A multi-physical field design and rapid simulation analysis method of an inverter welding machine

Abstract

The application discloses a kind of multi-physical field design and fast simulation analysis method of inverter welding machine, welding machine assembly parts model is established by software, welding machine assembly parts model is imported into Ansys discovery live, the transient heat flow field of the internal air-cooled aluminum alloy radiating fin of welding machine is established, the internal axial flow fan air inflow field of welding machine is established, the welding machine air inflow field from the external air inlet to the external air outlet is established, the air outflow field of welding machine and external air is established, after setting up good relevant corresponding simulation parameters, start calculating until simulation result is completed, according to corresponding simulation data is analyzed, further improve the heat dissipation capacity of welding machine radiating fin, the space layout of welding machine internal part system is optimized, and the design and fast simulation scheme with better welding machine heat dissipation performance is obtained.

Description

Technical Field

[0001] This invention relates to the field of heat dissipation technology for high-power inverter gas shielded welding machines, specifically to a multiphysics design and rapid simulation analysis method for inverter welding machines. Background Technology

[0002] Arc welding, as a fundamental hot-working process for metal materials, is widely used in many industrial enterprises, including metallurgy, petrochemicals, machinery manufacturing, and shipbuilding. Arc welding machines typically use air-cooled aluminum alloy heat sinks. The welding equipment generates a large amount of heat during operation, requiring effective heat dissipation for protection. Heat generation is a major enemy of electronic equipment; excessive heat not only affects work efficiency but can also severely shorten the equipment's lifespan. Summary of the Invention

[0003] To address the aforementioned technical shortcomings, the purpose of this invention is to provide a multiphysics field design and rapid simulation analysis method for inverter welding machines. This method solves the problems of poor heat dissipation and overheating alarms that frequently occur during the use of existing welding machines, and effectively controls the thermal temperature field of electrical components such as IGBT modules within a reasonable operating temperature range. It avoids the problem of overheating alarms caused by poor welding machine heat dissipation affecting the continuity of the entire processing and production process, equipment efficiency, and production capacity.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: The present invention provides a multiphysics field design and rapid simulation analysis method for an inverter welding machine, comprising the following steps:

[0005] S1: A welding machine assembly model is created using 3D software to form the welding machine; the welding machine assembly model includes at least an air-cooled aluminum alloy heat sink and an axial fan.

[0006] S2: Two types of air-cooled aluminum alloy heat sinks in S1 are modeled: air-cooled aluminum alloy heat sinks made by aluminum alloy profile extrusion process and air-cooled aluminum alloy heat sinks made by molybdenum wire cutting process. The air-cooled aluminum alloy heat sinks made by aluminum alloy profile extrusion process are set as T-shaped.

[0007] S3: Create an Ansys discovery live file and import the welding machine assembly model diagram;

[0008] S4: Establish the transient thermophysical field of the air-cooled aluminum alloy heat sink and set the parameters of the welding machine and its components;

[0009] S5: Establish the internal airflow field of the welding machine, forming a physical field of airflow-thermal-solid coupling from the air inlet to the air outlet of the welding machine; Select the axial fan to establish the physical field of airflow-thermal-solid coupling of the axial fan.

[0010] S6: Establish an external airflow field outside the welding machine to form a physical field of airflow-thermal-solid coupling from the air inlet to the air outlet of the welding machine.

[0011] S7: Calculate the parameters in the transient thermophysical field of the air-cooled aluminum alloy heat sink inside the welding machine;

[0012] Calculate the parameters in the physical field of thermal-fluid-structure interaction of the airflow in the axial fan inside the welding machine;

[0013] Calculate the parameters in the air-fluid-thermal-solid coupling physical field inside the welding machine from the air inlet to the air outlet;

[0014] Calculate the parameters in the air-fluid-thermal-solid coupling physical field outside the welding machine from the air inlet to the air outlet;

[0015] S8: Compare the heat dissipation performance of the two types of air-cooled aluminum alloy heat sinks based on the parameters.

[0016] Preferably, the welding machine assembly model further includes an internal electrical system, an internal sheet metal structure, and a sheet metal outer shell, and the ratio of the welding machine assembly model to the physical model is 1:1.

[0017] The welding machine's internal electrical system includes a transformer, rectifier module, CPU, and three-phase rectifier bridge.

[0018] Preferably, in step S4, setting the parameters of the welding machine includes:

[0019] Set the welding machine ambient temperature to 0℃~40℃;

[0020] Z-axis airflow velocity: 0–10 m / s;

[0021] Welding machine outlet pressure: 0~0.5Mpa.

[0022] Preferably, in step S4, the parameter settings for the components are as follows:

[0023] The thermal conductivity of aluminum alloy 6063-T5 is set at 209 W / (m·K);

[0024] A 500W transformer and a 180W rectifier module are installed on one side of the air-cooled aluminum alloy heat sink; on the other side, the CPU is 200W and the three-phase rectifier bridge is 160W.

[0025] Preferably, in step S7:

[0026] Calculate the parameters of the transient thermophysical field of the air-cooled aluminum alloy heat sink inside the welding machine, including the highest temperature, lowest temperature, average temperature, and total volume;

[0027] Calculate the parameters in the physical field of air fluid thermal-fluid-structure interaction of the axial fan inside the welding machine, including air fluid velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state. Observe the air flow field trajectory, particle state, vector display, and direction of motion in the physical field of air fluid thermal-fluid-structure interaction of the axial fan inside the welding machine.

[0028] Calculate the parameters in the air fluid thermal-fluid-structure interaction physical field inside the welding machine from the air inlet to the air outlet, including air fluid velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state. Observe the internal flow field trajectory, particle state, vector display, and motion direction in the air fluid thermal-fluid-structure interaction physical field inside the welding machine from the air inlet to the air outlet.

[0029] Calculate the parameters in the air-fluid thermal-fluid-structure interaction physical field outside the welding machine from the air inlet to the air outlet, including air fluid velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state. Observe the internal flow field trajectory, particle state, vector display, and motion direction in the air-fluid thermal-fluid-structure interaction physical field outside the welding machine from the air inlet to the air outlet.

[0030] Preferably, in step S8:

[0031] After the calculation in step S7, the simulation results are used to view the airflow trajectory, particle state, vector display, and motion direction of the axial fan. When the axial fan is based on a specific position inside the welding machine, the airflow trajectory, particle state, vector display, and motion direction of the axial fan corresponding to the two types of air-cooled aluminum alloy heat sinks are compared to obtain the comparison results.

[0032] The beneficial effects of this invention are as follows:

[0033] This invention employs 3D software to establish an equivalent model for thermo-fluid-structure interaction (TFI) analysis, thereby assisting in design improvement and optimization. The model file is imported into Ansys Discovery Live software to establish the thermal field of the aluminum alloy heat sink, the internal flow field of the fan, the internal flow field of the welding machine, and the external air flow field around the welding machine, forming a TFI cooling system model. The temperature field and air flow field of the welding machine are then systematically designed and simulated using TFI multiphysics field analysis, and calculations are performed. This invention utilizes TFI cooling analysis, employing 3D software to establish a temperature field simulation model of the welding machine's air-cooled cooling system. Then, by setting the corresponding parameters for the thermal field of the aluminum alloy heat sink, the internal flow field of the fan, the internal flow field of the welding machine, and the external air flow field around the welding machine in Ansys Discovery Live software, the required parameters for each physical field are obtained. This significantly reduces the product development cycle; simultaneously, it eliminates tedious experimental processes, improves the success rate and efficiency of product design, and is of great significance for optimizing the design of air-cooled heat sinks and ensuring the reliable operation of high-power inverter gas-shielded welding machines. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 This is a model of a welding machine for air-cooled aluminum alloy heat sinks (using molybdenum wire cutting technology).

[0036] Figure 2 This is a model of a welding machine for air-cooled aluminum alloy heat sinks (aluminum alloy profile extrusion process).

[0037] Figure 3 This is a schematic diagram of the rectifier module and transformer.

[0038] Figure 4 This is a schematic diagram of a three-phase rectifier bridge and a CPU.

[0039] Figure 5 This is a schematic diagram of the structure of an air-cooled aluminum alloy heat sink (using molybdenum wire cutting technology).

[0040] Figure 6 This is a schematic diagram of the structure of an air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process).

[0041] Figure 7 Calculation results for air-cooled aluminum alloy heat sinks (molybdenum wire cutting process) - Part 1.

[0042] Figure 8 Calculation result 2 for air-cooled aluminum alloy heat sink (molybdenum wire cutting process).

[0043] Figure 9 Calculation results for air-cooled aluminum alloy heat sinks (aluminum alloy profile extrusion process) - Part 1.

[0044] Figure 10 Calculation result 2 for air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process).

[0045] Figure 11 This study presents a simulation analysis of the physical field of the internal airflow of the axial fan in a welding machine for air-cooled aluminum alloy heat sinks (using molybdenum wire cutting technology).

[0046] Figure 12 This study simulates and analyzes the physical field of the internal airflow of the axial fan in a welding machine system for air-cooled aluminum alloy heat sinks (aluminum alloy profile extrusion process).

[0047] Figure 13 This is a simulation analysis of the internal airflow field in a welding machine for air-cooled aluminum alloy heat sinks (molybdenum wire cutting process).

[0048] Figure 14 This is a simulation analysis of the internal airflow field in a welding machine for air-cooled aluminum alloy heat sinks (aluminum alloy profile extrusion process).

[0049] Figure 15 This is a simulation analysis of the external airflow field in a welding machine for air-cooled aluminum alloy heat sinks (molybdenum wire cutting process).

[0050] Figure 16 This is a simulation analysis of the external airflow field in a welding machine for air-cooled aluminum alloy heat sinks (aluminum alloy profile extrusion process).

[0051] Figure 17 This is a measured image of a welding machine used for welding aluminum alloy heat sinks (using molybdenum wire cutting technology).

[0052] Explanation of reference numerals in the attached diagram: 1-Welding machine sheet metal casing; 2-Welding machine internal electrical system; 3-Welding machine internal sheet metal; 4-Axial flow fan; 5-Air-cooled aluminum alloy heat sink; 6-Rectifier module; 7-Transformer; 8-Three-phase rectifier bridge; 9-CPU Detailed Implementation

[0053] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. For those skilled in the art, the T-shaped design of the air-cooled aluminum alloy heat sink made by the aluminum alloy profile extrusion process is the conclusion reached by the technicians after comprehensive selection of multiple different detailed designs, such as why it is T-shaped and not other shapes. That is, the technical designers have compared different schemes in the design details of the aluminum alloy heat sink extrusion process.

[0054] Example:

[0055] This invention provides a multiphysics design and rapid simulation analysis method for inverter welding machines, which reduces the cost of components related to the heat dissipation system, shrinks the size of heat sinks, improves heat dissipation efficiency, and allows for flexible spatial layout of the entire machine. It also significantly shortens the product development cycle, eliminates tedious testing processes, increases the success rate and efficiency of product design, and is of great significance for optimizing the design of air-cooled heat sinks and ensuring the reliable operation of high-power inverter gas shielded welding machines.

[0056] This study addresses the common problem of poor heat dissipation and overheating alarms in existing welding machines. Poor heat dissipation leading to overheating alarms inevitably affects the continuity of the welding process and the efficiency of equipment, impacting production capacity. Therefore, effectively increasing the heat dissipation capacity of the aluminum alloy heat sink and optimizing the internal heat dissipation of the welding machine is crucial. A common method is to optimize the ventilation openings of the switchgear. This optimization mainly involves repeatedly testing and modifying the size of the ventilation openings to meet design requirements. However, this experimental method results in long product development cycles and high R&D costs, severely hindering the development speed of the welding machine.

[0057] This invention establishes a welding machine assembly part model using Solidworks software, imports the model into Ansys Discovery Live, establishes the transient thermal flow field of the internal air-cooled aluminum alloy heat sink, the internal air flow field of the internal axial fan, the internal air flow field of the welding machine from the external air inlet to the external air outlet, and the external air flow field between the welding machine and the outside air. After setting the relevant simulation parameters, the calculation begins until the simulation results are completed. Based on the simulation data, the heat dissipation capacity of the welding machine heat sink is further improved, and the spatial layout of the internal parts system of the welding machine is optimized to obtain a design and rapid simulation scheme with better heat dissipation performance of the welding machine.

[0058] The design includes internal components for a high-power inverter gas shielded welding machine, such as air-cooled aluminum alloy heat sinks, internal sheet metal, sheet metal housing, axial fan, and internal electrical system. The internal electrical system includes a transformer, rectifier module (IGBT rectifier module), CPU, and three-phase rectifier bridge.

[0059] Specifically, it includes the following:

[0060] S1: Using Solidworks software, create model drawings of the air-cooled aluminum alloy heat sink, transformer, rectifier module, CPU, three-phase rectifier bridge, internal sheet metal of the welding machine, sheet metal shell of the welding machine, and axial fan to form a 1:1 model drawing of the welding machine assembly and complete the welding machine scheme design drawing.

[0061] S2: Two types of air-cooled aluminum alloy heat sinks in S1 are modeled: air-cooled aluminum alloy heat sinks made by aluminum alloy profile extrusion process and air-cooled aluminum alloy heat sinks made by molybdenum wire cutting process. The air-cooled aluminum alloy heat sinks made by aluminum alloy profile extrusion process are set as T-shaped.

[0062] S3: Create an Ansys discovery live file and import the welding machine assembly model diagram;

[0063] S4: Retain the air-cooled aluminum alloy heat sink of the welding machine, hide other parts of the welding machine, establish the transient thermophysical field of the air-cooled aluminum alloy heat sink of the welding machine, set the welding machine ambient temperature to 25℃, set the thermal conductivity of aluminum alloy 6063-T5 to 209W / (m·K), set the transformer of 1 PCS of the welding machine to 500W and the 8 IGBT rectifier modules to 180W on one side of the air-cooled aluminum alloy heat sink, and the CPU1 to 160W and the three-phase rectifier bridge to 200W on the other side. After completion, click to hide the air-cooled aluminum alloy heat sink model.

[0064] S5: Reveal the previously hidden axial fan model, establish the internal airflow field of the welding machine, and form a fluid-thermal-solid coupling physical field of the airflow from the welding machine air inlet to the welding machine air outlet; display the air-cooled aluminum alloy heat sink, welding machine transformer, welding machine rectifier module, CPU, three-phase rectifier bridge, welding machine internal sheet metal, welding machine sheet metal shell, and axial fan model diagrams; set the welding machine air inlet and corresponding welding machine air outlet (i.e., the air inlet on the welding machine sheet metal shell and the welding machine sheet metal...). (Air outlet on the casing), set the welding machine ambient temperature to 25℃, the Z-axis airflow speed to 1m / s (Z-axis refers to the direction from the axial fan inlet to the axial fan outlet, the same below), and the welding machine outlet pressure to 0.15Mpa; select the axial fan to establish the air-fluid-thermal-solid coupling physical field of the axial fan, click the axial fan inlet and outlet, set the welding machine ambient temperature to 25℃, the Z-axis airflow speed to 1m / s, and the welding machine outlet pressure to 0.15Mpa;

[0065] S6: Establish the external airflow field of the welding machine, forming a physical field of airflow-thermal-solid coupling from the air inlet to the air outlet of the welding machine. Display the air-cooled aluminum alloy heat sink, welding machine transformer, welding machine rectifier module, CPU, three-phase rectifier bridge, internal sheet metal of the welding machine, sheet metal shell of the welding machine, and axial fan model diagram. Set the welding machine ambient temperature to 25℃, Z-axis airflow speed to 1m / s, and welding machine outlet pressure to 0.15Mpa.

[0066] S7: Calculate the highest, lowest, average temperature, and total volume of the thermal-fluid-structure interaction in the transient thermophysical field of the air-cooled aluminum alloy heat sink inside the welding machine;

[0067] Calculate the air velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state in the thermal-fluid-structure interaction physical field of the axial fan inside the welding machine. Observe the airflow trajectory, particle state, vector display, and direction of motion within the thermal-fluid-structure interaction physical field of the axial fan inside the welding machine.

[0068] Calculate the airflow velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state in the airflow thermo-fluid-structure interaction physical field inside the welding machine, from the air inlet to the air outlet. Observe the internal flow field trajectory, particle state, vector display, and direction of motion in the airflow thermo-fluid-structure interaction physical field inside the welding machine, from the air inlet to the air outlet.

[0069] Calculate the air velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state in the thermal-fluid-structure interaction (TFI) physical field of the air outside the welding machine, from the air inlet to the air outlet. Observe the internal flow field trajectory, particle state, vector display, and direction of motion of the air outside the welding machine, from the air inlet to the air outlet.

[0070] S8: Based on the parameters, compare the heat dissipation indicators of the two types of air-cooled aluminum alloy heat sinks. Specifically, examine the airflow trajectory, particle state, vector display, and movement direction of the axial fan through simulation results. When the axial fan is positioned at a specific location inside the welding machine (i.e., the distance between the axial fan outlet and the aluminum alloy heat sink is 100mm), compare the heat dissipation conditions of the two types of air-cooled aluminum alloy heat sinks and the overall heat dissipation conditions inside the welding machine. Specifically, compare the airflow trajectory, particle state, vector display, and movement direction of the axial fan corresponding to the two types of air-cooled aluminum alloy heat sinks to obtain the comparison results. It is concluded that the heat dissipation indicators of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) are superior to those of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process).

[0071] This application can quickly calculate the average temperature, maximum temperature, minimum temperature, and total volume of aluminum alloy heat sinks (aluminum alloy profile extrusion process) parts in welding machines based on the thermal-fluid-structure interaction within the welding machine; it can quickly calculate the volume velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state of the airflow in the axial fan inside the welding machine; it can quickly calculate the velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state of the airflow forming thermal-fluid-structure interaction within the welding machine from the air inlet to the air outlet; and it allows observation of local parameter information of any part within the welding machine components during simulation analysis; it can quickly calculate the velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state of the airflow forming local thermal-fluid-structure interaction within the welding machine from the external air inlet and outlet. This facilitates efficient analytical analysis of different parts under the same physical field conditions, providing valuable data for design improvement. It guides the design direction and provides simulation data references to meet enterprises' needs for cost control of different parts and judgment of overall machine performance.

[0072] The air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) has a "T" shaped heat dissipation structure. It is designed to be formed by extrusion die, which facilitates mass production, reduces costs, improves efficiency, and significantly enhances heat dissipation effect.

[0073] Forced air cooling using axial fans increases airflow speed to ensure effective heat dissipation for electronic devices. During operation, high-power components within electronic equipment generate significant heat, making efficient heat dissipation crucial for reliability. Forced air cooling is reliable, easy to maintain, and relatively inexpensive; therefore, it has become the primary method for cooling high-power components in electronic equipment cooling systems. However, the theoretical calculations for forced air cooling design are relatively complex. Furthermore, the temperature of the high-power device's casing, the heat sink, and the fan all interact, preventing designers from relying on a single factor to determine the heat sink structure or fan selection. The key to successful forced air cooling design for inverter welding machines lies in performing heat dissipation calculations within these interrelationships and ultimately controlling the internal temperature of the welding machine within the required range.

[0074] Axial fan forced air cooling technology, as a relatively traditional heat dissipation technology, is mainly used in the heat dissipation of the welding machine IGBT rectifier module of high-power inverter gas shielded welding equipment. Compared with water cooling technology, the application and processing of air cooling technology are simpler. As is well known, the main method involves installing an axial fan near the IGBT rectifier module of the welding machine, inside the air inlet, to dissipate heat from the IGBT rectifier module and reduce its operating temperature. The working principle is simple: utilizing the excellent heat dissipation function of 6063-T5 aluminum alloy parts, and through simulation optimization of the structural design, good heat dissipation performance is achieved. The axial fan generates convection airflow during operation, which circulates within the welding machine, resulting in good convection cooling. This conducts and dissipates the heat generated by the IGBT rectifier module, thereby controlling and reducing the welding machine's operating temperature. This application primarily applies heat conduction and convection, combining the optimized "T"-shaped aluminum alloy heat sink with the axial fan's airflow to achieve a synergistic effect of heat dissipation, thus cooling the IGBT rectifier module and other electrical components. Among them, the heat conduction cooling method is relatively complex. In the process of cooling the welding machine IGBT rectifier module using heat conduction, the heat generated by the optimized aluminum alloy heat sink, the welding machine IGBT rectifier module, and other electrical components is first conducted from the surface of the welding machine IGBT rectifier module to the inside of the heat sink. The heat is then conducted to the top of the fins on the surface of the heat sink, and then exhausted to the outside of the welding machine by an axial fan. This achieves heat dissipation for the welding machine IGBT rectifier module and other electrical components, ensuring their operating performance.

[0075] This application utilizes Ansys Discovery Live simulation software to guide and drive the design. Based on a traditional welding machine model, Solidworks was used to create assembly models of two welding machine systems: one with an air-cooled aluminum alloy heat sink (molybdenum wire cutting process) and the other with an air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process). Ansys Discovery Live software was then used to perform rapid simulation analysis on the two welding machine heat dissipation systems. A systematic comparison and optimization of the simulation data parameters of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) and the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) was conducted, achieving results that would otherwise require repeated testing in a very short simulation analysis time. Specifically, under the same physical conditions, the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) outperforms the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) in all heat dissipation indicators.

[0076] Ansys Discovery Live, in conjunction with Solidworks, yielded a well-designed "T"-shaped part structure diagram for the heat dissipation performance of an air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) component. Ansys Discovery Live software allows for real-time adjustment of the detailed dimensions of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) component in the welding machine assembly model, providing instant simulation parameters. By running Solidworks to design the "T"-shaped part structure for the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) component and then reverse-engineering the best simulation analysis results from the Ansys Discovery Live software on the welding machine assembly model, the optimal "T"-shaped part structure design diagram for the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) component can be obtained.

[0077] Furthermore, referring to the attached diagram:

[0078] 1) such as Figures 1 to 6 The figures shown are model diagrams of welding machines including two types of air-cooled aluminum alloy heat sinks. Specifically, they include a welding machine sheet metal shell 1, a welding machine internal electrical system 2, a welding machine internal sheet metal 3, an axial fan 4, and an air-cooled aluminum alloy heat sink 5. The welding machine internal electrical system 2 includes a transformer 7, a rectifier module 6 (specifically an IGBT rectifier module), a CPU 9, a three-phase rectifier bridge 8, etc.

[0079] in, Figure 5 It is an air-cooled aluminum alloy heat sink (molybdenum wire cutting process). Figure 6 This is an air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process). The T-shape specifically refers to the shape formed by localized protrusions, such as... Figure 6 As shown in the shaded area.

[0080] 2) such as Figure 7 and Figure 8 As shown, the solution state for the internal thermal-fluid-structure interaction physics field of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) welding machine is as follows: The ambient temperature of the welding machine is set to 25℃; the thermal conductivity of the 6063-T5 aluminum alloy heat sink (molybdenum wire cutting process) material is 209 W / (m²·℃); the transformer power is set to 500W; the power of the eight rectifier modules is 180W; the CPU power is 200W; the three-phase rectifier bridge power is 160W; and the total volume of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) is 4.318e6mm². 3 Average temperature 33.073℃, highest temperature 65.798℃, lowest temperature 25.246℃.

[0081] 3) such as Figure 9 and Figure 10 As shown, the solution state for the internal thermal-fluid-structure interaction physical field of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine is as follows: The ambient temperature of the welding machine is set to 25℃; the thermal conductivity of the 6063-T5 material of the aluminum alloy heat sink (aluminum alloy profile extrusion process) is 209 W / (㎡·℃); the transformer power is set to 500W; the power of the 8 rectifier modules is 180W; the CPU power is 200W; the three-phase rectifier bridge power is 160W; and the total volume of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) is 5.192e6mm. 3 Average temperature 32.334℃, highest temperature 64.991℃, lowest temperature 25.158℃.

[0082] 4) such as Figure 11 As shown, the simulation analysis of the physical field of the air fluid inside the axial fan in the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) welding machine is as follows: the ambient temperature is set to 25℃, the air flow velocity in the workshop is 1m / s, and the pressure at the outlet of the welding machine is 0.15Mpa. The simulation results can be used to view the trajectory of the air flow field inside the axial fan, the particle state, the vector display, and the direction of motion.

[0083] 5) such as Figure 12 As shown, the simulation analysis of the internal airflow physical field of the axial fan in the welding machine system of an air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) is as follows: the ambient temperature is set to 25℃, the airflow velocity in the workshop is 1m / s, and the pressure at the welding machine outlet is 0.15Mpa. The simulation results can be used to view the airflow trajectory, particle state, vector display, and motion direction of the axial fan. When the spatial position of the axial fan is the same, the airflow trajectory, particle state, vector display, and motion direction of the axial fan corresponding to the two air-cooled aluminum alloy heat sinks (molybdenum wire cutting process & aluminum alloy profile extrusion process) are compared. The preliminary conclusion is that the aluminum alloy heat sink of the aluminum alloy profile extrusion process is superior to the airflow parameters of the air-cooled aluminum alloy heat sink of the molybdenum wire cutting process.

[0084] 6) such as Figure 13 As shown, the simulation analysis of the internal airflow field in the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) welding machine is as follows: the ambient temperature is set to 25℃, the airflow velocity at the welding machine inlet is 0.5m / s, and the pressure at the welding machine outlet is 0.15Mpa. The simulation results can be used to view the airflow trajectory, particle state, vector display, motion direction, velocity, pressure, total pressure, dynamic pressure, temperature, and vortex degree of the internal airflow field of the axial flow welding machine. The maximum velocity of the internal airflow field of the welding machine at time 129.086S is 1.24e-7m / s.

[0085] 7) such as Figure 14 As shown, the simulation analysis of the internal airflow field in the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine is as follows: the ambient temperature is set to 25℃, the airflow velocity at the inlet duct of the welding machine is 0.5m / s, and the pressure at the outlet of the welding machine is 0.15Mpa. The simulation results can be used to view the trajectory of the airflow field inside the axial fan, particle state, vector display, motion direction, velocity, pressure, total pressure, dynamic pressure, temperature, and vortex degree. The maximum velocity of the airflow field inside the welding machine at time 129.467S is 0.5m / s. Therefore, the heat dissipation of the internal airflow field of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine is better than that of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process).

[0086] 8) For example Figure 15 As shown, the simulation analysis of the external airflow field in the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) welding machine is as follows: the ambient temperature of the external flow field of the welding machine is set to 20℃, the airflow velocity of the air inlet duct of the welding machine is 0.5m / s, and the air outlet pressure of the welding machine is 0.15Mpa. The air trajectory, particle state, vector display, and motion direction of the external flow field of the axial flow welding machine can be viewed through the simulation results. The maximum velocity of the external airflow field of the welding machine at time 5.018S is 0.606m / s.

[0087] 9) such as Figure 16 As shown, the simulation analysis of the external airflow field in the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine is as follows: the ambient temperature of the external flow field of the welding machine is set to 20℃, the airflow velocity of the air inlet duct of the welding machine is 0.5m / s, and the air outlet pressure of the welding machine is 0.15Mpa. The air trajectory, particle state, vector display, and motion direction of the external flow field of the axial flow welding machine can be viewed through the simulation results. The maximum velocity of the external airflow field of the welding machine at time 5.018S is 0.608m / s. Therefore, the heat dissipation of the external airflow field of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine is better than that of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process).

[0088] 10) such as Figure 7 and Figure 8As shown, the solution state for the internal thermal-fluid-structure interaction physics field of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) welding machine is as follows: the ambient temperature of the welding machine is set to 25℃, the thermal conductivity of the 6063-T5 aluminum alloy heat sink (molybdenum wire cutting process) material is 209w / (㎡·℃), the transformer power is set to 500W, the power of the 8 rectifier modules is 180W, the CPU power is 200W, the three-phase rectifier bridge power is 160W, and the total volume of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) is 4.318e6mm. 3 Average temperature 33.073℃, highest temperature 65.798℃, lowest temperature 25.246℃, such as Figure 17 As shown, the measured ambient temperature of the welding machine was 25℃. The thermal conductivity of the 6063-T5 aluminum alloy heat sink (molybdenum wire cutting process) was 209 W / (㎡·℃). The transformer power was set to 500W, the power of the eight rectifier modules was 180W, the CPU power was 200W, the three-phase rectifier bridge power was 160W, and the total volume of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) was 4.318e6mm. 3 The measured average temperature of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process) was 34℃.

[0089] Compare the average temperature of the simulated air-cooled aluminum alloy heat sink (molybdenum wire cutting process) of 33.073℃ with the measured average temperature of 34℃;

[0090] The accuracy rate is approximately 97.27352941176471%.

[0091] The air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine's internal and external heat dissipation flow systems, as well as the heat dissipation performance parameters of the internal air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process), are superior to those of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process). Furthermore, the design and production costs of the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) are significantly lower than those of the air-cooled aluminum alloy heat sink (molybdenum wire cutting process), thus controlling welding machine costs and improving the overall heat dissipation capacity of the welding machine's cooling system. Simultaneously, it provides electrical components with a superior heat dissipation environment under the same physical conditions, giving the air-cooled aluminum alloy heat sink (aluminum alloy profile extrusion process) welding machine a strong overall market and technological competitiveness.

[0092] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A multiphysics design and rapid simulation analysis method for an inverter welding machine, characterized in that, Includes the following steps: S1: A welding machine assembly model is created using 3D software to form the welding machine; the welding machine assembly model includes at least an air-cooled aluminum alloy heat sink and an axial fan. S2: Two types of air-cooled aluminum alloy heat sinks in S1 are modeled: air-cooled aluminum alloy heat sinks made by aluminum alloy profile extrusion process and air-cooled aluminum alloy heat sinks made by molybdenum wire cutting process. The air-cooled aluminum alloy heat sinks made by aluminum alloy profile extrusion process are set as T-shaped. S3: Create an Ansys discoverylive file and import the welding machine assembly model drawing; S4: Establish the transient thermophysical field of the air-cooled aluminum alloy heat sink and set the parameters of the welding machine and its components; S5: Establish the internal airflow field of the welding machine, forming a physical field of airflow-thermal-solid coupling from the air inlet to the air outlet of the welding machine; Select the axial fan to establish the physical field of airflow-thermal-solid coupling of the axial fan. S6: Establish an external airflow field outside the welding machine to form a physical field of airflow-thermal-solid coupling from the air inlet to the air outlet of the welding machine. S7: Calculate the parameters in the transient thermophysical field of the air-cooled aluminum alloy heat sink inside the welding machine; Calculate the parameters in the physical field of thermal-fluid-structure interaction of the airflow in the axial fan inside the welding machine; Calculate the parameters in the air-fluid-thermal-solid coupling physical field inside the welding machine from the air inlet to the air outlet; Calculate the parameters in the air-fluid-thermal-solid coupling physical field outside the welding machine, from the air inlet to the air outlet. S8: Compare the heat dissipation performance of the two types of air-cooled aluminum alloy heat sinks based on the parameters.

2. The multiphysics design and rapid simulation analysis method for an inverter welding machine as described in claim 1, characterized in that, The welding machine assembly model also includes the welding machine's internal electrical system, internal sheet metal, and sheet metal outer shell, and the ratio of the welding machine assembly model to the physical model is 1:

1. The welding machine's internal electrical system includes a transformer, rectifier module, CPU, and three-phase rectifier bridge.

3. The multiphysics design and rapid simulation analysis method for an inverter welding machine as described in claim 1, characterized in that, Step S4 involves setting the parameters for the welding machine, including: Set the welding machine ambient temperature to 0℃~40℃; Z-axis airflow velocity: 0–10 m / s; Welding machine outlet pressure: 0~0.5Mpa.

4. The multiphysics design and rapid simulation analysis method for an inverter welding machine as described in claim 1, characterized in that, In step S4, the parameters for the components are set as follows: The thermal conductivity of aluminum alloy 6063-T5 is set at 209 W / (m·K); A 500W transformer and a 180W rectifier module are installed on one side of the air-cooled aluminum alloy heat sink; on the other side, the CPU is 200W and the three-phase rectifier bridge is 160W.

5. The multiphysics design and rapid simulation analysis method for an inverter welding machine as described in claim 1, characterized in that, In step S7: Calculate the parameters of the transient thermophysical field of the air-cooled aluminum alloy heat sink inside the welding machine, including the highest temperature, lowest temperature, average temperature, and total volume; Calculate the parameters in the physical field of air fluid thermal-fluid-structure interaction of the axial fan inside the welding machine, including air fluid velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state. Observe the air flow field trajectory, particle state, vector display, and direction of motion in the physical field of air fluid thermal-fluid-structure interaction of the axial fan inside the welding machine. Calculate the parameters in the air fluid thermal-fluid-structure interaction physical field inside the welding machine from the air inlet to the air outlet, including air fluid velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state. Observe the internal flow field trajectory, particle state, vector display, and motion direction in the air fluid thermal-fluid-structure interaction physical field inside the welding machine from the air inlet to the air outlet. Calculate the parameters in the air-fluid thermal-fluid-structure interaction physical field outside the welding machine from the air inlet to the air outlet, including air fluid velocity, pressure, total pressure, dynamic pressure, temperature, and vortex state. Observe the internal flow field trajectory, particle state, vector display, and motion direction in the air-fluid thermal-fluid-structure interaction physical field outside the welding machine from the air inlet to the air outlet.

6. The multiphysics design and rapid simulation analysis method for an inverter welding machine as described in claim 1, characterized in that, In step S8: After the calculation in step S7, the simulation results are used to view the airflow trajectory, particle state, vector display, and motion direction of the axial fan. When the axial fan is based on a specific position inside the welding machine, the airflow trajectory, particle state, vector display, and motion direction of the axial fan corresponding to the two types of air-cooled aluminum alloy heat sinks are compared to obtain the comparison results.

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