,测量起弧,焊接,收弧及短路时的焊接参数与波形。进行了多种工艺试验,包括机器人MAG钢结构焊接、机器人MIG铝合金焊接以及双机器人的协调焊接。此外,该焊接电源还与管道焊接机器小车配合进行长输油气管道焊接试验,通过该实验测量的详实数据,建立了全位置焊接专家系统,为机器人的全位置焊接提供参考。经过测试与试验,发现了许多设计过程中没有注意到的问题和缺陷,通过分析和讨论,对可以解决的问题提出了解决方案,实现焊接电源的升级。测试与实验的结果表明:该焊接电源响应速度和稳定性符合焊接机器人的要求,硬件电路结构简单,抗干扰性能好,软件读写速度快,功能丰富,基本符合机器人焊接系统对焊接特性的要求,实现了研究目的。
[Abstract]:With the development of industrial robot technology, robot welding system is widely used in industrial production. The real-time and stability requirements of welding robot are more and more high. The welding power source must have the ability of quick response and can ensure the welding characteristics follow the given. This paper introduces the welding power source system based on DSP MCU dual control frame, analyzes the internal structure and working principle of the power supply, and puts forward the main circuit. The main control circuit, wire feeding mechanism, man-machine interaction system and communication module are studied from the aspects of hardware and software. The main circuit chooses the soft-switching full-bridge inverter, and adopts the soft-switching technology of phase-shift control resonance. The switching loss is eliminated. The new topology solves the commutation problem in the full load region of the soft switching circuit when it is applied to the inverter power supply, and increases the power of the power supply to 89. The principle of the phase-shifted PWM control technology is analyzed, and the UCC3859 chip is chosen to realize the PWM control. To ensure the stability and high efficiency of the main circuit, the droplet transfer process of MAG welding is analyzed, and several arc control methods, which are widely used at home and abroad, are studied and compared. An arc control method based on model reference adaptive control is proposed. The feedback of arc voltage and welding current is collected, and the control parameter matrix is obtained by the model reference adaptive method based on super stability theory. The current waveform is adjusted to ensure the constant voltage and arc length of the welding power supply. The working characteristics and minimum system of the MC56F8323 DSP chip are introduced in detail, and the main control system is designed around the chip. In the hardware aspect, the switching power supply circuit is designed. In the aspect of software, the programming environment of MC56F8323 is introduced, the flow chart of main program and arc starting, arc closing, waveform control subroutine is drawn, and the program is compiled. The anti-interference performance of hardware and software is fully considered. The performance of welding power source is tested. By welding the 5mm thick carbon steel plate 12, the starting arc and welding are measured. Welding parameters and waveforms for arc closing and short circuit. Various process tests have been carried out, including robot MAG steel structure welding, robot MIG aluminum alloy welding and dual robot coordinated welding. The welding power supply also cooperated with the pipe welding machine trolley to carry out the welding test of the long oil and gas pipeline. Through the detailed data measured in the experiment, the all-position welding expert system was established. Through testing and testing, many problems and defects that have not been noticed in the design process have been found. Through analysis and discussion, the solutions to the problems that can be solved are put forward. The test and experimental results show that the welding power supply meets the requirements of the welding robot, the hardware circuit is simple, the anti-interference performance is good, the software reading and writing speed is fast, and the function is rich. It basically meets the requirements of robot welding system for welding characteristics, and achieves the purpose of the research.
【学位授予单位】：北京建筑大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG409

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