Magnetic control auxiliary welding system and method for welding or additive manufacturing

Abstract

The invention provides a magnetic control auxiliary welding system for welding or additive manufacturing, and relates to the technical field of material processing. The welding system provided by the invention comprises a welding device used for carrying out cladding and material adding on a preset substrate or welding a to-be-connected base material; the magnetic control device comprises a connecting base and a magnetic control assembly, the connecting base is provided with a containing cavity, the magnetic control assembly is fixed in the containing cavity, and the magnetic control assembly comprises a plurality of magnet exciting coils arranged in a single row in the first direction; the control device is in signal connection with the guide device, the guide device is in transmission connection with the connecting base, and the control device is used for controlling the guide device to drive the connecting base to move to the position above the additive molten pool or the welding molten pool in the direction parallel or perpendicular to the preset base plate. And the energized excitation coils generate an excitation magnetic field perpendicular to the forming direction of the molten pool. According to the welding system, the solidification behavior of the molten pool is regulated and controlled in real time through the controllable magnetic field array, and the grain structure and the forming quality are optimized.

Description

Technical Field

[0001] The present application relates to the technical field of material processing, and in particular to a magnetic control assisted welding system and method for welding or additive manufacturing. Background Art

[0002] Welding and additive manufacturing are core technologies in the field of metal material connection and forming, and are widely used in aerospace, shipbuilding, high-end equipment manufacturing and other fields. However, during the welding process, high heat input can easily lead to residual stress in the weld, coarse grains and crack defects; additive manufacturing faces problems such as uneven solidification of the molten pool, interlayer flow, pores and stress concentration.

[0003] At present, magnetic field-assisted technology can refine grains and improve performance by non-contactly controlling the solidification behavior of the molten pool. However, traditional magnetic control systems have limitations such as severe interference between the magnetic field and the arc, bulky devices, and difficulty in integration into flexible manufacturing equipment (such as industrial robots), which restrict their application in complex working conditions. Summary of the invention

[0004] The present application provides a magnetically controlled assisted welding system and method for welding or additive manufacturing, which uses a controllable magnetic field array to control the solidification behavior of the molten pool in real time, optimizes the grain structure and forming quality, and is suitable for flexible manufacturing by industrial robots.

[0005] In order to achieve the above objectives, this application provides the following technical solutions:

[0006] A first aspect of the present application provides a magnetic control assisted welding system for welding or additive manufacturing, comprising: a welding device for cladding additive materials on a preset substrate or welding a parent material to be connected;

[0007] A magnetic control device, comprising a connection seat and a magnetic control assembly, wherein the connection seat has a receiving cavity, the magnetic control assembly is fixed in the receiving cavity, and the magnetic control assembly comprises a plurality of excitation coils arranged in a single row along a first direction;

[0008] A control device and a guide device, wherein the control device is connected to the guide device by signal, and the guide device is connected to the connecting seat by transmission, and the control device is used to control the guide device to drive the connecting seat to move along a direction parallel or perpendicular to the preset substrate to above the molten pool of the additive material or the molten pool of the welding, so that the multiple excitation coils that are energized generate an excitation magnetic field perpendicular to the direction in which the molten pool is formed.

[0009] In a possible implementation, among the multiple excitation coils, adjacent excitation coils are bonded and fixed by insulating glue;

[0010] Alternatively, the magnetron assembly further comprises a fixing frame, the fixing frame is fixedly connected to the inner wall of the connecting seat, the fixing frame has a plurality of slots, the plurality of slots are arranged in one-to-one correspondence with the plurality of excitation coils, and the excitation coils are fixed in the slots.

[0011] In a possible implementation manner, the number of the multiple excitation coils is 5-11, and the number of the excitation coils is an odd number.

[0012] In a possible implementation, it also includes a shielding baffle, which is fixedly connected to the connecting seat, and the shielding baffle is arranged on the side of the magnetic control device facing the welding device to block the magnetic field generated by the excitation coil from being applied to the welding arc generated by the welding device.

[0013] In one possible implementation, the shielding baffle includes a connecting portion and a shielding portion, the connecting portion is fixedly connected to the outer wall of the connecting seat, the shielding portion is fixedly connected to the connecting portion, the shielding portion extends along the arrangement direction of the multiple excitation coils, and along the height direction of the substrate, the edge of the shielding portion is flush with the edge of the connecting seat.

[0014] In a possible implementation, the guide device includes a driving device, a lifting module and a sliding module, the driving device includes a first motor and a second motor, the first motor is relatively fixed to the connecting seat, the first motor is drivingly connected to the lifting module, the first motor is signal-connected to the control device, the lifting module is drivingly connected to the connecting seat, and the first motor is used to drive the connecting seat to move up and down along the height direction of the substrate;

[0015] The second motor is relatively fixed to the connecting seat, the second motor is drivingly connected to the sliding module, the second motor is signal-connected to the control device, the sliding module is transmission-connected to the connecting seat, and the second motor is used to drive the connecting seat to move along the welding direction parallel to the welding device.

[0016] In a possible implementation, a distance sensor is further included, which is fixedly connected to the connection base, and the distance sensor is connected to the control device by signal. The control device obtains the target distance between the connection base and the molten pool through the distance sensor, and controls the movement of the guide device to make the target distance within a preset distance range;

[0017] The distance sensor is a laser sensor or an infrared sensor.

[0018] In a possible implementation, the control device includes a host computer, an acquisition card, and an induction power driver, the host computer is signal-connected to the acquisition card and the induction power driver, the acquisition card is signal-connected to the distance sensor, the induction power driver is electrically connected to the multiple excitation coils to output programmable current to the multiple excitation coils, and the host computer is signal-connected to the guide device to control the movement of the guide device;

[0019] And / or, the guiding device further comprises a robot end effector, which is transmission-connected to the driving device via a connecting flange, and the robot end effector can drive the guiding device to rotate and / or move along the height direction of the preset substrate.

[0020] The magnetic control assisted welding system for welding or additive manufacturing provided in the first aspect of the present application includes at least the following beneficial effects:

[0021] A molten pool is formed on the substrate by a welding device, and an excitation magnetic field perpendicular to the formation direction of the molten pool is generated above the molten pool by a magnetic control device to dynamically control the solidification behavior of the molten pool. The system includes a welding device, a magnetic control device, a control device and a guide device: the welding device provides a heat source and forms a molten pool; the excitation coil of the magnetic control device generates a high-intensity horizontal magnetic field after being energized; the control device drives the connecting seat to move in a direction parallel or perpendicular to the substrate through the guide device to ensure that the magnetic field terminal always covers the solidification zone behind the molten pool, and induces the flow of molten pool metal through the Lorentz force, refines the grains, reduces pores and cracks, improves the forming quality, and adapts to complex trajectories and flexible manufacturing requirements.

[0022] A second aspect of the present application provides a welding or additive manufacturing method, which is performed using the magnetic control assisted welding system provided by any of the above technical solutions, and the method comprises the following steps: forming a molten pool of a target layer on the preset substrate by the welding device;

[0023] The control device controls the magnetic control device to move above the molten pool, and obtains a first target distance between the connection seat and the target layer through a distance sensor. In response to the first target distance being within a preset range, the control device controls the induction power driver to energize the multiple excitation coils to generate an excitation magnetic field;

[0024] The control device further controls the guide device to drive the connecting seat to move within the preset range in response to the first target distance being outside the preset range;

[0025] The control device acquires the magnetic field strength of the excitation magnetic field through the acquisition card, and adjusts the intensity of the excitation current to the excitation coil through the induction power driver so that the magnetic field strength of the excitation magnetic field is within the target field strength range;

[0026] After the molten pool of the current target layer is completely solidified, the control device turns off the excitation current and controls the guide device to lift up.

[0027] In a possible implementation manner, the target field strength ranges from 200 mT to 1500 mT;

[0028] And / or, the preset range is 2-20 mm;

[0029] And / or, the method further includes the steps of: obtaining a second target distance through the distance sensor, along the height direction of the preset substrate, the second target distance being the distance between the positive projection of the edge of the excitation coil toward the side of the welding device on the target layer and the boundary interface between the pasty area and the molten pool area of ​​the target layer, and the control device controlling the connecting seat to move to a position less than or equal to the preset value in response to the second target distance being greater than a preset value, and the preset value is 2 mm.

[0030] The welding or additive manufacturing method provided in the second aspect of the present application has all the beneficial effects of the magnetic control assisted welding system provided in the first aspect of the present application, which will not be repeated here. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0032] Figure 1 A schematic diagram of the structure of a magnetic control assisted welding system provided in an embodiment of the present application;

[0033] Figure 2 for Figure 1 Schematic diagram of the structure of the magnetic control device;

[0034] Figure 3 A schematic structural diagram of another magnetic control device of the magnetic control assisted welding system provided in an embodiment of the present application.

[0035] Description of reference numerals:

[0036] 100, welding device; 110, welding power source; 120, gas cylinder; 130, wire feeder; 131, welding wire; 140, welding gun; 200, magnetron device; 210, connecting seat; 211, first sub-seat; 2111, supporting block; 2112, vertical plate; 212, second sub-seat; 2121, accommodating cavity; 2122, connecting block; 2123, magnetic housing; 2124, opening; 2125, connecting section; 2126, extension section; 220, magnetron assembly; 300, Control device; 310, host computer; 320, acquisition card; 330, induction power driver; 400, guide device; 410, drive device; 411, first motor; 412, second motor; 420, robot end effector; 430, connecting flange; 440, lifting module; 500, preset substrate; 600, shielding baffle; 610, connecting part; 620, shielding part; 700, distance sensor; 800, workpiece; 810, molten pool; 820, pasty area.

[0037] The above drawings have shown clear embodiments of the present application, which will be described in more detail later. These drawings and text descriptions are not intended to limit the scope of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0038] As mentioned in the background technology, welding and additive manufacturing are core technologies in the field of metal material connection and forming, and are widely used in aerospace, shipbuilding, high-end equipment manufacturing and other fields. However, during the welding process, high heat input can easily lead to residual stress in the weld, coarse grains and crack defects; additive manufacturing faces problems such as uneven solidification of the molten pool, interlayer flow, pores and stress concentration.

[0039] Among the related technologies, magnetic field-assisted technology can refine grains and improve performance by non-contactly regulating the solidification behavior of the molten pool. However, traditional magnetic control systems have limitations such as severe interference between the magnetic field and the arc, bulky equipment, and difficulty in integration into flexible manufacturing equipment (such as industrial robots), which restricts their application in complex working conditions.

[0040] In addition, the magnetic field-assisted system with a single magnetic field mode or a fixed magnetic field array lacks dynamic feedback and real-time adjustment capabilities, which will lead to insufficient matching accuracy between the magnetic field effect and the solidification stage of the molten pool, making it difficult to adapt to the complex scenario of dynamic position offset of the molten pool in welding or additive manufacturing. In addition, the existing devices have poor robot-carrying capabilities, insufficient magnetic field interference suppression, and lack of compact design, making it difficult to achieve real-time and precise control of magnetic field intensity, frequency, and range of action, resulting in limited optimization of the molten pool solidification structure.

[0041] In response to the above technical problems, the embodiment of the present application provides a method of forming a molten pool on a substrate through a welding device, and using a magnetic control device to generate an excitation magnetic field perpendicular to the formation direction of the molten pool above the molten pool to dynamically control the solidification behavior of the molten pool. The system includes a welding device, a magnetic control device, a control device and a guide device: the welding device provides a heat source and forms a molten pool; the excitation coil of the magnetic control device generates a high-intensity horizontal magnetic field after being energized; the control device drives the connecting seat to move in a direction parallel or perpendicular to the substrate through the guide device to ensure that the magnetic field terminal always covers the solidification zone behind the molten pool, and induces the flow of molten pool metal through the Lorentz force, refines the grains, reduces pores and cracks, improves the forming quality, and adapts to complex trajectories and flexible manufacturing requirements.

[0042] In order to make the above-mentioned purposes, features and advantages of the embodiments of the present application more obvious and understandable, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work belong to the scope of protection of this application.

[0043] Combination Figure 1 and Figure 2 In the first aspect, the magnetic control assisted welding system for welding or additive manufacturing provided by the embodiment of the present application includes: a welding device 100, which is used to perform cladding additive or welding of a parent material to be connected on a preset substrate 500; a magnetic control device 200, which includes a connection seat 210 and a magnetic control component 220 fixed in the connection seat 210, and the magnetic control component 220 includes a plurality of excitation coils arranged in a single row along a first direction, wherein Figure 1 For example, the first direction is the Y direction; the control device 300 and the guide device 400, the control device 300 is signal-connected with the guide device 400, the guide device 400 is transmission-connected with the connecting seat 210, and the control device 300 is used to control the guide device 400 to drive the connecting seat 210 to move in a direction parallel to or perpendicular to the preset substrate 500 to above the additive molten pool 810 or the welding molten pool 810, so that the multiple excitation coils that are energized generate an excitation magnetic field perpendicular to the formation direction of the molten pool 810.

[0044] In this way, an excitation magnetic field perpendicular to the formation direction of the molten pool 810 is generated above the molten pool 810 through the magnetic control device 200, and the solidification behavior of the metal in the molten pool 810 is regulated by the magnetic field force, so as to refine the grains, reduce pores and cracks, and improve the mechanical properties of the weld or additive layer; the guide device 400 and the control device 300 work together to achieve precise positioning of the magnetic field terminal and adapt to complex welding paths.

[0045] Exemplarily, the connection socket 210 is made of a high temperature resistant material and can shield external electromagnetic interference, and the preset substrate 500 can be a 2319 aluminum alloy plate.

[0046] In some embodiments, among multiple excitation coils, adjacent excitation coils are bonded and fixed by insulating glue. Exemplarily, the insulating glue is a high-temperature resistant epoxy resin (temperature resistance ≥ 300°C), which is coated on the sides of adjacent coils with a bonding thickness of ≤1mm. The insulating glue is set by injecting the glue after the coils are arranged and forming an integral structure after curing.

[0047] Alternatively, the magnetron assembly 220 also includes a fixing frame, which is fixedly connected to the inner wall of the connecting seat 210, and the fixing frame has a plurality of slots, and the plurality of slots are arranged one by one corresponding to the plurality of excitation coils, and the excitation coils are fixed in the slots. Exemplarily, the fixing frame is made of insulating ceramic, and a plurality of U-shaped slots are arranged on its inner wall, and the slot spacing matches the outer diameter of the coil. Furthermore, after the coil is embedded in the slot, it can be fixed by a locking screw to ensure axial alignment.

[0048] In this way, not only a better fixing method is provided for the combination of multiple excitation coils, but also the positioning accuracy and heat dissipation capacity of each coil are guaranteed.

[0049] In some embodiments, the number of the multiple excitation coils is 5-11, and the number of the excitation coils is an odd number. For example, the number of the excitation coils is 5, 7, or 11. In this way, a Halbach array magnetic field can be formed, and the current directions of adjacent excitation coils are alternated, and the magnetic field strength in the target area is enhanced by magnetic field superposition. An odd number of coils can eliminate the magnetic field unevenness caused by symmetry (such as a concave central magnetic field), and the central magnetic field strength can be significantly improved compared to an even number array.

[0050] In some embodiments, a shielding baffle 600 is further included, which is fixedly connected to the connecting base 210. The shielding baffle 600 is disposed on the side of the magnetron device 200 facing the welding device 100 to block the magnetic field generated by the excitation coil from being applied to the welding arc generated by the welding device 100.

[0051] Exemplarily, the shielding baffle 600 is made of Permalloy (high magnetic permeability) or silicon steel sheet, with a thickness of 2-5 mm.

[0052] With such arrangement, the shielding baffle 600 blocks the interference of the magnetic field of the excitation coil on the welding arc, thereby preventing arc blow or reduction in stability.

[0053] In some embodiments, the shielding baffle 600 includes a connecting portion 610 and a shielding portion 620. The connecting portion 610 is fixedly connected to the outer wall of the connecting seat 210, and the shielding portion 620 is fixedly connected to the connecting portion 610. The shielding portion 620 extends along the arrangement direction of the multiple excitation coils, and along the height direction of the substrate, the edge of the shielding portion 620 is flush with the edge of the connecting seat 210.

[0054] Exemplarily, the connecting portion 610 is fixed to the outer wall of the connecting base 210 by bolts, and is inclined at a 30° angle to the axis of the connecting base 210. The shielding portion 620 extends along the arrangement direction of the excitation coil. The length of the shielding portion 620 covers all coils, and the height is flush with the edge of the connecting base 210, forming a magnetic field shielding area.

[0055] During welding, the shielding baffle 600 is located between the excitation coil and the welding gun 140, which confines the magnetic field to the molten pool 810 area, and the arc stability is significantly improved.

[0056] In some embodiments, the guiding device 400 includes a driving device 410, a lifting module 440 and a sliding module. The driving device 410 includes a first motor 411 and a second motor 412. The first motor 411 is relatively fixed to the connecting seat 210, and the first motor 411 drives the lifting module 440 to be connected. The first motor 411 is signal-connected to the control device 300, and the lifting module 440 is transmission-connected to the connecting seat 210. The first motor 411 is used to drive the connecting seat 210 to move up and down along the height direction of the substrate; the second motor 412 is relatively fixed to the connecting seat 210, and the second motor 412 drives the sliding module to be connected. The second motor 412 is signal-connected to the control device 300, and the sliding module is transmission-connected to the connecting seat 210. The second motor 412 is used to drive the connecting seat 210 to move along the welding direction parallel to the welding device 100.

[0057] Exemplarily, the lifting module 440 includes a fixed seat, a lifting platform, a lifting guide rail, a first slider, a ball screw and a ball nut. The bottom of the lifting platform is fixed to the ball nut through a flange, the ball screw is fixed to the fixed seat through a bearing seat, and the ball nut cooperates with the screw to realize linear motion. The two sides of the lifting platform are slidably connected to the lifting guide rail through the first slider, the lifting guide rail is threadedly fixed to the fixed seat, the connecting seat 210 is fixed to the lifting platform through bolts, the first motor 411 is fixed to the fixed seat through the motor seat, and the output end of the first motor 411 is connected to the screw drive to transmit torque. It can be understood that Yes, the host computer 310 sends a pulse to the first motor 411, and the rotation of the first motor 411 drives the ball screw to rotate. When the ball screw rotates, the ball nut moves along the axial direction of the screw, driving the lifting platform to carry the connecting seat 210 to rise and fall vertically, and the distance sensor 700 detects the distance a between the connecting seat 210 and the molten pool 810 in real time, and feeds back to the host computer 310. When a exceeds the range of 2-20mm, the host computer 310 generates a pulse signal to drive the first motor 411 to adjust the position of the connecting seat 210. After the adjustment is completed, the distance sensor 700 detects the distance again to form a closed-loop control.

[0058] The sliding module includes a base, a sliding platform, a synchronous belt, a pulley, a tensioning wheel, a linear guide and a second slider. The base is threadedly fixed to the robot end effector 420, the linear guide is fixedly connected to the base, the sliding platform is slidably connected to the linear guide through the second slider, the top of the sliding platform is fixedly connected to the fixed seat of the lifting module 440, the bottom of the sliding platform is fixedly connected to the synchronous belt, the tensioning wheel is fixed on the base, the two ends of the synchronous belt are respectively wound around the pulley and the tensioning wheel, the second motor 412 is fixed on the base, the output end of the second motor 412 is connected to the pulley for transmission, the upper computer 310 controls the second motor 412 to rotate to drive the synchronous belt to move, when the synchronous belt moves, the sliding platform slides horizontally along the linear guide, driving the lifting module 440 and the connecting seat 210 to move laterally (along the X direction).

[0059] In some embodiments, a distance sensor 700 is also included, which is fixedly connected to the connecting socket 210. The distance sensor 700 is connected to the control device 300 by signal. The control device 300 obtains the target distance between the connecting socket 210 and the molten pool 810 through the distance sensor 700, and controls the movement of the guide device 400 to make the target distance within a preset distance range; the distance sensor 700 is a laser sensor or an infrared sensor.

[0060] In this case, the distance sensor 700 is used for closed-loop control to ensure that the magnetic field action distance is constant. For example, the sensor is fixed to the inner wall of the connecting seat 210, the sensor probe is aimed at the surface of the molten pool 810, and the electromagnetic interference is reduced by the shielding cover.

[0061] In some embodiments, the control device 300 includes a host computer 310, an acquisition card 320 and an induction power driver 330. The host computer 310 is signal-connected to the acquisition card 320 and the induction power driver 330. The acquisition card 320 is signal-connected to the distance sensor 700. The induction power driver 330 is electrically connected to multiple excitation coils to output programmable current to the multiple excitation coils. The host computer 310 is signal-connected to the guide device 400 to control the movement of the guide device 400; and / or, the guide device 400 also includes a robot end effector 420, which is transmission-connected to the drive device 410 via a connecting flange 430. The robot end effector 420 can drive the guide device 400 to rotate and / or move along the height direction of a preset substrate 500.

[0062] With such configuration, multi-device collaborative control is achieved through the host computer 310; the robot end effector 420 expands the system flexibility and adapts to complex trajectories. Specifically, the robot end effector 420 is a six-axis robot, and the connecting seat 210 can simultaneously achieve translation and rotation movements in three directions of X, Y, and Z axes.

[0063] Exemplarily, the software functions of the host computer 310 include magnetic field parameter programming, path planning and data storage (such as storing welding path G code), and the communication protocols used include EtherCAT to control the stepper cylinder and Modbus-TCP to connect the induction power driver 330.

[0064] That is to say, through the host computer 310 software, the output waveform of the magnetic field array composed of multiple excitation coils can be programmed and designed, and the parameters such as magnetic field strength, frequency, waveform and duty cycle can be flexibly set to meet the solidification requirements of the molten pool 810 under different materials and process conditions. The system supports automatic triggering function, which can dynamically adjust the magnetic field output according to the real-time working conditions of welding or additive manufacturing to ensure that the effect of the magnetic field on the molten pool 810 is always in the optimal state.

[0065] In more embodiments, the welding system also includes a cooling assembly, which includes a cooling plate, a circulating pump, a radiator, a fan, a liquid storage tank and a temperature sensor. A cooling microchannel is provided inside the cooling plate, which is fixedly arranged on the opposite side of the excitation coil group composed of multiple excitation coils, and can cover all the excitation coils. The cooling plate is connected to the circulating pump through a flexible pipeline, and the circulating pump is connected to the radiator. The fan is arranged on the side of the radiator, and the radiator is connected to the liquid storage tank, and the liquid storage tank is connected to the circulating pump. Two temperature sensors are respectively embedded in the surface of the cooling plate and the liquid storage tank. The working principle of the cooling assembly is as follows: The coolant circulation process includes: heat absorption stage: the coolant is pressurized from the liquid storage tank by a pump and flows into the microchannel of the cooling plate to absorb the heat generated by the excitation coil; heat dissipation stage: the high-temperature coolant flows through the radiator, and the fan forces convection to dissipate the heat to the environment (the liquid temperature drops below 35°C); reflux stage: the coolant returns to the liquid storage tank and circulates reciprocatingly.

[0066] Furthermore, a temperature closed-loop control design can be adopted. The cooling component also includes a PID controller, which is connected to the circulating pump and fan signals. The temperature sensor detects the cooling plate temperature (T1) and the liquid storage tank temperature (T2) in real time. If T1>60℃, the PID controller increases the pump speed to 2L / min and starts the fan at full speed; if T1<40℃, the pump speed drops to 0.5L / min and the fan enters standby mode.

[0067] Furthermore, the cooling plate and cooling pipes are made of non-magnetic materials (aluminum, PTFE) to avoid interfering with the magnetic field distribution.

[0068] In a second aspect, an embodiment of the present application provides a method for welding or additive manufacturing using a welding system provided by any embodiment of the first aspect, comprising the following steps:

[0069] A molten pool 810 of a target layer is formed on a preset substrate 500 by a welding device 100, wherein the welding device 100 includes a welding power source 110, a welding gun 140, a wire feeder 130, and a gas cylinder 120. The welding gun 140 is connected to the welding power source 110 through a cable to provide an arc heat source. The welding gun 140 is connected to the wire feeder 130 through a wire feeding hose. The welding power source 110 may be a Fronius welder, and the welding wire 131 may be a 2319 aluminum alloy with a diameter of 1.2 mm. The gas cylinder 120 delivers inert gas to the welding gun 140 through the gas pipe to prevent the molten pool 810 from being oxidized; the welding power source 110 and the wire feeder 130 are connected to the host computer 310 through a communication line to realize parameter control and closed-loop feedback; the preset substrate 500 is fixed by a clamp to ensure the stability of the workpiece 800; the magnetic control device 200 cooperates with the welding device 100 through the guide device 400 to regulate the solidification behavior of the molten pool 810, thereby forming a high-precision and high-stability welding system.

[0070] The control device 300 controls the magnetic control device 200 to move above the molten pool 810, and obtains the first target distance between the connecting socket 210 and the target layer through the distance sensor 700. In response to the first target distance being within a preset range, the control device 300 controls the induction power driver 330 to energize multiple excitation coils to generate an excitation magnetic field.

[0071] In response to the first target distance being outside the preset range, the control device 300 controls the guide device 400 to drive the connecting seat 210 to move into the preset range.

[0072] The control device 300 obtains the magnetic field strength of the excitation magnetic field through the acquisition card 320, and adjusts the excitation current strength to the excitation coil through the induction power driver 330 so that the magnetic field strength of the excitation magnetic field is within the target field strength range.

[0073] After the molten pool 810 of the current target layer is completely solidified, the control device 300 turns off the excitation current and controls the guide device 400 to lift up.

[0074] In this way, through dynamic distance and magnetic field intensity control, the solidification behavior of the molten pool 810 can be fully optimized, thereby improving the quality and efficiency of welding and additive manufacturing molten pool 810 forming.

[0075] In some embodiments, the target field strength range is 200mT to 1500mT; and / or, the preset range is 2-20mm; and / or, the method also includes the steps of: obtaining a second target distance through a distance sensor 700, along the height direction of the preset substrate 500, the second target distance is the distance between the positive projection of the edge of the excitation coil on the side of the welding device 100 on the target layer and the interface between the mushy area and the molten pool 810 area of ​​the target layer, and when the control device 300 responds to the second target distance being greater than a preset value, the control socket 210 is controlled to move to a position less than or equal to a preset value, and the preset value is 2mm.

[0076] It should be noted that between the additive or welding processes, the magnetic field mode of the excitation coil is first programmed and designed. For example, a sinusoidal magnetic field mode is used, and the target field strength range is set to 200mT to 1500mT, the frequency is 50Hz, and the duty cycle is 50%.

[0077] In this way, the welding method provided in the embodiment of the present application can keep the excitation magnetic field generated by the magnetron assembly 220 at a relatively suitable distance from the top of the molten pool 810. The system collects the actual current magnetic field strength in real time and dynamically adjusts the current input of the excitation coil to ensure that the magnetic field strength is always within the set range. At the same time, the drive device 410 makes fine adjustments based on the information fed back by the distance sensor 700 to ensure that the magnetic field terminal is always at the optimal working distance, thereby achieving precise control of the grain structure of the molten pool 810 and ensuring high-quality solidification of the weld or deposited layer.

[0078] Further, after the target layer weld or deposition layer is completed, the excitation coil stops working and the magnetron solidification process ends. The drive device 410 drives the connection seat 210 to automatically rise to a safe position (the starting position of the next layer of the target layer in the case of additive), and the distance sensor 700 stops monitoring.

[0079] Based on the above embodiment, it can be improved that, in combination with Figure 3 The connecting seat 210 includes a first sub-seat 211 and a second sub-seat 212. The first sub-seat 211 includes a support block 2111 and a vertical plate 2112 that are fixedly connected. The distance sensor is fixed on the side of the support block 2111 away from the vertical plate 2112. Further, the distance sensor can be fixed to the support block 2111 through the seat plate. The second sub-seat 212 includes a fixedly connected connecting block 2122 and a magnetic shell 2123. The magnetic shell 2123 is threadedly fixed to the side wall of the supporting block 2111 through the connecting block 2122. The magnetic shell 2123 is provided with a accommodating cavity 2121. The magnetic shell 2123 is provided with an opening 2124 connected to the accommodating cavity 2121. The setting of the opening 2124 not only facilitates the installation and fixation of the magnetic control component in the magnetic shell 2123, but also facilitates the routing of the excitation coil in the magnetic control component. Further, the magnetic shell 2123 is made of heat-resistant ceramic material.

[0080] Furthermore, the magnetic shell 2123 includes a connecting section 2125 and an extension section 2126, the connecting section 2125 is fixedly connected to the connecting block 2122, and the extension direction of the connecting section 2125 is parallel to the Z direction, the extension section 2126 is oblique to the connecting section 2125, and further, the extension section 2126 is inclined toward the side away from the connecting block 2122, that is, the extension section 2126 is inclined toward the side close to the molten pool. In this way, the shell can adapt to different welding inclination angles or additive layer thicknesses by adjusting the angle between the extension section and the connecting section of the magnetic shell (such as 30°-60°), thereby expanding the process window.

[0081] In the description of the present application, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0082] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of this application, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0083] In this application, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0084] In the present application, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being “above”, “above”, and “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below”, and “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0085] The various embodiments or implementation methods in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the various embodiments can be referenced to each other.

[0086] It should be noted that the embodiments represented by "one embodiment", "an embodiment", "an exemplary embodiment", "some embodiments", etc. mentioned in the specification may include specific features, structures or characteristics, but not every embodiment may include the specific features, structures or characteristics. In addition, such phrases do not necessarily refer to the same embodiment. In addition, when describing specific features, structures or characteristics in conjunction with an embodiment, it is within the knowledge of those skilled in the art to implement such features, structures or characteristics in conjunction with other embodiments that are explicitly or not explicitly described.

[0087] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit it. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A magnetically assisted welding system for welding or additive manufacturing, characterized in that: include: A welding device, used for cladding and adding materials on a preset substrate or welding a parent material to be connected; A magnetic control device, comprising a connection seat and a magnetic control assembly, wherein the connection seat has a receiving cavity, the magnetic control assembly is fixed in the receiving cavity, and the magnetic control assembly comprises a plurality of excitation coils arranged in a single row along a first direction; A control device and a guide device, wherein the control device is connected to the guide device by signal, and the guide device is connected to the connecting seat by transmission, and the control device is used to control the guide device to drive the connecting seat to move along a direction parallel or perpendicular to the preset substrate to above the molten pool of the additive material or the molten pool of the welding, so that the multiple excitation coils that are energized generate an excitation magnetic field perpendicular to the direction in which the molten pool is formed.

2. The welding system according to claim 1, characterized in that Among the multiple excitation coils, adjacent excitation coils are bonded and fixed by insulating glue; Alternatively, the magnetron assembly further comprises a fixing frame, the fixing frame is fixedly connected to the inner wall of the connecting seat, the fixing frame has a plurality of slots, the plurality of slots are arranged in one-to-one correspondence with the plurality of excitation coils, and the excitation coils are fixed in the slots.

3. The welding system according to claim 1 or 2, characterized in that: The number of the multiple excitation coils is 5-11, and the number of the excitation coils is an odd number.

4. The welding system according to claim 1 or 2, characterized in that: It also includes a shielding baffle, which is fixedly connected to the connecting seat. The shielding baffle is arranged on a side of the magnetron device facing the welding device to block the magnetic field generated by the excitation coil from being applied to the welding arc generated by the welding device.

5. The welding system according to claim 4, characterized in that The shielding baffle includes a connecting portion and a shielding portion, wherein the connecting portion is fixedly connected to the outer wall of the connecting seat, and the shielding portion is fixedly connected to the connecting portion. The shielding portion extends along the arrangement direction of the multiple excitation coils, and along the height direction of the substrate, the edge of the shielding portion is flush with the edge of the connecting seat.

6. The welding system according to claim 1 or 2, characterized in that: The guide device includes a driving device, a lifting module and a sliding module. The driving device includes a first motor and a second motor. The first motor is relatively fixed to the connecting seat. The first motor is drivingly connected to the lifting module. The first motor is signal-connected to the control device. The lifting module is drivingly connected to the connecting seat. The first motor is used to drive the connecting seat to move up and down along the height direction of the substrate. The second motor is relatively fixed to the connecting seat, the second motor is drivingly connected to the sliding module, the second motor is signal-connected to the control device, the sliding module is transmission-connected to the connecting seat, and the second motor is used to drive the connecting seat to move along the welding direction parallel to the welding device.

7. The welding system according to claim 6, characterized in that It also includes a distance sensor, which is fixedly connected to the connection base, and the distance sensor is connected to the control device by signal. The control device obtains the target distance between the connection base and the molten pool through the distance sensor, and controls the movement of the guide device to make the target distance within a preset distance range; The distance sensor is a laser sensor or an infrared sensor.

8. The welding system according to claim 7, characterized in that The control device includes a host computer, an acquisition card and an induction power driver, the host computer is connected to the acquisition card and the induction power driver by signal, the acquisition card is connected to the distance sensor by signal, the induction power driver is electrically connected to the multiple excitation coils to output programmable current to the multiple excitation coils, and the host computer is connected to the guide device by signal to control the movement of the guide device; And / or, the guiding device further comprises a robot end effector, which is transmission-connected to the driving device via a connecting flange, and the robot end effector can drive the guiding device to rotate and / or move along the height direction of the preset substrate.

9. A method for welding or additive manufacturing using the welding system according to any one of claims 1 to 8, characterized in that: The steps include: Forming a molten pool of a target layer on the preset substrate by the welding device; The control device controls the magnetic control device to move above the molten pool, and obtains a first target distance between the connection seat and the target layer through a distance sensor. In response to the first target distance being within a preset range, the control device controls the induction power driver to energize the multiple excitation coils to generate an excitation magnetic field; The control device further controls the guide device to drive the connecting seat to move within the preset range in response to the first target distance being outside the preset range; The control device acquires the magnetic field strength of the excitation magnetic field through the acquisition card, and adjusts the intensity of the excitation current to the excitation coil through the induction power driver so that the magnetic field strength of the excitation magnetic field is within the target field strength range; After the molten pool of the current target layer is completely solidified, the control device turns off the excitation current and controls the guide device to lift up.

10. The method according to claim 9, characterized in that The target field strength range is 200mT to 1500mT; And / or, the preset range is 2-20 mm; And / or, the method further includes the steps of: obtaining a second target distance through the distance sensor, along the height direction of the preset substrate, the second target distance being the distance between the positive projection of the edge of the excitation coil toward the side of the welding device on the target layer and the boundary interface between the pasty area and the molten pool area of ​​the target layer, and the control device controlling the connecting seat to move to a position less than or equal to the preset value in response to the second target distance being greater than a preset value, and the preset value is 2 mm.

Images