中頻感應(yīng)加熱電源的設(shè)計(jì)

摘  要

中頻感應(yīng)加熱以其加熱效率高、速度快，可控性好及易于實(shí)現(xiàn)機(jī)械化、自動(dòng)化等優(yōu)點(diǎn)，已在熔煉、鑄造、彎管、熱鍛、焊接和表面熱處理等行業(yè)得到廣泛的應(yīng)用。
本設(shè)計(jì)根據(jù)設(shè)計(jì)任務(wù)進(jìn)行了方案設(shè)計(jì)，設(shè)計(jì)了相應(yīng)的硬件電路，研制了20KW中頻感應(yīng)加熱電源。
本設(shè)計(jì)中感應(yīng)加熱電源采用IGBT作為開關(guān)器件，可工作在10 Hz～10 kHz頻段。它由整流器、濾波器、和逆變器組成。整流器采用不可控三相全橋式整流電路。濾波器采用兩個(gè)電解電容和一個(gè)電感組成Ⅱ型濾波器濾波和無源功率因數(shù)校正。逆變器主要由PWM控制器SG3525A控制四個(gè)IGBT的開通和關(guān)斷，實(shí)現(xiàn)DC-AC的轉(zhuǎn)換。
    設(shè)計(jì)中采用的芯片主要是PWM控制器SG3525A和光耦合驅(qū)動(dòng)電路HCPL-316J。設(shè)計(jì)過程中程充分利用了SG3525A的控制性能，具有寬的可調(diào)工作頻率，死區(qū)時(shí)間可調(diào)，具有輸入欠電壓鎖定功能和雙路輸出電流。由于HCPL-316J具有快的開關(guān)速度（500ns），光隔離，故障狀態(tài)反饋，可配置自動(dòng)復(fù)位、自動(dòng)關(guān)閉等功能，所以選擇其作為IGBT的驅(qū)動(dòng)。
對(duì)原理樣機(jī)的調(diào)試結(jié)果表明，所完成的設(shè)計(jì)實(shí)現(xiàn)了設(shè)計(jì)任務(wù)規(guī)定的基本功能。此外，為了滿足不同器件對(duì)功率需要的要求，設(shè)計(jì)了功率可調(diào)。這部分超出了設(shè)計(jì)任務(wù)書規(guī)定的任務(wù)。

關(guān)鍵詞：感應(yīng)加熱電源；串聯(lián)諧振；逆變電路；IGBT

Abstract

The Intermediate Frequency Induction Heating has been widely applied in melting, casting, bend, hot forging, welding, Surface Heat Treatment due to its advantages of high heating efficiency、high speed、easily controlled、easily being mechanized and automated.
The scheme has made a plan of designs based on the task of design, designed corresponding hardware circuit and developed 20kW intermediate frequency induction heating power system.
The thesis discusses the Choice of converter scheme in detail. Series Resonance Inverter has another name is Voltage Inverter. Its Output Voltage approaches square wave and load current approaches sine-wave. Inversion must follow the Principles of break before make and there is enough dead-time between turn-off and turn on in order to avoiding direct through in upper and lower bridges.     The thesis discussed the Choice of converter scheme in detail as well as introduced the control circuit of this power source and its design principle. Develop 20kW intermediate frequency induction heating power system with switch element IGBT. Make a research on Converter Circuit, control circuit, driver circuit etc.
The CMOS chip that is applied in the design is mainly PWM Controller SG3525A and optical coupler Drive Circuit HCPL-316J. The controlled feature of PWM Controller SG3525A is fully utilized in the process of design, which has wide adjustable operating frequency and dead time, input under voltage lock function and twin channel output current. The optical coupler Drive Circuit HCPL-316J is chosen as the driven of IGBT due to its functions, such as fast switch speed (500ns), optical isolation, the feedback of fault situation, wide operating voltage (15V～30V), automatic reset and automatic close down etc.

Key words：Induction heating power supply; series resonance；inverse circuit；IGBT

目    錄

引言 1
1  緒論 2
1.1 感應(yīng)加熱的工作原理 2
1.2 感應(yīng)加熱電源技術(shù)發(fā)展現(xiàn)狀與趨勢 3
2  感應(yīng)加熱電源實(shí)現(xiàn)方案研究 5
2.1 串并聯(lián)諧振電路的比較 5
2.2 串聯(lián)諧振電源工作原理 7
2.3 電路的功率調(diào)節(jié)原理 8
2.4 本課題設(shè)計(jì)思路及主要設(shè)計(jì)內(nèi)容 8
3  感應(yīng)加熱電源電路的主回路設(shè)計(jì) 9
3.1 主電路的主要設(shè)計(jì)元器件參數(shù) 9
3.2 感應(yīng)加熱電源電路的主回路結(jié)構(gòu) 9
3.2.1主回路的等效模型 10
3.2.2整流部分電路分析 13
3.2.3逆變部分電路分析 15
3.3 系統(tǒng)主回路的元器件參數(shù)設(shè)定 16
3.3.1整流二極管和濾波電路元件選擇 16
3.3.2IGBT和續(xù)流二極管的選擇 17
3.3.3槽路電容和電感的參數(shù)設(shè)定 18
4  控制電路的設(shè)計(jì) 19
4.1控制芯片SG3525A 19
4.1.1內(nèi)部邏輯電路結(jié)構(gòu)分析 20
4.1.2芯片管腳及其功能介紹 21
4.2 電流互感器 23
5  驅(qū)動(dòng)電路的設(shè)計(jì) 24
5.1 絕緣柵雙極型晶體管（IGBT）對(duì)驅(qū)動(dòng)電路的要求 24
5.1.1門極電壓對(duì)開關(guān)特性的影響及選擇 24
5.1.2門極串聯(lián)電阻 對(duì)開關(guān)特性的影響及選擇 25
5.2 IGBT過壓的原因及抑制 25
5.3 IGBT的過流保護(hù) 26
5.3.1設(shè)計(jì)短路保護(hù)電路的幾點(diǎn)要求 27
5.4 集成光電隔離驅(qū)動(dòng)模塊HCPL-316J 27
5.4.1器件特性 27
5.4.2芯片管腳及其功能介紹 28
5.4.3內(nèi)部邏輯電路結(jié)構(gòu)分析 28
5.4.4器件功能分析 29
5.4.5驅(qū)動(dòng)電路的試驗(yàn)和注意問題 30
6  輔助直流穩(wěn)壓電源 31
6.1 三端固定穩(wěn)壓器 31
6.2 本次設(shè)計(jì)用的的電源 32
6.2.1 18伏，15伏穩(wěn)壓電壓電源 32
6.2.2 ±12伏，±5伏雙路穩(wěn)壓電源 32
6.2.3元器件選擇及參數(shù)計(jì)算 33
7  硬件調(diào)試 34
8  結(jié)論 35
致謝 37
參考文獻(xiàn) 38
附錄一 整體電路原理圖 39
附錄二控制電路PCB 40