Pulsed MIG Welding Power Source Rapid Control Prototyping System Developing Platform Design

Pulse Gas Metal Arc Welding (GMAW-P) in the industrial production of increasingly widespread. Currently, extensive use of aluminum alloy and other materials, which brings the welding equipment and other new technology on higher requirements.Research and development on arc welding power source of digital control technology is of great significance.In this paper, a rapid prototyping pulsed MIG welding power source development platform is built by using rapid control prototyping technology,that based on xPC Target. The system has the advantage of fast response, the controller developed rapidly, the control program can be adjusted quickly.so as to realize the real-time control to simultaneous high-speed collection, real-time display and storage of welding current, voltage and video images and work table, hardware equipments etc.Use of platform software development system carries on the pulse waveform generator and special waveform design test for digital pulse MIG welding power system development platform test,which laid a good foundation.Based on the welding power system control structure, signal transduction and pulse welding process control characteristics,the dynamic simulation model of the rapid prototyping pulsed MIG welding power source development platform design of Matlab/Simulink software is built,and established a dynamic simulation model of arc length, melting rate simulation model, the arc load voltage simulation model and analysis the simulation results, implementation of the power control pulse MIG welding parameters optimization program design, verification control algorithm, control strategy, and analysis of the pulse duty cycle and frequency on arc stability.The results of simulation are well in consistent with those of welding experiments,which proves the correctness of this simulation model,the adaptability of controller dynamic performance of welding control system.The real-time control test process for Arc length was carried out based on the rapid prototyping Pulsed MIG Welding Power Source Development Platform,the process respectively carried out the low carbon steel, galvanized sheet, stainless steel, aluminum alloy for a large number of process test, and determine the range of pulse welding parameters.Due to Pulsed MIG welding for aluminum welding specifications in constant poor weld appearance,on the basis of use the electric arc voltage feedback signal, the use of pulsed MIG welding power source rapid prototyping platform, by adjusting the pulse duty cycle and pulse frequency of two control program strategy, carried out the arc control adjustment test.Step test and climbing test showed that the control method used in regulating the fast and stable.To achieve the full current range of arc length and speed stability and regulation and effective control, access to the more stable of the welding process, welding back to prevent burning, short circuit phenomenon, have been forming a good weld appearance.