针对传统晶体管式电阻点焊电源负载持续率低，电源输出模式单一和焊接接头一致性差等问题，设计了一种可实现电容快速充放电的变极性晶体管式微电阻点焊电源. 分析了电源负载特性，设计了基于全桥逆变 + H桥双相斩波电路的电源主电路拓扑，设计了基于高性能STM32双核控制器的数字化电源控制系统，提出了多阶段变脉宽式电容组快速充电方法，开展了电源输出特性测试和铜-镍薄片单面双点工艺试验. 试验结果表明，设计的电源输出负载持续率可达5%以上，极性切换时间可低至0.1 ms以下，变极性输出模式可有效解决单极性模式下因极性效应现象造成的焊点尺寸不一的问题，电压控制模式焊接过程焊接接头性能优于电流控制模式和功率控制模式.
Aiming at the problems of low load duration, single power output mode, and poor consistency of welding joints of traditional transistor resistance spot welding power source, a variable polarity transistor micro resistance spot welding power source which can realize fast charge and discharge of the capacitor is designed. The load characteristics of the power supply are analyzed. The main circuit topology of the power supply based on the full-bridge inverter + H-bridge dual-phase chopper circuit is designed. The digital power control system based on the high-performance STM32 dual-core controller is designed. A multi-stage variable pulse width capacitor group fast charging method is proposed. The power output characteristic test and the copper-nickel sheet single-sided double-point process test are carried out. The test results show that the designed power supply output load persistence rate can reach more than 5%, and the polarity switching time can be as low as 0.1 ms or less. The variable polarity output mode can effectively solve the problem of different solder joint sizes caused by the polarity effect in the unipolar mode. The performance of the welded joint in the voltage control mode is better than that in the current control mode and the power control mode.
[1] 莫华, 郭钟宁. 微型电阻焊技术的研究进展[J]. 材料导报, 2009, 23(23): 85 - 88
Mo Hua, Guo Zhongning. Review of Resistance Micro welding Technology[J]. Materials Review, 2009, 23(23): 85 - 88
[2] 刘成玉, 王笑川, 赵建华. 微型件精密点焊技术[J]. 电焊机, 2007(5): 47 - 50
Liu Chengyu, Wang Xiaochuan, Zhao Jianhua. The technology of minimizing piece spot welding[J]. Electric Welding Machine, 2007(5): 47 - 50
[3] 高星鹏, 陈峰, 王宇盛, 等. 基于遗传算法与神经网络微电阻点焊工艺参数优化[J]. 宇航材料工艺, 2018, 48(3): 33 - 37
Gao Xingpeng, Chen Feng, Wang Yusheng, et al. Optimization of micro resistance spot welding process parameters based on genetic algorithm and neural network[J]. Aerospace Materials & Technology, 2018, 48(3): 33 - 37
[4] 杨景卫, 曹彪. 微型零件精密电阻点焊技术及其应用[J]. 焊接, 2009(6): 43 - 47
Yang Jingwei, Cao Biao. Precision resistance spot welding technology and application in micro-parts[J]. Welding & Joining, 2009(6): 43 - 47
[5] 曹彪, 王晓东, 范丰欣, 等. 高频晶体管式电阻点焊电源的研制[J]. 焊接学报, 2009, 30(7): 73 - 76
Cao Biao, Wang Xiaodong, Fang Fengxin, et al. Design of transistor-style high-frequency resistance spot-welding power supply[J]. Transactions of the China Welding Institution, 2009, 30(7): 73 - 76
[6] Zhou K, Yao P. Overview of recent advances of process analysis and quality control in resistance spot welding[J]. Mechanical Systems and Signal Processing, 2019, 124: 170 - 198.
[7] 李浩东, 李光尧, 陈家兑, 等. 电源控制模式对镍片微电阻点焊过程的影响[J]. 焊接, 2022(3): 19 - 25
Li Haodong, Li Guangyao, Chen Jiadui, et al. Influence of power supply control mode on micro-resistance spot welding process of nickel chip[J]. Welding & Joining, 2022(3): 19 - 25
[8] 周磊磊, 李远波, 张驰. 基于ARM的精密逆变电阻点焊电源[J]. 电焊机, 2016, 46(11): 55 - 59
Zhou Leilei, Li Yuanbo, Zhang Chi. Precise inverter resistance spot welding power supply based on ARM[J]. Electric Welding Machine, 2016, 46(11): 55 - 59
[9] 钟磊, 黄增好, 杨凯, 等. 晶体管式电阻点焊电源及其复合模式控制研究[J]. 电焊机, 2020, 50(2): 14 - 18
Zhong Lei, Huang Zenghao, Yang Kai. Research on transistorized resistance spot welding power supply and its composite mode control[J]. Electric Welding Machine, 2020, 50(2): 14 - 18
[10] 王新, 曹彪, 杨凯. 晶体管式精密电阻点焊电源的设计[J]. 焊接, 2018(4): 51 - 56
Wang Xin, Cao Biao, Yang Kai. Design of transistor-style precise resistance spot-welding power supply[J]. Welding & Joining, 2018(4): 51 - 56
[11] Zhang D D. The Constant Current Charging Analysis Super Capacitor[J]. Applied Mechanics and Materials, 2013, 274: 3 - 315.
[12] 崔忠阳. 车用动力电池系统电连接及机械结构设计[D]. 清华大学, 2016.
Cui Zhongyang. The Electrical Connections and Mechanical Structure Design of Electric Vehicle Power Battery System [D]. Tsinghua university, 2016.
[13] 中国机械工程学会焊接学会编. 焊接手册[M]. 第三版. 北京: 机械工业出版社, 2008.
Welding Society of China Mechanical Engineering Society. Manual welding [M]. The third edition. Bei Jing: China Machine Press, 2008.
[14] 袁臣虎, 杜永恒, 刘晓明, 等. LCC谐振式永磁机构储能电容恒流充电控制[J]. 电工技术学报, 2020, 35(z2): 432 - 439
Yuan Chenhu, Du Yongheng, Liu Xiaoming, et al. Constant Current Charging Control of LCC Resonant Permanent Magnet Mechanism Energy Storage Capacitor[J]. Transactions of China Electrotechnical Society, 2020, 35(z2): 432 - 439
[15] 张凯锋. 板材自阻加热成形中电流的热效应与极性效应研究进展[J]. 锻压技术, 2018, 43(7): 71 - 90
Zhang Kaifeng. Study progress on heat and polarity effects of current in sheet metal forming with resistance heating[J]. Forging & Stamping Technology, 2018, 43(7): 71 - 90
[16] 赵伟, 任中根, 迟恩田. 电火花加工中极性效应的研究[J]. 宇航材料工艺, 2001, 31(2): 59 - 61
Zhao Wei, Ren Zhonggen, Chi Entian. Discussion on Polarity Effect in EDM[J]. Aerospace Materials & Technology, 2001, 31(2): 59 - 61
