Intelligent Magnetically Controlled Arc System Based on Programmable Dot Matrix Magnetic Field

Abstract

The present invention relates to an intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field. Aiming at the problem that the arc shape and movement trajectory cannot be accurately controlled during the arc welding process, the present invention discloses an intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field. The system controls the excitation current waveform by using an excitation current waveform control method based on the fusion feedback of arc signals and real-time excitation current signals, generates a programmable magnetic field by using a programmable dot matrix magnetic field generator, and accurately controls the arc shape and movement trajectory by using an arc shape and movement trajectory control method.

Description

Technical Field

[0001] The present invention relates to the field of magnetic field assisted arc welding, and is an intelligent magnetic control arc system based on a programmable dot matrix magnetic field. Background Art

[0002] Welding is an extremely important material forming and processing technology in the manufacturing field. Among them, arc welding, as one of the most traditional welding methods, is widely used in important industrial fields such as aerospace, marine engineering equipment, and nuclear power construction due to its good flexibility, low cost, and good stability. Especially in recent years, the rapid development of arc additive manufacturing technology has put forward higher requirements for the precision, quality, and efficiency of arc welding. Using magnetic field assisted arc welding technology is an effective way to improve the quality of arc welding, welding precision, and efficiency.

[0003] Domestic and foreign scholars have conducted extensive research on axial magnetic fields, transverse magnetic fields, alternating magnetic fields, and sharp corner magnetic fields. Through experiments and numerical simulations, it has been proven that these types of magnetic fields improve the welding process by improving the shape and movement trajectory of the arc, and improve the welding quality and efficiency. However, these types of magnetic fields only target a single working condition and cannot accurately and intelligently control the shape and movement trajectory of the arc according to changes in the welding process, making it difficult to meet the requirements of high quality, high precision, and intelligence for precision welding and arc additive manufacturing. To address these problems, the present invention discloses an intelligent magnetic control arc system based on a programmable dot matrix magnetic field. Summary of the Invention

[0004] An intelligent magnetic control arc system based on a programmable dot matrix magnetic field, as Figure 1 shown, is used for precise control of the arc shape and movement trajectory. The intelligent magnetic control arc system based on a programmable dot matrix magnetic field controls the excitation electromagnetic current waveform using an excitation current waveform control method based on the fusion feedback of arc signals and real-time excitation current signals, generates a programmable magnetic field using a programmable dot matrix magnetic field generator, and precisely controls the arc shape and movement trajectory using an arc shape and movement trajectory control method.

[0005] The intelligent magnetic control arc system based on a programmable dot matrix magnetic field consists of a main control system, a programmable dot matrix magnetic field generator, a programmable dot matrix magnetic field excitation power supply, an arc signal monitoring system, an array Hall current sensor, and a communication bus; the main control system communicates with the array Hall current sensor in real time through the communication bus; the array Hall current sensor is composed of 25 bidirectional Hall current sensor units, which correspond one by one to the 25 magnetic poles of the programmable dot matrix magnetic field generator, and is used to monitor the magnitude and direction of the excitation current of each magnetic pole in real time; the bidirectional Hall current sensor unit, as Figure 4As shown in the figure, it is composed of a forward current monitoring Hall unit and a reverse current monitoring Hall unit, and is used to monitor the magnitude and direction of the excitation current of a single magnetic pole in real time; the programmable dot matrix magnetic field excitation power supply is connected to the main control system through a communication bus, and can generate 25 programmable excitation currents under the control of the main control system to provide electrical energy for 25 magnetic poles; the arc signal monitoring system uses a Hall voltage sensor to obtain the arc voltage signal, uses a Hall current sensor to obtain the arc current signal, filters the arc signal, extracts the arc signal characteristics, and then realizes the real-time monitoring of the arc signal, and feeds back the arc signal information to the main control system in real time through the communication bus.

[0006] The excitation current waveform control method based on the fusion feedback of the arc signal and the real-time excitation current signal is as Figure 2 shown in the figure. The feedback control is used to eliminate the excitation current output error caused by the circuit system by comparing the real-time excitation current waveform with the input excitation current waveform; the input excitation current waveform is corrected by the feedback control of the arc shape and motion trajectory characteristics; the real-time excitation current signal is obtained by the array Hall current sensor during the magnetically controlled arc shape and motion trajectory process.

[0007] The programmable dot matrix magnetic field generator is as Figure 3 shown in the figure. It is composed of 4 magnetic pole arrays: longitudinal magnetic poles, inner ring magnetic poles, middle ring magnetic poles, and outer ring magnetic poles. By programming and controlling the excitation current in the magnetic pole array, a magnetic circuit is formed between different magnetic poles, so as to generate a programmable control magnetic field in the area where the arc is located, and then accurately control the arc shape and motion trajectory; the center line of the longitudinal magnetic pole solenoid coincides with the center line of the welding torch; the inner ring magnetic pole is composed of eight magnetic poles, arranged in a circle with the center line of the welding torch as the center, and the difference between the circular radius and the radius of the longitudinal magnetic pole solenoid is the inner ring spacing; the middle ring magnetic pole is composed of eight magnetic poles, arranged in a circle with the center line of the welding torch as the center, and the difference between the radius of its arranged circle and the radius of the inner ring magnetic pole is the middle ring spacing; the outer ring magnetic pole is composed of eight magnetic poles, arranged in a circle with the center line of the welding torch as the center, and the difference between the radius of its circular arrangement and the radius of the middle ring magnetic pole circular is the outer ring spacing.

[0008] The arc shape and motion trajectory control method is as Figure 5As shown, it is a control method based on the feedback of arc shape, motion trajectory, and arc signal characteristics. By comparing the preset arc shape, motion trajectory characteristics with the feedback quantity, the excitation current is controlled, thereby achieving precise control of the arc shape and motion trajectory. By comparing the arc shape and motion trajectory characteristics obtained in real time with the preset arc shape and motion trajectory and correcting the excitation current waveform, precise control of the arc shape and motion trajectory is achieved. The arc signal is obtained in real time by the arc signal monitoring system during the real-time control of the arc shape and motion trajectory. The arc shape and motion trajectory characteristics obtained in real time are calculated through the arc shape, motion trajectory, and arc signal feature mapping model. The arc shape, motion trajectory, and arc signal feature mapping model are obtained by training with a large amount of arc signal feature data and arc shape, motion trajectory feature data using deep learning algorithms. The arc signal characteristics are used to obtain the feature information related to the arc shape and motion trajectory in the arc signal through the signal feature extraction algorithm.

[0009] Advantages of the invention:

[0010] The present invention relates to the process of magnetic field-assisted arc welding and is an intelligent magnetic control arc system based on a programmable dot matrix magnetic field. Aiming at the problem that the arc shape and motion trajectory cannot be precisely controlled during the welding process, the present invention discloses an intelligent magnetic control arc system based on a programmable dot matrix magnetic field. The system controls the excitation current waveform using an excitation current waveform control method based on the fusion feedback of arc signals and real-time excitation current signals, generates a programmable magnetic field using a programmable dot matrix magnetic field generator, and achieves precise control of the arc shape and motion trajectory using an arc shape and motion trajectory control method. Brief description of the drawings

[0011] Figure 1 It is a schematic diagram of an intelligent magnetic control arc system based on a programmable dot matrix magnetic field.

[0012] Figure 2 It is a flowchart of an excitation current waveform control method based on the fusion feedback of arc signals and real-time excitation current signals.

[0013] Figure 3 It is a schematic diagram of a programmable dot matrix magnetic field generator.

[0014] Figure 4 It is a bidirectional Hall current sensor unit.

[0015] Figure 5 It is a flowchart of an arc shape and motion trajectory control method. Detailed implementation manners

[0016] To better illustrate the technical solutions and beneficial effects of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. The implementation methods of the present invention are not limited thereto.

[0017] Step 1: Before welding starts, preset the arc signal form and movement trajectory through the Figure 1 master control system shown.

[0018] Step 2: The master control system controls the Figure 1 programmable excitation power supply shown to generate an excitation current through the communication bus according to the preset arc form and movement trajectory, and then controls the programmable dot matrix magnetic field generator to generate a programmable magnetic field, thereby controlling the form and movement trajectory of the arc.

[0019] Step 3: Figure 1 The master control system shown actively acquires the real-time excitation current data of the array Hall current sensor and the arc signal data of the arc signal monitoring system, and controls the excitation current waveform by using the Figure 2 excitation current waveform control method based on the fusion feedback of the arc signal and the real-time excitation current signal shown.

[0020] Step 4: Figure 1 The master control system shown actively acquires the real-time arc data of the arc signal monitoring system, and accurately controls the form and movement trajectory of the arc by using the Figure 5 arc form and movement trajectory control method shown.

Claims

1. An intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field, which is used for precise control of the arc shape and movement trajectory during the arc welding process. Characterized in that: The intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field controls the excitation current waveform by using an excitation current waveform control method based on the fusion feedback of arc signals and real-time excitation current signals, generates a programmable magnetic field by using a programmable dot matrix magnetic field generator, and precisely controls the arc shape and movement trajectory by using an arc shape and movement trajectory control method; the arc signals include an arc voltage signal and an arc current signal; the intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field consists of a main control system, a programmable dot matrix magnetic field generator, a programmable dot matrix magnetic field excitation power supply, an arc signal monitoring system, an array Hall current sensor, and a communication bus; the main control system communicates with the array Hall current sensor in real time through the communication bus. The array Hall current sensor is composed of 25 bidirectional Hall current sensor units, which correspond one by one to the 25 magnetic poles of the programmable dot matrix magnetic field generator, and is used to monitor the magnitude and direction of the excitation current of each magnetic pole in real time; the bidirectional Hall current sensor unit is composed of a forward current monitoring Hall unit and a reverse current monitoring Hall unit, and is used to monitor the magnitude and direction of the excitation current of a single magnetic pole in real time; the programmable dot matrix magnetic field excitation power supply is connected to the main control system through the communication bus, and can generate 25 programmable excitation currents under the control of the main control system to provide electrical energy for 25 magnetic poles respectively. The arc signal monitoring system uses a Hall voltage sensor to obtain the arc voltage signal, uses a Hall current sensor to obtain the arc current signal, filters the arc signal, extracts the arc signal characteristics, and then realizes the real-time monitoring of the arc signal, and feeds back the arc signal information to the main control system in real time through the communication bus.

2. An intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field according to claim 1, Characterized in that: The excitation current waveform control method based on the fusion feedback of arc signals and real-time excitation current signals uses the comparison between the real-time excitation current waveform and the input excitation current waveform to achieve feedback control and eliminate the excitation current output error caused by the circuit system; uses the feedback control of arc shape and movement trajectory characteristics to correct the input excitation current waveform; the real-time excitation current signal is obtained through the array Hall current sensor during the process of magnetically controlling the arc shape and movement trajectory.

3. An intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field according to claim 1, Characterized in that: The programmable dot matrix magnetic field generator described above consists of four magnetic pole arrays, namely longitudinal magnetic poles, inner ring magnetic poles, middle ring magnetic poles, and outer ring magnetic poles. By programming and controlling the excitation current in the magnetic pole arrays, a magnetic circuit is formed between different magnetic poles, thereby generating a programmable magnetic field in the area where the arc is located, and further precisely controlling the arc shape and movement trajectory. The center line of the longitudinal magnetic pole solenoid coincides with the center line of the welding torch. The inner ring magnetic poles are composed of eight magnetic poles, arranged in a circular pattern with the center line of the welding torch as the center. The difference between the circular radius and the radius of the longitudinal magnetic pole solenoid is the inner ring spacing. The middle ring magnetic poles are composed of eight magnetic poles, arranged in a circular pattern with the center line of the welding torch as the center. The difference between the radius of its arranged circle and the radius of the inner ring magnetic poles is the middle ring spacing. The outer ring magnetic poles are composed of eight magnetic poles, arranged in a circular pattern with the center line of the welding torch as the center. The difference between the radius of its circular arrangement and the radius of the circular arrangement of the middle ring magnetic poles is the outer ring spacing.

4. An intelligent magnetically controlled arc system based on a programmable dot matrix magnetic field according to claim 1, characterized in that: The method for controlling the arc shape and movement trajectory is to compare the arc shape and movement trajectory characteristics obtained in real time with the preset arc shape and movement trajectory, and correct the excitation current waveform to achieve precise control of the arc shape and movement trajectory. The arc shape and movement trajectory characteristics obtained in real time are calculated through the arc shape, movement trajectory, and arc signal feature mapping model. The arc shape, movement trajectory, and arc signal feature mapping model are obtained by training with a large amount of arc signal feature data and arc shape, movement trajectory feature data using deep learning algorithms. The arc signal features are the feature information related to the arc shape and movement trajectory in the arc signal obtained through the signal feature extraction algorithm.

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