Plasma welding equipment for intelligent manufacturing of aluminum veneer
The aluminum single panel plasma welding device addresses alignment and thermal issues through precise angle and distance adjustment, along with temperature control, enhancing weld quality and reducing defects.
Patent Information
- Application Number
- CN202510736741.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-04
- Publication Date
- 2025-07-15
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
The existing aluminum veneer plasma welding equipment cannot adjust the distance between the two aluminum veneers to be welded according to the bevel of the aluminum veneer, resulting in the partial unfusion or burn-through of the aluminum veneer after welding, the weld strength is uneven, and the high thermal expansion and thermal conductivity of aluminum lead to the melt pool offset, affecting the welding quality and workpiece deformation.
The adjustment mechanism and the temperature control mechanism are linked to real-time monitoring of the angle and distance of the aluminum veneer through a high-frame rate thermal imager, and precise adjustment and fixation are performed by combining the sliding block and the vacuum suction block. Preheating and temperature control are achieved using the heating wire and the refrigeration plate to ensure welding quality.
It realizes precise adjustment and temperature control of aluminum veneer welding, avoids unfused, burned through and molten pool offset, improves welding quality and efficiency, and is suitable for automated welding scenarios.
Smart Images
Figure CN120306774A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of plasma welding of aluminum single plates, and particularly to a plasma welding device for intelligent manufacturing of aluminum single plates. Background Technique
[0002] The plasma welding technology of aluminum single plates is a high-precision welding process based on a high-temperature plasma arc, which realizes fast and stable welding. Compared with traditional welding methods, plasma welding has the characteristics of high efficiency, excellent weld quality, and strong adaptability. It is widely used in the processing fields of aluminum single plates such as building curtain walls and decoration projects, and can be compatible with the spot welding, segment welding, and full welding requirements of plates with different thicknesses, meeting the dual requirements of modern design for precision and aesthetics.
[0003] Therefore, when the existing plasma welding device for aluminum single plates is actually used, it is impossible to adjust the distance between two aluminum single plates to be welded according to the groove of the aluminum single plate, resulting in local non-fusion or burn-through of the welded aluminum single plate, uneven weld strength, and easy failure at weak points. At the same time, when the plasma welding device welds the aluminum single plate, due to the high thermal expansion and thermal conductivity of aluminum, the influence of uneven temperature distribution will be amplified, easily leading to the offset of the molten pool, which not only affects the weld quality (such as pores and non-fusion), but may also cause workpiece deformation, residual stress, and an increase in rework costs. Moreover, the thermal expansion coefficient of aluminum is relatively large (about 23×10 -6 / °C). During welding, local high temperature will cause the aluminum single plate to expand rapidly. If the workpiece is not firmly fixed, the stress generated by thermal expansion may cause the plate to undergo a small displacement, which will further lead to the offset of the molten pool. For this reason, we propose a plasma welding device for intelligent manufacturing of aluminum single plates. Summary of the Invention
[0004] The purpose of the present invention is to provide a plasma welding device for intelligent manufacturing of aluminum single plates to solve the problems raised in the above background technique.
[0005] To achieve the above purpose, the present invention provides the following technical solution: A plasma welding device for intelligent manufacturing of aluminum single plates, including A welding machine, the welding machine includes a machine shell and a welding torch, and a moving frame is fixedly installed on the top of the machine shell; A welding table, the welding table includes a mounting table slidably installed on the top of the moving frame, and a high-frame-rate thermal imager is fixedly installed on the top of the mounting table; An adjusting mechanism, the adjusting mechanism includes two sliding blocks slidably connected to each other on the top of the mounting table, a placing table is rotatably connected to the top of each of the two sliding blocks, and a fixing mechanism is arranged on the top of the placing table; Temperature control mechanism, the temperature control mechanism includes heating shells respectively slidably connected inside two placement platforms, a heating wire is rotatably connected inside the heating shell, and refrigeration sliders are also respectively slidably connected to the tops of the two heating shells, and a refrigeration plate is fixedly installed on the top of the refrigeration slider.
[0006] Preferably, the adjustment mechanism further includes a sliding bidirectional motor fixedly installed on the top of the installation platform. Both output ends of the sliding bidirectional motor are fixedly connected with sliding threaded rods. Both of the sliding blocks are threadedly connected to the outside of the adjacent sliding threaded rod. A limiting strip is fixedly connected to the top of the installation platform. Both of the sliding blocks are slidably connected to the top of the limiting strip. Rotating motors are fixedly installed on the tops of both of the sliding blocks. Output ends of both of the rotating motors are fixedly connected to one side of the adjacent placement platform.
[0007] Preferably, the temperature control mechanism further includes a heating motor fixedly installed on one side of the heating shell. The output end of the heating motor extends into the heating shell. The output end of the heating motor is fixedly connected with a heating rotating shaft. The heating wire is spirally wound around the outside of the heating rotating shaft for one week.
[0008] Preferably, a driving frame is slidably connected inside both of the placement platforms. A plurality of spring sleeves arranged at intervals are fixedly connected to the top of the driving frame. Ball heads are rotatably connected to the tops of a plurality of the spring sleeves. Tops of a plurality of the ball heads are fixedly connected to the bottom of the adjacent heating shell. Magnetic attraction blocks are fixedly connected to the tops of both ends of the heating shell. Two magnetic attraction strips are fixedly connected to the top inner walls of both of the placement platforms. The two magnetic attraction blocks on the top of the two heating shells are respectively adapted to the adjacent magnetic attraction strips.
[0009] Preferably, refrigeration shells are fixedly connected to the separated sides of the two heating shells. A refrigeration motor is fixedly installed on one side of the refrigeration shell. The output end of the refrigeration motor extends into the refrigeration shell. The output end of the refrigeration motor is fixedly connected with a refrigeration threaded rod. Both of the refrigeration sliders are threadedly connected to the outside of the adjacent refrigeration threaded rod.
[0010] Preferably, driving threaded rods are rotatably connected to the bottoms of both of the placement platforms. The opposite ends of the two driving threaded rods are fixedly connected with the same universal transmission shaft. A driving motor is fixedly installed on the bottom of one of the placement platforms. The output end of the driving motor is fixedly connected to one end of the adjacent driving threaded rod. Driving grooves are opened at the bottoms of both of the placement platforms. Both of the driving frames are threadedly connected to the outside of the adjacent driving threaded rod through the adjacent driving groove.
[0011] Preferably, the fixing mechanism includes vacuum suction blocks fixedly installed on the tops of two placement tables respectively. Driving bidirectional motors are fixedly installed on the tops of both placement tables. Both output ends of the driving bidirectional motor are fixedly connected with driving wheels. A driving belt is rotatably sleeved outside the driving wheels, and the driving belt is rotatably sleeved outside the adjacent vacuum suction block.
[0012] Preferably, the opposite sides of the two placement tables are fixedly connected with the same spring sheet, and the opposite sides of the two placement tables are fixedly connected with the same rubber pad.
[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Through the linkage of the adjustment mechanism and the high-frame-rate thermal imager provided in the invention, the angles and distances of the two aluminum single plates can be accurately adjusted according to the groove angle and the thickness of the aluminum single plate. Through the fixing mechanism provided, the two aluminum single plates to be welded can be respectively fixed on the tops of the corresponding placement tables in a large area and damage to the aluminum single plates can be avoided. At the same time, the two aluminum single plates can be finely adjusted to ensure the gap accuracy of the two aluminum single plates to be welded.
[0014] 2. Through the linkage of the temperature control mechanism and the high-frame-rate thermal imager provided in the invention, the two aluminum single plates to be welded can be preheated, and at the same time, the temperature of the aluminum single plate being welded can be controlled. Problems such as too slow or too fast cooling of the molten pool and excessive inclination can be avoided, indirectly avoiding problems such as incomplete fusion or burn-through at local parts of the welded aluminum single plate, resulting in uneven weld strength and molten pool offset, thereby improving the welding quality.
[0015] 3. Through the real-time linkage of the adjustment mechanism, the temperature control mechanism, the fixing mechanism and the high-frame-rate thermal imager provided in the invention, a closed-loop control of "monitoring - feedback - adjustment" is realized. The thermal imaging data is transmitted to the equipment control system in real time, and the rotation speed of the heating wire and the position of the cooling plate are automatically adjusted. There is no need to manually intervene in the parameters of the welding torch, which is suitable for automated welding scenarios. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 is a schematic diagram of the overall structure of the present invention; Figure 2 is a three-dimensional structure diagram inside the welding machine of the present invention; Figure 3 is a three-dimensional structure diagram of the welding table part of the present invention; Figure 4 is Figure 3 an enlarged structure diagram of part A; Figure 5 is a three-dimensional structure diagram of the driving motor part of the present invention; Figure 6 is a three-dimensional structure diagram of the high-frame-rate thermal imager part of the present invention; Figure 7 is Figure 6 a schematic enlarged view of part B; Figure 8 is a three-dimensional structure schematic diagram of the temperature control mechanism part of the present invention.
[0017] In the attached drawings, the list of components represented by each reference numeral is as follows: 1. Welding machine; 2. Welding table; 3. Adjusting mechanism; 4. Temperature control mechanism; 5. Fixing mechanism; 6. Welding torch; 7. Machine shell; 8. Moving frame; 9. Installation table; 10. Placement table; 11. Sliding block; 12. Sliding two-way motor; 13. Sliding threaded rod; 14. Limiting strip; 15. Rotating motor; 16. Vacuum suction block; 17. Driving two-way motor; 18. Driving wheel; 19. Driving belt; 20. Rubber pad; 21. Spring piece; 22. Driving frame; 23. Driving motor; 24. Driving threaded rod; 25. Universal transmission shaft; 26. Driving groove; 27. Spring sleeve; 28. Ball head; 29. Heating shell; 30. Heating motor; 31. Heating rotating shaft; 32. Heating wire; 33. Magnetic attraction block; 34. Magnetic attraction strip; 35. Refrigeration shell; 36. Refrigeration motor; 37. Refrigeration threaded rod; 38. Refrigeration slider; 39. Refrigeration plate; 40. High-frame-rate thermal imager. Detailed implementation manners
[0018] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts shall fall within the protection scope of the present invention.
[0019] The present invention provides a technical solution: a plasma welding device for intelligent manufacturing of aluminum single plates as Figures 1 - 8 shown, including, A welding machine 1, the welding machine 1 includes a machine shell 7 and a welding torch 6, and a moving frame 8 is fixedly installed on the top of the machine shell 7; A welding table 2, the welding table 2 includes an installation table 9 slidably installed on the top of the moving frame 8, and a high-frame-rate thermal imager 40 is fixedly installed on the top of the installation table 9. The high-frame-rate thermal imager 40 is a prior art, which can capture the dynamic changes of the molten pool (such as the flow direction, filling process), and at the same time can quickly capture the temperature distribution of the aluminum single plate, display the thermal gradient change in real time, and detect the distance between two aluminum single plates according to the temperature contrast of the aluminum single plate; Adjusting mechanism 3, the adjusting mechanism 3 includes two sliding blocks 11 that are relatively slidably connected to the top of the mounting table 9. The tops of the two sliding blocks 11 are both rotatably connected to a placement table 10. The adjusting mechanism 3 further includes a sliding two-way motor 12 fixedly installed on the top of the mounting table 9. Both output ends of the sliding two-way motor 12 are fixedly connected to a sliding threaded rod 13. The two sliding blocks 11 are both threadedly connected to the outside of the adjacent sliding threaded rod 13. A limiting strip 14 is fixedly connected to the top of the mounting table 9. The two sliding blocks 11 are both slidably connected to the top of the limiting strip 14. The tops of the two sliding blocks 11 are both fixedly installed with a rotating motor 15. The output ends of the two rotating motors 15 are both fixedly connected to one side of the adjacent placement table 10; With the above-described structure provided, the angles and distances of the two aluminum single plates can be accurately adjusted according to the groove angle and the thickness of the aluminum single plate. Specifically, before welding the two aluminum single plates, the aluminum single plates need to be preheated: The preheating temperature of the welded aluminum single plate is generally controlled at 50 - 150 °C (adjusted according to the plate thickness): Thin plate (1 - 3 mm): 50 - 80 °C; Thick plate (> 6 mm): 100 - 150 °C; After preheating the aluminum single plates and placing the two aluminum single plates on the tops of the two placement tables 10 respectively, in combination with the high-frame-rate thermal imager 40, the distance between the two aluminum single plates can be detected. At this time, according to the groove angles of the two aluminum single plates and the angle to be welded, the sliding two-way motor 12 and the two rotating motors 15 are started simultaneously. At this time, the output ends of the sliding two-way motor 12 rotate and drive the two sliding threaded rods 13 to rotate. The two sliding threaded rods 13 rotate to drive the two sliding blocks 11 thereon to move relatively. The two sliding blocks 11 move relatively and drive the placement tables 10 thereon to move respectively. At the same time, the output ends of the two rotating motors 15 rotate and drive the placement tables 10 fixedly connected thereto to rotate respectively, realizing the linkage adjustment of the angle and the distance, and improving the welding efficiency.
[0020] A fixing mechanism 5 is provided on the top of the placement table 10. The fixing mechanism 5 includes vacuum suction blocks 16 respectively fixedly installed on the tops of the two placement tables 10. A driving two-way motor 17 is fixedly installed on the top of each of the two placement tables 10. Both output ends of the driving two-way motor 17 are fixedly connected to a driving wheel 18. A driving belt 19 is rotatably sleeved on the outside of the driving wheel 18. The driving belt 19 is rotatably sleeved on the outside of the adjacent vacuum suction block 16; With the above - set structure, two aluminum single - plates to be welded can be respectively fixed on the top of the corresponding placement table 10 in a large area. At the same time, the two aluminum single - plates can be finely adjusted to ensure the gap precision between the two aluminum single - plates to be welded. Specifically, when welding the two aluminum single - plates, the two pre - heated aluminum single - plates are respectively placed on the top of the two placement tables 10. At this time, the vacuum suction block 16 is started to adsorb and fix the aluminum single - plate on the top of the vacuum suction block 16. Then, the adjusting mechanism 3 can be started to adjust the angles and gaps of the two aluminum single - plates, and the high - frame - rate thermal imager 40 is used to detect the gap between the two aluminum single - plates. When an error in the gap is detected, two driving bidirectional motors 17 are started. The output ends of the two driving bidirectional motors 17 respectively drive the driving wheels 18 thereon to rotate. The rotation of the driving wheels 18 drives the driving belts 19 outside the two vacuum suction blocks 16 to rotate. The rotation of the driving belts 19 drives the aluminum single - plates thereon to move, so as to adjust the gap between the two aluminum single - plates. It is worth mentioning that, compared with the adjustment of horizontally adjusting the two aluminum single - plates by starting the sliding bidirectional motor 12, starting the driving bidirectional motor 17 to adjust the inclination angle of the two aluminum single - plates can achieve the effect of large moving distance of the aluminum single - plates but small moving distance of the gap between the two aluminum single - plates, improving the adjustment precision of the gap between the two aluminum single - plates. At the same time, the large - area adsorption and fixation of the aluminum single - plates by the vacuum suction block 16 can improve the fixation effect of the aluminum single - plates during welding and avoid damage to the aluminum single - plates.
[0021] The temperature - control mechanism 4, the temperature - control mechanism 4 includes heating shells 29 respectively slidably connected inside the two placement tables 10. A heating wire 32 is rotatably connected inside the heating shell 29. Refrigeration sliders 38 are also respectively slidably connected to the tops of the two heating shells 29. A refrigeration plate 39 is fixedly installed on the top of the refrigeration slider 38. The temperature - control mechanism 4 further includes a heating motor 30 fixedly installed on one side of the heating shell 29. The output end of the heating motor 30 extends into the heating shell 29. The output end of the heating motor 30 is fixedly connected with a heating rotating shaft 31. The heating wire 32 is spirally wound around the outside of the heating rotating shaft 31 for one week. Drive frames 22 are respectively slidably connected inside the two placement tables 10. A plurality of spring sleeves 27 arranged at intervals are fixedly connected to the top of the drive frame 22. Ball heads 28 are rotatably connected to the tops of the plurality of spring sleeves 27. The tops of the plurality of ball heads 28 are fixedly connected to the bottom of the adjacent heating shell 29. Magnetic attraction blocks 33 are fixedly connected to the tops of both ends of the heating shell 29. Two magnetic attraction strips 34 are fixedly connected to the top inner walls of the two placement tables 10. The two magnetic attraction blocks 33 on the top of the two heating shells 29 are respectively adapted to the adjacent magnetic attraction strips 34. On the separated sides of the two heating shells 29, a refrigeration shell 35 is fixedly connected. On one side of the refrigeration shell 35, a refrigeration motor 36 is fixedly installed. The output end of the refrigeration motor 36 extends into the refrigeration shell 35. The output end of the refrigeration motor 36 is fixedly connected with a refrigeration threaded rod 37. The two refrigeration sliders 38 are both screwed onto the outer part of the adjacent refrigeration threaded rod 37. At the bottom of the two placement platforms 10, a driving threaded rod 24 is rotatably connected. The opposite ends of the two driving threaded rods 24 are fixedly connected with the same universal transmission shaft 25. At the bottom of one of the placement platforms 10, a driving motor 23 is fixedly installed. The output end of the driving motor 23 is fixedly connected with one end of the adjacent driving threaded rod 24. Driving grooves 26 are formed at the bottoms of the two placement platforms 10. The two driving frames 22 are both screwed onto the outer part of the adjacent driving threaded rod 24 through the adjacent driving grooves 26. Thermocouples are respectively arranged inside the two placement platforms 10. Furthermore, in the above solution, through the above - set structure, the two aluminum single - plates to be welded can be pre - heated, and at the same time, the temperature of the aluminum single - plate being welded can be controlled, avoiding problems such as incomplete fusion or burn - through at local parts of the welded aluminum single - plate, resulting in uneven weld strength and molten pool offset, thereby improving the welding quality. Specifically, when two aluminum single - plates need to be welded, first place the two aluminum single - plates on the tops of the corresponding placement platforms 10 respectively. At this time, start the fixing mechanism 5 to fix the two aluminum single - plates. After fixing the two aluminum single - plates, start the two heating wires 32 to pre - heat the welding parts of the two aluminum single - plates, and use the high - frame - rate thermal imager 40 to monitor the pre - heating situation of the aluminum single - plates in real - time. During the pre - heating process of the two aluminum single - plates, the high - frame - rate thermal imager 40 is linked with the adjusting mechanism 3 to adjust the gap and angle between the two aluminum single - plates, and then the high - frame - rate thermal imager 40 is linked with the fixing mechanism 5 to further adjust the gap between the two aluminum single - plates. After the adjustment is completed, at this time, the welding torch 6 can be started to weld the two aluminum single - plates. During the welding of the two aluminum single - plates by the welding torch 6, the high - frame - rate thermal imager 40 monitors the molten pool situation in real - time: In the first case, when the molten pool situation is normal, at this time, since the heating wire 32 is wound around the heating rotating shaft 31 for one week in a spiral manner, there is always a point on the top of the heating wire 32 that is closer to the aluminum single - plate, and a relatively high pre - heating temperature is generated at the closer point in a short time. At this time, combined with the welding movement of the welding torch 6, the welding effect is improved. More specifically, start the heating motor 30. The output end of the heating motor 30 drives the heating rotating shaft 31 to rotate. The rotation of the heating rotating shaft 31 drives the heating wire 32 to rotate, and always moves the top of the heating wire 32 in front of the welding point of the welding torch 6, pre - heating the to - be - welded point at a high temperature for a short time. After the welding torch 6 completes the welding, the top of the heating wire 32 gradually moves away from the current welding point, providing a cooling condition for the molten pool after welding and forming a perfect weld. It is worth mentioning that the short - time temperature rise only targets the solder joints, avoiding the energy consumption and time cost of overall preheating. Moreover, aluminum has a large coefficient of thermal expansion. Local preheating before welding can cause the solder joint area to expand in advance, reducing the thermal stress generated by the temperature gradient during welding and decreasing the risk of post - welding deformation and cracks. This can not only ensure the welding quality but also control deformation and cost.
[0022] In the second case, when the molten pool cools too quickly, air bubbles will appear at the weld seam. At this time, start the heating motor 30 to drive the heating wire 32 to control its top behind the solder joint of the welding torch 6, maintain the existence time of the molten pool, so that the air bubbles in the molten pool have time to disappear, and improve the weld quality.
[0023] In the third case, when the molten pool cools too slowly, drive the two refrigeration motors 36 at this time. The output ends of the two refrigeration motors 36 rotate and respectively drive the refrigeration threaded rods 37 thereon to rotate, indirectly driving the refrigeration sliders 38 to slide on the top of the heating shell 29, so that the refrigeration sliders 38 always slide behind the solder joint of the welding torch 6. At this time, the heating shell 29 is in an inclined state, and the spring sleeve 27 telescopic ball head 28 rotates on the top of the spring sleeve 27. At the same time, the magnetic - absorption blocks 33 on one side of the two heating shells 29 are magnetically adsorbed to the magnetic - absorption strips 34 on their tops, and the magnetic - absorption blocks 33 on the other side are far away from the magnetic - absorption strips 34 on their tops, making the force on the side where the magnetic - absorption block 33 is magnetically adsorbed to the magnetic - absorption strip 34 greater than the side where the magnetic - absorption block 33 is not magnetically adsorbed to the magnetic - absorption strip 34, preventing the refrigeration sliders 38 from losing the preheating of the aluminum single - board to be welded by the heating wire 32 during the sliding process on the top of the heating shell 29, thereby improving the overall welding effect. When no preheating measure is taken for the welded molten pool or the molten pool cools too slowly, the refrigeration plate 39 on the top of the refrigeration slider 38 can be started at this time to directly cool the bottom of the molten pool of the aluminum single - board; It is worth mentioning that aluminum is prone to absorbing hydrogen at high temperatures. Slow cooling of the molten pool will lead to an extended hydrogen precipitation time, forming pores. Rapid cooling can shorten the time the molten pool is at a high temperature, inhibiting the escape and aggregation of gases, thereby reducing pore defects. At the same time, long - term high temperature of the molten pool will expand the heat - affected zone (HAZ), resulting in coarsening of the base - metal grains and a decrease in mechanical properties. Reasonable cooling accelerates the solidification of the molten pool, limits the range of the HAZ, retains the strength and toughness of the base metal, reduces the overall thermal deformation of the welded part by rapid cooling, and improves the weld density and mechanical properties.
[0024] In the fourth case, when the molten pool tilts to one side, control the refrigeration slider 38 on the side with a higher molten - pool slope to move along with the molten pool at this time, and use the refrigeration plate 39 to cool one side of the welded molten pool. After cooling the side with a higher slope, the surface tension of the molten pool in this area increases (the surface tension of liquid metal increases with decreasing temperature). The difference in surface - tension gradients will drive the molten pool to flow from the high - tension area (cooling side) to the low - tension area (uncooled side), thereby promoting the transfer of the molten pool to the other side and alleviating the high inclination; It is worth mentioning that the molten pool after welding the cooling plate 39 is cooled in a stepped manner (for example, gradually decreasing from 200 °C to 100 °C) to reduce thermal stress.
[0025] On the opposite sides of the two placement platforms 10, the same spring piece 21 is fixedly connected, and on the opposite sides of the two placement platforms 10, the same rubber pad 20 is fixedly connected. The provided spring piece 21 can prevent foreign objects from entering the interior of the placement platform 10 during the welding process of the aluminum single plate, facilitating the cleaning of the equipment after welding. The provided rubber pad 20 can provide a part of the tensile force during the relative movement of the two placement platforms 10, improving the service life of the spring piece 21.
[0026] Experimental example: Experimental purpose: Verify the control ability of the equipment of the present invention for the abnormal cooling rate (too fast / too slow) and inclination of the molten pool through the heating wire 32 and the cooling plate 39 without adjusting the welding torch parameters (current 120 A, speed 4 mm / s), and optimize the temperature control logic in combination with the real-time feedback of the high-frame-rate thermal imager 40; Experimental materials and equipment: Aluminum single plate specimens: 5 mm thick, V-shaped groove (60°), 3 pairs in each group (simulating scenarios of too fast cooling, too slow cooling, and inclination); Temperature monitoring: High-frame-rate thermal imager 40 (real-time capturing of the molten pool temperature field, accuracy ±2 °C), thermocouple (arranged 5 mm on both sides of the weld); Equipment parameters: Welding torch parameters fixed: current 120 A, welding speed 4 mm / s, plasma gas flow rate 2.0 L / min; Temperature control mechanism: Heating wire 32: Spirally wound around the heating rotating shaft 31, heating power adjustable from 0 to 200 W, and the rotation speed (rotation speed 0 - 10 r / min) is controlled by the heating motor 30; Cooling plate 39: Semiconductor refrigeration sheet, cold surface temperature -10 °C to 50 °C, and the position is adjusted by driving the refrigeration threaded rod 37 through the refrigeration motor 36 (stroke 0 - 50 mm); Experimental steps: Scenario 1: Welding torch parameters fixed, the heating wire 32 stops rotating (default position: 10 mm away from the welding point), and the cooling plate 39 retracts to the end of the heating shell 29; Welding observation: The molten pool solidifies rapidly, the thermal imaging shows a peak temperature of 590 °C (lower than the aluminum melting point of 660 °C), the cooling rate is 82 °C / s, and unfused lines appear in the weld; Start the heating motor 30, set the rotation speed to 5 r / min, and perform preheating on the groove area; Synchronous recording: The surface temperature of the heating wire 32 rises to 150°C, the peak temperature of the molten pool increases to 645°C, the cooling rate drops to 65°C / s, and the weld fusion is good.
[0027] Scenario 2: The welding torch parameters are fixed, and the heating wire 32 is continuously heated (rotation speed 10 r / min) to simulate over-preheating; Welding observation: The molten pool metal flows, the peak temperature is 710°C, the cooling rate is 25°C / s, and burn-through holes appear in the weld; Start the refrigeration motor 36 to drive the refrigeration plate 39 to move 20 mm backward from the solder joint (as shown in the Figure 7 indicated position) to perform gradient cooling on the rear side of the molten pool (cold surface temperature 20°C); Synchronous recording: The temperature of the molten pool drops to 658°C, the cooling rate increases to 58°C / s, the burn-through phenomenon disappears, and the weld formation is flat; Scenario 3: Manually loosen the right fixture, and the molten pool shifts 1.1 mm to the right during welding. Thermal imaging shows that the temperature on the right side is 22°C higher than that on the left side; Move the right refrigeration plate 39 to the right edge of the molten pool, set the cold surface temperature to 30°C to reduce the temperature on the right side, and increase the rotation speed of the left heating wire 32 to 8 r / min to perform supplementary preheating on the left groove (temperature rises to 120°C); Synchronous recording: The temperature difference between the two sides is reduced to 9°C, the offset of the molten pool is reduced to 0.3 mm, and thermal imaging shows that the temperature field tends to be symmetrical.
[0028] The data table of the cooling rate control is as follows: Scenario Temperature control action Heating wire rotation speed (r / min) Refrigeration plate temperature (°C) Peak temperature (°C) Cooling rate (°C / s) Weld defect Excessive cooling - initial None 0 - 590 82 Incomplete fusion Excessive cooling - adjustment Preheating of heating wire in front 5 - 645 65 None Insufficient cooling - initial Continuous heating of heating wire 10 - 710 25 Burn - through Insufficient cooling - adjustment Gradient cooling of refrigeration plate 10 20 658 58 None The data table of the molten pool tilt control is as follows: Temperature control action Left - hand side temperature (°C) Right - hand side temperature (°C) Temperature difference (°C) Offset (mm) Temperature control time (s) Initial (fixture loose) 25 (room temperature) 47 22 1.1 - Right - hand side refrigeration + left - hand side preheating 120 38 9 0.3 3 Experimental conclusion: 1. Dynamic preheating mechanism of the heating wire: By controlling the rotation speed of the heating wire 32 through the heating motor 30, precise adjustment of the preheating position and temperature in the front can be achieved: When the rotation speed is 5 r / min, the heating wire 32 provides 150°C local preheating 5 mm in front of the solder joint to compensate for the heat conduction loss of the aluminum single plate, increasing the temperature of the molten pool from 590°C to 645°C and solving the lack of fusion problem caused by excessive cooling; Over-preheating (rotation speed 10 r / min) will cause the molten pool to overheat and requires rapid heat dissipation in cooperation with the refrigeration plate 39 (such as cold surface 20°C), verifying the necessity of coordinated control of preheating and cooling.
[0029] 2. Gradient cooling effect of the refrigeration plate: The refrigeration plate 39 can perform dynamic cooling on the rear of the molten pool by being driven by the refrigeration motor 36 for displacement: When the cooling is too slow, the refrigeration plate 39 applies a cold surface of 20 °C at 20 mm behind the solder joint, increasing the cooling rate from 25 °C / s to 58 °C / s, suppressing the excessive thermal expansion of the aluminum single plate, and avoiding burn-through and grain coarsening; When the molten pool is tilted, asymmetric temperature control (right-side refrigeration + left-side preheating) can reduce the temperature difference from 22 °C to 9 °C. Utilizing the surface tension gradient (lower temperature → greater surface tension) to push the molten pool to flow towards the high-temperature side, the offset decreases from 1.1 mm to 0.3 mm, verifying the influence of temperature field regulation on molten pool dynamics.
[0030] 3. Advantages of equipment linkage: The real-time linkage between the high-frame-rate thermal imager 40 and the temperature control mechanism realizes a closed-loop control of "monitoring - feedback - adjustment": The thermal imaging data is transmitted to the equipment control system in real time, automatically adjusting the rotation speed of the heating wire and the position of the refrigeration plate. There is no need to manually intervene in the parameters of the welding torch, which is suitable for automated welding scenarios; The flexible connection between the spring sleeve 27 and the ball head 28 (as Figure 7 shown) ensures that the heating shell 29 adapts and fits with the slight deformation of the aluminum plate. The cooperation between the magnetic attraction block 33 and the magnetic attraction strip 34 guarantees the stability of the temperature control position, improving the temperature control accuracy of complex groove welding.
[0031] Working principle: When two aluminum single plates need to be welded, first place the two aluminum single plates on the top of the corresponding placement tables 10 respectively. At this time, start the vacuum suction block 16 to adsorb and fix the aluminum single plate on the top of the vacuum suction block 16; After fixing the two aluminum single plates, start the two heating wires 32 to preheat the welding joints of the two aluminum single plates, and use the high-frame-rate thermal imager 40 to monitor the preheating situation of the aluminum single plates in real time. During the preheating process of the two aluminum single plates, the high-frame-rate thermal imager 40 and the adjustment mechanism 3 are linked to adjust the gap and angle between the two aluminum single plates. Combined with the high-frame-rate thermal imager 40, the distance between the two preheated aluminum single plates can be detected. At this time, according to the groove angle and the angle to be welded of the two aluminum single plates, start the sliding bidirectional motor 12 and the two rotating motors 15 simultaneously. At this time, the output end of the sliding bidirectional motor 12 rotates and drives the two sliding threaded rods 13 to rotate. The two sliding threaded rods 13 rotate and drive the two sliding blocks 11 on them to move relatively. The two sliding blocks 11 move relatively and drive the placement tables 10 on them to move respectively. At the same time, the output ends of the two rotating motors 15 rotate and drive the placement tables 10 fixedly connected to them to rotate respectively, realizing the linkage adjustment of the angle and distance; Then, use the high - frame - rate thermal imager 40 to detect the gap between the two aluminum single - plates. When an error in the gap is detected, start the two driving bidirectional motors 17 at this time. The output ends of the two driving bidirectional motors 17 respectively drive the driving wheels 18 on them to rotate. The rotation of the driving wheels 18 drives the driving belts 19 outside the two vacuum suction blocks 16 to rotate. The rotation of the driving belts 19 drives the aluminum single - plates on them to move, and further adjusts the gap between the two aluminum single - plates. After the adjustment is completed, the welding torch 6 can be started at this time to weld the two aluminum single - plates. During the welding of the two aluminum single - plates by the welding torch 6, the high - frame - rate thermal imager 40 monitors the situation of the molten pool in real - time: In the first case, when the situation of the molten pool is normal, at this time, since the heating wire 32 is wound around the heating rotating shaft 31 in a spiral for one week, there is always a point on the top of the heating wire 32 that is relatively close to the aluminum single - plate, and a relatively high pre - heating temperature is generated at this close point in a short time. At this time, in cooperation with the welding movement of the welding torch 6, the welding effect is improved. More specifically, start the heating motor 30. The output end of the heating motor 30 drives the heating rotating shaft 31 to rotate. The rotation of the heating rotating shaft 31 drives the heating wire 32 to rotate, and always moves the top of the heating wire 32 in front of the welding point of the welding torch 6, pre - heating the point to be welded at a high temperature for a short time. After the welding torch 6 completes welding, the top of the heating wire 32 gradually moves away from the current welding point, providing a cooling condition for the molten pool after welding, and forming a perfect weld seam. In the second case, when the molten pool cools too fast, air bubbles will appear at the weld. At this time, start the heating motor 30 to drive the heating wire 32 to control its top behind the welding point of the welding torch 6, keep the existence time of the molten pool, and give the air bubbles in the molten pool time to disappear, improving the weld quality. In the third case, when the molten pool cools too slowly, drive the two refrigeration motors 36 at this time. The output ends of the two refrigeration motors 36 rotate and respectively drive the refrigeration threaded rods 37 on them to rotate, indirectly driving the refrigeration sliders 38 to slide on the top of the heating shell 29, so that the refrigeration sliders 38 always slide behind the welding point of the welding torch 6. At this time, the heating shell 29 is in an inclined state, the spring sleeve 27 telescopic ball head 28 rotates on the top of the spring sleeve 27. At the same time, the magnetic - absorption blocks 33 on one side of the two heating shells 29 are magnetically adsorbed to the magnetic - absorption strips 34 on their tops, and the magnetic - absorption blocks 33 on the other side are away from the magnetic - absorption strips 34 on their tops, making the force on the side where the magnetic - absorption block 33 is magnetically adsorbed to the magnetic - absorption strip 34 greater than the side where the magnetic - absorption block 33 is not magnetically adsorbed to the magnetic - absorption strip 34, preventing the refrigeration sliders 38 from losing the pre - heating of the heating wire 32 to the area to be welded of the aluminum single - plate during the sliding process on the top of the heating shell 29, thereby improving the overall welding effect. When no pre - heating measure is taken for the molten pool after welding or the molten pool cools too slowly, the refrigeration plate 39 on the top of the refrigeration slider 38 can be started at this time to directly cool the bottom of the molten pool area of the aluminum single - plate. In the fourth case, when the molten pool tilts to one side, the cooling slider 38 on the side with a higher slope of the molten pool is controlled to move along with the molten pool at this time, and the cooling plate 39 is used to cool one side of the molten pool after welding. After cooling the side with a higher slope, the surface tension of the molten pool in this area increases (the surface tension of liquid metal increases as the temperature decreases), and the difference in surface tension gradient will drive the molten pool to flow from the high-tension area (cooling side) to the low-tension area (uncooled side), thereby pushing the molten pool to transfer to the other side and alleviating the high inclination. Thus, the welding of two aluminum veneers is completed.
[0032] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprising", "including" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.
[0033] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A plasma welding device for the intelligent manufacturing of aluminum single plates, characterized in that: Including, A welding machine (1), the welding machine (1) includes a machine shell (7) and a welding torch (6), and a moving frame (8) is fixedly installed on the top of the machine shell (7); A welding table (2), the welding table (2) includes a mounting table (9) slidably installed on the top of the moving frame (8), and a high-frame-rate thermal imager (40) is fixedly installed on the top of the mounting table (9); An adjusting mechanism (3), the adjusting mechanism (3) includes two sliding blocks (11) slidably connected to each other on the top of the mounting table (9), and a placing table (10) is rotatably connected to the top of each of the two sliding blocks (11), and a fixing mechanism (5) is arranged on the top of the placing table (10); A temperature control mechanism (4), the temperature control mechanism (4) includes heating shells (29) slidably connected to the inside of the two placing tables (10) respectively, a heating wire (32) is rotatably connected to the inside of the heating shell (29), and refrigeration sliders (38) are also slidably connected to the tops of the two heating shells (29) respectively, and a refrigeration plate (39) is fixedly installed on the top of the refrigeration slider (38).
2. The plasma welding equipment for the intelligent manufacturing of aluminum single plates according to claim 1, wherein: The adjusting mechanism (3) further includes a sliding two-way motor (12) fixedly installed on the top of the mounting table (9), two output ends of the sliding two-way motor (12) are fixedly connected with sliding threaded rods (13) respectively, and the two sliding blocks (11) are both screwed on the outside of the adjacent sliding threaded rod (13), a limiting strip (14) is fixedly connected to the top of the mounting table (9), the two sliding blocks (11) are both slidably connected to the top of the limiting strip (14), and a rotating motor (15) is fixedly installed on the top of each of the two sliding blocks (11), and the output ends of the two rotating motors (15) are fixedly connected to one side of the adjacent placing table (10).
3. The plasma welding equipment for the intelligent manufacturing of aluminum single plates according to claim 1, characterized in that: The temperature control mechanism (4) further includes a heating motor (30) fixedly installed on one side of the heating shell (29), the output end of the heating motor (30) extends into the heating shell (29), and the output end of the heating motor (30) is fixedly connected with a heating rotating shaft (31), and the heating wire (32) is spirally wound around the outside of the heating rotating shaft (31) for one week.
4. The plasma welding equipment for the intelligent manufacturing of aluminum veneers according to claim 3, characterized in that: A driving frame (22) is slidably connected to the inside of each of the two placing tables (10), a plurality of spring sleeves (27) arranged at intervals are fixedly connected to the top of the driving frame (22), and a ball head (28) is rotatably connected to the top of each of the plurality of spring sleeves (27), and the top of each of the plurality of ball heads (28) is fixedly connected to the bottom of the adjacent heating shell (29).
5. The plasma welding equipment for the intelligent manufacturing of aluminum single plates according to claim 4, characterized in that: Magnetic attraction blocks (33) are fixedly connected to the tops of both ends of the heating shell (29), two magnetic attraction strips (34) are fixedly connected to the top inner walls of the two placing tables (10), and the two magnetic attraction blocks (33) on the top of the two heating shells (29) are adapted to the adjacent magnetic attraction strips (34).
6. The plasma welding equipment for the intelligent manufacturing of aluminum single plates according to claim 5, characterized in that: A refrigeration shell (35) is fixedly connected to the separated side of each of the two heating shells (29). A refrigeration motor (36) is fixedly installed on one side of the refrigeration shell (35). The output end of the refrigeration motor (36) extends into the refrigeration shell (35). The output end of the refrigeration motor (36) is fixedly connected to a refrigeration threaded rod (37). Each of the two refrigeration sliders (38) is threadedly connected to the outside of the adjacent refrigeration threaded rod (37).
7. The plasma welding equipment for intelligent manufacturing of aluminum single plates according to claim 6, characterized in that: A driving threaded rod (24) is rotatably connected to the bottom of each of the two placing tables (10). The opposite ends of the two driving threaded rods (24) are fixedly connected to the same universal transmission shaft (25). A driving motor (23) is fixedly installed on the bottom of one of the placing tables (10). The output end of the driving motor (23) is fixedly connected to one end of the adjacent driving threaded rod (24).
8. The plasma welding equipment for the intelligent manufacturing of aluminum single plates according to claim 7, wherein: Driving grooves (26) are formed in the bottoms of the two placing tables (10). Each of the two driving frames (22) is threadedly connected to the outside of the adjacent driving threaded rod (24) through the adjacent driving groove (26).
9. The plasma welding equipment for intelligent manufacturing of aluminum single plates according to claim 1, characterized in that: The fixing mechanism (5) includes vacuum suction blocks (16) respectively fixedly installed on the tops of the two placing tables (10). Driving two-way motors (17) are fixedly installed on the tops of the two placing tables (10). Two output ends of the driving two-way motor (17) are fixedly connected to driving wheels (18). A driving belt (19) is rotatably sleeved on the outside of the driving wheel (18). The driving belt (19) is rotatably sleeved on the outside of the adjacent vacuum suction block (16).
10. The plasma welding equipment for the intelligent manufacturing of aluminum single plates according to claim 1, wherein: A spring plate (21) is fixedly connected to the opposite sides of the two placing tables (10). A rubber pad (20) is fixedly connected to the opposite sides of the two placing tables (10).