自动等离子喷焊控制系统研究
摘要
三偏心蝶阀因其具有零泄漏,密封副零摩擦、耐高温高压的特点,应用范围较为广泛。三偏心蝶阀的密封面需要表面加工,通常是采用人工焊条堆焊的方法,因其焊接技术难度高,生产效率低,生产成本高,故需要用其他的方法来实现。
等离子喷焊是一种先进的表面强化技术,它采用等离子弧作为高温热源,在金属基体表面喷焊,形成具有耐磨、耐高温、抗腐蚀等特殊性能的喷焊层。等离子喷焊不仅在工程修复方面有应用,而且在产品的表面强化方面也得到了广泛应用。等离子喷焊技术能够提高三偏心蝶阀的密封性能,具有实际的应用价值。为了实现三偏心蝶阀喷焊工艺,提高劳动效率,需要研制一套自动等离子喷焊跟踪控制系统。
所研制的三偏心蝶阀等离子喷焊控制系统包括等离子喷焊系统、电气控制系统、跟踪控制系统三部分。这三部分系统均在单片机80C196KC的控制下工作,相对于PLC控制系统降低了制造成本。
采用两只传感器进行跟踪是该设计的特色,文中详细说明了双传感器的设计思想。阐述了等离子喷焊设备的组成,以及各组件在设计中应特别注意的问题,并设计了喷焊主电路。详细介绍了控制系统与单片机跟踪系统软硬件设计。硬件设计包括位移传感器的选型、单片机的选型、单片机最小系统、开关量输入输出电路、信号调理电路、MAX7219实时显示电路、脉冲信号输出电路和直流电机调速电路。软件部分的设计包括主控程序结构与程序流程框图和跟踪控制软件流程等。除此之外,由于喷焊系统工作环境恶劣,还采取了一系列的措施来提高系统的抗干扰性能。
The triple eccentric butterfly valve is widely used because of its characteristics of no-leakage, no-friction, anti-high temperature and anti-high pressure. The sealing face of the triple eccentric butterfly valve need to be strengthened, the method most used is manual welding, but it is complicated, low efficient and high cost. So the other method is needed.
Plasma transferred arc welding(PTAW) is an advanced surface strengthen method, which adopts plasma arc as high temperature source and welds on the base-material to form an anti-abrasion, anti-high temperature, anti-corruption layer. It is used not only in repairing project but also in surface consolidation of product. Thus, the technology of PTAW can improve airproof performance of the triple eccentric butterfly valve. In order to meet with the triple eccentric butterfly valve welding craft, the automatic track control system is designed.
The control system consists of three parts: plasma transferred arc welding system, electric control system, tracking control system. Compared with the PLC-control system, these three parts are all under the control of 80C196KC, so the cost is low.
The specialty of the design is using two displacement transducers to realize tracking. And the double-transducer design idea is explained systematically. The components of PTAW system and the highlight problems in design of welding system are expatiated. The designing of software and hardware about control tracing system are introduced in detailed .The hardware design include type choosing of controller and displacement transducer, microprocessor minimum system, discrete input and output circuit, signal adjustment circuit, MAX7219 display circuit in real time, pulse signal outputting circuit and DC motor speed adjustment circuit. The software design include main programmable frame,flow chart of MCU and tracing control software. Because of the hard working circumstance,serious of effective measures are taken to improve the anti-interference ability of the system.
等离子喷焊是一种先进的表面强化技术,它采用等离子弧作为高温热源,在金属基体表面喷焊,形成具有耐磨、耐高温、抗腐蚀等特殊性能的喷焊层。等离子喷焊不仅在工程修复方面有应用,而且在产品的表面强化方面也得到了广泛应用。等离子喷焊技术能够提高三偏心蝶阀的密封性能,具有实际的应用价值。为了实现三偏心蝶阀喷焊工艺,提高劳动效率,需要研制一套自动等离子喷焊跟踪控制系统。
所研制的三偏心蝶阀等离子喷焊控制系统包括等离子喷焊系统、电气控制系统、跟踪控制系统三部分。这三部分系统均在单片机80C196KC的控制下工作,相对于PLC控制系统降低了制造成本。
采用两只传感器进行跟踪是该设计的特色,文中详细说明了双传感器的设计思想。阐述了等离子喷焊设备的组成,以及各组件在设计中应特别注意的问题,并设计了喷焊主电路。详细介绍了控制系统与单片机跟踪系统软硬件设计。硬件设计包括位移传感器的选型、单片机的选型、单片机最小系统、开关量输入输出电路、信号调理电路、MAX7219实时显示电路、脉冲信号输出电路和直流电机调速电路。软件部分的设计包括主控程序结构与程序流程框图和跟踪控制软件流程等。除此之外,由于喷焊系统工作环境恶劣,还采取了一系列的措施来提高系统的抗干扰性能。
The triple eccentric butterfly valve is widely used because of its characteristics of no-leakage, no-friction, anti-high temperature and anti-high pressure. The sealing face of the triple eccentric butterfly valve need to be strengthened, the method most used is manual welding, but it is complicated, low efficient and high cost. So the other method is needed.
Plasma transferred arc welding(PTAW) is an advanced surface strengthen method, which adopts plasma arc as high temperature source and welds on the base-material to form an anti-abrasion, anti-high temperature, anti-corruption layer. It is used not only in repairing project but also in surface consolidation of product. Thus, the technology of PTAW can improve airproof performance of the triple eccentric butterfly valve. In order to meet with the triple eccentric butterfly valve welding craft, the automatic track control system is designed.
The control system consists of three parts: plasma transferred arc welding system, electric control system, tracking control system. Compared with the PLC-control system, these three parts are all under the control of 80C196KC, so the cost is low.
The specialty of the design is using two displacement transducers to realize tracking. And the double-transducer design idea is explained systematically. The components of PTAW system and the highlight problems in design of welding system are expatiated. The designing of software and hardware about control tracing system are introduced in detailed .The hardware design include type choosing of controller and displacement transducer, microprocessor minimum system, discrete input and output circuit, signal adjustment circuit, MAX7219 display circuit in real time, pulse signal outputting circuit and DC motor speed adjustment circuit. The software design include main programmable frame,flow chart of MCU and tracing control software. Because of the hard working circumstance,serious of effective measures are taken to improve the anti-interference ability of the system.
引文
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[41]吕耀辉,殷树言等.变极性穿孔等离子弧焊接系统的研制.电焊机,2003,(5),29-31
[42]韩孝义.三偏心蝶阀密封面的加工.阀门,2003,(5),16-17
[43]高辉云.数字化埋弧自动焊成套设备的研究.[兰州理工大学硕士论文].兰州:兰州理工大学,2004,18-21
[44]王晓明.电动机的单片机控制.北京:北京航空航天大学出版社,2002,181-211
[45]邓集杰.逆变TIG焊机引弧噪声的研究[天津大学硕士论文].天津:天津大学,2004.24-20
[46]Organ David.A handbook for EMC Testing and Measurement.Landon:Petter Peregrinus Ltd.On behalf of the Institute of Electrical Engineers,1993.5-13
[47]邓集杰,路登平.国内焊接设备电磁兼容性研究进展.电焊机,2003,(9):1-4.
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[2]高荣发,马小雄.等离子弧喷焊.北京:机械工业出版社,1979,1-2
[3]王娟等编著.表面堆焊与热喷涂技术.北京:化学工业出版社,2004,119-129
[4]H.Herman,S.Sampath,R.McCune,Thermal spray:current statusand future trends,MRS Bull.7 2000,17-25
[5]裴海,杜万才,温强.热喷涂热喷焊技术在设备维修中的应用.机械工程师,1995,(2):35-36
[6]谭昌瑶,王钧石.实用表面工程技术.北京:新时代出版社,1998,1-2
[7]高清宝.阀门堆焊技术.北京:机械工业出版社,1994,26-28
[8]高捷,胡远银.等离子粉末喷焊技术在阀门密封副上的应用.阀门,2006,(1):17-19
[9]郝承明.阀门技术的新进展.阀门,2001,(5):32-34
[10]余晓庆.三偏心蝶阀的发展及应用.中国仪器仪表(2001增刊):15-17
[11]李小明.三偏心金属密封蝶阀的原理及特性.阀门,1998,(3):1-2
[12]陈有志,邢卫平,张勤等.等离子喷焊技术在大口径冶金阀门密封副生产的应用.河北冶金,1995,(8):43-46
[13]J.M.Houben,General Aspects of Thermal Spraying,International Thermal Spraying Conference,Hague,Netherlands,1980,(5):19 - 23.
[14]Craig,E.The Plasma Transferred Arc Welding -A Review.Welding Journal,1988.(2):19-25
[15]V.Bogachek,A new approach to powder spraying.Weld.J.2000,(2):45-46.
[16]Akira.Y,Yoshizo.H New Surface Treatment Technology with a Plasma Transferred Arc Welding Process.KOBELCO TECHNOLOGY REVIEW No.20,April,1997,(4):20-22
[17]B.Irving,HVIF process improves densities of many thermal sprayed coatings.Weld.J.2 2000,(2):42-44
[18]张长红,张仁甫.8098单片机系统抗高频引弧器干扰设计.电焊机,1996,(5):35-37
[19]王克争,孙洪源,李国金,何方殿.高频焊接设备电磁兼容性的研究.电焊机,1999,(1):20-23
[20]刘立君,付继连,吴林.遥控管道焊接机器人抗高频干扰布线机理研究.机器人, 2005,(3):118-122
[21]李春旭,陈克选,张成.微机控制的等离子喷涂设备抗高频干扰的研究.甘肃工业大学学报,1999,(6):5-8
[22]李春旭,陈克选,张志坚.单片机控制等离子喷涂(焊)电源研制.甘肃工业大学学报,2000,(2):9-11
[23]吴祥淼,黄石生,王志强,方平,薛家祥.逆变焊接电源的发展及其可靠性研究.电焊机,2001,(2):8-11
[24]王振民,黄石生,薛家祥等.等离子喷涂设备的现状与进展.中国表面工程,2004,(4):5-8
[25]许雪,赵程.等离子弧热喷焊技术的发展与现状.甘肃冶金,2006,(6):63-64
[26]陈焕明,江淑园,葛志雄.等离子喷焊过程PLC控制.新技术新工艺,2003,(7):35-37
[27]张智杰,李莹.LOGO!在等离子喷焊过程控制中的应用.北京工商大学学报,2002,(9):40-42
[28]王伟,华厚生,张海鸥.基于I~2C总线技术的等离子喷焊系统的研究.电焊机,2003.(3):17-20
[29]Richard E.M.:Study of the plasma arc behavior during VPPAW using the split anode method[dissertation].El Paso:Univ.of Texas,1994,95-98
[30]李京龙,田丽,林谦生.PC控制等离子喷焊设备的研制.电焊机,1994,(4):22-24
[31]焦雷.三偏心蝶阀等离子喷焊系统的研制.[兰州理工大学硕士论文].兰州:兰州理工大学,2006,37-39
[32]陈克选,杜永鹏,腾玉林等.特殊型面等离子堆焊传感跟踪系统研究.电焊机2007,(12):10-12
[33]刘灿军.实用传感器.北京:国防工业出版社,2004
[34]曲波,肖圣岳等.工业常用传感器选型指南.北京:清华大学出版社,2002
[35]孙廷才,王杰等著.工业控制计算机组成原理.北京:清华大学出版社.2001,1-21
[36]张晓坤编著.可编程序控制器原理及应用.西安:西北工业大学出版社,1998.1-33
[37]陈在平,赵相宾编著.可编程序控制器技术与应用系统设计.北京:机械工业出版社,2002,3-23
[38]徐爱卿.Intel16位单片机(修订版).北京:北京航空航天大学出版社,2002,152-153
[39]汪建等.MCS-96系列单片机原理及应用技术.武汉:华中理工大学出版社,1998,2-19
[40]赫晓龙.微机控制等离子喷焊系统研究.[兰州理工大学硕士论文].兰州:兰州理工大学,2004,5-13
[41]吕耀辉,殷树言等.变极性穿孔等离子弧焊接系统的研制.电焊机,2003,(5),29-31
[42]韩孝义.三偏心蝶阀密封面的加工.阀门,2003,(5),16-17
[43]高辉云.数字化埋弧自动焊成套设备的研究.[兰州理工大学硕士论文].兰州:兰州理工大学,2004,18-21
[44]王晓明.电动机的单片机控制.北京:北京航空航天大学出版社,2002,181-211
[45]邓集杰.逆变TIG焊机引弧噪声的研究[天津大学硕士论文].天津:天津大学,2004.24-20
[46]Organ David.A handbook for EMC Testing and Measurement.Landon:Petter Peregrinus Ltd.On behalf of the Institute of Electrical Engineers,1993.5-13
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