Multi-field regulation and control excitation welding device and system and magnetic field control method

Abstract

The invention provides a multi-field regulation and control excitation welding device and system and a magnetic field control method. The welding device comprises a welding gun; the excitation magnetic poles are symmetrically arranged on the two sides of the welding gun. The at least one group of common magnetic poles are arranged on one side of the welding gun and are respectively connected with a pair of excitation magnetic poles; in a first power-on state, one of the pair of excitation magnetic poles and the common magnetic pole are communicated with first current at the same time; in a second power-on state, the other one of the pair of excitation magnetic poles and the common magnetic pole are communicated with second current at the same time; and when the welding gun is in a working state, the first current and the second current are alternately started to form double-path pulse current so as to generate a pulse composite magnetic field capable of acting on the electric arc, the molten pool and the molten drops. According to the welding device, molten pool flowing and molten drop transition can be regulated and controlled in the transverse direction, the longitudinal direction and the vertical direction correspondingly, electric arc energy distribution is optimized, the penetration depth and molten pool swinging are increased, the welding speed is increased, root penetration is enhanced, weld joint forming is improved, welding heat input is reduced, welding deformation is reduced, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The present invention relates to the field of welding, and provides a multi-field regulated excitation welding device, a system and a magnetic field control method. Background Art

[0002] In modern industrial production, aluminum alloys are widely used in the field of rail vehicles due to their excellent properties. However, traditional arc welding technology has many problems when welding long and thin-walled aluminum alloy components. For example, there is a large heat input, resulting in tissue damage and a decrease in strength performance; serious deformation leads to post-weld repair and stress concentration; poor accessibility of the closed structure results in incomplete fusion at the root and deterioration of fatigue performance, etc., which seriously affect the welding quality and production efficiency. With the development of trains towards higher speed grades, the bottleneck of arc welding technology is further exacerbated, and it cannot meet the requirements of high-efficiency deep penetration welding. Especially for the aluminum alloy arc welding process of rail vehicles, in addition to the above defects, traditional arc welding also has defects such as too fast flow rate of liquid metal in the weld, uneven flow distribution, and poor weld fusion quality. Summary of the Invention

[0003] The present invention provides a multi-field regulated excitation welding device to solve the defects in related arc welding technologies, such as too fast flow rate of liquid metal in the weld, uneven flow distribution, and poor weld fusion quality.

[0004] The present invention also provides a multi-field regulated excitation welding system based on the above multi-field regulated excitation welding device.

[0005] The present invention also provides a magnetic field control method based on the above multi-field regulated excitation welding device.

[0006] The present invention provides a multi-field regulated excitation welding device, including: a welding torch; a pair of excitation magnetic poles symmetrically arranged on both sides of the welding torch; at least one group of common magnetic poles arranged on one side of the welding torch and respectively connected to a pair of the excitation magnetic poles; in a first energization state, one of the pair of excitation magnetic poles and the common magnetic pole are simultaneously connected to a first current; in a second energization state, the other of the pair of excitation magnetic poles and the common magnetic pole are simultaneously connected to a second current; when the welding torch is in a working state, the first current and the second current are alternately started to form a dual-channel pulsed current, so as to generate a pulsed composite magnetic field that can act on the arc, molten pool and molten droplets.

[0007] A multi-field regulated excitation welding device provided according to the present invention, wherein the common magnetic pole and a pair of the excitation magnetic poles each include: a core column disposed on one side of the welding torch; a coil winding wound around the core column, and the coil winding is supplied with the first current and / or the second current; a magnetic head connected to an end of the core column; the common magnetic pole further includes a pair of connecting rods, one end of which is connected to the core column of the same common magnetic pole, and the other ends are respectively connected to the core columns of a pair of the excitation magnetic poles.

[0008] A multi-field regulated excitation welding device provided according to the present invention, wherein the welding torch includes: a spray gun having a nozzle at an end, and the nozzle faces; a welding wire passing through an axial position of the spray gun and extending out from the nozzle; the magnetic heads of the common magnetic pole and a pair of the excitation magnetic poles are respectively arranged around the welding wire with the welding wire as a central axis.

[0009] A multi-field regulated excitation welding device provided according to the present invention, wherein the core column and the magnetic head are both parallel to the welding wire, and the distance between the core column and the welding wire is greater than the distance between the magnetic head and the welding wire.

[0010] A multi-field regulated excitation welding device provided according to the present invention, with the welding direction as the front, the common magnetic pole is arranged behind the welding torch.

[0011] A multi-field regulated excitation welding device provided according to the present invention includes: a first excitation magnetic pole arranged on one side of the welding torch; a second excitation magnetic pole symmetrically arranged on the other side of the welding torch; a common magnetic pole arranged behind the welding torch and respectively connected to the first excitation magnetic pole and the second excitation magnetic pole; with the axis of the welding torch as the center of a circle, the common magnetic pole forms a first included angle with the first excitation magnetic pole, and the common magnetic pole forms a second included angle with the second excitation magnetic pole, and the ranges of the first included angle and the second included angle are respectively 45 degrees to 135 degrees.

[0012] A multi-field regulated excitation welding device provided according to the present invention, wherein the pulsed composite magnetic field includes: a first magnetic field formed between the first excitation magnetic pole and the second excitation magnetic pole, and the direction of the first magnetic field in the first energized state is opposite to the direction of the first magnetic field in the second energized state; the first magnetic field is used to generate a forward first electromagnetic force on the molten pool of the welding torch; a second magnetic field formed between the second excitation magnetic pole and the common magnetic pole, and the direction of the second magnetic field in the first energized state is opposite to the direction of the second magnetic field in the second energized state; the second magnetic field is used to generate a forward second electromagnetic force and a lateral third electromagnetic force on the molten pool; under the action of the pulsed composite magnetic field, the arc, the molten pool and the molten droplet move forward under the superposition of the first electromagnetic force and the second electromagnetic force, and swing left and right under the action of the third electromagnetic force.

[0013] A multi-field controlled excitation welding device provided by the present invention, the first excitation magnetic pole has a first inductance, the common magnetic pole has a second inductance, and the second excitation magnetic pole has a third inductance; under the action of the pulsed composite magnetic field, the second inductance is successively connected in parallel with the first inductance and the third inductance.

[0014] In the first energized state, the total inductance of the multi-field controlled excitation welding device is: ; In the second energized state, the total inductance of the multi-field controlled excitation welding device is: ; wherein, L ALL is the total inductance of the multi-field controlled excitation welding device; L 1 is the first inductance; L 2 is the second inductance; L 3 is the third inductance.

[0015] A multi-field controlled excitation welding device provided by the present invention, the ranges of the first included angle and the second included angle are respectively 90 degrees to 120 degrees.

[0016] A multi-field controlled excitation welding device provided by the present invention, the first excitation magnetic pole, the welding torch and the second excitation magnetic pole are in the same plane, and both the first included angle and the second included angle are 90 degrees.

[0017] A multi-field controlled excitation welding device provided by the present invention further includes a protective shell; the protective shell includes: a shell body; a welding torch positioning channel constructed at the axial position of the shell body, and the welding torch positioning channel is adapted to be sleeved outside the welding torch; a pair of excitation coil grooves constructed inside the shell body and symmetrically arranged on both sides of the welding torch positioning channel, and the pair of excitation coil grooves are respectively adapted to assemble the excitation magnetic poles on the corresponding sides; a common coil groove constructed inside the shell body and arranged behind the welding torch positioning channel, and the common coil groove is adapted to assemble the common magnetic pole.

[0018] A multi-field controlled excitation welding device provided by the present invention, the protective shell further includes: a limiting hole penetratingly constructed at the bottom of the excitation coil groove; a limiting groove penetratingly constructed at the bottom of the common coil groove; a wire passing hole penetratingly constructed on the side wall of at least one of the excitation coil groove and the common coil groove.

[0019] A multi-field regulated excitation welding device provided according to the present invention, the protective housing further includes: a plurality of weight reduction grooves, which are formed through the side wall of the housing; each of the weight reduction grooves is respectively arranged to avoid the common coil groove and each of the excitation coil grooves.

[0020] The present invention also provides a multi-field regulated excitation welding system, including: the multi-field regulated excitation welding device as described above; a welding power supply, connected to the welding torch of the multi-field regulated excitation welding device, and the welding torch is adapted to be arranged towards the welding joint; an excitation power supply, connected to the multi-field regulated excitation welding device, and used to alternately input a first current and a second current to the multi-field regulated excitation welding device respectively; a Hall sensor, connected between the welding power supply and the welding joint, and connected to the excitation power supply.

[0021] A multi-field regulated excitation welding system provided according to the present invention further includes: a control panel, connected to the excitation power supply; a pair of excitation ammeters, respectively arranged on the control panel, and used to monitor the first current and the second current respectively; an excitation frequency meter, arranged on the control panel, and used to monitor the frequency of the pulsed composite magnetic field.

[0022] A multi-field regulated excitation welding system provided according to the present invention further includes at least one of the following components: a pair of 5G remote control air switches, one of which is connected to the excitation power supply, and the other is adapted to be connected between the power supply network and the welding power supply; an aviation quick connector, connecting the multi-field regulated excitation welding device; a current interface, one end of which is connected to the aviation quick connector, and the other end is adapted to be connected to the current output end of the excitation power supply; an alarm mechanism, connected between the current access end and the excitation power supply, and the current access end is connected between the aviation quick connector and the current interface.

[0023] The alarm mechanism of a multi-field regulated excitation welding system provided according to the present invention includes: a logic circuit board, connected between the current access end and the excitation power supply; a sound and light warning lamp, connected to the logic circuit board; a wireless signal generator, connected to the logic circuit board.

[0024] The welding joint of a multi-field regulated excitation welding system provided according to the present invention includes: a groove part, formed at the butt joint of a pair of welding members; a pair of root faces, respectively formed at the butt joint of a pair of the welding members, and the pair of root faces are located below the groove part, and a groove gap is formed between the pair of root faces; a backing part, one end of which is integrally connected to the bottom of one of the pair of welding members, and the other end is mounted on the bottom of the other of the pair of welding members.

[0025] The present invention also provides a magnetic field control method, which is executed by the above-mentioned multi-field regulated excitation welding device; the magnetic field control method includes the following steps.

[0026] In the first energized state, a first current is simultaneously input to one of a pair of exciting magnetic poles and the common magnetic pole.

[0027] In the second energized state, a second current is simultaneously input to the other of the pair of exciting magnetic poles and the common magnetic pole.

[0028] The first energized state and the second energized state are alternately switched to generate a pulsed composite magnetic field that can act on the arc, molten pool, and molten droplets.

[0029] The multi-field controlled excitation welding device provided by the present invention (hereinafter referred to as the "welding device" for short) includes a welding torch, a pair of exciting magnetic poles, and at least one set of common magnetic poles. The pair of exciting magnetic poles are symmetrically arranged on both sides of the welding torch; at least one set of common magnetic poles is arranged on one side of the welding torch and is respectively connected to the pair of exciting magnetic poles; in the first energized state, one of the pair of exciting magnetic poles and the common magnetic pole are simultaneously connected to a first current; in the second energized state, the other of the pair of exciting magnetic poles and the common magnetic pole are simultaneously connected to a second current; when the welding torch is in the working state, the first current and the second current are alternately started to form a two-way pulsed current to generate a pulsed composite magnetic field that can act on the arc, molten pool, and molten droplets. This welding device adopts the technology of assisting the pulsed composite magnetic field to cooperate with traditional arc welding, breaking through the limitations of welding speed and penetration ability in traditional arc welding technology. By inputting a two-way pulsed current, the first energized state and the second energized state are switched, so as to utilize the pulsed composite magnetic field to generate electromagnetic force acting on the arc, molten pool, and molten droplets, and then respectively control the flow of the molten pool and the transition of the molten droplets in the transverse, longitudinal, and vertical directions, optimize the arc energy distribution, increase the penetration depth and the swing of the molten pool, refine the grains, and achieve the effects of improving the welding speed (the welding speed can be increased from 0.6 m / min of traditional arc welding to 2.2 m / min), enhancing the root penetration, improving the weld formation, reducing the welding heat input, reducing the welding deformation, improving the welding quality, and reducing the manufacturing cost, and the performance of the welded joint after welding can be at least equivalent to that of traditional arc welding.

[0030] Moreover, by adding a common magnetic pole to this welding device, the welding device has a lower inductive reactance, shortens the current ramp-up time, makes the current waveform change faster and the waveform more stable. Under the same magnetic field and current conditions, the peak value of the excitation frequency is larger. Also, it effectively reduces the backward inclination degree of the molten droplets and the arc, reduces the impact kinetic energy from the molten droplets in the longitudinal and backward liquid flows of the molten pool, and cancels the pushing effect of the arc force on the backward liquid flow, thereby reducing the flow rate of the backward liquid flow, suppressing the lack of fusion defect, and at the same time avoiding the uneven distribution of the liquid metal along the weld direction.

[0031] The multi-field controlled excitation welding system provided by the present invention (hereinafter referred to as "welding system" for short) includes: the above-mentioned multi-field controlled excitation welding device; a welding power source connected to the welding torch of the multi-field controlled excitation welding device, and the welding torch is adapted to be arranged towards the welding joint; an excitation power source connected to the multi-field controlled excitation welding device for alternately inputting a first current and a second current to the multi-field controlled excitation welding device respectively; a Hall sensor connected between the welding power source and the welding joint and connected to the excitation power source. By setting the above-mentioned welding device, this welding system can at least achieve all the advantages of the above-mentioned welding device, and the details are not described herein again.

[0032] This welding system can also use the Hall sensor to monitor the current states of the welding current and the dual-channel pulsed current in real time, and flexibly adjust and monitor the current output state of the excitation power source. Thus, through the synergistic effect of the welding parameters of the welding machine and the excitation parameters output by the excitation power source, the ratio of the transverse and forward electromagnetic forces can be flexibly adjusted, so as to closely adjust the states of the arc, molten droplet and molten pool, and improve the flexibility and precision of adjustment.

[0033] The magnetic field control method provided by the present invention is executed by the above-mentioned multi-field controlled excitation welding device, so that at least all the advantages of the above-mentioned welding device can be achieved, and the details are not described herein again. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0035] Figure 1 It is one of the connection schematic diagrams of the multi-field controlled excitation welding system provided by the present invention.

[0036] Figure 2 It is the structural schematic diagram of the multi-field controlled excitation welding device provided by the present invention.

[0037] Figure 3 It is the current-time relationship diagram of the first current provided by the excitation power source provided by the present invention.

[0038] Figure 4 It is one of the schematic diagrams of the molten pool and molten droplets of the multi-field controlled excitation welding device in the first energized state provided by the present invention.

[0039] Figure 5 It is one of the top view diagrams of the molten pool of the multi-field controlled excitation welding device in the first energized state provided by the present invention.

[0040] Figure 6It is a current-time relationship diagram of the second current provided by the excitation power supply of the present invention.

[0041] Figure 7 It is the second schematic diagram of the molten pool and molten droplet of the multi-field controlled excitation welding device provided by the present invention in the second energized state.

[0042] Figure 8 It is the second top view of the molten pool of the multi-field controlled excitation welding device provided by the present invention in the second energized state.

[0043] Figure 9 It is the installation schematic diagram of the multi-field controlled excitation welding device provided by the present invention.

[0044] Figure 10 It is the structural schematic diagram of the first housing provided by the present invention.

[0045] Figure 11 It is the structural schematic diagram of the second housing provided by the present invention.

[0046] Figure 12 It is the second connection schematic diagram of the multi-field controlled excitation welding system provided by the present invention.

[0047] Figure 13 It is the structural schematic diagram of the welded joint provided by the present invention.

[0048] Figure 14 It is the post-welding appearance effect diagram of the welded joint provided by the present invention.

[0049] Figure 15 It is the macroscopic structure effect diagram of the welded joint provided by the present invention.

[0050] Reference numerals: 1. First excitation ammeter; 2. Second excitation ammeter; 3. Excitation frequency meter; 4. Multifunctional button; 5. Manual power switch; 6. Control panel; 7. Excitation power supply; 71. Current output terminal; 72. Handle; 73. Air switch; 74. Sensor access terminal; 8. Multi-field controlled excitation welding device; 9. First excitation magnetic pole; 91. First core column; 92. First magnetic head; 93. First coil winding; 10. Second excitation magnetic pole; 101. Second core column; 102. Second magnetic head; 103. Second coil winding; 11. Common magnetic pole; 111. Third core column; 112. Third magnetic head; 113. Third coil winding; 12. Spray gun; 13. Nozzle; 14. Welding wire; 15. Connecting rod; 16. Protective shell; 160. Spray gun positioning channel; 161. First housing; 162. Second housing; 163. First excitation coil slot; 164. Second excitation coil slot; 165. Common coil slot; 166. Limit hole; 167. Limit groove; 168. Threading hole; 169. Weight reduction groove; 17. Welding power supply; 18. Hall sensor; 19. Welding joint; 191. First component; 192. Second component; 193. Groove part; 194. Root face; 195. Pad part; 20. Manipulator; 21. Power cord; 22. 5G remote control air switch; 23. Aviation quick connector; 24. Current access terminal; 25. Current interface; 26. Logic circuit board; 27. Acousto-optic warning light; 28. Wireless signal generator; 29. Molten pool; 30. Molten droplet; I1. First current; I2. Second current; A. Welding direction. Detailed implementation manners

[0051] The following further describes in detail the implementation manners of the present invention in conjunction with the accompanying drawings and embodiments. The following embodiments are used to illustrate the present invention, but cannot be used to limit the scope of the present invention.

[0052] The following refers to Figures 1 to 11 and describes in detail the multi-field controlled excitation welding device 8 of the present invention (abbreviated as "welding device 8" in the present invention) as shown.

[0053] As Figure 1 and Figure 2 shown, the welding device 8 of the embodiment of the present invention includes a welding torch and a magnetic pole group. The magnetic pole group includes a pair of excitation magnetic poles and at least one group of common magnetic poles 11. The pair of excitation magnetic poles are symmetrically arranged on both sides of the welding torch. At least one group of common magnetic poles 11 is arranged on one side of the welding torch and is respectively connected to the pair of excitation magnetic poles. Each magnetic pole of the magnetic pole group is arranged around the circumference of the welding torch to form a polygonal structure, so that the magnetic field formed between every two magnetic poles can accurately act on the arc generated by the welding torch and can act on the molten pool 29 and the molten droplet 30. The welding torch applies heat input to the welding joint 19 through the welding arc in the working state, thereby generating the molten pool 29 and the molten droplet 30.

[0054] In the welding device 8 of this embodiment, in the first energized state, one of a pair of exciting magnetic poles and the common magnetic pole 11 are simultaneously connected to the first current I1. In the second energized state, the other of the pair of exciting magnetic poles and the common magnetic pole 11 are simultaneously connected to the second current I2. When the welding torch is in the working state, the first current I1 and the second current I2 are alternately started to form a two-way pulsed current. By alternately switching between the first energized state and the second energized state, the two-way pulsed current is alternately switched, and thus the magnetic pole group can generate a pulsed composite magnetic field. The pulsed composite magnetic field can act on the arc, the molten pool 29, and the molten droplet 30. This welding device 8 adopts the technology of assisting pulsed composite magnetic field to cooperate with traditional arc welding, breaking through the limitations of welding speed and penetration ability in traditional arc welding technology. By inputting a two-way pulsed current to realize the switching between the first energized state and the second energized state, the electromagnetic force is generated by the pulsed composite magnetic field and acts on the arc, the molten pool 29, and the molten droplet 30, and then the flow of the molten pool 29 and the transition of the molten droplet 30 are respectively regulated in the transverse, longitudinal, and vertical directions, the arc energy distribution is optimized, the penetration depth and the oscillation of the molten pool 29 are increased, the grain is refined, and the effects of improving the welding speed, enhancing the root penetration, improving the weld formation, reducing the welding heat input, reducing the welding deformation, improving the welding quality, and reducing the manufacturing cost are achieved, and the post-weld joint performance of the welded joint 19 can be at least equivalent to that of traditional arc welding.

[0055] Moreover, this welding device 8 adopts intermittent pulses to increase the maximum current during the welding process, thereby improving the melting efficiency of the welded joint 19, enhancing the penetration ability and welding efficiency of a single arc, and realizing a high-energy welding mode of "superposition combination of magnetic control energy field and high-efficiency arc".

[0056] It can be understood that, as Figure 1 shown, the welding device 8 described in the embodiment of the present invention is preferably connected to an exciting power supply 7. The exciting power supply 7 can provide the above-mentioned two-way pulsed current for this welding device 8 to generate a pulsed composite magnetic field. In order to facilitate the real-time monitoring and flexible adjustment of the exciting parameters of the exciting power supply 7, so as to flexibly and accurately adjust the parameters of the two-way pulsed current and the parameters of the pulsed composite magnetic field, it is preferred that the exciting power supply 7 is connected to a control panel 6. The specific integrated components of the control panel 6 will be described in detail in the welding system part later and will not be elaborated here.

[0057] In some embodiments, as Figure 2As shown, a pair of exciting magnetic poles and a common magnetic pole 11 in the welding device 8 both include a core column, a coil winding, and a magnetic head. The core column is arranged on one side of the welding torch. The coil winding is wound around the core column. The magnetic head is connected to the end of the core column. The coil winding is passed through by a first current I1 and / or a second current I2. That is, in the first energized state, the coil windings of one of the exciting magnetic poles and the coil winding of the common magnetic pole 11 are both passed through by the first current I1; in the second energized state, the coil windings of the other exciting magnetic pole and the coil winding of the common magnetic pole 11 are both passed through by the second current I2. That is, the coil windings of a pair of exciting magnetic poles are intermittently passed through by the first current I1 or the second current I2 according to the energized state, while the common magnetic pole 11 is alternately passed through by the first current I1 and the second current I2 according to the energized state. The specific current flow state and the action principle of the pulsed composite magnetic field will be elaborated in detail in the subsequent content and will not be elaborated here for the time being.

[0058] On the basis of the above structure, the common magnetic pole 11 further includes a pair of connecting rods 15. One ends of a pair of connecting rods 15 are connected to the core column of the same common magnetic pole 11, and the other ends of a pair of connecting rods 15 are respectively connected to the core columns of a pair of the exciting magnetic poles. That is, magnetic heads are provided at one ends of the core columns of each magnetic pole facing the welding joint 19, and electromagnetic force acts on the arc, the molten pool 29, and the molten droplet 30 through the corresponding magnetic fields formed between the magnetic heads of the two groups of magnetic poles. The end of the core column of the common magnetic pole 11 facing away from the welding joint 19 is respectively connected to the corresponding ends of the core columns of a pair of exciting magnetic poles through a pair of connecting rods 15, so as to form a current loop between the arc of the welding torch, the common magnetic pole 11, and any one of the exciting magnetic poles, and further form two parallel circuits between the common magnetic pole 11 and a pair of exciting magnetic poles, and further form two parallel relationships between the inductance of the common magnetic pole 11 and the inductance of a pair of exciting magnetic poles, so that the total inductive reactance of the welding device 8 during the working process is lower, the current ramp-up time is shortened, and the current waveform changes more quickly and the waveform is more stable. Under the same magnetic field and current conditions, the peak value of the excitation frequency is larger. Moreover, it effectively reduces the backward inclination degree of the molten droplet 30 and the arc, reduces the impact kinetic energy from the molten droplet 30 in the longitudinal and backward liquid flows of the molten pool 29, and cancels the pushing effect of the arc force on the backward liquid flow, thereby reducing the flow rate of the backward liquid flow, suppressing the lack of fusion defect, and avoiding the uneven distribution of the liquid metal along the weld direction.

[0059] It can be understood that preferably, the above core columns are all ferromagnetic cores, and most preferably DCT4 cores and are treated with a copper plating process to prevent corrosion and rust.

[0060] It can be understood that preferably, the above coil windings are all copper coils. The number of turns of the coil is preferably 200 to 500 turns to ensure the stability and reliability of the generated magnetic field parameters.

[0061] It can be understood that as Figure 2As shown in the figure, the welding torch in the embodiment of the present invention is preferably a MIG arc welding torch. The welding torch includes a spray gun 12 and a welding wire 14. A nozzle 13 is provided at the end of the spray gun 12 for spraying a shielding gas. The welding wire 14 is disposed along the axis of the spray gun 12 and extends out from the nozzle 13. The magnetic heads of the above-mentioned common magnetic pole 11 and the magnetic heads of a pair of exciting magnetic poles are respectively arranged around the welding wire 14 with the welding wire 14 as the central axis. During the welding process, the welding wire 14 acts on the welding joint 19 through the arc, so that the groove portion 193 of the welding joint 19 forms a molten droplet 30 and a molten pool 29. The spray gun 12 sprays the shielding gas to the arc position through the nozzle 13. The externally applied pulsed composite magnetic field generated by the magnetic pole group passes through and acts on the arc, the molten droplet 30 and the molten pool 29. The structure of the welding torch and the positional relationship between the welding torch and the above-mentioned magnetic pole group can enable the externally applied magnetic field to accurately pass through the arc, the molten droplet 30 and the molten pool 29, so that the electromagnetic force has a stable and reliable effect on the arc, the molten droplet 30 and the molten pool 29.

[0062] It can be understood that, in order to improve the magnetic field stability and achieve structural optimization, it is preferred that the core columns and magnetic heads of each of the above magnetic poles are parallel to the welding wire 14. Further preferably, the distance between the core column and the welding wire 14 is greater than the distance between the magnetic head and the welding wire 14. This structural setting can, on the one hand, realize the integrated installation of the welding device 8 and the robotic equipment, which is beneficial to being compatible with various types of manipulators 20 of existing automatic welding robots and realizing the collaborative use with the original welding machine, reducing the transformation difficulty; on the other hand, this structure can meet the requirements of structural compactness and device lightweight, has extremely little influence on traditional arc welding operations, and is more conducive to the installation and use of the production line.

[0063] It can be understood that the welding device 8 in the embodiment of the present invention is suitable for being integrally connected and used with an automatic welding manipulator 20 device. Figure 9 The assembled structure of the welding device 8 and the manipulator 20 of the automatic welding robot is shown. Preferably, the exciting power supply 7 is connected to the manipulator 20. As Figure 9 shown, a welding torch is connected to the controllable extended end of the manipulator 20. The protective shell 16 of the welding device 8 reliably connects the above-mentioned magnetic pole group around the nozzle 13 of the welding torch to realize the structural relationship of the above-mentioned welding device 8. The manipulator 20 drives the welding torch to move and applies the above-mentioned pulsed composite magnetic field to the arc, the molten droplet 30 and the molten pool 29 of the welding torch in the working state. The specific structure of the protective shell 16 will be elaborated in the subsequent part and will not be elaborated here for the time being. After being assembled in place, ensure that the common magnetic pole 11 is arranged in the welding direction A (welding line) of the operation of the spray gun 12, manually tighten the fastening screws, and use a Tesla meter to test that the magnetic field intensities of the pulsed composite magnetic field of the magnetic pole group all meet the requirements before it can be used. That is, a pulsed composite magnetic field generating device is installed on a standard arc welding torch (such as Figure 1 and Figure 2As shown in the figure, an externally applied pulsed composite magnetic field is applied to the molten pool 29 from the front of the welding joint 19 of the workpiece, which not only improves the interaction between the externally applied magnetic field and the arc / droplet 30, enhances the control effect, but also facilitates the compact design of the structure of the welding torch and the magnetic pole group, and improves its accessibility.

[0064] In some embodiments, as Figures 3 to 8 shown, the welding device 8 preferably has the welding direction A as the front, and all the common magnetic poles 11 in the above-mentioned magnetic pole group are arranged behind the welding torch to ensure that the magnetic field generated by the common magnetic pole 11 and any exciting magnetic pole generates an obliquely forward electromagnetic force. This obliquely forward electromagnetic force has a forward component and a lateral component, and thus stably acts on the arc, droplet 30 and molten pool 29 from the rear. On the one hand, this setting can reduce the tilting degree of the droplet 30 and the arc, reduce the impact kinetic energy of the droplet 30 in the longitudinal backward liquid flow of the molten pool 29, and offset the pushing effect of the arc force on the backward liquid flow, thereby reducing the flow rate of the backward liquid flow, suppressing the lack of fusion defect, and at the same time avoiding the uneven distribution of the liquid metal along the weld direction. On the other hand, due to the action of the above-mentioned dual-channel pulsed current, the magnetic pole group generates a pulsed composite magnetic field, that is, among the electromagnetic forces generated by the magnetic fields between the common magnetic pole 11 and a pair of exciting magnetic poles respectively, the forward components of the two groups of electromagnetic forces always remain forward, but the lateral components of the two groups of electromagnetic forces are opposite in direction and act on the arc, droplet 30 and molten pool 29 alternately during the switching process of the energized state. Therefore, the droplet 30 and the arc are periodically driven to swing left and right along the width direction of the molten pool 29, thereby promoting the lateral spreading of the liquid metal in the molten pool 29, increasing the weld width, and at the same time avoiding the increase in the flow rate of the longitudinal backward liquid flow due to the narrowing of the flow width of the liquid metal.

[0065] In some specific embodiments, as Figure 2 shown, the magnetic pole group of the welding device 8 includes a first exciting magnetic pole 9, a second exciting magnetic pole 10 and a common magnetic pole 11. The common magnetic pole 11 is arranged behind the welding torch and is respectively connected to the first exciting magnetic pole 9 and the second exciting magnetic pole 10 to form the above-mentioned two mutually parallel circuits. The first exciting magnetic pole 9 is arranged on one side of the welding torch. The second exciting magnetic pole 10 is symmetrically arranged on the other side of the welding torch. The core columns of the three magnetic poles form a triangular prism structure surrounding the outside of the welding torch, with a compact structure and convenient for integrated installation.

[0066] It can be understood that preferably, the symmetry plane of the first exciting magnetic pole 9 and the second exciting magnetic pole 10 is the plane where the welding torch and the common magnetic pole 11 are located, so that the magnetic field ranges and electromagnetic forces corresponding to the following generated first magnetic field and second magnetic field can fully cover the arc, droplet 30 and molten pool 29, and improve the following action effects on the arc, droplet 30 and molten pool 29.

[0067] In some specific embodiments, as Figures 3 to 8As shown, the above-mentioned pulsed composite magnetic field includes a first magnetic field and a second magnetic field. The first magnetic field is formed between the first excitation magnetic pole 9 and the second excitation magnetic pole 10. The first magnetic field is used to generate a forward first electromagnetic force on the molten pool 29 of the welding torch. The first magnetic field in the first energized state is opposite to the first magnetic field in the second energized state, but the first electromagnetic force always remains forward, that is, the same as the welding direction A, thereby reducing the backward inclination degree of the molten droplet 30 and the arc, reducing the impact kinetic energy from the molten droplet 30 in the longitudinal backward liquid flow of the molten pool 29, and canceling the pushing effect of the arc force on the backward liquid flow, and further reducing the flow rate of the backward liquid flow. Similarly, the second magnetic field is formed between the second excitation magnetic pole 10 and the common magnetic pole 11. The second magnetic field is used to generate a forward second electromagnetic force and a transverse third electromagnetic force on the molten pool 29. The second magnetic field in the first energized state is opposite to the second magnetic field in the second energized state. Therefore, the second electromagnetic force in the first energized state and the second energized state always remains forward, but the third electromagnetic force in the first energized state and the second energized state is opposite in direction.

[0068] In the first energized state, the common magnetic pole 11 and the first excitation magnetic pole 9 conduct electricity simultaneously for a time period t 1 -t 2 of the first current I1. The relationship between the current and time of the first current I1 is as Figure 3 shown. Referring to Figure 4 and Figure 5 shown, in this energized state, since the common magnetic pole 11 and the first excitation magnetic pole 9 both generate N poles due to the simultaneous conduction of the first current I1, the second excitation magnetic pole 10 correspondingly generates an S pole. Therefore, as Figure 4 shown, a first magnetic field B 1 (t 1 -t 2 ) is formed between the first excitation magnetic pole 9 and the second excitation magnetic pole 10, and at the same time, a second magnetic field B 2 (t 1 -t 2 ) is formed between the common magnetic pole 11 and the second excitation magnetic pole 10. The first magnetic field B 1 (t 1 -t 2 ) and the second magnetic field B 2 (t 1 -t 2 ) respectively pass through and act on the arc, the molten droplet 30 and the molten pool 29. Referring to Figure 5 shown, the first magnetic field B 1 (t 1 -t 2 ) generates a forward first electromagnetic force on the arc, the molten droplet 30 and the molten pool 29, that is, the first magnetic field electromagnetic force F1 in the first energized state; the second magnetic field B 2 (t 1 -t 2)The second magnetic field electromagnetic force F2 in the first energized state generated by the electric arc, the molten droplet 30, and the molten pool 29 acts on the electric arc, the molten droplet 30, and the molten pool 29 from the right rear to the left front direction. Therefore, the second magnetic field electromagnetic force F2 in the first energized state is decomposed into a forward second electromagnetic force and a leftward third electromagnetic force. Therefore, under the superimposed action of the first magnetic field electromagnetic force F1 in the first energized state and the second magnetic field electromagnetic force F2 in the first energized state, the molten droplet 30 converges more at the left front of the welding wire 14 as shown in Figure 4 , and the molten pool 29 shows a movement trend of being pushed forward to the left front as shown in Figure 5 .

[0069] In the second energized state, the second current I2 of the common magnetic pole 11 and the second excitation magnetic pole 10 flows simultaneously during the time period t 2 -t 3 . The current-time relationship of the second current I2 is as shown in Figure 6 . Referring to Figure 7 and Figure 8 , in this energized state, since the common magnetic pole 11 and the second excitation magnetic pole 10 both generate S poles due to the simultaneous flow of the second current I2, the first excitation magnetic pole 9 correspondingly generates an N pole. Therefore, as shown in Figure 7 , a first magnetic field B 1 (t 2 -t 3 ) is formed between the first excitation magnetic pole 9 and the second excitation magnetic pole 10. At the same time, a second magnetic field B 2 (t 2 -t 3 ) is formed between the common magnetic pole 11 and the first excitation magnetic pole 9. The first magnetic field B 1 (t 2 -t 3 ) and the second magnetic field B 2 (t 2 -t 3 ) respectively pass through and act on the electric arc, the molten droplet 30, and the molten pool 29. Referring to Figure 8 , the first magnetic field B 1 (t 2 -t 3 ) generates a forward first electromagnetic force on the electric arc, the molten droplet 30, and the molten pool 29, that is, the first magnetic field electromagnetic force F3 in the second energized state; the second magnetic field B 2 (t 2 -t 3)The second magnetic field electromagnetic force F4 generated by the electric arc, molten droplet 30, and molten pool 29 acts on the electric arc, molten droplet 30, and molten pool 29 from the left rear to the right front direction. Therefore, the second magnetic field electromagnetic force F2 in the second energized state is decomposed into a forward second electromagnetic force and a rightward third electromagnetic force. Thus, under the superposition of the first magnetic field electromagnetic force F1 in the second energized state and the second magnetic field electromagnetic force F2 in the second energized state, the molten droplet 30 converges more at the right front of the welding wire 14 as shown in Figure 7 , and the molten pool 29 shows a movement trend of being pushed forward to the right front as shown in Figure 8 .

[0070] Due to the alternating switching of the above first energized state and second energized state, under the action of the pulsed composite magnetic field, the electric arc, molten pool 29, and molten droplet 30 move forward under the superposition of the first electromagnetic force and the second electromagnetic force, further enhancing the tilting effect of the molten droplet 30, reducing the tilting degree of the molten droplet 30 and the electric arc, reducing the impact kinetic energy from the molten droplet 30 in the longitudinal backward liquid flow of the molten pool 29, and offsetting the pushing effect of the arc force on the backward liquid flow. Furthermore, the flow rate of the backward liquid flow is reduced, the lack of fusion defect is inhibited, and the uneven distribution of the liquid metal along the weld direction is avoided; moreover, the electric arc, molten pool 29, and molten droplet 30 swing left and right under the action of the third electromagnetic force, driving the molten droplet 30 and the electric arc to swing left and right along the weld width direction, thereby promoting the lateral spreading of the liquid metal in the molten pool 29, increasing the weld width, and also avoiding the increase in the longitudinal backward liquid flow velocity due to the narrowing of the flow width of the liquid metal. Moreover, it can also generate a vertical regulation effect on the electric arc, molten droplet 30, and molten pool 29 as shown in Figure 4 and Figure 7 .

[0071] It can be understood that based on the electromagnetic induction principle, the magnetic induction intensity of the pulsed composite magnetic field is: ; where B is the magnetic induction intensity of the magnetic field; N is the number of turns of the coil; I is the current passing through the coil; L e is the effective length of the magnetic circuit.

[0072] The welding device 8 increases the common magnetic pole 11 and winds the coil winding on the common magnetic pole 11, so that the common magnetic pole 11 can directly generate a stronger magnetism, effectively and intuitively increasing the magnetic field intensity of the second magnetic field in each of the above energized states, and greatly improving the second magnetic field electromagnetic force F2 in the first energized state and the second magnetic field electromagnetic force F4 in the second energized state. That is, under the condition of the same excitation current, not only the left-right swinging ability of the electric arc is improved, but also the forward tilting ability of the electric arc is improved.

[0073] It can be understood that based on the electromagnetic induction principle, the inductive reactance of the pulsed composite magnetic field is: ; Wherein, X L is the inductive reactance of the magnetic pole; f is the frequency of the exciting current; L is the inductance of the coil winding.

[0074] And, the inductance of the coil winding is: ; Wherein, μ 0 is the permeability of free space; N is the number of turns of the coil; A is the cross-sectional area of the coil winding.

[0075] In the welding device 8, the first exciting magnetic pole 9 has a first inductance, the common magnetic pole 11 has a second inductance, and the second exciting magnetic pole 10 has a third inductance. Based on the above structural arrangement, under the action of the pulsed composite magnetic field, the second inductance is successively connected in parallel with the first inductance and the third inductance.

[0076] In the first energized state, the total inductance of the multi-field controlled exciting welding device 8 is: ; In the second energized state, the total inductance of the multi-field controlled exciting welding device 8 is: ; Wherein, L ALL is the total inductance of the welding device 8, that is, the total inductance of the magnetic pole group; L 1 is the first inductance; L 2 is the second inductance; L 3 is the third inductance.

[0077] By adding the common magnetic pole 11 to the welding device 8, the total inductance of the magnetic pole group has a lower inductive reactance, the corresponding ramp-up time of the exciting current is shorter, the waveform change of the exciting current is faster, and the waveform is more stable. And, under the parameter conditions of the same exciting power supply 7, the peak value of the exciting frequency is larger.

[0078] It can be understood that the welding device 8 of the embodiment of the present invention generates an alternately pulsed composite magnetic field by applying an intermittent dual-channel pulsed current, which can not only stir the molten pool 29 based on the broken grain - mechanical crushing mechanism; at the same time, it can further drive the heat fluctuation inside the molten pool 29, so as to remelt the just-formed columnar crystals at the vulnerable parts based on the weld grain - heat melting mechanism to achieve grain refinement. During high-speed welding, the above-mentioned dual-channel pulsed current (that is, as Figure 3 and Figure 6The alternating excitation current shown) prompts the molten alloy liquid to flow perpendicular to the traveling direction, thereby forming turbulence in the molten pool 29 and a planar fusion line. The dendrites grown epitaxially are prone to breakage under the bending stress generated by the turbulence in the molten pool 29. As a result, more nucleation particles are generated, and the grains are significantly refined. The broken columnar grains re-nucleate and grow in a direction perpendicular to the fusion line, which is almost parallel to the forming direction. As the grains grow, the volume of the columnar crystals increases, and mutual hindrance occurs between the columnar crystals. The force generated by the above hindrance is parallel to the fusion line direction, which reduces the minor axis and increases the major axis of the fitted ellipse of the columnar crystal. This process leads to the formation of columnar crystals with a high ratio of the major axis to the minor axis of the fitted ellipse, achieving the effect of grain refinement and improving the joint performance. In addition, the intermittent dual-path alternating pulse excitation current can generate a rapidly alternating magnetic field, thereby improving the arc stiffness, increasing the arc force, and enhancing the ability of the arc to penetrate the workpiece.

[0079] It can be understood that, as Figure 2 shown, the welding device 8 is preferably centered on the axis of the welding torch. The common magnetic pole 11 forms a first included angle with the first excitation magnetic pole 9, and the common magnetic pole 11 forms a second included angle with the second excitation magnetic pole 10. The ranges of the first included angle and the second included angle are respectively 45 degrees to 135 degrees to ensure that the magnetic field range can more fully cover the arc, the molten droplet 30, and the molten pool 29, and improve the following effect on the arc, the molten droplet 30, and the molten pool 29. Further preferably, the ranges of the first included angle and the second included angle are respectively 90 degrees to 120 degrees to ensure that the first magnetic field electromagnetic force and the second magnetic field electromagnetic force in the above different energization states can perfectly cover the front and rear of the arc, the molten droplet 30, and the molten pool 29, thereby enhancing the coverage range and the effect of the first electromagnetic force, the second electromagnetic force, and the third electromagnetic force, and better applying force from the rear of the welding torch forward. The structure shown in the embodiment of the present invention is the best embodiment, that is, the first excitation magnetic pole 9, the welding torch, and the second excitation magnetic pole 10 are in the same plane (the first included angle formed by the first excitation magnetic pole 9 and the second excitation magnetic pole 10 is 180 degrees), and both the first included angle and the second included angle are 90 degrees.

[0080] It should be noted that, in order to ensure that the first magnetic field electromagnetic force mentioned above always remains forward, the first excitation magnetic pole 9 and the second excitation magnetic pole 10 are preferably symmetrically arranged with respect to the above symmetry plane, that is, the first included angle is equal to the second included angle.

[0081] In some specific embodiments, such as Figure 2As shown, based on the above-mentioned magnetic pole structure and the principle of pulsed composite magnetic field action, in the welding device 8 of this embodiment, the first excitation magnetic pole 9 includes a first core column 91, a first magnetic head 92, and a first coil winding 93. The first core column 91 is parallel to the welding torch, the first coil winding 93 is spirally wound around the outside of the first core column 91, the first magnetic head 92 is integrally connected to the end of the first core column 91 and is parallel to the nozzle 13, and the distance between the first magnetic head 92 and the nozzle 13 is less than the distance between the first core column 91 and the welding gun 12. Similarly, the second excitation magnetic pole 10 includes a second core column 101, a second magnetic head 102, and a second coil winding 103. The second core column 101 is parallel to the welding torch, the second coil winding 103 is spirally wound around the outside of the second core column 101, the second magnetic head 102 is integrally connected to the end of the second core column 101 and is parallel to the nozzle 13, and the distance between the second magnetic head 102 and the nozzle 13 is less than the distance between the second core column 101 and the welding gun 12. The first core column 91 and the second core column 101 are symmetrically arranged on both sides of the welding gun 12, and the first core column 91, the welding gun, and the second core column 101 are in the same plane. The common magnetic pole 11 includes a third core column 111, a third magnetic head 112, and a third coil winding 113. The third core column 111 is located behind the welding gun. The first included angle between the third core column 111 and the first core column 91 is 90 degrees, and the second included angle between the third core column 111 and the second core column 101 is also 90 degrees. The third magnetic head 112 is integrally connected to the end of the third core column 111 and is parallel to the nozzle 13, and the distance between the third magnetic head 112 and the nozzle 13 is less than the distance between the third core column 111 and the welding gun 12. The first core column 91, the second core column 101, and the third core column 111 as a whole form a triangular prism structure with an equilateral triangle cross-section, and the first magnetic head 92, the second magnetic head 102, and the third magnetic head 112 also as a whole form a triangular prism structure with an equilateral triangle cross-section, so as to achieve the maximum integration of the assembly structure.

[0082] In some embodiments, the welding device 8 further includes a protective shell 16. Referring to Figure 10 and Figure 11 shown, the protective shell 16 includes a housing, a welding torch positioning channel 160, a pair of excitation coil slots, and a common coil slot 165. As Figure 10 and Figure 11As shown, the housing preferably includes a first housing 161 and a second housing 162 assembled by butting, so as to facilitate the assembly of the magnetic pole group on the spray gun 12 without removing the spray gun 12. The spray gun positioning channel 160 is constructed at the axial position of the housing, and the spray gun positioning channel 160 is adapted to be sleeved outside the welding gun. Preferably, the spray gun positioning channel 160 penetrates through the upper and lower end faces of the housing along the housing axis, and positioning holes are constructed on at least one end face of the first housing 161 and the second housing 162, so as to perform reliable limit fixation on the spray gun 12 from both ends. Specifically in this embodiment, preferably, a through hole is constructed at the bottom of the first housing 161 (i.e., the end where the spray gun 12 is provided) as the positioning hole at one end of the housing, and a through hole is constructed at the top of the second housing 162 (i.e., the end facing away from the spray gun 12) as the corresponding positioning hole at the other end of the housing, and further preferably, the side wall of the positioning hole at the bottom of the first housing 161 has a certain height, so as to perform more reliable and stable positioning and limiting on the spray gun 12 from the height direction.

[0083] In some specific embodiments, a pair of exciting coil grooves are constructed inside the housing and are symmetrically arranged on both sides of the spray gun positioning channel 160. Each of the pair of exciting coil grooves is adapted to assemble the exciting magnetic poles on the corresponding side. The common coil groove 165 is constructed inside the housing and is arranged behind the spray gun positioning channel 160. The common coil groove 165 is adapted to assemble the common magnetic pole 11. The pair of exciting coil grooves and the common coil groove 165 are isolated from each other and surround the spray gun positioning channel 160, thereby avoiding current interference between the magnetic poles.

[0084] It can be understood that based on the above magnetic pole group structure, preferably, the housing of this embodiment is set as a triangular prism structure, and corresponding coil grooves are constructed inside the positions where every two sides of the housing intersect, which can not only realize reliable protection of the magnetic pole group, but also maximize the structural integration.

[0085] It can be understood that preferably, the overall front part of the protective housing 16 is triangular, and the magnetic heads of the respective magnetic poles extend out from the bottom of the coil groove and face the welding advancing direction together with the spray gun 12, which is convenient for quickly confirming the clamping direction of the housing.

[0086] It can be understood that a heat-resistant layer is provided outside the housing to enhance the heat-resistant protection of the protective housing 16 for the internal magnetic pole group. Preferably, the housing is an outer shell made of aluminum alloy material and is manufactured by 3D printing technology.

[0087] It can be understood that the protective shell 16 further includes a limiting hole 166, a limiting groove 167 and a wire passing hole 168. The limiting hole 166 is formed through the bottom of the excitation coil groove for the magnetic head of the excitation magnetic pole to pass through. The limiting groove 167 is formed through the bottom of the common coil groove 165 for the magnetic head of the common magnetic pole 11 to pass through. The wire passing hole 168 is formed through the side wall of at least one of the excitation coil groove and the common coil groove 165 to facilitate the wire of the coil winding to pass in and out.

[0088] It can be understood that a limiting hole 166 can also be provided at the bottom of the common coil groove 165. The purpose of providing the limiting groove 167 is to facilitate the assembly of the common magnetic pole 11. Similarly, a limiting groove 167 can also be provided at the bottom of the excitation coil groove.

[0089] It can be understood that the protective shell 16 further includes a plurality of weight reduction grooves 169. The weight reduction grooves 169 are formed through the side wall of the shell. Each weight reduction groove 169 is respectively arranged to avoid the common coil groove 165 and each excitation coil groove. As Figure 10 shown, the upper part of the positioning hole of the spray gun positioning channel 160 of the first shell 161 is removed to form the weight reduction groove 169. As Figure 11 shown, the lower part of the positioning hole of the spray gun positioning channel 160 of the second shell 162 is removed, and the side walls of the excitation coil groove and the common coil groove 165 with a certain height are reserved, so as to form the weight reduction groove 169 of the second shell 162. The weight reduction groove 169 of the second shell 162 is also formed by removing the part between the excitation coil groove and the common coil groove 165, and only reserving the coil groove side walls enough to avoid current interference and have a corresponding limiting and fixing effect on the excitation magnetic pole or the common magnetic pole 11.

[0090] Thus, the structural setting of the above-mentioned protective shell 16 can improve the impact resistance, radiation resistance, positioning and rapid assembly capabilities of the magnetic heads of the magnetic pole group. The flow channel type groove structure setting and the heat-resistant layer in the shell together improve the heat resistance of the magnetic heads and coils, and can ensure that each coil winding works for a long time in an environment of 300 °C.

[0091] As Figure 10As shown, the longitudinal section of the first housing 161 is generally rectangular in shape, and the cross-section is generally fan-shaped or rectangular. A partial positioning hole of the spray gun positioning channel 160 is formed in the center of the first housing 161, and a wire passing hole 168 is formed through the side wall of the positioning hole to facilitate the passage of the power cord 21 of the spray gun 12. A partial first excitation coil groove 163 is formed on one side of the partial positioning hole of the spray gun positioning channel 160, and a partial second excitation coil groove 164 is formed on the other side. The upper part of the partial positioning hole of the spray gun positioning channel 160 is hollowed out to form a weight reduction groove 169. Limiting holes 166 are formed through the bottom axis positions of the first excitation coil groove 163 and the second excitation coil groove 164. Wire passing holes 168 are formed through the side walls of the first excitation coil groove 163 and the second excitation coil groove 164 respectively.

[0092] As Figure 11 shown, the longitudinal section of the second housing 162 is generally rectangular in shape, and the cross-section is generally triangular. The middle part of the second housing 162 is hollowed out to form a weight reduction groove 169, and a partial positioning hole of the spray gun positioning channel 160 is formed through the top end face of the second housing 162. Partial first excitation coil grooves 163 and partial second excitation coil grooves 164 are respectively formed at a pair of bottom corner positions of the triangular cross-section inside the second housing 162. The first excitation coil grooves 163 and the second excitation coil grooves 164 inside the second housing 162 can be butted with the first excitation coil grooves 163 and the second excitation coil grooves 164 inside the first housing 161 to form complete first excitation coil grooves 163 and second excitation coil grooves 164. A public coil groove 165 with an open side wall is formed at the top corner position of the triangular cross-section inside the second housing 162. The side wall radian of the public coil groove 165 only needs to satisfy the circumferential positioning of the public magnetic pole 11. Weight reduction grooves 169 are formed by hollowing out the adjacent two of the first excitation coil groove 163, the second excitation coil groove 164 and the public coil groove 165, but at least the side walls with sufficient height at the bottom of the above three coil grooves should be reserved to realize the circumferential positioning of the corresponding magnetic poles. Limiting holes 166 are respectively formed through the bottom axis positions of the first excitation coil groove 163 and the second excitation coil groove 164. A limiting groove 167 is formed through the bottom of the public coil groove 165.

[0093] Referring Figure 1 、 Figure 2 and Figure 12 shown, based on the above welding device 8, an embodiment of the present invention proposes a multi-field controlled excitation welding system (abbreviated as "welding system" in the present invention).

[0094] In some embodiments, Figure 1 the connection structure of a welding system shown is elaborated in detail in the above welding device 8 and will not be repeated here.

[0095] In some embodiments, asFigure 12 As shown, the welding system according to the embodiment of the present invention includes a welding device 8, a welding power source 17, an exciting power source 7, and a Hall sensor 18. The structure and installation method of the welding device 8 are as described above, and will not be elaborated here. The welding power source 17 is connected to the welding torch of the welding device 8, and the welding torch is adapted to be arranged facing the welding joint 19, as Figure 2 shown. The exciting power source 7 is connected to the welding device 8. The exciting power source 7 is used to alternately input a first current I1 and a second current I2 into the welding device 8 respectively, so as to apply a pulsed composite magnetic field that can act on the arc, the molten droplet 30, and the molten pool 29 to the welding torch. The Hall sensor 18 is connected between the welding power source 17 and the welding joint 19, and is connected to the above-mentioned exciting power source 7. When the welding device 8 is in the working state, the Hall sensor 18 is inserted into the secondary wire of the welding machine, and the other end is connected to the sensor access end 74 of the exciting power source 7, so that the exciting power source 7 can be automatically powered according to whether welding is in progress or not.

[0096] It can be understood that the exciting power source 7 includes a box body, a power cord 21, a current output end 71, a handle 72, an air switch 73, and a sensor input end. The handle 72 is fixed on the top of the box body to facilitate the user to move the exciting power source 7. One end of the power cord 21 is connected to the inside of the box body, and the other end is connected to the power supply network to supply power to the exciting power source 7. The current output end 71, the air switch 73, and the sensor input end are evenly arranged on the surface of the box body. Among them, the current output end 71 is connected to the welding device 8 to input a dual-channel pulsed current to the welding device 8. The sensor access end 74 is connected to the Hall sensor 18. The air switch 73 is used to control the opening and closing of the exciting switch.

[0097] In some specific embodiments, as Figure 12 shown, the welding system further includes a control panel 6, at least a pair of exciting ammeters, and an exciting frequency meter 3. The control panel 6 is connected to the exciting power source 7 to facilitate the user to monitor various data of the exciting power source 7. A pair of exciting ammeters are respectively arranged on the control panel 6 to respectively monitor the first current I1 and the second current I2. The exciting frequency meter 3 is arranged on the control panel 6 to monitor the frequency of the pulsed composite magnetic field.

[0098] It can be understood that the control panel 6 includes a multifunctional button 4 and a manual power switch 5. The multifunctional button 4 is used to flexibly adjust the parameters of the first current I1 and the second current I2. The specific parameter adjustment process will be elaborated in detail in the following magnetic field control method, and will not be elaborated here for the time being. The manual power switch 5 is used to turn on and off the control panel 6.

[0099] In some specific embodiments, as Figure 12As shown, the welding system also includes at least one of the following components: a pair of 5G remote-controlled air switches 2273, an aviation quick connector 23, a current interface 25, and an alarm mechanism. One of the pair of 5G remote-controlled air switches 2273 is connected to the excitation power supply 7, and the other is suitable for being connected between the power supply network and the welding power supply 17, so as to facilitate power supply for the welding power supply 17 and the excitation power supply 7. The aviation quick connector 23 is connected to the above-mentioned welding device 8, one end of the current interface 25 is connected to the aviation quick connector 23, and the other end is suitable for being connected to the current output end 71 of the excitation power supply 7. The current interface 25 is used to introduce the output current of the excitation power supply 7 into the welding device 8. The aviation quick connector 23 can connect the excitation power supply 7 and the welding device 8 more conveniently and quickly, and is easier to disassemble and assemble.

[0100] In some specific embodiments, Figure 12 As shown, the alarm mechanism is connected between the current access terminal 24 and the excitation power supply 7, and the current access terminal 24 is connected between the aviation quick connector 23 and the current interface 25. Preferably, the alarm mechanism includes a logic circuit board 26, an audible and visual warning light 27, and a wireless signal generator 28. The logic circuit board 26 is connected between the current access terminal 24 and the excitation power supply 7. The audible and visual warning light 27 is connected to the logic circuit board 26. The wireless signal generator 28 is connected to the logic circuit board 26.

[0101] It can be understood that when the welding current detection value, the duration of the welding current and the excitation current detection value do not meet the normal conditions of the preset excitation state, the alarm mechanism generates an abnormal prompt signal, such as transmitting an air switch 73 circuit breaker signal to the production line abnormal control system, thereby prompting to stop welding and notifying the operator to deal with the abnormal situation.

[0102] Abnormal warning signals can be sound and light alarms, text prompts on the display screen, or alarm messages sent to the operator's mobile device. For example: Sound and light alarm: an alarm sounds and the sound and light warning lamp 27 flashes red to remind the operator that the welding process is abnormal.

[0103] Display screen prompt: The display screen of the welding system's control panel 6 displays the prompt message "Welding abnormality, please check the excitation current".

[0104] Mobile device alerts: Push alerts to operators’ phones via SMS or APP, informing them to check welding equipment immediately.

[0105] By setting the above-mentioned alarm mechanism, the welding system can prevent the excitation power supply 7 from being abnormal, and at the same time output an abnormal signal to be transmitted to the production abnormality control system, so as to stop the welding operation in time and avoid quality defects, thereby improving the practicality and reliability of the multi-field control method and device.

[0106] It is understandable that in the welding system of this embodiment, the preferred welding parameter ranges are provided as follows: the dual-channel pulsed current output by the exciting power supply 7 is 4 A to 10 A, the exciting frequency is 100 Hz to 120 Hz, the magnetic field strength of the pulsed composite magnetic field is 20 mT to 40 mT, the welding current is 200 A to 280 A, the welding voltage is 20 V to 26 V, and the welding speed is 0.9 m / min to 2.2 m / min.

[0107] It can be seen that the welding system of the embodiment of the present invention can coordinate the arc welding technology, the regulation of the exciting power supply 7, and the parameter monitoring of the welding device 8, so as to flexibly and accurately adjust the force direction and swing frequency of the plasma in the molten pool 29, and realize the control of the lateral swing, longitudinal stiffness, and vertical arc penetration of the molten pool 29.

[0108] Based on at least one of the above-mentioned welding device 8 or welding system, an embodiment of the present invention proposes a magnetic field control method (abbreviated as "method" in the present invention).

[0109] In some embodiments, the method is executed by the above-mentioned welding device 8.

[0110] In some embodiments, the method includes the following steps.

[0111] In the first energized state, a first current I1 is simultaneously input to one of a pair of exciting magnetic poles and the common magnetic pole 11.

[0112] In the second energized state, a second current I2 is simultaneously input to the other of the pair of exciting magnetic poles and the common magnetic pole 11.

[0113] The first energized state and the second energized state are alternately switched to generate a pulsed composite magnetic field that can act on the arc, the molten pool 29, and the molten droplet 30.

[0114] In some specific embodiments, the method is executed by the above-mentioned welding system. Through the control panel 6, the following function selection and stage operations are sequentially realized.

[0115] I. Parameter adjustment stage (1) The exciting power supply 7 outputs a dual-channel pulsed current: Click the manual power switch 5, and the LED light of the multifunctional button 4 lights up to supply power to the exciting magnetic head. At this time, the LED light displays the power self-check mode. If it is a pure data display, it means that the exciting power supply 7 has no fault.

[0116] When the LED light of the first exciting ammeter 1 lights up for the first time when the multifunctional button 4 is pressed, it means that the first current I1 is in the adjustment stage. By rotating the multifunctional button 4 clockwise / counterclockwise, the magnitude of the first current I1 is adjusted, and the current adjustment range is 1 A to 120 A.

[0117] After the value is confirmed, press the multi-functional button 4 for the second time to save the data and jump to the adjustment of the second current I2. At this time, the LED light of the second exciting ammeter 2 lights up. The adjustment method is the same as described in (2) above, and the current adjustment range is from 1 A to 120 A. If no adjustment is required, do not rotate the multi-functional button 4.

[0118] After the value is confirmed, press the multi-functional button 4 for the third time to save the data and jump to the adjustment of the exciting frequency. At this time, the LED light of the exciting frequency meter 3 lights up. Rotate the multi-functional button 4 clockwise / counterclockwise to adjust the magnitude of the exciting frequency. The adjustment range of the exciting frequency is from 1 Hz to 120 Hz. If no adjustment is required, do not rotate the multi-functional button 4.

[0119] After the value is determined, press the multi-functional button 4 for the fourth time to save the exciting frequency data and exit the data adjustment mode, and jump back to the standby state again.

[0120] (2) The exciting power supply 7 enters the working state: stop the power supply and press the manual power switch 5.

[0121] II. Welding stage (1) Confirm that the welding device 8 is in good condition and set the welding parameters as follows: The welding current is from 200 A to 280 A, the voltage is from 20 V to 26 V, the welding speed is from 0.9 m / min to 2.2 m / min, the flow rate of the shielding gas sprayed by the welding gun 12 of the welding torch is from 25 L / min to 30 L / min, the exciting frequency is from 100 Hz to 120 Hz, and the magnetic field strength of the pulsed composite magnetic field is from 20 mT to 40 mT.

[0122] (2) During the welding process, pay attention to keeping the magnetic head angle of the magnetic pole group of the welding device 8 consistent with the welding direction A. If there is any deflection, it will affect the welding quality and needs to be adjusted in time.

[0123] Refer to Figure 13 As shown, the welded joint 19 described in the embodiment of the present invention includes a groove portion 193, a pair of root faces 194, and a backing portion 195. The groove portion 193 is formed at the butt joint of a pair of welded members. A pair of root faces 194 are respectively formed at the butt joint of a pair of welded members, and a pair of root faces 194 are located below the groove portion 193, and a groove gap is formed between the pair of root faces 194. One end of the backing portion 195 is integrally connected to the bottom of one of the pair of welded members, and the other end of the backing portion 195 is mounted on the bottom of the other of the pair of welded members.

[0124] In some specific embodiments, such as Figure 13As shown, in the welded joint 19, a pair of welded members includes a butt-jointed first member 191 and a second member 192. A backing plate portion 195 extends from the bottom of the first member 191 towards the second member 192, and the second member 192 overlaps on the backing plate portion 195. Due to the existence of the backing plate portion 195, the thickness of the first member 191 is greater than that of the second member 192. The thickness d of the second member 192 is ≥ 3 mm. The thickness spacing between the backing plate portion 195 of the first member 191 and the bevel portion 193 is the thickness c of the root face 194 of the second member 192. The thickness c of the root face 194 of the second member 192 is at least 2 mm. The angle α between a pair of slopes of the bevel portion 193 is 40 degrees to 50 degrees. The assembly gap is 0 to 2 mm.

[0125] For the above-mentioned welded joint 19, the following test examples are set with the optimal parameter ranges of the above-mentioned welding system: The welded joint 19 is an aluminum alloy roof joint structure. The welding torch uses MIG arc welding. The welding power source 17 is 270 A, the welding voltage is 23 V, the welding speed is 2.2 m / min, the flow rate of the shielding gas sprayed by the torch 12 of the welding torch is 30 L / min, the excitation frequency is 120 Hz, and the magnetic field strength range of the pulsed composite magnetic field is 30 mT to 35 mT. Refer to Figure 14 and Figure 15 As shown, the welded joint 19 is welded by the above-mentioned welding device 8, and the welding quality after welding fully meets the requirements of ISO10042-B "Aluminum and Its Alloy Arc Welds - Quality Defect Grades", achieving the expected effect.

[0126] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A multi-field controlled excitation welding device, characterized in that: include: Welding gun; A pair of excitation magnetic poles are symmetrically arranged on both sides of the welding gun; At least one set of common magnetic poles is arranged on one side of the welding gun and is respectively connected to a pair of the excitation magnetic poles; In a first power-on state, one of the pair of excitation magnetic poles and the common magnetic pole are simultaneously connected to a first current; In a second power-on state, the other of the pair of excitation magnetic poles and the common magnetic pole are simultaneously connected to a second current; When the welding gun is in working state, the first current and the second current are started alternately to form a dual-path pulse current, so as to generate a pulse composite magnetic field that can act on the arc, the molten pool and the molten droplets.

2. The multi-field controlled excitation welding device according to claim 1, characterized in that: The common magnetic pole and the pair of excitation magnetic poles each include: A core column, arranged on one side of the welding gun; a coil winding, wound around the core column, the first current and / or the second current flowing through the coil winding; A magnetic head connected to the end of the core column; The common magnetic pole also includes: A pair of connecting rods, one end of which is connected to the core column of the same common magnetic pole, and the other end of which is respectively connected to the core columns of a pair of excitation magnetic poles.

3. The multi-field controlled excitation welding device according to claim 2, characterized in that: The welding gun comprises: A spray gun, with a nozzle at the end, the nozzle facing; A welding wire is passed through the axis of the spray gun and extends from the nozzle; The magnetic head of the common magnetic pole and the magnetic heads of the pair of excitation magnetic poles are respectively arranged around the welding wire with the welding wire as the central axis.

4. The multi-field controlled excitation welding device according to claim 3, characterized in that: The core column and the magnetic head are both parallel to the welding wire, and the distance between the core column and the welding wire is greater than the distance between the magnetic head and the welding wire.

5. The multi-field controlled excitation welding device according to any one of claims 1 to 4, characterized in that: With the welding direction as the front, the common magnetic pole is arranged at the rear of the welding gun.

6. The multi-field controlled excitation welding device according to claim 5, characterized in that: include: A first excitation magnetic pole is arranged on one side of the welding gun; A second excitation magnetic pole is symmetrically arranged on the other side of the welding gun; A common magnetic pole, arranged at the rear of the welding gun and connected to the first excitation magnetic pole and the second excitation magnetic pole respectively; With the axis of the welding gun as the center, the common magnetic pole and the first excitation magnetic pole form a first angle, and the common magnetic pole and the second excitation magnetic pole form a second angle, and the ranges of the first angle and the second angle are 45 degrees to 135 degrees respectively.

7. The multi-field controlled excitation welding device according to claim 6, characterized in that: The pulse composite magnetic field comprises: A first magnetic field is formed between the first excitation magnetic pole and the second excitation magnetic pole, wherein the first magnetic field in the first power-on state is opposite in direction to the first magnetic field in the second power-on state; the first magnetic field is used to generate a first forward electromagnetic force on the molten pool of the welding gun; a second magnetic field, formed between the second excitation magnetic pole and the common magnetic pole, wherein the second magnetic field in the first power-on state is opposite in direction to the second magnetic field in the second power-on state; the second magnetic field is used to generate a second forward electromagnetic force and a third lateral electromagnetic force on the molten pool; Under the action of the pulse composite magnetic field, the arc, molten pool and molten droplet move forward under the superposition of the first electromagnetic force and the second electromagnetic force, and swing left and right under the action of the third electromagnetic force.

8. The multi-field controlled excitation welding device according to claim 7, characterized in that: The first excitation magnetic pole has a first inductance, the common magnetic pole has a second inductance, and the second excitation magnetic pole has a third inductance; under the action of the pulse composite magnetic field, the second inductance is sequentially connected in parallel with the first inductance and the third inductance; In the first power-on state, the total inductance of the multi-field controlled excitation welding device is: ； In the second power-on state, the total inductance of the multi-field controlled excitation welding device is: ； Among them, L ALL is the total inductance of the multi-field controlled excitation welding device; L1 is the first inductance; L2 is the second inductance; and L3 is the third inductance.

9. The multi-field controlled excitation welding device according to claim 6, characterized in that: The first angle and the second angle range from 90 degrees to 120 degrees respectively.

10. The multi-field controlled excitation welding device according to claim 9, characterized in that: The first excitation magnetic pole, the welding gun and the second excitation magnetic pole are located in the same plane, and the first angle and the second angle are both 90 degrees.

11. The multi-field controlled excitation welding device according to claim 6, characterized in that: Also includes protective case; The protective shell comprises: case; A spray gun positioning channel is constructed at the axis position of the housing, and the spray gun positioning channel is suitable for being sleeved outside the welding gun; A pair of excitation coil slots are constructed in the housing and symmetrically arranged on both sides of the spray gun positioning channel, and the pair of excitation coil slots are respectively suitable for assembling the excitation magnetic poles on the corresponding sides; The common coil groove is constructed in the shell and arranged behind the spray gun positioning channel. The common coil groove is suitable for assembling the common magnetic pole.

12. The multi-field controlled excitation welding device according to claim 11, characterized in that: The protective shell also includes: A limiting hole is formed through the bottom of the excitation coil slot; A limiting groove is formed through the bottom of the common coil groove; A threading hole is formed through the side wall of at least one of the excitation coil slot and the common coil slot.

13. The multi-field controlled excitation welding device according to claim 11, characterized in that: The protective shell also includes: A plurality of weight-reducing grooves are formed through the side wall of the shell; each of the weight-reducing grooves is arranged to avoid the common coil groove and each of the excitation coil grooves.

14. A multi-field controlled excitation welding system, characterized in that: include: The multi-field controlled excitation welding device according to any one of claims 1 to 13; A welding power source connected to a welding gun of the multi-field controlled excitation welding device, wherein the welding gun is suitable for being arranged toward a welding joint; An excitation power supply connected to the multi-field regulation excitation welding device, and used to alternately input a first current and a second current to the multi-field regulation excitation welding device; The Hall sensor is connected between the welding power source and the welding joint, and is connected to the excitation power source.

15. The multi-field controlled excitation welding system according to claim 14, characterized in that: Also includes: A control panel connected to the excitation power supply; a pair of excitation current meters, respectively disposed on the control panel, for respectively monitoring the first current and the second current; An excitation frequency meter is arranged on the control panel and is used to monitor the frequency of the pulse composite magnetic field.

16. The multi-field controlled excitation welding system according to claim 14, characterized in that: Also includes at least one of the following components: a pair of 5G remote-controlled air switches, one of which is connected to the excitation power supply, and the other is suitable for being connected between the power supply grid and the welding power supply; Aviation quick connector, connected to the multi-field control excitation welding device; A current interface, one end of which is connected to the aviation quick connector, and the other end of which is suitable for connecting to the current output end of the excitation power supply; The alarm mechanism is connected between the current access terminal and the excitation power supply, and the current access terminal is connected between the aviation quick connector and the current interface.

17. The multi-field controlled excitation welding system according to claim 16, characterized in that: The alarm mechanism comprises: A logic circuit board connected between the current input terminal and the excitation power supply; An audible and visual warning light connected to the logic circuit board; A wireless signal generator is connected to the logic circuit board.

18. The multi-field controlled excitation welding system according to claim 14, characterized in that: The welded joint comprises: The groove portion is formed at the butt joint of a pair of welded components; A pair of blunt edges, respectively formed at the butt joints of the pair of welding components, and the pair of blunt edges are located below the groove portion, and a groove gap is formed between the pair of blunt edges; The backing plate has one end integrally connected to the bottom of one of the pair of welding members, and the other end mounted on the bottom of the other of the pair of welding members.

19. A magnetic field control method, characterized in that: Executed by the multi-field controlled excitation welding device according to any one of claims 1 to 13; The magnetic field control method comprises the following steps: In a first energized state, a first current is simultaneously input to one of the pair of excitation magnetic poles and the common magnetic pole; In a second energized state, a second current is simultaneously input to the other of the pair of excitation magnetic poles and the common magnetic pole; The first energizing state and the second energizing state are switched alternately to generate a pulse composite magnetic field that can act on the arc, the molten pool and the molten droplets.

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