基于FPGA的电阻焊电源的研究与设计

发布时间：2018-02-11 11:58

本文关键词： 电阻焊电源 FPGA 恒流控制 2SD315A驱动模块 Simulink　出处：《河北大学》2017年硕士论文　论文类型：学位论文

【摘要】：目前市场上的电阻焊电源主要以单片机、DSP芯片为控制核心,且工作频率一般都在1kHz~2kHz。由于电阻焊具有焊接电流大、焊接时间短等特殊的工艺特点,同时为了满足工业自动化生产对焊接工艺和焊接质量的更高要求,对电阻焊电源的控制提出了新的要求,要求其过程控制更加稳定可靠、焊接能量能够高精度的控制。因此本文选用了实时性和控制精度相比单片机、DSP都要好的FPGA芯片作为控制核心对电阻焊电源进行了研究与设计。为了获得控制精度高、实时性好的控制效果,本文充分运用FPGA并行架构的特点对电源的恒流控制器的各个功能模块进行了设计,特别是对数字PID进行了改进,以及避免电源启动和不同电流值间进行切换时的电流冲击,设计了软切换模块。应用模块化的设计思想将电源控制的各个功能模块都以数字电路的形式集成于芯片中,有效的提高了控制器的抗干扰能力。同时本文还详细的分析了电阻焊的基本原理及焊接工艺。然后确定了电源的整体设计方案,对主电路进行了分析和设计,以及对关键元器件进行了选型和参数的确定。最后基于2SD315A模块对大功率IGBT的驱动电路进行了研究与设计。另外为了保证整个系统安全可靠的运行,本文还设计了电源保护电路、电流反馈电路等,以及对改善驱动效果的不对称栅极电路进行了分析和设计。最后,在不同负载的条件下,对设计的恒流控制器在Modesim中进行了时序仿真,仿真结果达到预期的设计目的。对功率IGBT的驱动脉冲进行了实验测试,测试结果表明该驱动脉冲能可靠驱动IGBT。同时在空载的条件下,对变压器进行了实验测试,测试结果良好。并在Matlab的Simulink中对电源的各个功能模块进行仿真测试,仿真结果进一步检验了设计的可靠性。
[Abstract]:At present, the main control core of resistance welding power source in the market is single chip microcomputer DSP chip, and the working frequency is generally in 1 kHz or 2 kHz. Because resistance welding has special technological characteristics, such as large welding current and short welding time, etc. At the same time, in order to meet the higher requirements of welding process and welding quality in industrial automation production, a new requirement for the control of resistance welding power source is put forward, which requires the process control to be more stable and reliable. The welding energy can be controlled with high precision. Therefore, FPGA chip, which has better real-time and control precision than single-chip microcomputer, is used as the control core to study and design the resistance welding power source. This paper makes full use of the characteristics of FPGA parallel architecture to design each functional module of constant current controller of power supply, especially the improvement of digital PID. The soft switching module is designed by avoiding the current shock when the power supply is started and switching between different current values. The function modules of the power supply control are integrated into the chip in the form of digital circuit by using the modular design idea. At the same time, the basic principle and welding process of resistance welding are analyzed in detail. Then, the overall design scheme of power supply is determined, and the main circuit is analyzed and designed. Finally, based on 2SD315A module, the driving circuit of high-power IGBT is studied and designed. In addition, in order to ensure the safe and reliable operation of the whole system, the power supply protection circuit is designed. The current feedback circuit and the asymmetric gate circuit to improve the driving effect are analyzed and designed. Finally, the timing simulation of the designed constant current controller in Modesim is carried out under different load conditions. The experimental results show that the driving pulse can drive the IGBT reliably. At the same time, the transformer is tested under the condition of no load. The test results are good, and the simulation test of each function module of power supply is carried out in the Simulink of Matlab. The simulation results further verify the reliability of the design.
【学位授予单位】：河北大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TN86;TN791

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