Design And Implementation Of The Embedded Control System For Consumable DE-GMAW

Consumable DE-GMAW is a novel and efficient welding method, which has manyadvantages: it can improve the welding efficiency, reduce the base metal heat input,apply to the sheet metal welding and ensure the performance of the base metal afterwelding. But during the open-loop state, coupling and influence between two arcsmakes the welding spatter greater and welding beam molding bad; externalinterference factors make the current of the base metal have the large fluctuation anddestroy the stability of the welding process, which make the advantages of theConsumable DE-GMAW unable to show. The task of this project is to design andimplement the embedded control system based on the ARM7microcontroller, andimplement close-loop control of the Consumable DE-GMAW.Embedded control system is simulated by the simulating software Proteus prior tothe developing of the system. Simulation result principally proves that design ispracticable; embedded system can work well and welding process can be controlled.Build the hardware platform for the embedded control systems and write softwareprograms. The hardware platform consists of the master control board based on theLPC, indication module of the welding parameter and control board of the weldingwire feed speed based on the AT89C52. The three circuit boards apply thebus-structure to connect and perform the digital communication based on theAT89C52. System program is written by C language and apply the incremental PIDcalculation to control the bypass wire feed. System communication protocol selects the Modbus protocol and applies the12864LCD modules to real-time display thewelding parameter.Set up the Consumable DE-GMAW welding system and data collecting system tojointly debug the embedded system, and apply the embedded system control in thisproject to perform the control tests for Consumable DE-GMAW. Tests consist ofstability test of the welding process based on the arc voltage feedback, and stabilitytest of the welding process based on the circuit control. Test result proves thatembedded system in this project can timely feedback the bypass arc voltage, adjustthe feed wire speed, ensure the bypass arc length is stable and adjust the circuit tomake the base metal circuit stable. The two aspects of integrated control ensure thatwelding process of the Consumable DE-GMAW is stable and forms the well weldingbeam.