【摘要】：隨著有色金屬在現(xiàn)代工業(yè)生產(chǎn)中的需求越來越大,有色金屬微型零件焊接困難的問題越來越受到重視。超聲能-電阻熱復(fù)合焊是結(jié)合超聲波金屬焊和電阻點(diǎn)焊特點(diǎn),針對(duì)有色金屬微型零件提出的一種焊接方法,通過超聲能和電阻熱兩種能量的復(fù)合作用,來提高焊接接頭的性能。由于此方法尚處于研究初期,缺乏復(fù)合焊專用電源,因此設(shè)計(jì)超聲能-電阻熱復(fù)合焊電源控制系統(tǒng),實(shí)現(xiàn)超聲激勵(lì)信號(hào)和電阻焊電流的協(xié)調(diào)輸出,提高復(fù)合能量輸出的可控性,以滿足不同的工藝實(shí)驗(yàn)及研究需求。本文首先確定電源的整體方案,搭建超聲及電阻焊功率主電路,并確定控制策略;根據(jù)復(fù)合焊電源控制需要,設(shè)計(jì)以DSP為核心的控制系統(tǒng),主要包括信號(hào)反饋電路、DDS電路、移相脈沖調(diào)制電路、CPLD電路、開關(guān)量控制電路等,并根據(jù)要求設(shè)計(jì)制作了控制電路PCB板;完成控制軟件的設(shè)計(jì)與調(diào)試,包括超聲頻率跟蹤程序、A/D采樣程序、輸入捕捉程序、PI控制程序等。組裝復(fù)合焊電源并搭建復(fù)合焊接試驗(yàn)平臺(tái),對(duì)復(fù)合焊電源進(jìn)行調(diào)試,通過超聲電壓反饋及頻率跟蹤實(shí)現(xiàn)了超聲振幅恒定輸出且連續(xù)可調(diào),通過電流反饋控制實(shí)現(xiàn)了電阻焊恒流輸出;可靈活設(shè)置三段超聲電壓及電阻焊電流,實(shí)現(xiàn)多種復(fù)合能量波形輸出,可滿足不同的工藝需求。利用復(fù)合焊電源對(duì)銅鋁焊件進(jìn)行工藝試驗(yàn),結(jié)果表明在超聲能及電阻熱共同作用下,復(fù)合焊界面出現(xiàn)擴(kuò)散層,進(jìn)一步的拉伸試驗(yàn)結(jié)果表明,復(fù)合焊接頭的拉伸性能及延展性比單一超聲作用下的有所提高。
[Abstract]:With the increasing demand of nonferrous metals in modern industrial production, more and more attention has been paid to the difficulty of welding non-ferrous metals micro parts. Combined with the characteristics of ultrasonic metal welding and resistance spot welding, ultrasonic energy-resistance thermal composite welding is a welding method for non-ferrous metal micro-parts. The performance of welded joints can be improved by the combination of ultrasonic energy and resistance heat. Because this method is still in the early stage of research and lacks of special power supply for composite welding, the control system of ultrasonic energy-resistance heat welding power source is designed to realize the coordinated output of ultrasonic excitation signal and resistance welding current, so as to improve the controllability of composite energy output. To meet the needs of different process experiments and research. In this paper, the overall scheme of the power supply is first determined, the main circuit of ultrasonic and resistance welding power is built, and the control strategy is determined. According to the control needs of composite welding power supply, a control system based on DSP is designed, which includes signal feedback circuit, DDS circuit, phase-shift pulse modulation circuit, CPLD circuit, switch control circuit, etc. The PCB board of the control circuit is designed and manufactured according to the requirement. Complete the design and debugging of control software, including ultrasonic frequency tracking program, A / D sampling program, input capture program, PI control program and so on. The composite welding power source was assembled and the test platform was set up to debug the composite welding power source. The ultrasonic amplitude was constant output and continuously adjustable by ultrasonic voltage feedback and frequency tracking. The constant current output of resistance welding is realized by current feedback control. The three-stage ultrasonic voltage and resistance welding current can be flexibly set to realize the output of multiple composite energy waveforms, which can meet different process requirements. The process test of the brazed parts is carried out by using the composite welding power source. The results show that the diffusion layer appears at the interface of the composite welding under the combined action of ultrasonic energy and resistance heat, and the further tensile test results show that, The tensile properties and ductility of the composite welded joints are higher than that of the single ultrasonic joint.
【學(xué)位授予單位】：華南理工大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG409

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