Welding machine chopper circuit control method and device based on multistage power regulation

Abstract

The invention discloses a welding machine chopper circuit control method and device based on multistage power regulation, and relates to the related field of chopper control, and the method comprises the steps: determining a circuit topology structure which comprises a main circuit topology and an auxiliary circuit topology based on chopper control; the dual-drive control module is supervised and trained based on hybrid modulation of the duty ratio and the switching frequency; receiving a welding task and determining a frequency modulation sequence; dividing multi-stage power features and mining a Markov frequency modulation chain; the combined digital signal processor and the programmable controller construct a control loop; and receiving a frequency modulation sequence and a precursor control signal, executing a chopping frequency modulation control decision and signal conversion based on a control loop, and performing chopping circuit control response. The technical problem that the welding process is unstable due to the fact that the control precision of an existing chopper circuit of the welding machine is insufficient is solved, and the technical effect of improving the control precision and stability of the welding process is achieved.

Description

Technical Field

[0001] The present application relates to the field of chopper control, and in particular to a welding machine chopper circuit control method and device based on multi-stage power regulation. Background Art

[0002] In the field of welding, with the rapid development of industrial automation and intelligent manufacturing, higher requirements are placed on the precise control of the welding process. The stability of parameters such as voltage and current during the welding process directly affects the quality and production efficiency of the welded joint. Traditional welding machine control systems mostly use a single power adjustment method, which is difficult to adapt to the complex and changeable welding process requirements, especially in high-power and high-precision welding scenarios. Its control accuracy is often insufficient, affecting the quality of the final welded joint.

[0003] In the current related technologies, the control accuracy of the welding machine chopper circuit is insufficient, which leads to the technical problem of unstable welding process. Summary of the invention

[0004] The present application provides a welding machine chopper circuit control method and device based on multi-stage power regulation, adopts a circuit structure designed to include a main circuit topology and an auxiliary circuit topology, adopts a hybrid modulation method based on duty cycle and switching frequency, trains a dual-drive control module, determines a frequency modulation sequence according to specific requirements of a welding task, divides multi-stage power characteristics and mines a Markov frequency modulation chain, predicts and controls power changes during welding using multi-stage power frequency conversion and intra-stage static and steady-state errors as baselines, combines a digital signal processor with a programmable controller to construct a control loop, receives a frequency modulation sequence and a precursor control signal, executes a chopper frequency modulation control decision and signal conversion based on the control loop, performs a chopper circuit control response, and other technical means, thereby achieving the technical effect of improving the control accuracy and stability of the welding process.

[0005] The present application provides a welding machine chopper circuit control method based on multi-stage power regulation, comprising:

[0006] Determine the circuit topology structure, including the main circuit topology and the auxiliary circuit topology based on chopping control, wherein the auxiliary circuit topology at least includes the driving circuit topology, the filtering circuit topology and the protection circuit topology; supervise and train the dual-drive control module with hybrid modulation based on duty cycle and switching frequency, wherein the dual-drive control includes the master-slave drive based on the main circuit topology and the auxiliary circuit topology; receive the welding task, determine the frequency modulation sequence, wherein each sequence node is marked with a power frequency conversion vector; divide the multi-stage power characteristics and mine the Markov frequency modulation chain, wherein the Markov frequency modulation chain takes the multi-stage power frequency conversion and the intra-stage static steady-state error as the baseline; combine the digital signal processor and the programmable controller to construct the control loop, wherein the programmable controller is configured based on the Markov frequency modulation chain and the dual-drive control module; receive the frequency modulation sequence and the precursor control signal, execute the chopping frequency modulation control decision and signal conversion based on the control loop, and perform the chopping circuit control response.

[0007] In a possible implementation, the supervised training dual-drive control module performs the following processing:

[0008] The dual-drive control module includes a parallel main control branch and an auxiliary control branch, and a lateral interaction channel is established between the branches; for the chopping control under the main circuit topology, sample drive training is performed in a mixed modulation manner to construct the main control branch; for the error compensation under the auxiliary circuit topology, sample drive training is performed with chopping control as the main factor to construct the auxiliary control branch.

[0009] In a possible implementation, the multi-level power features are divided and the Markov frequency modulation chain is mined, and the following processing is performed:

[0010] A frequency modulation chain is constructed with the multi-level power characteristics as the control state; industrial big data retrieval is performed to determine the chopping control record, record clustering processing and common frequency modulation feature mining within the cluster are performed based on the frequency modulation chain, the frequency modulation chain is initialized, and a dynamic frequency modulation chain is determined; the record clustering clusters are traversed, the static-state errors within the clusters are mined, and a static-state compensation chain is determined, wherein the static-state error takes the maximum error value within the cluster; the dynamic frequency modulation chain and the static-state compensation chain are mapped to determine the Markov frequency modulation chain.

[0011] In a possible implementation, the chopping frequency modulation control decision and signal conversion based on the control loop are performed, and the following processing is performed:

[0012] Identify the front-drive control signal, perform signal preprocessing and signal digital conversion in combination with the digital signal processor, and determine the digital signal; perform rear-drive control analysis and programming based on the frequency modulation sequence and the digital signal, and determine the rear-drive control program, wherein the same power segment is used as the analysis standard; and perform chopping signal conversion on the digital control signal output by the rear-drive control program in combination with the digital signal processor, and perform chopping circuit control response.

[0013] In a possible implementation, the rear drive control analysis and programming are performed to perform the following processing:

[0014] Based on the Markov frequency modulation chain, a rear-drive control node based on the frequency modulation sequence and the digital signal is determined, wherein the rear-drive control node is a lower-level control node of the same power segment; in combination with the dual-drive control module, a rear-drive control strategy is determined by frequency modulation control based on the main circuit and error compensation based on the auxiliary circuit; the programmable controller programs and outputs the rear-drive control strategy at a fixed point to determine the digital control signal.

[0015] In a possible implementation, the following processing is performed:

[0016] The control loop is connected to the welding machine control system through a communication system, and the control loop is a digital signal processor-programmable controller-digital signal processor.

[0017] In a possible implementation, the following processing is performed:

[0018] The welding task is identified and a load change curve is determined; the load change curve is traversed to determine a parameter control threshold curve, wherein the parameter control threshold includes a duty cycle threshold and a switching frequency threshold mapped to a multi-stage load, and the duty cycle, switching frequency and load are positively correlated; the parameter control threshold curve is used as a rigid constraint condition for executing a full cycle of the welding task.

[0019] The present application also provides a welding machine chopper circuit control device based on multi-stage power regulation, comprising:

[0020] A circuit topology determination module, the circuit topology determination module is used to determine the circuit topology, including a main circuit topology and an auxiliary circuit topology based on chopping control, wherein the auxiliary circuit topology at least includes a driving circuit topology, a filtering circuit topology and a protection circuit topology; a dual-drive control training module, the dual-drive control training module is used to supervise the training of the dual-drive control module with a hybrid modulation based on duty cycle and switching frequency, wherein the dual-drive control includes a master-slave drive based on the main circuit topology and the auxiliary circuit topology; a frequency modulation sequence determination module, the frequency modulation sequence determination module is used to receive a welding task and determine a frequency modulation sequence, wherein each sequence node is marked with a power frequency conversion vector; a Markov modulation A frequency chain mining module, the Markov frequency modulation chain mining module is used to divide multi-stage power characteristics and mine Markov frequency modulation chains, wherein the Markov frequency modulation chain takes multi-stage power frequency conversion and intra-stage static steady-state errors as baselines; a control loop construction module, the control loop construction module is used to combine a digital signal processor and a programmable controller to construct a control loop, and the programmable controller is configured based on the Markov frequency modulation chain and the dual-drive control module; a chopping circuit control response module, the chopping circuit control response module is used to receive the frequency modulation sequence and the precursor control signal, execute chopping frequency modulation control decision and signal conversion based on the control loop, and perform chopping circuit control response.

[0021] The welding machine chopper circuit control method and device based on multi-level power regulation proposed in this application first determine the circuit topology structure, including the main circuit topology and auxiliary circuit topology based on chopper control, wherein the auxiliary circuit topology at least includes the driving circuit topology, the filtering circuit topology and the protection circuit topology, and then supervise the training of the dual-drive control module based on the mixed modulation of duty cycle and switching frequency, wherein the dual-drive control includes the master-slave drive based on the main circuit topology and the auxiliary circuit topology, and then receive the welding task, determine the frequency modulation sequence, wherein each sequence node is marked with a power frequency conversion vector, and then divide the multi-level power characteristics and mine the Markov frequency modulation chain, wherein the Markov frequency modulation chain takes the multi-level power frequency conversion and the static and steady-state error within the level as the baseline, and then combines the digital signal processor and the programmable controller to construct the control loop, the programmable controller is configured based on the Markov frequency modulation chain and the dual-drive control module, and finally receives the frequency modulation sequence and the precursor control signal, executes the chopper frequency modulation control decision and signal conversion based on the control loop, and performs the chopper circuit control response, thereby achieving the technical effect of improving the control accuracy and stability of the welding process. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the accompanying drawings of the embodiment of the present invention will be briefly introduced below. A flow chart is used in the present application to illustrate the operations performed by the device according to the embodiment of the present application. It should be understood that the previous or following operations are not necessarily performed accurately in order. On the contrary, various steps can be processed in reverse order or simultaneously as needed. At the same time, other operations can also be added to these processes, or one or more operations can be removed from these processes.

[0023] Figure 1 A flow chart of a welding machine chopper circuit control method based on multi-stage power regulation provided in an embodiment of the present application.

[0024] Figure 2 A schematic diagram of the structure of a welding machine chopper circuit control device based on multi-stage power regulation provided in an embodiment of the present application.

[0025] Explanation of the reference numerals: circuit topology determination module 10 , dual-drive control training module 20 , frequency modulation sequence determination module 30 , Markov frequency modulation chain mining module 40 , control loop construction module 50 , chopper circuit control response module 60 . DETAILED DESCRIPTION

[0026] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0027] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0028] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict. The terms "including" and "having" and any variations are intended to cover non-exclusive inclusions. For example, a process, method, device, product, or server that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field of this application. The terms used herein are for the purpose of describing the embodiments of the present application only.

[0029] The embodiment of the present application provides a welding machine chopper circuit control method based on multi-stage power regulation, such as Figure 1 As shown, the method includes:

[0030] Step S100, determine the circuit topology structure, including the main circuit topology and auxiliary circuit topology based on chopping control, and the auxiliary circuit topology at least includes the driving circuit topology, the filtering circuit topology and the protection circuit topology. Specifically, clarify the specific needs of the welding machine, including the required welding current range, voltage level, power level, etc. Design a main circuit based on chopping control, including IGBT (insulated gate bipolar transistor) or other types of power switching elements, as well as energy storage elements such as inductors and capacitors, for realizing current and voltage regulation, wherein chopping control is a method of controlling current or voltage by fast switching power devices. Design an auxiliary circuit topology, wherein the driving circuit topology is a circuit for driving the power switching element in the main circuit, so that the switching element can switch accurately and quickly; the filtering circuit topology is used to reduce the ripple of the output voltage and current and improve the welding quality; the protection circuit topology is a protection circuit for overcurrent, overvoltage, overheating, etc., which is used to enable the welding machine to stop working safely under abnormal conditions.

[0031] Step S200, supervise the training of the dual-drive control module based on the mixed modulation of duty cycle and switching frequency, wherein the dual-drive control includes the master-slave drive based on the main circuit topology and the auxiliary circuit topology. Specifically, combined with the adjustment of duty cycle (the proportion of the conduction time of the switching element to the total cycle) and switching frequency (the switching speed of the switching element), the master-slave drive control strategy based on the main circuit topology and the auxiliary circuit topology is designed and implemented, the master drive controls the main circuit, and the slave drive controls the auxiliary circuit, and the two work together. Use historical data or simulation data to train the dual-drive control module, optimize the control parameters, and improve the control accuracy and stability.

[0032] In a possible implementation, the supervised training dual-drive control module, step S200 further includes step S210, the dual-drive control module includes a parallel main control branch and an auxiliary control branch, and a lateral interaction channel is established between the branches. Specifically, the dual-drive control module is composed of a parallel main control branch and an auxiliary control branch, and the two branches are responsible for the control of the main circuit and the auxiliary circuit respectively. A lateral interaction channel is established between the main control branch and the auxiliary control branch, that is, a channel for transmitting data between the main control branch and the auxiliary control branch, which is used to achieve collaborative work between the two branches, allowing them to exchange key control information and status data. This interaction can be periodic or event-triggered. Step S220, for the chopping control under the main circuit topology, sample drive training is performed in a hybrid modulation mode to construct the main control branch. Specifically, various operating data about the chopping control under the main circuit topology are collected, including parameters such as current, voltage, and power under different duty cycles and switching frequencies. Representative samples are screened out from the collected data, and these samples cover various working conditions that the main circuit may encounter. According to the sample data, a hybrid modulation strategy based on duty cycle and switching frequency is designed to achieve efficient control of the main circuit. The sample data is used to train the main control branch, optimize the control algorithm and parameters, and ensure that the main control branch can accurately and quickly respond to the control instruction. Step S230, for the error compensation under the auxiliary circuit topology, the chopping control is taken as the leading factor, and the sample drive training is carried out to construct the auxiliary control branch. Specifically, the errors that may be generated by the auxiliary circuit topology during the chopping control process are analyzed, such as unsatisfactory filtering effect, protection circuit response delay, etc. For the analyzed errors, a corresponding compensation strategy is designed to improve the performance and stability of the auxiliary circuit. In the design of the compensation strategy, the chopping control is taken as the leading factor to ensure that the control of the auxiliary circuit is synchronized and coordinated with the main circuit. The sample data is used to train the auxiliary control branch, optimize the compensation algorithm and parameters, and ensure that the auxiliary control branch can effectively reduce the error and improve the overall performance of the system. This implementation method uses the parallel main control branch and the auxiliary control branch to respectively perform fine control on the main circuit and the auxiliary circuit. The main control branch is responsible for realizing the basic chopping control function, and the auxiliary control branch focuses on error compensation and optimization, thereby achieving the technical effect of improving the control accuracy of the entire system.

[0033] Step S300, receiving a welding task and determining a frequency modulation sequence, wherein each sequence node is marked with a power frequency conversion vector. Specifically, specific requirements for welding, such as welding materials, thickness, speed, etc., are received from an external system or user interface. According to the welding task requirements, a series of instruction sequences for adjusting the output power of the welding machine are generated, and each instruction corresponds to a specific power output, which is achieved by adjusting the duty cycle and switching frequency.

[0034] In a possible implementation, step S300 further includes step S310, identifying the welding task and determining the load change curve. Specifically, the welding task includes specific parameters such as welding material, thickness, length, and speed. According to the parameters of the welding task, the model is used to estimate the change trend of the load during the welding process, wherein the load refers to the energy output such as current and voltage that the welder needs to provide during the welding process. The estimated load change trend is expressed in the form of a curve, wherein the horizontal axis is time or welding length, and the vertical axis is the load size. Step S320, traversing the load change curve, determining the parameter control threshold curve, wherein the parameter control threshold includes a duty cycle threshold and a switching frequency threshold mapped to the multi-stage load, and the duty cycle and the switching frequency are positively correlated with the load. Specifically, the load change curve is traversed to analyze the characteristics and change trend of the load at different stages. According to the change trend of the load and the performance of the welder, the corresponding duty cycle threshold and the switching frequency threshold are set for the multi-stage load to ensure that the welder can operate stably under different loads. The set duty cycle threshold and switching frequency threshold are expressed in the form of a curve, the horizontal axis is consistent with the load change curve, and the vertical axis is the duty cycle and the switching frequency. Step S330, the parameter control threshold curve is used as a rigid constraint condition for the full cycle of the welding task execution. Specifically, the parameter control threshold curve is integrated into the control system of the welding machine as part of the control strategy. During the execution of the welding task, the load change is monitored in real time, and the duty cycle and switching frequency of the welding machine are adjusted in real time according to the parameter control threshold curve to ensure that the welding machine output is always kept within a reasonable range. If it is detected that the load change exceeds the preset range or the welding machine output cannot meet the parameter control threshold requirement, the abnormal handling mechanism is triggered, such as reducing the welding speed, suspending welding, etc., to avoid equipment damage or welding quality degradation. This implementation method prevents the welding machine from running under overload or abnormal conditions by setting the parameter control threshold curve, and ensures that the welding machine maintains stable output performance throughout the full cycle of the welding task execution, thereby achieving the technical effect of protecting the welding machine from damage and improving control accuracy and stability.

[0035] Step S400, divide the multi-level power characteristics and mine the Markov frequency modulation chain, wherein the Markov frequency modulation chain is based on the multi-level power frequency conversion and the intra-level static and steady-state error. Specifically, the power output range of the welding machine is divided into multiple levels, and each level corresponds to different welding requirements. The Markov chain model (a mathematical system with the property of "no memory", that is, the next state of the system is only related to the current state, but not to the previous state) is used to predict and analyze the power changes in the frequency modulation sequence to improve the foresight and accuracy of the control. At the same time, the intra-level static and steady-state error (the difference between the actual output and the expected output of the system in a stable state) is considered to ensure that a stable output can be achieved at each power level.

[0036] In a possible implementation, the multi-level power features are divided and the Markov frequency modulation chain is mined, and step S400 further includes step S410, using the multi-level power features as the control state to construct a frequency modulation chain. Specifically, according to the power change during the welding process, the power is divided into multiple levels (such as low, medium, and high power), and each level corresponds to a specific power range. Each power level is regarded as a control state, and these states form the basis of the frequency modulation chain. Based on these control states, a chain structure representing the order of power change is constructed, that is, a frequency modulation chain, each node in the frequency modulation chain represents a power level (control state), and the connection between the nodes represents the conversion of the power level. Step S420, perform industrial big data retrieval, determine the chopping control record, perform record clustering processing and common frequency modulation feature mining within the cluster based on the frequency modulation chain, initialize the frequency modulation chain, and determine the dynamic frequency modulation chain. Specifically, retrieve the chopping control record related to the current welding task from the industrial big data database (data recording the chopping control parameters and results during the welding process). Clustering algorithms (such as K-means, DBSCAN, etc.) are used to cluster the retrieved records and classify the records with similar frequency modulation features into one category. In each cluster, common frequency modulation features are mined, that is, the frequency modulation patterns and rules shared by the records in the cluster. Based on the mined common frequency modulation features, the initial frequency modulation chain is initialized to form a dynamic frequency modulation chain, which is used to more accurately reflect the power changes in the actual welding process.

[0037] Step S430, traverse the recorded clusters, mine the static and steady-state errors within the clusters, and determine the static and steady-state compensation chain, wherein the static and steady-state error takes the maximum error value within the cluster. Specifically, traverse each cluster in turn, and in each cluster, calculate the error between the actual frequency modulation result and the expected frequency modulation result under the power stable state. Take the maximum error value within the cluster as the representative of the static and steady-state error of the cluster, and build a static and steady-state compensation chain based on these error values, which is used to adjust the control parameters in the subsequent welding process to reduce the static and steady-state error. Step S440, map the dynamic frequency modulation chain with the static and steady-state compensation chain to determine the Markov frequency modulation chain. Specifically, the dynamic frequency modulation chain is mapped with the static and steady-state compensation chain, that is, the compensation value in the static and steady-state compensation chain is mapped to the corresponding node of the dynamic frequency modulation chain. Through the mapping process, a Markov frequency modulation chain containing dynamic frequency modulation characteristics and static and steady-state compensation information is obtained, that is, the Markov frequency modulation chain not only reflects the dynamic change process of power, but also includes a compensation mechanism for reducing the static and steady-state error. This implementation method achieves the technical effect of improving the accuracy and stability of power control during welding by dividing multi-level power characteristics, constructing a frequency modulation chain, mining common frequency modulation characteristics and static steady-state errors, and finally determining the Markov frequency modulation chain.

[0038] Step S500, combining a digital signal processor and a programmable controller to construct a control loop, wherein the programmable controller is configured based on the Markov frequency modulation chain and the dual-drive control module. Specifically, select a suitable digital signal processor (DSP, a microprocessor specifically used for digital signal processing) and a programmable controller (PLC, a digital computing device for industrial automation control) to ensure that they can meet the control requirements of the welding machine. Connect the DSP and the PLC to construct a closed-loop control system, in which the DSP is responsible for complex calculations and processing, and the PLC is responsible for logical control and execution. According to the Markov frequency modulation chain and the dual-drive control strategy, configure the control parameters and programs in the DSP and the PLC.

[0039] In a possible implementation, step S500 further includes step S510, wherein the control loop establishes a communication connection with the welding machine control system, and the control loop is a digital signal processor-programmable controller-digital signal processor. Specifically, the DSP-PLC-DSP control loop communicates with the welding machine control system through a standard industrial communication protocol, and a physical interface is established between the control loop and the welding machine control system through a network cable. This implementation utilizes the DSP-PLC-DSP control loop structure, where PLC is good at logic control and strategy execution, and DSP is good at high-speed signal processing. By combining these two controllers, the technical effect of further improving the control accuracy and response speed in the welding process is achieved.

[0040] Step S600, receiving the frequency modulation sequence and the precursor control signal, executing the chopping frequency modulation control decision and signal conversion based on the control loop, and performing the chopping circuit control response. Specifically, the DSP and PLC receive the frequency modulation sequence and the precursor control signal from the external system. According to the received signal and the internal control logic, the DSP and PLC jointly make the control decision of the chopping frequency modulation. The control decision is converted into a specific control signal, such as a PWM signal (pulse width modulation signal), and output to the power switch element in the chopping circuit to realize the power regulation of the welding machine. The embodiment of the present application adopts a circuit structure that designs a main circuit topology and an auxiliary circuit topology, adopts a hybrid modulation method based on duty cycle and switching frequency, trains the dual-drive control module, determines the frequency modulation sequence according to the specific requirements of the welding task, divides the multi-stage power characteristics and mines the Markov frequency modulation chain, uses the multi-stage power frequency conversion and the intra-stage static steady-state error as the baseline, predicts and controls the power change in the welding process, combines the digital signal processor and the programmable controller to construct a control loop, receives the frequency modulation sequence and the precursor control signal, executes the chopping frequency modulation control decision and signal conversion based on the control loop, performs the chopping circuit control response and other technical means, and achieves the technical effect of improving the control accuracy and stability of the welding process.

[0041] In a possible implementation, the chopping frequency modulation control decision and signal conversion based on the control loop are performed, and step S600 further includes step S610, identifying the front drive control signal, combining the digital signal processor, performing signal preprocessing and signal digital conversion, and determining the digital signal. Specifically, the control system receives the front drive control signal from the welding machine or other external equipment, including parameters such as voltage, current, temperature, speed, etc., which are used to indicate the real-time status during the welding process. The digital signal processor performs preprocessing operations such as filtering and amplification on the received front drive control signal to remove noise and improve signal quality, and converts the preprocessed signal into a digital signal through an analog-to-digital converter (ADC). Step S620, based on the frequency modulation sequence and the digital signal, the rear drive control analysis and programming are performed to determine the rear drive control program, wherein the same power section is used as the analysis standard. Specifically, the frequency modulation sequence and the digital signal are comprehensively analyzed with the same power section as the analysis standard, wherein the same power section refers to a period of time or interval during the welding process when the power is relatively stable. Analyze the influence of the frequency modulation sequence on the welding quality and efficiency, and the correlation between the digital signal and the frequency modulation sequence. According to the analysis results, a rear-drive control program is written, and the rear-drive control program is a program that converts the frequency modulation sequence and the digital signal into a chopper control instruction, which is used to realize accurate chopper frequency modulation control. Step S630, in combination with the digital signal processor, the digital control signal output by the rear-drive control program is converted into a chopping signal, and a chopping circuit control response is performed. Specifically, the digital control signal output by the rear-drive control program is converted into a chopping signal using a DSP. The chopping signal is a high-frequency pulse signal. The chopping signal is input into a chopping circuit (a circuit for adjusting the output voltage and current) to control the switching state of the chopper. The chopper adjusts the output voltage and current according to the frequency and duty cycle of the chopping signal, thereby realizing accurate control of the welding process. This implementation method improves the quality of the received front-drive control signal through pre-processing operations such as filtering and amplification, and achieves the technical effect of improving the accuracy and stability of the control system.

[0042] In a possible implementation, the rear drive control analysis and programming are performed, and step S620 further includes step S621, based on the Markov frequency modulation chain, determining the rear drive control node based on the frequency modulation sequence and the digital signal, wherein the rear drive control node is the control node of the lower same power segment. Specifically, the frequency modulation sequence is analyzed by using the Markov frequency modulation chain, and the digital signal (such as voltage, current, temperature, etc.) of the current power segment is combined to predict or determine the best or expected state of the next same power segment (i.e., the rear drive control node), i.e., the control reference point or target state of the same power segment in the next position (or time window). Step S622, combined with the dual drive control module, the rear drive control strategy is determined by frequency modulation control based on the main circuit and error compensation based on the auxiliary circuit. Specifically, according to the requirements of the rear drive control node, the frequency of the main circuit is adjusted to meet the basic requirements of the welding process. The auxiliary circuit is used to monitor and compensate for the errors in the main circuit control process in real time to improve the accuracy and stability of the control. The control effects of the main and auxiliary circuits are integrated to generate a detailed rear-drive control strategy, including control parameters, timing, logic, etc. In step S623, the programmable controller programs and outputs the rear-drive control strategy at a fixed point to determine the digital control signal. Specifically, the programmable controller (PLC) writes a corresponding control program according to the rear-drive control strategy. At a specified time point or trigger condition, the control instruction is output at a fixed point in the form of a digital control signal to control the chopper circuit. This implementation method uses a Markov frequency modulation chain and a dual-drive control module to more accurately predict and control frequency changes and errors in the welding process, thereby achieving the technical effect of improving the quality and consistency of the welded joint.

[0043] In the above, refer to Figure 1 The welding machine chopper circuit control method based on multi-stage power regulation according to an embodiment of the present invention is described in detail. Figure 2 A welding machine chopper circuit control device based on multi-stage power regulation according to an embodiment of the present invention is described.

[0044] The welding machine chopper circuit control device based on multi-stage power regulation according to the embodiment of the present invention is used to solve the technical problem that the control accuracy of the existing welding machine chopper circuit control is insufficient, resulting in an unstable welding process, and achieves the technical effect of improving the control accuracy and stability of the welding process. The welding machine chopper circuit control device based on multi-stage power regulation includes: a circuit topology determination module 10, a dual-drive control training module 20, a frequency modulation sequence determination module 30, a Markov frequency modulation chain mining module 40, a control loop construction module 50, and a chopper circuit control response module 60.

[0045] The circuit topology determination module 10 is used to determine the circuit topology, including the main circuit topology and the auxiliary circuit topology based on chopping control, wherein the auxiliary circuit topology at least includes the driving circuit topology, the filtering circuit topology and the protection circuit topology; the dual-drive control training module 20 is used to supervise the training of the dual-drive control module by hybrid modulation based on duty cycle and switching frequency, wherein the dual-drive control includes the master-slave drive based on the main circuit topology and the auxiliary circuit topology; the frequency modulation sequence determination module 30 is used to receive the welding task and determine the frequency modulation sequence, wherein each sequence node is marked with a power frequency conversion vector; The Markov frequency modulation chain mining module 40 is used to divide the multi-stage power characteristics and mine the Markov frequency modulation chain, wherein the Markov frequency modulation chain takes the multi-stage power frequency conversion and the intra-stage static steady-state error as the baseline; the control loop construction module 50 is used to combine the digital signal processor and the programmable controller to construct the control loop, and the programmable controller is based on the Markov frequency modulation chain and the dual-drive control module configuration; the chopper circuit control response module 60 is used to receive the frequency modulation sequence and the precursor control signal, execute the chopper frequency modulation control decision and signal conversion based on the control loop, and perform the chopper circuit control response.

[0046] The specific configuration of the dual-drive control training module 20 will be described in detail below. As described above, the dual-drive control module is supervised for training, and the dual-drive control training module 20 may further include: a main control branch construction unit is used for the dual-drive control module to include a parallel main control branch and an auxiliary control branch, and a lateral interaction channel is established between the branches. For the chopping control under the main circuit topology, sample drive training is performed in a mixed modulation manner to construct the main control branch; the auxiliary control branch construction unit is used for error compensation under the auxiliary circuit topology, with chopping control as the main factor, sample drive training is performed to construct the auxiliary control branch.

[0047] The specific configuration of the Markov frequency modulation chain mining module 40 will be described in detail below. As described above, the multi-level power features are divided and the Markov frequency modulation chain is mined. The Markov frequency modulation chain mining module 40 can further include: a frequency modulation chain construction unit is used to construct a frequency modulation chain with the multi-level power features as the control state; a dynamic frequency modulation chain determination unit is used to perform industrial big data retrieval, determine the chopping control record, perform record clustering processing and common frequency modulation feature mining within the cluster based on the frequency modulation chain, initialize the frequency modulation chain, and determine the dynamic frequency modulation chain; a static state compensation chain determination unit is used to traverse the record clustering cluster, mine the static state error within the cluster, and determine the static state compensation chain, wherein the static state error takes the maximum error value within the cluster; the Markov frequency modulation chain determination unit is used to map the dynamic frequency modulation chain and the static state compensation chain to determine the Markov frequency modulation chain.

[0048] The specific configuration of the chopper circuit control response module 60 will be described in detail below. As described above, the chopper frequency modulation control decision and signal conversion based on the control loop are executed, and the chopper circuit control response module 60 may further include: a digital signal determination unit for identifying the front drive control signal, combining with the digital signal processor, performing signal preprocessing and signal digital conversion, and determining the digital signal; a rear drive control program determination unit for performing rear drive control analysis and programming based on the frequency modulation sequence and the digital signal, and determining the rear drive control program, wherein the same power segment is used as the analysis standard; a chopper signal conversion unit for combining with the digital signal processor, performing chopper signal conversion on the digital control signal output by the rear drive control program, and performing chopper circuit control response.

[0049] Among them, the rear-drive control analysis and programming, the rear-drive control program determination unit may further include: a rear-drive control node determination subunit is used to determine the rear-drive control node based on the frequency modulation sequence and the digital signal based on the Markov frequency modulation chain, wherein the rear-drive control node is a lower-level control node of the same power segment; a rear-drive control strategy determination subunit is used to combine the dual-drive control module to determine the rear-drive control strategy based on the frequency modulation control of the main circuit and the error compensation based on the auxiliary circuit; the digital control signal determination subunit is used for the programmable controller to program and output the rear-drive control strategy at a fixed point to determine the digital control signal.

[0050] The specific configuration of the control loop building module 50 will be described in detail below. As described above, the control loop building module 50 may further include: the control loop is in communication connection with the welding machine control system, and the control loop is a digital signal processor-programmable controller-digital signal processor.

[0051] The specific configuration of the frequency modulation sequence determination module 30 will be described in detail below. As described above, the frequency modulation sequence determination module 30 may further include: a load change curve determination unit for identifying the welding task and determining the load change curve; a parameter control threshold curve determination unit for traversing the load change curve and determining the parameter control threshold curve, wherein the parameter control threshold includes a duty cycle threshold and a switching frequency threshold mapped to a multi-level load, and the duty cycle, switching frequency and load are positively correlated; and a rigid constraint condition determination unit for using the parameter control threshold curve as a rigid constraint condition for executing the full cycle of the welding task.

[0052] The welding machine chopper circuit control device based on multi-stage power regulation provided in the embodiment of the present invention can execute the welding machine chopper circuit control method based on multi-stage power regulation provided in any embodiment of the present invention, and has the corresponding functional modules and beneficial effects of the execution method.

[0053] Although the present application makes various references to certain modules in the device according to the embodiments of the present application, any number of different modules may be used and run on the user terminal and / or server, and the various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of the functional units are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention.

[0054] The above specific implementation manner does not constitute a limitation to the protection scope of the present application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be performed in an order different from that in the embodiment and can still achieve the desired results. In addition, the process depicted in the accompanying drawings does not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. A welding machine chopper circuit control method based on multi-stage power regulation, characterized in that: The method comprises: Determine a circuit topology structure, including a main circuit topology and an auxiliary circuit topology based on chopping control, wherein the auxiliary circuit topology at least includes a driving circuit topology, a filtering circuit topology, and a protection circuit topology; Supervise and train a dual-drive control module by hybrid modulation based on duty cycle and switching frequency, wherein the dual-drive control includes master-slave drive based on the main circuit topology and the auxiliary circuit topology; Receive welding tasks and determine frequency modulation sequences, wherein each sequence node is marked with a power frequency conversion vector; Divide multi-stage power features and mine Markov frequency modulation chains, wherein the Markov frequency modulation chain is based on multi-stage power frequency conversion and intra-stage static steady-state errors; A control loop is constructed by combining a digital signal processor and a programmable controller, wherein the programmable controller is configured based on the Markov frequency modulation chain and the dual-drive control module; The frequency modulation sequence and the preceding control signal are received, a chopping frequency modulation control decision and a signal conversion based on the control loop are executed, and a chopping circuit control response is performed.

2. The welding machine chopper circuit control method based on multi-stage power regulation according to claim 1, characterized in that: The supervised training dual-drive control module includes: The dual-drive control module includes a parallel main control branch and an auxiliary control branch, and a lateral interaction channel is established between the branches; For the chopping control under the main circuit topology, sample drive training is performed in a hybrid modulation manner to construct the main control branch; For error compensation under the auxiliary circuit topology, sample drive training is performed with chopping control as the main control to construct the auxiliary control branch.

3. The welding machine chopper circuit control method based on multi-stage power regulation according to claim 1, characterized in that: The method of dividing the multi-level power features and mining the Markov frequency modulation chain includes: A frequency modulation chain is constructed using the multi-level power characteristics as a control state; Perform industrial big data retrieval to determine chopping control records, perform record clustering processing and common frequency modulation feature mining within the cluster based on the frequency modulation chain, initialize the frequency modulation chain, and determine a dynamic frequency modulation chain; Traverse the record clusters, mine the static-state error within the cluster, and determine the static-state compensation chain, wherein the static-state error takes the maximum error value within the cluster; The dynamic frequency modulation chain and the static state compensation chain are mapped to determine the Markov frequency modulation chain.

4. The welding machine chopper circuit control method based on multi-stage power regulation according to claim 1, characterized in that: Executing chopper frequency modulation control decision and signal conversion based on the control loop, including: Identify the front drive control signal, perform signal preprocessing and signal digital conversion in combination with the digital signal processor, and determine the digital signal; Based on the frequency modulation sequence and the digital signal, rear-wheel drive control analysis and programming are performed to determine a rear-wheel drive control program, wherein the same power section is used as an analysis standard; In combination with the digital signal processor, the digital control signal output by the rear drive control program is converted into a chopper signal to perform a chopper circuit control response.

5. The welding machine chopper circuit control method based on multi-stage power regulation according to claim 4, characterized in that: The rear drive control analysis and programming includes: Based on the Markov frequency modulation chain, determining a rear-drive control node based on the frequency modulation sequence and the digital signal, wherein the rear-drive control node is a control node of a lower level with the same power segment; In combination with the dual-drive control module, a rear-drive control strategy is determined by frequency modulation control based on the main circuit and error compensation based on the auxiliary circuit; The programmable controller programs and outputs the rear-drive control strategy at a fixed point to determine the digital control signal.

6. The welding machine chopper circuit control method based on multi-stage power regulation according to claim 1, characterized in that: The control loop is connected to the welding machine control system through a communication system, and the control loop is a digital signal processor-programmable controller-digital signal processor.

7. The welding machine chopper circuit control method based on multi-stage power regulation according to claim 1, characterized in that: The method further comprises: identifying the welding task and determining a load variation curve; Traversing the load change curve to determine a parameter control threshold curve, wherein the parameter control threshold includes a duty cycle threshold and a switching frequency threshold mapped to the multi-level load, and the duty cycle, the switching frequency and the load are positively correlated; The parameter control threshold curve is used as a rigid constraint condition for executing the entire cycle of the welding task.

8. A welding machine chopper circuit control device based on multi-stage power regulation, characterized in that: The device is used to implement the welding machine chopper circuit control method based on multi-stage power regulation according to any one of claims 1 to 7, and the device comprises: A circuit topology determination module, the circuit topology determination module is used to determine the circuit topology, including a main circuit topology and an auxiliary circuit topology based on chopping control, the auxiliary circuit topology at least including a driving circuit topology, a filtering circuit topology and a protection circuit topology; A dual-drive control training module, the dual-drive control training module is used to supervise the training of the dual-drive control module by hybrid modulation based on duty cycle and switching frequency, wherein the dual-drive control includes master-slave driving based on the main circuit topology and the auxiliary circuit topology; A frequency modulation sequence determination module, the frequency modulation sequence determination module is used to receive a welding task and determine a frequency modulation sequence, wherein each sequence node is marked with a power frequency conversion vector; A Markov frequency modulation chain mining module, wherein the Markov frequency modulation chain mining module is used to divide the multi-stage power characteristics and mine the Markov frequency modulation chain, wherein the Markov frequency modulation chain takes the multi-stage power frequency conversion and the intra-stage static steady-state error as the baseline; A control loop building module, the control loop building module is used to combine a digital signal processor and a programmable controller to build a control loop, the programmable controller is configured based on the Markov frequency modulation chain and the dual-drive control module; The chopper circuit control response module is used to receive the frequency modulation sequence and the precursor control signal, execute the chopper frequency modulation control decision and signal conversion based on the control loop, and perform the chopper circuit control response.

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