高效绿色逆变弧焊电源非线性优化控制

The arc welding power source holds an important position in national defense and national economic construction, which is called industrial sewing machine. However, the complex nonlinear time-varying characteristic of the arc welding power source, not only limits the great improvement of welding quality, but also makes some shortcomings have not been completely resolved, such as big energy consumption, high electromagnetic pollution and low reliability, so new theories and methods are needed urgently. First, a new high frequency soft switching inverter topology is proposed based on passive auxiliary resonant network to improve the system efficiency and dynamic response. Then, an intergrated modeling, analysis and energy optimal control method is researched and proposed based on Hamilton theory to ensure efficient energy output and fine control for droplet transfer from the point of view of the circuit and control. The method will also improve the welding quality of non-ferrous metal, high-strength steel and so on. Third, a new high performance and fast response filtering algorithm is researched based on robust estimation theory of uncertain time-varying system for welding feedback signals to overcome adverse effects of strong interferences and improve robustness and reliability for the arc welding power source. At last, a full digital inverter arc welding power source is designed based on system on a programmable chip (SOPC) to verify the research results. The project needs the knowledge of power electronics technology and nonlinear control science, which has great value not only on promoting relevant theories and their application, but also on developing advanced welding technology with independent intellectual property, and pushing their industrialization.

有"工业缝纫机"之称的弧焊电源在国防和国民经济建设中的作用举足轻重。然而，弧焊电源异常复杂的非线性时变特性，不仅制约着焊接质量大幅提高，而且使其能耗大、电磁污染严重、可靠性低等顽疾长期未得到彻底解决，亟需新的理论和方法予以突破。本项目拟首先研究基于无源辅助谐振网络的高频软开关逆变拓扑，提高系统效率和动态响应；然后研究并提出一种基于哈密顿理论的弧焊电源整体建模、分析与能量优化控制方法，从电路和控制的角度全面保证能量的高效利用和熔滴过渡的精细控制，解决有色金属、高强钢等的高质量焊接难题；并运用不确定时变系统鲁棒估计理论，研究高性能、快响应的焊接反馈信息滤波算法，克服强干扰因素的不利影响，提升系统可靠性；最后构建基于SOPC的实验平台验证成果。本项目属电力电子技术和非线性科学交叉前沿方向，不仅对相关理论研究与应用有显著促进作用，而且对发展具有自主知识产权的先进弧焊技术和推进其产业化具有重大意义。

逆变弧焊电源在国防和国民经济建设中的作用举足轻重。焊接质量的好坏直接影响生产效能甚至人身安全。因此，提高焊接过程的可控性和效率，保证焊接质量，具有重大的现实意义。本项目按照立项时的申请书计划顺利执行, 全面研究了逆变弧焊电源的拓扑电路、非线性建模与控制、焊接信息精确检测方法等关键科学与技术问题，以期全面提升系统的效率和鲁棒性。.（1）设计了单逆变器大功率逆变弧焊电源主电路拓扑.本项目研究了适合于大功率逆变弧焊电源的新型软开关逆变拓扑，提出了一种单逆变器大功率逆变弧焊电源主电路拓扑结构，并探索了基于新型SiC器件的功率变换电路，计算和分析了吸收电容和电阻、谐振电容和电感等参数，并通过实验验证，为进一步提高焊接过程的可控性和效率奠定了基础。.（2）提出了全桥逆变电路偏磁抑制方法.针对全桥逆变电路易产生偏磁而造成系统可靠性低的难题，提出了一种模拟检测与数字控制相结合的偏磁实时检测与抑制方法，并设计了偏磁控制器，能够实时输出偏磁信号产生的时刻和强弱，并快速、有效地抑制偏磁。可推广应用于全桥逆变电路。.（3）研究了基于双闭环的全桥逆变器数字控制方法并优化了熔滴过渡控制策略.通过对逆变弧焊电源整体建模，提出了基于双闭环的全桥逆变器数字控制方法，通过仿真实验对比，新方法能够加快系统收敛速度，提高稳定精度。设计基于模糊算法的弧长与熔滴过渡控制策略，实现了焊接电弧的精准控制，保证了焊接过程的稳定和不同工艺条件下的焊接质量。.（4）研究了执行器饱和时端口控制的Hamilton系统的干扰容限和鲁棒估计方法.研究了执行器饱和时，开环可能不稳定的多输入Hamilton系统的干扰容限和H∞控制问题；提出了焊接电源信号的H∞数字滤波方法，实验表明当系统的状态和噪声变化时，H∞滤波器对外界干扰的影响具有更强的鲁棒性，滤波效果良好。.（5）搭建了基于SOPC的全数字逆变弧焊电源试验平台.本项目设计了基于混合信号FPGA的控制系统，集A/D采样、控制策略、焊接工艺专家库等多任务于一体，验证了所研究成果的性能；设计的全数字逆变弧焊电源系统性能可靠，能够确保稳定的焊接过程，满足逆变弧焊工艺要求，保证焊接质量。.该项研究的成果不仅对相关理论研究与应用具有促进作用，而且对发展具有自主知识产权的先进弧焊技术和推进其产业化重大意义。