基于Proteus軟件的數(shù)字式等離子切割機(jī)控制系統(tǒng)的設(shè)計(jì)與仿真

1、第30卷第2期2009年2月焊接學(xué)報(bào)TRANSACTIONSOFTHECHINAWELDINGINSTITUTIONVol.30No.2February2009基于Proteus軟件的數(shù)字式等離子切割機(jī)控制系統(tǒng)的設(shè)計(jì)與仿真朱錦洪,丁書娜,李志剛,石紅信(河南科技大學(xué)河南省有色金屬材料科學(xué)與加工技術(shù)重點(diǎn)實(shí)驗(yàn)室,洛陽471003)摘要:介紹了Proteus軟件的特點(diǎn)、功能及在焊割設(shè)備中應(yīng)用以進(jìn)行嵌入式數(shù)字化控制系統(tǒng)設(shè)計(jì)與仿真的實(shí)現(xiàn)方法.在Proteus環(huán)境下結(jié)合Keil工具,對(duì)基于AT89S51單片機(jī)控制的逆變空氣等離子切割機(jī)的控制系統(tǒng)進(jìn)行了電路設(shè)計(jì)、程序開發(fā)與仿真調(diào)試.結(jié)果表明,.該方法可以提高

2、開發(fā)效率、縮短周期和降低成本,.關(guān)鍵詞:Proteus軟件;空氣等離子切割機(jī);數(shù)字控制;仿真中圖分類號(hào):TG115.28文獻(xiàn)標(biāo)識(shí)碼:A)-0049-04朱錦洪0序隨著現(xiàn)代工業(yè)和微電子技術(shù)的飛速發(fā)展,焊割設(shè)備正在向智能化、數(shù)字化方向大踏步邁進(jìn).數(shù)字化焊接電源具有控制精度高、穩(wěn)定性好、接口兼容性好、焊機(jī)功能升級(jí)方便等諸多優(yōu)點(diǎn),在全世界范圍內(nèi)得到了迅速的發(fā)展.因此,將數(shù)字化控制技術(shù)應(yīng)用于逆變式空氣等離子切割電源是其重要發(fā)展方向之一.一般情況下,數(shù)字化空氣等離子切割電源開發(fā)時(shí)只有當(dāng)PCB電路板和原型機(jī)制作之后,才能進(jìn)行軟件開發(fā)和硬件調(diào)試.電路板制作及元器件安裝費(fèi)時(shí)費(fèi)力,若設(shè)計(jì)出現(xiàn)問題,則整個(gè)過程還得從

3、頭再來.如果采用數(shù)字控制系統(tǒng)的虛擬仿真軟件Proteus進(jìn)行仿真,在系統(tǒng)虛擬開發(fā)成功之后再制作電路板,則會(huì)縮短開發(fā)周期、提高設(shè)計(jì)效率、降低開發(fā)成本,具有明顯的經(jīng)濟(jì)性和可移植性、可推廣性.文中在Proteus軟件環(huán)境下對(duì)單片機(jī)控制的空氣等離子切割機(jī)的控制系統(tǒng)進(jìn)行了仿真設(shè)計(jì).和其它EDA工具一樣具有原理圖布線、PCB自動(dòng)生成及基于Spice標(biāo)準(zhǔn)的電路仿真的功能外,其獨(dú)特的功能是將電路仿真和微處理器仿真協(xié)同進(jìn)行,直接在基于原理圖的虛擬原型機(jī)上進(jìn)行處理器程序調(diào)試,并進(jìn)行功能驗(yàn)證,通過外設(shè)部件與系統(tǒng)的虛擬儀器如示波器、邏輯分析儀等配合,實(shí)時(shí)看到運(yùn)行后的輸入輸出效果.因此,Proteus軟件建立了完備的電

4、子設(shè)計(jì)開發(fā)環(huán)境.Proteus軟件由ISIS和ARES兩個(gè)軟件構(gòu)成,其中ISIS是原理圖編輯與仿真軟件,ARES是布線編輯軟件.ISIS軟件支持MCS51及其派生系列、Microchip公司的PIC系列及Motorola公司等多款MCU,Proteus軟件所提供的30多個(gè)元件庫共計(jì)數(shù)千種元器件,而且還提供了虛擬示波器、邏輯分析儀、信號(hào)發(fā)生器、計(jì)數(shù)器、電表、虛擬終端等虛擬儀器儀表可供選用1,2.在軟件調(diào)試方面,Proteus軟件自身帶有匯編編譯器,不支持C語言,但可以與KeilC集成開發(fā)環(huán)境連接,將用匯編和C語言編寫的程序編譯好之后,可以立即進(jìn)行軟、硬件結(jié)合的系統(tǒng)仿真.當(dāng)仿真成功后,直接點(diǎn)擊AR

5、ES生成PCB板,同時(shí)又能夠生成多種格式的網(wǎng)絡(luò)表文件,供其它EDA軟件工具調(diào)用,方便了后續(xù)PCB的設(shè)計(jì).1Proteus軟件Proteus軟件是來自英國Labcenterelectronics公司的EDA工具軟件,它既可以仿真模擬電路,又可以仿真數(shù)字電路以及數(shù)字、模擬混合電路,而最大的特色在于能夠仿真基于微控制器的控制系統(tǒng).除了收稿日期:2008-09-16基金項(xiàng)目:河南省科技計(jì)劃重點(diǎn)項(xiàng)目(624260007)2控制系統(tǒng)的硬件設(shè)計(jì)2.1空氣等離子切割機(jī)的控制方案所設(shè)計(jì)的空氣等離子切割電源為IGBT逆變器,© 1994-2010 China Academic Journal Elect

6、ronic Publishing House. All rights reserved. 50焊接學(xué)報(bào)第30卷采用了“模擬脈寬調(diào)制+數(shù)字微控制器”的系統(tǒng)方案,更利于發(fā)揮成熟的模擬控制與單片機(jī)的各自特長,控制系統(tǒng)原理如圖1所示.在該方案中是以脈寬調(diào)制集成芯片TL494為核心組成電流負(fù)反饋閉環(huán)調(diào)節(jié)系統(tǒng),從而獲得恒流外特性,電路穩(wěn)定可靠.單片機(jī)不直接參與閉環(huán)控制,它負(fù)責(zé)輸出相應(yīng)的電流給定信號(hào)和控制信號(hào),完成參數(shù)預(yù)置、切割時(shí)序、實(shí)際參數(shù)測試、顯示與存儲(chǔ)、串行通訊、異常報(bào)警等輔助功能.采樣電壓、采樣電流、轉(zhuǎn)移弧控制電流分別由電壓、電流傳感器接入,并轉(zhuǎn)換成連續(xù)的05V的模擬信號(hào),經(jīng)A/D轉(zhuǎn)換送入微控制器.

7、微控制器響應(yīng)中斷后執(zhí)行中斷服務(wù)程序,將反饋電壓和電流的數(shù)字量分別存儲(chǔ)起來,然后調(diào)用進(jìn)行實(shí)時(shí)處理并顯示.給定電流由電位器給定,也需要經(jīng)過A/D轉(zhuǎn)換后送入微型計(jì)數(shù)機(jī)進(jìn)行實(shí)時(shí)處理,然后對(duì)該輸入電流信號(hào)進(jìn)行D/A轉(zhuǎn)換,控制PWM的脈寬輸出.同時(shí),單片機(jī)還分別輸出開關(guān)量信號(hào),經(jīng)光電耦合后控制氣閥和高頻引弧等.為了防止外圍設(shè)備對(duì)主機(jī)的干擾,該系統(tǒng)采取了光電隔離措施,從而提高了系統(tǒng)的穩(wěn)定性.2.2AT,控制系統(tǒng)包括A/轉(zhuǎn)換電路、顯示電路、串口通訊電圖1空氣等離子切割機(jī)的控制系統(tǒng)原理Fig11Diagramofcontrol,因頁面原因,僅顯示電路圖的主要部分如圖2所示.圖2Proteus軟件中控制系統(tǒng)電路的

8、仿真設(shè)計(jì)Fig12DesignandsimulationofcontrolcircuitinProteusA/D轉(zhuǎn)換電路由ADC0809芯片和地址鎖存器組成,主要完成對(duì)給定電流、采樣電流、采樣電壓和弧控電流等模擬量轉(zhuǎn)換為數(shù)字量并送入單片機(jī).ADC0809是8路模擬輸入逐次逼近式8位A/D轉(zhuǎn)換數(shù)據(jù)輸入寄存器和(R22R)T形電阻網(wǎng)絡(luò)的8位D/A轉(zhuǎn)換器,可以直接和微機(jī)連接,轉(zhuǎn)換控制容易,且價(jià)格便宜,因此在實(shí)際中得到廣泛應(yīng)用.在設(shè)計(jì)中,D/A轉(zhuǎn)換電路主要任務(wù)是控制PWM脈寬,但不生成PWM波,PWM脈寬調(diào)制由專門的脈寬調(diào)制芯片TL494生成.器,由模擬輸入、A/D轉(zhuǎn)換和三態(tài)輸出鎖存器三個(gè)部分組成,可

9、以直接與CPU系統(tǒng)總線連接3.ADC0809芯片主要用于采集輸入電流I0,采樣電流I1,弧控電流I2,采樣電壓U.DAC0832是內(nèi)部帶有割槍開關(guān)信號(hào)與單片機(jī)13管腳相連,通過單片機(jī)的外部中斷INT1來判斷割槍的狀態(tài).交流接觸© 1994-2010 China Academic Journal Electronic Publishing House. All rights reserved. 第2期朱錦洪,等:基于Proteus軟件的數(shù)字式等離子切割機(jī)控制系統(tǒng)的設(shè)計(jì)與仿真51器由單片機(jī)的2管腳控制,電磁閥控制和高頻引弧控制分別與3,4管腳相連.由于仿真設(shè)計(jì)時(shí)不可能像聯(lián)機(jī)調(diào)試一樣采集到

10、數(shù)據(jù),為了驗(yàn)證可采用滑動(dòng)變阻器作為模擬信號(hào)的輸入,通過A/D轉(zhuǎn)換為數(shù)字信號(hào)后顯示,然后把A/D轉(zhuǎn)換的結(jié)果D/A轉(zhuǎn)換輸出,通過電壓表或者示波器可以看到D/A轉(zhuǎn)換的結(jié)果.同時(shí),可在繼電器線圈上并接指示燈,在不同的輸出信號(hào)時(shí)觀察燈的亮滅判斷繼電器的動(dòng)作.3控制系統(tǒng)的軟件設(shè)計(jì)3.1控制程序組成空氣等離子切割控制程序主要完成對(duì)切割過程的時(shí)序控制及參數(shù)管理,其主程序設(shè)計(jì)流程如圖3所示.系統(tǒng)通電后,首先進(jìn)行單片機(jī)的初始化,完成對(duì)I/O口、A/D模塊、D/A模塊的設(shè)置,流接觸器,給切割機(jī)主電路供電,此時(shí),始對(duì)輸入電流進(jìn)行A/D工作狀態(tài).2s后,高轉(zhuǎn)移弧.當(dāng)工件與電極之間的電流大于某門檻值時(shí),打開轉(zhuǎn)移弧控制繼電

11、器,引燃轉(zhuǎn)移電弧,此時(shí)應(yīng)將高頻引弧繼電器斷開,切割機(jī)進(jìn)入正常工作狀態(tài)4.在等離子切割機(jī)工作的任何過程(如提前送氣階段或高頻引弧階段),只要檢測到并確認(rèn)割槍開關(guān)彈起,立即進(jìn)入中斷處理程序,執(zhí)行延遲送氣等操作,并修改堆棧指針,中斷處理后進(jìn)入復(fù)位狀態(tài),等待下一個(gè)工作過程和割槍開關(guān)動(dòng)作.中斷服務(wù)子程序流程如圖4所示.4ofstopcontrol2軟件與KeilC聯(lián)合調(diào)試仿真KeiluVision是優(yōu)秀的51單片機(jī)的匯編和C語言的開發(fā)工具,具備功能強(qiáng)大的軟件仿真功能,新版的Keil還能對(duì)部分PIC單片機(jī)和ARM單片機(jī)進(jìn)行軟件調(diào)試和編譯.采用C語言編程,對(duì)于啟動(dòng)和停機(jī)過程,割槍的閉合信號(hào)作為一般的IO信號(hào)

12、查詢,通過if語句來進(jìn)行判斷;割槍斷開信號(hào)使用外部中斷,利用INT1的下降沿向CPU發(fā)出中斷請求,進(jìn)行中斷.程序部分代碼如下#include<reg51.h>#include<stdio.h>#include<absacc.h>#defineD/AXBYTE0XDFFF/D/A轉(zhuǎn)換輸出sbitkey=P33/割槍開關(guān)sbitgas=P11sbitgpin=P12;sbitpw=P13voidInitall(void)/初始化子程序voiddelays(intx)/x秒延時(shí)子程序voiddisp(intn)/數(shù)碼顯示子程序voidadchn(intchn)/A

13、/D轉(zhuǎn)換程序voidmain(void)IntaInitall()while(1)a=adchn(0);disp(a)圖3控制主程序流程圖Fig13Flowchartofmaincontrolprogramif(key=1)/割槍啟動(dòng)查詢gas=0© 1994-2010 China Academic Journal Electronic Publishing House. All rights reserved. 52delays(2)gpin=0焊接學(xué)報(bào)第30卷int1()interrupt1/割槍停止中斷pw=1/pw=1禁止電源PWMdelays(2)gas=0;P=0;/修改

14、堆棧指針,返回復(fù)位狀發(fā)中多次修改和燒寫程序的過程.(3)Proteus軟件的仿真設(shè)計(jì)不受時(shí)間和空間的限制,便于自主設(shè)計(jì)和驗(yàn)證方案,便于實(shí)現(xiàn)自上向下的系統(tǒng)設(shè)計(jì),更好地實(shí)現(xiàn)電子設(shè)計(jì)自動(dòng)化,提高焊割電源和設(shè)備的計(jì)算機(jī)輔助設(shè)計(jì)技術(shù)和研究開發(fā)水平.參考文獻(xiàn):1周潤景,張麗娜.基于PROTEUS的電路及單片機(jī)系統(tǒng)設(shè)計(jì)與態(tài)在KeilC51集成開發(fā)環(huán)境下將編寫好的程序進(jìn)行編譯、調(diào)試,調(diào)試通過后生成HEX文件,運(yùn)行Pro2teus模擬仿真軟件,打開已繪制好的仿真電路原理圖,選中單片機(jī)AT89C51,左鍵點(diǎn)擊AT89C51,出現(xiàn)對(duì)應(yīng)的對(duì)話框,在ProgramFile中找到編譯好的HEX文件,然后點(diǎn)擊“OK”就可以

15、配置程序5.點(diǎn)擊模擬調(diào)試的運(yùn)行按鈕,進(jìn)入調(diào)試狀態(tài).看到是否達(dá)到了預(yù)期控制目的.,直接點(diǎn)擊軟件右上角的ARES仿真M.北京:北京航空航天大學(xué)出版社,2006.2曹洪奎,馬瑩瑩.基于Proteus的單片機(jī)系統(tǒng)設(shè)計(jì)與仿真J.遼寧工學(xué)院學(xué)報(bào),2007,27(4):-241.CaoHongkui,MaYandsimulationofMCUsystembasedTTechnologyInstitute,:238-241.M.北京:機(jī)械工業(yè)出版社,王琳化,朱志明.基于DSP的數(shù)字化控制逆變式空氣等離子切割電源研究J.電焊機(jī),2007,37(9):1-4.WangLinhua,ZhuZhiming.Study

16、onDSPbaseddigitalairplasmacuttinginverterJ.ElectricWeldingMachine,2007,37(9):1-4.5沙春芳.PROTEUSVSM在單片機(jī)系統(tǒng)仿真中的應(yīng)用J.現(xiàn)代4結(jié)(1)Proteus軟件的仿真設(shè)計(jì)應(yīng)用方便,形象直電子技術(shù),2004(24):60-63.ShaCunfang.ProteusVSMapplicationinapplicationsofMCUsystemJ.ModernElectronicsTechnique,2004(24):60-63.觀.不需要制作PCB板,硬件電路設(shè)計(jì)可根據(jù)需要隨時(shí)更改,只要原理圖正確,程序修改

17、、編譯后馬上就可看到效果.(2)Proteus軟件的仿真設(shè)計(jì)省時(shí)高效,提高實(shí)際開發(fā)效率.當(dāng)系統(tǒng)仿真完全通過后再制板,保證了所制PCB板的正確性,也省去了微控制器系統(tǒng)開作者簡介:朱錦洪,男,1965年出生,博士,教授.主要從事焊接工藝與設(shè)備的研究.發(fā)表論文50余篇.Email:zjh163cn© 1994-2010 China Academic Journal Electronic Publishing House. All rights reserved. 2009,Vol.30,No.2TRANSACTIONSOFTHECHINAWELDINGINSTITUTIONpaper,we

18、ldingflowfieldandtemperaturefieldofnimonic263withTIGandA2TIGweresimulatedandthesimulatedweldshapeandpe2nastrationwerecomparedwiththeexperimentalresults.ItisfoundthatthedepthofweldedmoltenpoolofA2TIGisdeeperthanthatofTIGweldinganditswidthissmallerwhentheweldingcurrentisthesame.Moreover,withincreasing

19、weldingcurrentordecreasingtravelspeedthedepthofweldedmoltenpoolofA2TIGincreaseslinealyandtheincreaseismoreremarkablefortheA2TIGthantheTIGwelding.ThemechanismofincreasingweldingpenetrationbyA2TIGweldingisfurtherdeducedbysimulatingthefluidflowmodeintheweldedmoltenpool.Itisindicatedthatflowmodeinweldin

20、gpoolisthema2jorfactorwhichcauseestheincreaseofweldingpenetration.Theflowrateinthecenterisobviouslylargerthanthatattheedgeoftheweldedmoltenpoolandthecircularflowfromtheoutsidetothein2sideistheleadingflowdirectionandbringsthefluidwithhightem2peratureintheedgetothecenterwhichleadstotheincreaseofmetalm

21、eltingrateinthecenterthanthatintheedge.Besides,theeffectofincreasingweldingpenetrationisenhancedconstantlybyincreas2ingweldingcurrent.Keywords:A2TIGwelding;nimonic2tionincrease;weldingflowfield;Characteristicsignalsemittedfromresis2tancespotweldingbasedonindependentcomponentanalysisBUXianzheng,SHANP

22、ing,LUOZhen,TANGXinx2in(SchoolofMaterialScienceandEngineering,TianjinUniversity,Tianjin300072,China).p41-44Abstract:Inthispaper,independentcomponentanalysis(ICA)andmultisensorarraytechnologywereusedtoresearchthea2cousticemissionsignalsfromresistancespotwelding.Anindepen2dentcomponentanalysisalgorith

23、mfortheacousticsignalsfromspotweldingwasestablished.Amultisensorarraysystemwith8micro2phoneswasusedtomeasuretheacousticemissionsignalsfromspotweldingsynchronously.Accordingtothecalculationofthekurtosiscoefficient,theacousticsignalswerefoundtobenon2Gaussiandis2tribution.Sotheacousticsignalsweredecomp

24、osedbytheindepen2dentcomponentanalysis.TheresultsshowethattheindependentcomponentanalysisbasedonFastICAalgorithmcanextractthecharacteristicsignalsofthespotweldingfromsuperimposednoisesobviously,whichprovidesanewtechnologyfortheprofoundanalysisofspotwelding.Furthermore,thisalgorithmcanbeusedinotherwe

25、ldingmethords.Keywords:aluminumalloyspotwelding;noise;acousticsignal;independentcomponentanalysisEstablishmentandapplicationofmaterialmodelsfornumericalsimulationofweldingprocessZHANGZenglei,SHIQingyu,LIUYuan,YANDongyang(1.DepartmentofMechanicalEngineer2ing,TsinghuaUniversity,Beijing100084,China).p4

26、5-48Abstract:Temperatureandtemperaturehistorydependentmaterialmodelandtemperaturehistorydependentworkhardeningmodelwereestablishedbasedonthethermal2mechanicalexperimen2talresults.Theresultsofthermal2mechanicalexperimentsindicatedthatmaterialpropertiesofaluminumalloy5A06duringthecoolingstageoftypical

27、thermalcyclesfollowedonesetofcurves,whichweredifferentfromthoseduringtheheatingstage.Theestablishedmodelswereappliedinnumericalsimulationtostudytheevolutionofstressduringweldingprocessmoreactuallyandpredictthedistributionofresidualstressmoreaccurately.Takingtheworkhardeningeffectin2toconsideration,t

28、hedifferentevolutionsofyieldstressledtothedif2ferentevolutionsoflongitudinalstress.Yieldstressofthematerialattheweldzonedecreasedalotafterhavingexperiencedweldthermalhistoryandlongitudinalcompressiveplasticstrainattheweldzonerecoveredtosomeextentduringthecoolingstage.Thesearethemaincauseforthelowerp

29、eaklongitudinalresidualtensilestressinhistorydependentmodels.Keywords:weld;materialmodel;temperaturehistory;workofcontrolsystemofairplasmabProteusZHUJinhong,DINGShu2na,SHIHongxin(KeyLaboratoryofScienceandPro2TechnologyofNon2ferrousMetals,HenanUniversityofSci2enceandTechnology,Luoyang471003,China).p4

30、9-52Abstract:ThispaperbrieflyintroducedthecharacteristicandfunctionofProteussoftware,andthendescribedtheapproachofitsapplicationinthedevelopmentofembeddeddigitalcontrolsystemforweldingandcutting.AnAT89S51MCUbasedcontrolsystem,whichwasdevelopedforinverter2typeairplasmacuttingmachine,wasde2signed,prog

31、rammed,simulatedanddebuggedbyusingProteusandKeilC.Resultsverifythatitispossibletotestthesystemaccuratelyandthesystemhasexpectedfunctions.Thismethodisprovedtobeaneffectivemeanswhichraisesthedevelopmentefficiency,reducesthecycletimeandsavescosts.Keywords:Proteus;airplasmacuttingmachine;digitalcontrol;simulationInversingparametervaluesofdoubleellipsoidsourcemodelduringmultiple