Research On CO₂Gas Shielded Welding Machine Based On ZigBee Single-chip Microcomputer

CO2gas shielded welding with high efficiency and energy saving, the advantages oflow cost, easy to realize automation welding is widely applied in the welding production.But the problem of bigger welding spatter, poor welding appearance and inconvenientparameter adjustment has not been well solved. Foreign fully digital welding power sourcecan achieve low splash welding, but it also has the problem of high equipment costs,complex operating system, maintenance difficulties. So it is difficult to be widely used.Therefore in this paper, we study a new kind of small welding spatter, low cost, stableperformance and convenient welding parameters wireless remote control CO2arc weldingmachine based on ZigBee technology single-chip microcomputer control. This has a greatscientific and engineering value.In this paper, based on ZigBee technology single-chip microcomputer control, the CO2gas shielded welding machine main circuit and control system is well designed. The maincircuit topology of the double tube single end forward inverter is designed. Using the resettransformer bias diode to solve the problem, compared with the whole bridge and halfbridge circuit is more simple. The control system is more flexible and welding machine is ata lower cost. Based on single chip microcomputer context LM4F232and UC3845, the peakcurrent modes of and double closed loop control system has been designed. During the dropshort circuit transition, the current negative feedback control system for drop short circuittransition welding current output waveform real-time control can reduce the welding spatter.During the arc burning time, the real-time fine control for welding voltage and weldingcurrent on arc stage can improve the appearance of weld.In this paper, the short-range wireless communications based on ZigBee technology isalso used. Using two CC2530RF chips which use8051as the core, the wirelesscommunications hardware and software programs have been designed. One of the chips isused to realize serial port communication with the LM4F232host microcontroller. Thusremote display and adjustment of welding parameters can be realized. So welders canimmediately grasp the welding parameters and the welding parameters do not need to beadjusted at the wire feeder. This will help to improve the control of welding and weldingproductivity effect. Compared to the wired control box, it’s easier to solve the complex lines,inconvenient to carry,interference and other issues. Meanwhile, it can lay the foundation forthe network surveillance of future welding machine. This article also designed the welding parameters unified program, making it easier toadjust the welding parameters. In this paper, the external characteristics of the switchingprocess is designed. Welding machine can realize the welding flat and falling characteroutput. Both manual SMAW and GMAW welding methods can be achieved. So it can beused in more extensive engineering applications.Finally, the designed welding machine is used and the welding output waveforms weretested. Remote display and adjustment of welding parameters was verified. Tests showedthat the Welding machine’s main circuit structure is designed reasonably, the powerswitching devices is reliable, the welding spatter is small, the weld forming is good, themulti parameter adjustment is convenient, wireless remote welding parameters can beadjusted. The purpose of the paper design has been reached.