全位置管道自动焊接控制系统的研究

【作者】 周文奇；

【导师】 田新诚； 彭勃； 张东亮；

【作者基本信息】 山东大学 ， 控制理论与控制工程， 2006， 硕士

【摘要】 在管道焊接施工技术中，全位置自动焊接技术以其高效率、高质量的优点成为现代焊接技术发展的方向，进行全位置自动焊接控制技术的研究，具有理论意义、工程意义和经济意义。 本文研究开发了一种关于管道全位置自动焊接控制系统，主要内容包括以下几个方面： (1)简要介绍了全位置自动焊接机的发展历程和发展现状，通过对其发展趋势的分析，论述了开发全位置自动焊接控制系统的目的和意义。并根据全位置自动焊接机的工作特点，设计了符合施工要求的开发方案。 (2)采用具有精简指令集的高档ATmega128单片机和符合USB1.0协议的Cypress AN2131接口芯片以及大容量FIF0缓冲器件AL422B开发了一个数据高速传输、信息实时处理和性能稳定的控制系统。该系统接受上位机的数据、控制信息，驱动伺服和步进电机，调节焊接电源，并行采样工作电压和电流，实时控制整个焊接运行过程。 (3)针对不同的管径和臂厚，对管口进行合理的空间分段。根据各段典型曲型点的焊接规范，采用三次B样条插值算法进行参数曲线拟合，然后将目标点进一步细化。然后，在圆率法的基础上进行了三次B样条曲线的控制顶点的定量修正，使曲线的局部能量积分取得极小值，从而得到局部光顺的三次B样条曲线。下位机将按照得到的数据集合线性插值，从而实现焊接过程中工艺参数的平滑连续变化，很好的解决了管道全位置焊接过程中熔池稳定性控制问题。 (4)在整个系统的软件设计中，上位机采用Visual C++语言编程实现焊接参数的人机界面输入和控制算法的实现以及与下位机的通信。下位机主控制系统采用AVR ICC语言编写通信程序、焊接动作控制程序和调节子程序。 (5)论文最后论述了电磁干扰的原理，并针对焊机的实际工作环境，提出了硬件设计、软件编制、PCB制作等方面行之有效的抗干扰措施。 (6)实践表明，该控制系统不但具有快速、准确、可靠的特点，而且性价比较高。同时，本文的软硬件设计方案和控制策略也为焊接控制领域的发展与应用提供了新的参考。更多还原

【Abstract】 In the engineering techniques of pipeline ,all-position automatic welding has become the new development direction with the good nature of high efficiency and high qulity .Thus making research for the control technique about all-position automatic welding has great sense in both thoey and engineering as well as economy.This paper has exploited an all-position welding control system on pipeline, its content includes as followings:(1) This paper introduces the development course and its present condition.Through analyzing the development trend, discusses the purpose and meaning of exploiting all-position automatic welding control system. .Then design the exploiture scheme that accords with builder requirement based on the work characteristics.(2) Adopting high-performance advanced RISC architecture AVR single-chip ATmega128 and USB1.0 Protocol based interface Cypress AN2131QC chip as well as large capacity FIFO buffering chip AL422B to exploit a control system with data’s high-speed transmission,information processing in real time and performance stability .This system receives data and control information from up computer to driver servo motors and stepper motors .manager welding power supply , sampling work voltage and current and hence control the whole welding process .(3) In allusion to different caliber and pipe wall thickness, make rational space divisions .Based on welding criterion at typical space positons, utilize cubic B sample interpolation arithmetic to make object points thinner.At the same time, quantificationally modify some control peaks circle ratio on cubic B sample curve to make local energetic integral have the minimus value , thus getting local fairing cubic B sample curve. Down control system would have linear interplating according with the data volume from up computer in order to achieve welding parameters’ smoth and consecutive charging, preferably resolving stabilitily control on weld pools.(4) Among the whole software design, up computer adopts Visual C++ language to human-computer interface data input .control arithmetic and communication with down control system. Down control system adopts AVR ICC language to program communication .welding actions control and adjusting subprogram.(5) This paper discusses the principle of electromagnetic disturbance .Then put forward tried and true anti-jamming measures about hardware design .software programming and PCB circuit borad facture.(6) Practice indicates this system not only is high-speed .exact and reliable.but also has high capability price ratio .Moreover.the design scheme and strategy in this paper will supply a new consult for the development and application in welding fields.更多还原