Research On High-efficiency And Energy-saving Short Arc Milling Pulse Power Supply

The emergence of short arc machining technology provides an efficient and feasible means for the processing of difficult-to-machine materials such as super-hard brittle,high strength,high toughness and high wear resistance.It has been successfully applied in the fields of agricultural equipment,petrochemical industry,hydroelectric power generation,aerospace and other fields relying on its extremely high material removal rate and continuous and stable electrical discharge machining process.At present,the short arc milling technology applied to complex parts processing is still immature.As an important part of the short arc milling system,the performance index of the short arc pulse power supply will directly affect the processing efficiency,surface quality and processing cost.Therefore,this paper studies the efficiency and energy saving of short arc milling pulse power supply in order to improve the processing efficiency and energy utilization of short arc milling.In this paper,by studying the actual short arc milling system and the principle of arc discharge,the relationship between electrical parameters and processing efficiency is analyzed,and it is concluded that improving the single pulse discharge energy can improve the processing efficiency.By analyzing the electrical characteristics of the discharge gap in short arc milling,it is concluded that the appropriate pulse base can improve the energy-saving effect and the continuous arc discharge rate,and then improve the processing efficiency.By analyzing the energy consumption of the traditional pulse power supply topology circuit and comparing the energy consumption of the new energy-saving short arc pulse power supply,a feasible high-efficiency energy-saving scheme of the pulse power supply is obtained.The overall scheme of high efficiency and energy saving short arc processing pulse power supply is constructed,the main circuit topology of the power supply is designed,and its working principle is analyzed in detail.Finally,through theoretical calculation and engineering practice,the parameters of key components in the main circuit topology are calculated and selected.The hardware of the control system based on DSP and UCC3895 is modularized,including the peripheral circuit,driving circuit,driver interface circuit and protection circuit of the phase-shifting pulse generator.A PID controller is constructed by combining RBF neural network and differential evolution algorithm,which is used for constant voltage control of the output voltage of the pulse power supply.The simulation results show that the controller has excellent stabilization efficiency.Finally,the software flow design of DSP and the man-machine interface design of PLC touch panel are completed,and a complete power supply system is constructed.The simulation model of phase-shifting pulse generator is improved by using the principle of digital pulse phase-shifting and Silmulink module in MATLAB.A load catastrophe model is constructed to simulate the changing load in short arc machining.The phase-shifting inverter full bridge of the pulse power supply core and the whole power supply is modeled and simulated.The feasibility of the power supply and the characteristics of high efficiency and energy saving are verified by the experiment of short arc milling.