Magnetic field welding process for bus soft bag in online production of aluminum electrolysis cell

Abstract

The invention discloses a magnetic field welding process for an aluminum electrolysis cell online production bus soft bag, and belongs to the technical field of aluminum electrolysis cell bus connection. The method is achieved through the four steps of surface treatment, soft bag installation, magnetic field application and welding. Under the combined action of the soft bag and the welding material, the magnetic field and current parameters are accurately controlled, so that the welding material is rapidly heated to a molten state, the welding speed is high, and the production efficiency is remarkably improved. And through the measures of multiple layers of partition plates, turbulence promoters and the like, the cooling efficiency of the large water tank is improved, it is ensured that temperature control in the welding process is more efficient and stable, and the production rhythm and efficiency are further improved. The soft bag magnetic field welding process and the perfect temperature control system thereof can meet the high requirement of the aluminum electrolysis cell for bus connection, ensure stable transmission of current and improve the operation stability and the product quality of the electrolysis cell.

Description

Technical Field

[0001] The invention relates to the technical field of busbar connection of aluminum electrolysis cells, and more specifically to a magnetic field welding process for online production of busbar soft bags of aluminum electrolysis cells. Background Art

[0002] Aluminum reduction cell is one of the key equipment in the modern aluminum production process. Its efficiency and stability directly affect the quality and cost of aluminum production. As the main channel for current transmission, the busbar system of aluminum reduction cell has a vital connection reliability and stability. However, in the traditional busbar welding process, there are often problems such as unstable welding quality, many welding defects, and low welding efficiency, which seriously affect the operation effect and production efficiency of aluminum reduction cell.

[0003] In the prior art, busbar welding generally adopts ordinary electric welding or gas welding methods, which have the following defects:

[0004] ① The welding surface is not clean: Traditional cleaning methods are difficult to completely remove the oil and oxides on the busbar surface, resulting in poor welding quality, insufficient connection strength, and prone to cold welding and welding cracks.

[0005] ② Inaccurate temperature control: It is difficult to accurately control the temperature during the welding process. Too high a temperature may cause excessive melting or burning of the busbar material, while insufficient temperature will cause loose welding and affect the connection effect.

[0006] ③ Low cooling efficiency: The heat generated by welding is difficult to be taken away quickly, and the temperature in the welding area is too high, which can easily lead to welding defects such as pores and cracks, affecting the welding quality and the service life of the busbar.

[0007] ④Low welding efficiency: The traditional welding process is complicated to operate, with uneven heating, slow welding speed and low production efficiency, which cannot meet the needs of large-scale production.

[0008] Based on the above problems, a new welding process is urgently needed to improve welding quality, stability and production efficiency to meet the high standards and high requirements of modern aluminum electrolytic cells for busbar connections. Summary of the invention

[0009] 1. Technical problems to be solved

[0010] In view of the problems existing in the prior art, the purpose of the present invention is to provide a magnetic field welding process for online production of busbar soft bags for aluminum electrolytic cells, which can effectively remove oil stains and oxides, ensure high cleanliness of the welding surface, improve welding quality and connection strength, meet the high requirements of aluminum electrolytic cells for busbar connection, ensure stable transmission of current, and improve the operating stability and product quality of the electrolytic cell.

[0011] 2. Technical solution

[0012] To solve the above problems, the present invention adopts the following technical solutions.

[0013] The magnetic field welding process for online production of busbar soft bags in aluminum electrolytic cells includes the following steps:

[0014] 1) Surface treatment: Treat the busbar surface to be welded, remove the oil and oxide on the surface, ensure the cleanliness of the welding surface, and prepare the equipment for soft bag magnetic field welding, which includes a magnetic field generator, soft bag material and welding electrodes;

[0015] 2) Soft bag installation: Lay the soft bag material on the busbar to be welded, ensure that the soft bag fits tightly to the busbar surface, and use a clamp to fix the soft bag on the busbar to prevent the soft bag from moving during welding;

[0016] 3) Applying magnetic field: starting the magnetic field generator to generate a uniform magnetic field around the soft bag, and adjusting the intensity and direction of the magnetic field as needed;

[0017] 4) Welding: Use a laser welder to weld the busbar. During the welding process, the temperature of the welding area is controlled by the cooling system. The cooling water circulates through the cooling pipe connected near the welding part to promptly remove the heat generated by the welding to prevent overheating. The welding material is heated to a molten state and filled into the welding part of the busbar.

[0018] Furthermore, in the step 3), a uniform magnetic field is generated around the soft bag, the magnetic field strength is adjusted to 1000-1100 Gauss, and the direction is perpendicular to the surface of the busbar.

[0019] Furthermore, in the step 4), the welding electrode is brought into contact with the busbar, the applied current is 500 to 540 amperes, and the welding time is 30 to 50 seconds.

[0020] Preferably, in step 1), a mixed solution of alcohol and dilute hydrochloric acid is used for cleaning to remove oil stains and oxides.

[0021] According to the above characteristics, the welding electrode in step 4) will be made of composite materials, and the temperature control during the welding process will be assisted by infrared temperature measurement to monitor the temperature of the welding area in real time.

[0022] In some embodiments, multiple infrared temperature measurement points are arranged in the welding area to obtain comprehensive temperature distribution information, and the temperature data is transmitted to the monitoring system in real time. The temperature trend prediction and abnormal alarm are carried out in combination with data analysis software. According to the temperature feedback, the cooling water flow is adjusted in time to ensure the temperature stability of the welding area.

[0023] According to the above characteristics, on the basis of the existing water tank system, additional water tanks are added, and multiple water tanks are connected in parallel. Lightweight and high-strength composite materials are selected to manufacture the water tanks to increase the capacity without significantly increasing the weight.

[0024] In some embodiments, cooling pipes are added inside and outside the water tank to increase the contact area with the cooling medium by increasing the water flow path.

[0025] According to the above characteristics, the volume ratio of the alcohol to the dilute hydrochloric acid is 15-20:16-18.

[0026] 3. Beneficial effects

[0027] Compared with the prior art, the advantages of the present invention are:

[0028] ① The present invention uses a mixed solution of alcohol and dilute hydrochloric acid to clean the busbar surface, which can effectively remove oil stains and oxides, ensure the high cleanliness of the welding surface, and improve the welding quality and connection strength. A uniform magnetic field is generated around the soft bag by a magnetic field generator, and the magnetic field strength and direction are adjustable to ensure the stability of the welding process, so that the welding point is heated evenly, the material filling is more complete, and the welding firmness and sealing are significantly increased.

[0029] ② By connecting the cooling water pipe in the large water tank to the vicinity of the welding part, the circulating flow of cooling water can be used to promptly remove the heat generated by welding, avoid welding defects caused by excessive temperature, and extend the service life of the equipment. Composite material welding electrodes are used in conjunction with infrared temperature measurement technology to monitor the temperature distribution of the welding area in real time. Through data analysis and abnormal alarms, the cooling water flow rate is adjusted in time to ensure the stability of the temperature in the welding area and further improve the welding quality.

[0030] ③Add additional water tanks and connect them in parallel. Choose lightweight and high-strength composite materials to make water tanks, which not only increases capacity but also does not significantly increase weight, adapting to different working environments and needs. By adding cooling pipes inside and outside the water tank, increasing the water flow path and the contact area with the cooling medium, the cooling efficiency is improved to ensure the continuous and stable progress of the welding process.

[0031] ④ Under the joint action of the soft bag and welding materials, the welding materials are quickly heated to a molten state by precisely controlling the magnetic field and current parameters, the welding speed is fast, and the production efficiency is significantly improved. Through measures such as multi-layer partitions and turbulence promoters, the cooling efficiency of the large water tank is improved to ensure that the temperature control during the welding process is more efficient and stable, further improving the production rhythm and efficiency.

[0032] ⑤ The soft bag magnetic field welding process and its perfect temperature control system can meet the high requirements of the aluminum electrolytic cell for busbar connection, ensure the stable transmission of current, and improve the operating stability and product quality of the electrolytic cell. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present invention will be described clearly and completely below; obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments, and all other embodiments obtained by ordinary technicians in this field without making creative work based on the embodiments of the present invention are within the scope of protection of the present invention.

[0034] Embodiment 1:

[0035] The magnetic field welding process for online production of busbar soft bags in aluminum electrolytic cells includes the following steps:

[0036] 1. Surface treatment

[0037] The busbar surface to be welded is treated and cleaned with a mixed solution of alcohol and dilute hydrochloric acid, where the volume ratio of alcohol to dilute hydrochloric acid is 15-20:16-18, to effectively remove surface oil and oxides and ensure that the welding surface has sufficient cleanliness. At the same time, equipment for soft bag magnetic field welding is prepared, including a magnetic field generator, soft bag materials, and welding electrodes.

[0038] 2. Soft bag installation

[0039] Lay the soft bag material on the busbar to be welded, ensuring that the soft bag fits tightly to the busbar surface without any gaps. Then use a clamp to fix the soft bag on the busbar to prevent the soft bag from moving during welding and affecting the welding quality.

[0040] 3. Magnetic field application

[0041] Start the magnetic field generator to generate a uniform magnetic field around the soft bag, adjust the magnetic field strength to 1000-1100 Gauss, and the direction is perpendicular to the surface of the busbar. By accurately controlling the magnetic field parameters, the stability and reliability of the welding process can be ensured.

[0042] 4. Welding operation

[0043] The busbar is welded using a laser welder. During the welding process, the temperature of the welding area is controlled by a cooling system. Cooling water circulates through cooling pipes connected near the welding site to promptly remove the heat generated by welding to prevent overheating. The welding material is heated to a molten state and filled into the welding site of the busbar.

[0044] In order to effectively control the temperature of the welding area, during the welding process, the cooling water pipe in the large water tank is connected to the vicinity of the welding part, and the circulating flow of cooling water is used to promptly remove the heat generated by welding. The welding electrode is made of composite materials. The temperature control during the welding process is assisted by infrared temperature measurement. Multiple infrared temperature measurement points are arranged in the welding area to obtain comprehensive temperature distribution information. The temperature data is transmitted to the monitoring system in real time, and the temperature trend prediction and abnormal alarm are carried out in combination with the data analysis software. According to the temperature feedback, the cooling water flow is adjusted in time to ensure the temperature stability of the welding area.

[0045] 5. Water tank system optimization

[0046] On the basis of the existing water tank system, additional water tanks are added and multiple water tanks are connected in parallel. Lightweight and high-strength composite materials are selected to manufacture the water tanks, which can increase the capacity without significantly increasing the weight.

[0047] Add cooling pipes inside and outside the water tank to increase the contact area with the cooling medium by increasing the water flow path, thereby improving cooling efficiency.

[0048] The soft bag magnetic field welding process has the following advantages:

[0049] 1. High welding quality

[0050] Meticulous surface treatment: By cleaning the busbar surface with a mixed solution of alcohol and dilute hydrochloric acid, oil stains and oxides are effectively removed to ensure the cleanliness of the welding surface, laying the foundation for high-quality welding.

[0051] Precise magnetic field effect: a uniform magnetic field is generated around the soft bag, and the magnetic field strength and direction can be adjusted, which can make the welding process more stable, ensure uniform heating and material filling of the welding part, and improve the firmness and sealing of the welding.

[0052] 2. Good temperature control

[0053] Efficient cooling system: By connecting the cooling water pipe in the large water tank to the vicinity of the welding part, the circulating flow of cooling water is used to promptly remove the heat generated by welding, effectively controlling the temperature of the welding area, avoiding welding defects caused by excessive temperature, and extending the service life of the equipment.

[0054] Infrared temperature measurement assistance: composite material welding electrodes are used and infrared temperature measurement is assisted. Multiple temperature measurement points are arranged in the welding area to monitor temperature distribution information in real time. Combined with data analysis software, temperature trend prediction and abnormal alarm are carried out. The cooling water flow is adjusted in time according to temperature feedback to ensure stable temperature in the welding area and further improve welding quality.

[0055] 3. Strong equipment adaptability

[0056] Water tank system optimization: adding additional water tanks and connecting them in parallel, and selecting lightweight and high-strength composite materials to manufacture water tanks, while increasing capacity without significantly increasing weight, to adapt to different working environments and needs.

[0057] Increase of internal and external cooling pipes: Add cooling pipes inside and outside the water tank to increase the water flow path, increase the contact area with the cooling medium, improve the cooling efficiency, and ensure the continuous and stable progress of the welding process.

[0058] In the online production of aluminum electrolytic cells, the connection of busbars is crucial. The soft bag magnetic field welding process can efficiently and reliably complete the welding task of the busbars and ensure the stable operation of the electrolytic cells. Its precise magnetic field control and good temperature management system can meet the high requirements of aluminum electrolytic cells for busbar connections, ensure the stable transmission of current, and improve production efficiency and product quality.

[0059] The principles of soft bag magnetic field welding process mainly include the following aspects:

[0060] 1. Magnetic field effect

[0061] A uniform magnetic field is generated around the soft bag by a magnetic field generator. The magnetic field strength is usually adjusted to 1000-1100 Gauss, and the direction is perpendicular to the surface of the busbar. Under the action of the magnetic field, when the welding electrode applies current to the busbar and the soft bag, the electrons and ions in the welding area are affected by the Lorentz force. This force causes the charged particles in the welding material to move in a directional manner, thereby generating heat inside the welding material and heating the welding material.

[0062] 2. Current Heating

[0063] The welding electrode is placed in contact with the busbar, and current is applied to the busbar and the soft bag through the electrode. The current is usually 500 to 540 amperes. When the current passes through the welding material, since the welding material has a certain resistance, according to Joule's law, the current will generate heat in the welding material, causing the temperature of the welding material to rise. Under the combined action of the magnetic field and the current, the welding material in the soft bag is quickly heated to a molten state.

[0064] 3. Soft bag function

[0065] The soft bag material is laid on the busbar to be welded and fits tightly to the busbar surface. On the one hand, the soft bag can contain the welding material. On the other hand, during the welding process, the soft bag can evenly distribute the welding material on the welding part to ensure the uniformity of welding quality. At the same time, the soft bag can also isolate the external environment to a certain extent and reduce the interference of external factors on the welding process.

[0066] 4. Temperature control

[0067] In order to effectively control the temperature of the welding area, the cooling water pipe in the large water tank is connected to the vicinity of the welding part during the welding process. The circulating flow of cooling water is used to promptly remove the heat generated by welding to prevent welding defects caused by excessive temperature in the welding area. At the same time, composite material welding electrodes are used, and infrared temperature measurement is assisted. Multiple temperature measurement points are arranged in the welding area to monitor the temperature distribution information in real time. The temperature data is transmitted to the monitoring system in real time, and the temperature trend prediction and abnormal alarm are carried out in combination with the data analysis software. According to the temperature feedback, the cooling water flow is adjusted in time to ensure the temperature stability of the welding area.

[0068] The present invention improves the cooling effect of the large water tank by the following methods:

[0069] Multi-layer partitions are set in the existing large water tank to make the cooling water flow in multiple layers, increasing the contact area between the cooling water and the welding part and the heat exchange time. At the same time, flow guide devices can be set between different layers to ensure uniform distribution of water flow.

[0070] Turbulence promoters, such as propellers and stirrers, are installed in the water tank to make the cooling water turbulent and improve the heat exchange efficiency. The cooling water in a turbulent state can be better mixed, making the temperature distribution more uniform, thereby improving the cooling effect.

[0071] When space is limited, you can choose a vertical or horizontal compact water tank, or use a combination of multiple small water tanks.

[0072] When the ambient temperature is high, the cooling water in the water tank will heat up faster, so a larger capacity is needed to slow down the temperature rise. At the same time, increasing the heat dissipation area can improve the heat dissipation efficiency and reduce the temperature of the cooling water.

[0073] The above is only a preferred specific implementation of the present invention; however, the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solution and its improved conception within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. Aluminum electrolytic cell online production busbar soft bag magnetic field welding process, characterized by The steps include: 1) Surface treatment: Treat the busbar surface to be welded, remove the oil and oxide on the surface, ensure the cleanliness of the welding surface, and prepare the equipment for soft bag magnetic field welding, which includes a magnetic field generator, soft bag material and welding electrodes; 2) Soft bag installation: Lay the soft bag material on the busbar to be welded, ensure that the soft bag fits tightly to the busbar surface, and use a clamp to fix the soft bag on the busbar to prevent the soft bag from moving during welding; 3) Applying magnetic field: starting the magnetic field generator to generate a uniform magnetic field around the soft bag, and adjusting the intensity and direction of the magnetic field as needed; 4) Welding: Use a laser welder to weld the busbar. During the welding process, the temperature of the welding area is controlled by the cooling system. The cooling water circulates through the cooling pipe connected near the welding part to promptly remove the heat generated by the welding to prevent overheating. The welding material is heated to a molten state and filled into the welding part of the busbar.

2. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 1 is characterized in that: In the step 3), a uniform magnetic field is generated around the soft bag, the magnetic field strength is adjusted to 1000-1100 Gauss, and the direction is perpendicular to the surface of the busbar.

3. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 1 is characterized in that: In the step 4), the welding electrode is brought into contact with the busbar, the applied current is 500 to 540 amperes, and the welding time is 30 to 50 seconds.

4. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 1 is characterized in that: In the step 1), a mixed solution of alcohol and dilute hydrochloric acid is used for cleaning to remove oil stains and oxides.

5. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 1 is characterized in that: In step 4), the welding electrode will be made of composite materials, and the temperature control during the welding process will be assisted by infrared temperature measurement to monitor the temperature of the welding area in real time.

6. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 5 is characterized in that: Arrange multiple infrared temperature measurement points in the welding area to obtain comprehensive temperature distribution information, transmit temperature data to the monitoring system in real time, combine data analysis software to predict temperature trends and issue abnormal alarms, and adjust cooling water flow in time according to temperature feedback to ensure stable temperature in the welding area.

7. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 1 is characterized in that: On the basis of the existing water tank system, additional water tanks are added, and multiple water tanks are connected in parallel. Lightweight and high-strength composite materials are selected to manufacture the water tanks to increase the capacity without significantly increasing the weight.

8. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 1 is characterized in that: Add cooling pipes inside and outside the water tank to increase the contact area with the cooling medium by increasing the water flow path.

9. The magnetic field welding process for online production of busbar soft bags for aluminum electrolysis cells according to claim 4 is characterized in that: The volume ratio of the alcohol to the dilute hydrochloric acid is 15-20:16-18.