新型电子束焊机高压电源的设计与实现

范霁康; 齐铂金; 刘方军; 张伟; 齐秦; 王海涛

doi:10.13700/j.bh.1001-5965.2016.0072

新型电子束焊机高压电源的设计与实现

doi: 10.13700/j.bh.1001-5965.2016.0072

北京航空航天大学机械工程及自动化学院, 北京 100083

基金项目:

工业与信息化部科技重大专项 2010ZX04007-041

详细信息

作者简介:
范霁康,男,博士研究生。主要研究方向:电子束焊接工艺与设备

齐铂金,男,博士,教授。主要研究方向:焊接工艺与设备,先进电源技术及应用

通讯作者:
齐铂金,E-mail:qbj@buaa.edu.cn

中图分类号: TG439.3
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出版历程
- 收稿日期: 2016-01-20
- 录用日期: 2016-03-11
- 网络出版日期: 2017-02-20

Design and implementation of a novel high-voltage power supply in electron beam welding machine

School of Mechanical Engineering and Automation, Beijing University of Aeronautics and Astronautics, Beijing 100083, China

Funds:

Special Major Science and Technology of Ministry of Industry and Information Technology 2010ZX04007-041

More Information

Corresponding author: QI Bojin,E-mail:qbj@buaa.edu.cn

摘要

摘要:
传统的电子束焊机高压电源电路结构复杂、体积庞大，为此研发了一种新型60 kV/100 mA逆变式电子束焊机高压电源，电路结构简单、电压输出稳定。电源调压电路采用脉宽调制（PWM）技术控制的全桥变换器，使三相整流后的约540 V电压转化为0~500 V幅值可调的稳压直流电，然后经全桥逆变电路逆变为频率为20 kHz方波交流电；升压电路采用变压器串联与倍压整流的方式，将前级20 kHz方波交流电转变为60 kV的直流高压；控制电路采用基于比例积分微分（PID）调节的电压双闭环控制策略，能够使电源实现稳定的高压输出。搭建了高压测试平台对所研制的高压电源进行了测试，结果表明电源高压输出稳定、控制精度高，高压输出纹波与稳定度均能稳定在1%范围内，能够满足电子束焊机的要求。
- 电子束焊接 /
- 高压电源 /
- 全桥逆变 /
- 倍压整流 /
- 双闭环控制
Abstract:
Traditional high-voltage power supply of electron beam welding machine has complicated circuit and huge volume. For improving the property of electron beam welding machine, a novel 60 kV/100 mA high-voltage power supply is developed in this paper. First, the three-phase electric is rectified to 540 V DC voltage. Then The voltage regulator circuit part adopts a full-bridge direct current converter controlled by pulse width modulation (PWM) method to regulate the 540 V DC voltage to adjustable 0-500 V DC voltage. A full-bridge inverter is used to change the DC voltage to 20 kHz AC voltage. Cascade-connected transformers and voltage doubling rectifiers are employed in the high voltage circuit part to achieve the 60 kV high-voltage output. In order to make the high-voltage output more stable, the double closed-loop control system based on proportion integration differentiation (PID) is adopted in the control circuit part. A high-voltage testing platform is established to measure the assembled high-voltage power supply and the test results show that the power supply has stable output voltage and high control accuracy. The ripple factor and stability are all in the 1% range, which can meet the requirement of electron beam welding machine.
- electron beam welding /
- high-voltage power supply /
- full-bridge inverter /
- double voltage rectification /
- double closed-loop control

HTML全文

图 1 电子束焊机高压电源整体结构设计方案

P₊—三相整流输出正极；P_-—三相整流输出负极；P₁₊—DC-DC全桥变换器输出正极；P_1-—DC-DC全桥变换器输出负极；AC₁—全桥逆变输出交流电压第一相；AC₂—全桥逆变输出交流电压第二相；U_HG—高压外环给定电压；U_HF—高压外环反馈电压；U_LG—高压内环给定电压；U_LF—高压内环反馈电压；U_IF—束流反馈电压。

Figure 1. Integrated structural design scheme of high-voltage power supply of electron beam welding machine

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图 2 DC-DC全桥变换电路拓扑

V_DC—电容C₁两端电压;U_OL—电容C₃两端电压。

Figure 2. Circuit topology of DC-DC full-bridge converter

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图 3 IGBT全桥逆变电路工作原理示意图

Figure 3. Fundamental diagram of IGBT full-bridge inverter

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图 4 DC-DC全桥变换器实物

Figure 4. Real products of DC-DC full-bridge converter

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图 5 变压器主要升压方式

Figure 5. Common methods of boosting transformer

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图 6 后级高压电路拓扑

Figure 6. Topology of post high-voltage circuit

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图 7 2种倍压整流电路拓扑

Figure 7. Two kinds of voltage-doubling rectifier circuit topology

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图 8 油箱内后级高压电路实物

Figure 8. Real product of post high-voltage circuit in tank

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图 9 高压电源电压双闭环控制策略

Figure 9. Double-loop voltage control strategy of high-voltage power supply

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图 10 高压电源测试平台

Figure 10. Testing equipment of high-voltage power supply

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图 11 负载为400 kΩ时电源输出特性

Figure 11. Output characteristics of high-voltage power supply with load 400 kΩ

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表 1 高压电源负载测试数据

Table 1. Testing data of high-voltage power supply with load

电压设置/kV	电压反馈/V	电压测量/kV	电流测量/mA
0	0	0	0
5	-0.51	-5.02	12.61
10	-1.01	-10.21	25.42
15	-1.50	-15.12	37.74
20	-1.99	-19.89	49.60
25	-2.51	-25.13	62.49
30	-3.00	-30.02	75.01
35	-3.47	-34.59	86.52
40	-4.01	-40.15	100.39
45	-4.55	-45.22	113.20
50	-5.02	-50.35	126.01
55	-5.53	-55.31	138.32
60	-6.01	-60.31	150.68

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