电熔焊机智能控制系统的研制

发布时间：2019-02-22 21:14

【摘要】：聚乙烯塑料管道(PE管道)凭借其寿命长、耐腐蚀、成本低等许多优良特性,在建筑业、工业、农业等领域得到了广泛的应用。PE管道系统中,管道接头的质量是影响管道系统寿命的最主要因素,电熔焊接是管道连接施工中最通用的技术。由于目前还没有出现成熟的非破坏性PE管道电熔接头质量检测方法,因此,在电熔焊接过程中严格执行焊接规范、减少人为因素的干扰是保证管道接头焊接质量的关键。本文针对电熔焊机在管道电熔焊接应用中的不足,研究了电熔焊机的自动焊接技术,设计了一套电熔焊机智能控制系统,从而提高焊接质量和焊接效率。论文主要工作如下：首先,研究了电熔焊机焊接技术的发展现状,结合目前市面上的电熔焊机以及实际应用需求,设计了电熔焊机控制系统的总体方案。控制系统采用主从式结构,由嵌入式ARM主板和电源输出控制板两部分组成,嵌入式ARM主板通过连接外接设备实现人机交互、数据保存、信息查询等功能,电源输出控制板与焊机电源相连,实现对焊机电源输出控制和采样等功能。其次,根据电熔焊机控制系统的总体设计方案以及功能需求,设计了控制系统的硬件实现方案,以此为基础设计了嵌入式ARM主板以及电源输出控制板的硬件电路,制定了针对焊机电源产生的噪声与纹波的抑制方法。完成了控制系统的嵌入式软件设计,结合硬件电路实现了相应的功能。再次,研究了电熔焊机恒温焊接的实现方式,提出了一种通过控制发热电阻丝阻值从而实现对焊接温度进行控制的恒温焊接方法,确定了恒温焊接的控制策略。通过理论推导和实验测试的方法得出了电熔管件的数学模型,并以此为基础进行了PID控制、模糊控制、模糊PID控制三种控制方式的仿真实验,通过对仿真结果进行对比分析,确定了恒温焊接模式的控制方案。最后,将整个控制系统应用在现场焊接实验中,分别对控制系统的恒电压模式、恒电流模式、恒温模式三种焊接模式进行了管道焊接实验,实验结果表明,本文设计的电熔焊机控制系统在三种焊接模式下均具有良好的控制效果,能够保证电熔管件接头的质量,满足实际应用需求。
[Abstract]:Polyethylene plastic pipe (PE) has been widely used in many fields such as construction, industry and agriculture because of its long life, corrosion resistance and low cost. The quality of pipe joint is the most important factor affecting the life of pipeline system, and electric fusion welding is the most common technology in pipeline connection construction. Because there is no mature quality testing method for non-destructive PE pipe fused joints at present, the key to ensure the welding quality is to strictly implement the welding specifications and reduce the interference of human factors in the process of electric fusion welding. In order to improve the welding quality and efficiency, this paper studies the automatic welding technology of the electric fusion welding machine and designs a set of intelligent control system for the electric fusion welding machine in order to improve the welding quality and the welding efficiency in view of the deficiency of the electric welding machine in the application of the electric fusion welding machine. The main work of this paper is as follows: firstly, the development status of the welding technology of the electric fusion welding machine is studied, and the overall scheme of the control system of the electric fusion welding machine is designed according to the current market of the electric fusion welding machine and the practical application requirements. The control system adopts master-slave structure, which is composed of embedded ARM motherboard and power output control board. Embedded ARM motherboard realizes man-machine interaction, data saving, information query and so on by connecting external equipment. The power output control board is connected with the welding machine power supply to realize the function of welding machine power output control and sampling. Secondly, according to the overall design scheme and function requirement of the control system of the electric fusion welding machine, the hardware realization scheme of the control system is designed. Based on this, the hardware circuit of the embedded ARM motherboard and the power output control board is designed. The method of restraining noise and ripple produced by welding machine power supply is established. The embedded software design of the control system is completed, and the corresponding function is realized with the hardware circuit. Thirdly, the realization mode of constant temperature welding of electric fusion welding machine is studied, and a constant temperature welding method is put forward to control the welding temperature by controlling the resistance of heating wire, and the control strategy of constant temperature welding is determined. The mathematical model of the fused pipe is obtained by theoretical derivation and experimental test, and the simulation experiments of three control modes, PID control and fuzzy PID control, are carried out. The simulation results are compared and analyzed. The control scheme of constant temperature welding mode is determined. Finally, the whole control system is applied in the field welding experiment. The pipe welding experiments are carried out on the three welding modes of constant voltage mode, constant current mode and constant temperature mode, respectively. The experimental results show that, The control system of the electric fusion welding machine designed in this paper has good control effect under three welding modes, which can guarantee the quality of the joint of the electric melting pipe fittings and meet the practical application requirements.
【学位授予单位】：东南大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG432;TP273

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