焊接技術在科技趨使下快速進步，隨著工業發展焊接開始走向精細化，本論文研究之MIG即為多種類型手工焊其中之一，如何在降低成本與提高安全性的情況下使焊接達到更好的結果，是現今高端產品開發上需要考量之處。
　　為解決電焊機使用時在IGBT上消耗大功率的問題，本研究應用ZVS(Zero-Voltage Switch)、ZCS(Zero Current Switch)技術做改善，並且在傳統電焊機中，為了調整焊縫成形、短路過渡、焊絲溶化速度等等現象，需要電感來控制過於麻煩，且不具備適應性，本文將使用德州儀器的DSP晶片TMS320f2808做為數位控制器，利用分段波形控制電壓和電流，分別對於電壓和電流做精細的控制。
　　實驗結果顯示ZCS和ZVS的可行性，並且使用數位控制器能精準的控制電壓和電流完成預期的波形。

Welding technology has made rapid progress under the trend of science and technology. As the industrial development of welding begins to become more refined, the MIG studied in this paper is one of many types of manual welding. What needs to be considered in the development of high-end products today is to achieve better results in welding with lower costs and improved safety.
In order to solve the problem of high power consumption on the IGBT when the electric welder is used, this study uses ZVS (Zero-Voltage Switch) and ZCS (Zero Current Switch) technology to improve. In the conventional electric welder, in order to adjust the weld forming and short-circuit transition and the wire melting speed, etc., the inductor is required to be controlled too much trouble and is not adaptable.
This article uses Texas Instruments' DSP chip TMS320f2808 as a digital controller, using segmented waveforms to control voltage and current, and fine-grained waveform control for voltage and current, respectively.
The experimental results show the feasibility of ZCS and ZVS, and the digital controller can accurately control the voltage and current to complete the expected waveform.

Contents
Abstract in Chinese I
Abstract in English II
Contents III
List of Figures V
List of Tables VII
1 Introduction 1
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Fusion Welding Technical . . . . . . . . . . . . . . . . . . . . . 4
1.2 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Problem Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Welding Machine Inverter Circuit 12
2.1 Three Types of Inverter Principle . . . . . . . . . . . . . . . . . . . . . 13
2.1.1 Single-Ended Forward Circuit . . . . . . . . . . . . . . . . . . . 13
2.1.2 Half-bridge Inverter Circuit . . . . . . . . . . . . . . . . . . . . 14
2.1.3 Full-bridge Inverter Circuit . . . . . . . . . . . . . . . . . . . . 14
2.2 Soft-Switching Technology . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Power Switching Compare . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Drive IGBT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Control Strategies 22
3.1 PI Control with Anti-windup . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Waveform Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Experiment Result 27
4.1 Software Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1.1 Main Program Flow Diagram . . . . . . . . . . . . . . . . . . . 27
4.1.2 ePWM Interrupt Flow Diagram . . . . . . . . . . . . . . . . . . 27
4.2 Hardware Experiment Environment . . . . . . . . . . . . . . . . . . . . 29
4.3 ZVS and ZCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4 Constant Voltage,Current . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 Waveform Control Result . . . . . . . . . . . . . . . . . . . . . . . . . 43
5 Conclusion 45
References 46
Appendix A DSP TMS320F2808 Configuration 49
A.1 Enhanced Pulse Width Modulator (ePWM) Module Setup . . . . . . . 49
A.2 Analog-to-Digital Converter(ADC) (ePWM) Setup . . . . . . . . . . . 52
A.3 ADC Software Lowpass Filter . . . . . . . . . . . . . . . . . . . . . . . 54
Appendix B OP amp cutoff Frequency Design 55
List of Figures
1.1 Type of Wlelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Pressure Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Soldering Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Fusion Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Block Diagram of Hardware Environment . . . . . . . . . . . . . . . . 12
2.2 Single-Ended Forward Circuit . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Half-Bridge Inverter Circuit . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Full-Bridge Inverter Circuit . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Switching Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Full Bridge Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 25 % Phast-Shift Soft-Switching PWM Waveform . . . . . . . . . . . . 18
2.8 IGBT Module: DM2G100SH6N . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Pulse Transformer Drive Circuit . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Flow chart of PI controller . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Block Diagram of PI Controller With Anti-wind-up . . . . . . . . . . . 24
3.3 Short Circuit Transition . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Block Diagram of Waveform Control System . . . . . . . . . . . . . . . 26
4.1 Program flow chart of main program and ePWM interrupt . . . . . . . 28
4.2 Experiment environment . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Diagram of Welding Machine . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Welding Machine Schematic Diagram . . . . . . . . . . . . . . . . . . . 32
4.5 Voltage Feedback Circuit Using OP amp . . . . . . . . . . . . . . . . . 33
4.6 Drive Signal of Full-Bridge Inverter . . . . . . . . . . . . . . . . . . . . 34
4.7 Zero Current Switching with Duty Cycle = 8,25,40 % . . . . . . . . . . 35
4.8 Zero Voltage Switching with Duty Cycle = 8,25,40 % . . . . . . . . . . 36
4.9 ZVS and ZCS Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.10 Constant Voltage Experiments Result . . . . . . . . . . . . . . . . . . . 39
4.11 Settling Time Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.12 Switch 50 ohm and 2 ohm . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.13 Switch 5A and 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.14 Switch 0.5R and 0R . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.15 Waveform Control and Set Current on 140A . . . . . . . . . . . . . . . 43
4.16 Waveform Control and Set Current on 160A . . . . . . . . . . . . . . . 44
List of Tables
2.1 Operating Waveforms of Proposed ZVS ZCS Full-Bridge Inverter . . . 15
2.2 Power Switching Device Comparison Table . . . . . . . . . . . . . . . . 19
3.1 Table of PID Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 List of Experimental Instruments . . . . . . . . . . . . . . . . . . . . . 29

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