超音频复合脉冲GMAW电源设计

王强; 齐铂金; 王义朋; 郑敏信

doi:10.13700/j.bh.1001-5965.2016.0813

超音频复合脉冲GMAW电源设计

doi: 10.13700/j.bh.1001-5965.2016.0813

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:

国家自然科学基金 51675031

详细信息

作者简介:
王强, 男, 博士研究生。主要研究方向:高频脉冲焊接技术; 齐铂金, 男, 博士, 教授。主要研究方向:焊接设备与工艺、先进电源技术及应用

齐铂金男，博士，教授。主要研究方向：焊接设备与工艺、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: TG434.5
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出版历程
- 收稿日期: 2016-10-19
- 录用日期: 2016-11-18
- 网络出版日期: 2017-10-20

Design of hybrid ultrasonic frequency pulsed GMAW power source

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

Funds:

National Natural Science Foundation of China 51675031

More Information

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

摘要

摘要:
提出了一种全新的脉冲熔化极气体保护焊（GMAW）方法，并研制出新型超音频复合脉冲GMAW电源，即在传统脉冲GMAW电流基础上复合叠加频率为20~80 kHz、电流幅值为0~100 A、占空比为0%~100%的连续可调的超音频脉冲电流。设计了并联结构的主电路拓扑及MCU+DSP双处理器数字化控制系统，通过软件编程实现了电流给定信号与PWM信号的同步输出及不同逻辑组合，可实现不同工作模式的焊接电流波形输出。对电源输出电流波形的测试结果表明：本文所设计的超音频复合脉冲GMAW电源输出电流波形满足不同工作模式的设计目标，超音频脉冲电流频率在80 kHz时，仍保持较快的电流上升沿与下降沿变化速率。初步进行了铝合金平板堆焊试验，焊缝成形良好。
- 脉冲GMAW /
- 超音频脉冲 /
- 焊接电源 /
- 并联拓扑 /
- 双处理器
Abstract:
A new type of gas metal arc welding (GMAW) method was proposed and a novel hybrid ultrasonic frequency pulsed GMAW power source was developed. In this method, an ultrasonic frequency pulse current was superposed upon the conventional pulsed GMAW current with frequency from 20 to 80 kHz, current amplitude from 0 to 100 A, and duty cycle from 0% to 100%. Main circuit topology in parallel structure and dual-processor digital control system consisting of MCU and DSP were designed. Synchronized output and different logical combinations of current given signal and PWM signal were realized through software programming, resulting in several output current waveforms for different work modes. Testing results of the output current indicate that output current waveforms of the designed hybrid ultrasonic frequency pulsed GMAW power source satisfy the requirement of different work modes with a fast current rising and falling rate even at ultrasonic frequency pulse current frequency of 80 kHz. Aluminium alloy bead-on-plate experiment was conducted with this power source and a good weld bead appearance was obtained.
- pulsed GMAW /
- ultrasonic frequency pulse /
- welding power source /
- parallel topology /
- dual-processor

HTML全文

图 1 超音频复合脉冲GMAW波形示意图

Figure 1. Schematic of waveform ofhybrid ultrasonic frequency pulsed GMAW

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图 2 电源主电路拓扑^[12]

Figure 2. Main circuit topology of power source^[12]

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图 3 MCU+DSP双处理器控制系统框图

Figure 3. Block diagram of MCU+DSP dual-processor control system

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图 4 控制软件流程图

Figure 4. Flowchart of control software

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图 5 不同工作模式下的焊接电流波形示意图

Figure 5. Schematic of welding current waveforms under different work modes

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图 6 电阻负载下的输出电流波形

Figure 6. Output current waveform with resistive load

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图 7 不同频率下的超音频脉冲电流波形

Figure 7. Ultrasonic frequency pulsed current waveform with different frequencies

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图 8 铝合金超音频复合脉冲GMAW电流波形及焊缝外观

Figure 8. Current waveform and weld bead appearance of aluminium alloy hybrid ultrasonic frequency pulsed GMAW

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表 1 焊接电流参数

Table 1. Welding current parameters

参数	I_p/A	I_b/A	T_p/ms	T_b/ms	I_pp/A	f/kHz	D/%
数值	325	60	1.5	5.8	50	20	50

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