Abstract
The control system based on the primary current feedback mode can effectively suppress the magnetic bias and avoid the overcurrent for the full bridge inverter. But in the process of its digitalization, the magnetic bias signal can be missed easily and the control accuracy is low, resulting in poor system stability and reliability. First, a new double closed-loop digital control method is proposed, which has advantages of the magnetic bias suppression in the primary current feedback mode and fast fine current adjustment in the secondary current feedback mode. Second, results of theoretical analysis on system stability and simulation prove that the method is feasible. Third, a single-chip design idea based on analog-digital mixed field-programmable gate array (FPGA) is proposed, and the detailed design program is described for the submerged arc welding system, which has high integration and strong anti-interference. Experimental results show that the digital control system has high stability and reliability to produce high submerged arc welding quality.
Similar content being viewed by others
References
Kah P, Suoranta R, Martikainen J (2013) Advanced gas metal arc welding processes. Int J Adv Manuf Technol 67:655–674
Sadek CAA (2012) Sensors for quality control in welding. Soldag Insp 17(3):192–200
Luisa Q, Olga L, Louriel V, Américo S (2013) Heat input in full penetration welds in gas metal arc welding. Int J Adv Manuf Technol 68:2833–2840
Zhou K, Cai LL (2013) Online nugget diameter control system for resistance spot welding. Int J Adv Manuf Technol 68(9–12):2571–2588
Sha DS, Deng K, Liao XZ (2012) Duty cycle exchanging control for input-series-output-series connected two PS–FB DC–DC converters. IEEE T Power Electr 27(3):1490–1501
Souza OD, Alencar SCE, Torrico BRP, Tlfoli FL, Bissochi CA, Vieira JBJ, Farias VJ, Freitas LC (2011) Design and experimentation of a double forward converter with soft switching characteristics for all switches. IEEE T Power Electr 26(8):2137–2149
Ebrahim B (2014) A new pulse width modulation technique for inverters. Arab J Sci Eng 39(8):6235–6247
Li M, Dai D, Ma XK (2008) Slow-scale and fast-scale instabilities in voltage-mode controlled full-bridge inverter. Circ Syst Signal Pr 27(6):811–831
Yu WS, Lai JS, Park SY (2010) An improved zero-voltage-switching inverter using two coupled magnetics in one resonant pole. IEEE T Power Electr 25(4):952–961
Wang CM, Lin CH, Su CH, Chang SY (2011) A novel single-phase soft-switching AC chopper without auxiliary switches. IEEE T Power Electr 26(7):2041–2049
Klemen D, Gorazd Š, Drago D, Beno K (2010) Artificial neural network applied for detection of magnetization level in the magnetic core of a welding transformer. IEEE T Magn 46(2):634–638
Cherepov S, Moroz O, Derecha D, Hesse O (2011) A scanning visualizer of the magnetic field distribution. Instrum Exp Tech 54(2):273–275
Bardin VM, Borisov DA (2009) Simulation of transient processes in the welding inverter. Russ Electr Eng 80(6):337–339
Ehsan A, Hosein F (2009) Family of soft-switching PWM converters with current sharing in switches. IEEE T Power Electr 24(4):979–986
Duan B, Sun TJ, Li ZH, Mei GQ, Zhang GX (2009) Research and realization of PWM drive control digitalization for the full digital welding power supply. T China Weld Inst 18(4):76–80
Tan FD, Middlebrook RD (1995) A unified model for current-programmed converter. IEEE T Power Electr 10(4):397–408
Saidi B, Amairi M, Najar S, Aoun M (2014) Bode shaping-based design methods of a fractional order PID controller for uncertain systems. Nonlinear Dynam. doi:10.1007/s11071-014-1698-1
Fang CF, Yin SY, Hou RS, Yu M, Wang JC (2005) Double close loops control system of peak current mode of inverter arc welding power supply. T China Weld Inst 26(10):14–18
Duan B, Zhang CH, Sun TJ, Zhang GX, Guo M (2012) Modeling and simulation of pulsed welding inverter. T China Weld Inst 33(4):57–60
Aniruddha G, Himadri C (2013) Mathematical modeling of moving heat source shape for submerged arc welding process. Int J Adv Manuf Technol 69(9–12):2691–2701
Ganjigatti JP, Pratihar DK, RoyChoudhury A (2008) Modeling of the MIG welding process using statistical approaches. Int J Adv Manuf Technol 35(11–12):1166–1190
Yan WH, Pi CT, Cheng YW (2007) Tuning PID control of an automatic arc welding system using a SMAW process. Int J Adv Manuf Technol 34(2):56–61
Venkata Rao R, Kalyankar VD (2013) Experimental investigation on submerged arc welding of Cr–Mo–V steel. Int J Adv Manuf Technol 69(1–4):93–106
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Duan, B., Zhang, C., Guo, M. et al. A new digital control system based on the double closed-loop for the full-bridge inverter. Int J Adv Manuf Technol 77, 241–248 (2015). https://doi.org/10.1007/s00170-014-6463-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6463-6