Research and realization of PWM drive control digitalization for the full digital welding power supply

Pulse width modulation （ PWM） drive control digitalization is the key for the full digital invert power supply. New ideas are proposed, which are based on field programmable gate array （ FPGA ）. First, digital PWM principles are discussed. The primary and secondary current characteristics are analyzed when the transformer is in both normal and magnetic bias conditions. Second, two digitalization methods are put forward after the research on PWM adjustment principles, which are based on the primary current feedback. Though the two methods could restrain magnetic bias, their realization is difficult. A new method is researched on double close-loops to overcome the above shortcomings, which uses the secondary current as the feedback signal and the primary current as the protection signal. Finally, the secondary current control made is discussed and realized. Welding experimental results show that the method has strong flexibility and adaptability, which can be used to realize the full digital welding power supply.

Study on intelligent digital welding machine with a self-learning function

A design idea was proposed that it was about intelligent digital welding machine with self-learning and self- regulation functions. The overall design scheme of software and hardware was provided. It was introduced that a parameter self-learning algorithm was based on large-step calibration and partial Newton interpolation. Furthermore, experimental verification was carried out with different welding technologies. The results show that weld bead is pegrect. Therefore, good welding quality and stability are obtained, and intelligent regulation is realized by parameters self-learning.

Residual stress determination in friction stir butt welded joints using a digital image correlation-aided slitting technique

This paper presents an incremental cutting method for evaluating the longitudinal residual stresses in a butt welded thin plate via combining the traditional residual stress measurement methods and the advanced optical technique.The proposed approach,which can be called digital image correlation（DIC）-aided slitting technique,introduces a successive extension slot to a specimen and employs the DIC technique to measure the released displacement profiles of the cutting sections after each cutting increment.Then the displacement profiles are used to directly calculate the residual stress distributions up to the slot tip and hence,a stress distribution can be obtained after a cutting increment.Finally,all of the stress distributions are averaged to ultimately determine the original residual stress field.This method does not include any complex experimental operations or tedious derivation,and the resolution of stress variation is greatly improved by the continuous measurement of the released displacements.The presented method has been preliminarily verified by a specimen with residual stress introduced by a four-point bending test.The results show that residual stresses determined by the DIC-aided slitting technique agree well with those from finite element（FE） prediction.The residual stress in a friction stir welded aluminum specimen obtained by the presented technique is also consistent with the evaluations given by X-ray diffraction.Furthermore,the residual stresses obtained by the DIC-aided slitting technique demonstrate higher accuracy and stability than the evaluations derived by the DIC-aided contour method.