Rocking seat product magnetic powder detection device for railway wagon
By introducing grid marks, circular raised structures, pronounced electrode chucks and brass pads into the welding equipment, the current and magnetic field distribution are optimized, and the accuracy and efficiency of surface welding and detection of complex workpieces are solved, achieving efficient welding and detection effects.
Patent Information
- Application Number
- CN202510619494.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-14
- Publication Date
- 2025-08-29
AI Technical Summary
The existing welding equipment and detection methods have large deviations, low efficiency, insufficient accuracy when surface treatment of complex workpieces, and lack real-time feedback and adaptive adjustment capabilities, resulting in unstable welding quality and inaccurate detection results.
The grid-like marking and circular raised structure are used for precise positioning, the current density distribution is optimized, the contoured electrode chuck and brass pad are designed, and the magnetic suspension spraying device and coil are combined to achieve uniform current distribution and precise magnetic field control, and real-time feedback adjustment is carried out.
It improves welding quality and detection accuracy, reduces welding errors, improves detection sensitivity and equipment service life, and is suitable for a variety of industrial scenarios.
Smart Images
Figure CN120551633A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of welding and non-destructive testing, and specifically is a technical solution for improving welding and testing efficiency by optimizing current distribution, magnetic field distribution and defect detection methods. Background Art
[0002] In the field of modern industrial manufacturing and inspection, the application of welding, electrode processing and magnetic field related technologies is becoming increasingly widespread, especially in high-precision processing and defect detection scenarios, where they have an irreplaceable position. Traditional welding equipment and inspection methods usually rely on manual operation or simple mechanical control. These methods are prone to problems such as excessive deviation, low efficiency and insufficient detection accuracy in complex workpiece surface processing and dynamic environments. For example, during the contact between the welding gun and the workpiece, due to uneven current distribution or magnetic field interference, the welding quality may be unstable or even defective. In addition, the existing technology has poor adaptability to the electrode shape, making it difficult to meet the profiling requirements of different workpiece surfaces, resulting in reduced work efficiency and an increase in the defective product rate.
[0003] At the same time, existing detection technologies also have significant shortcomings in identifying surface defects of workpieces. Traditional methods are mostly based on analysis of a single current density distribution or magnetic field change, and lack comprehensive consideration of the coupling effects of multiple physical fields, which limits the accuracy and reliability of the detection results. Especially when faced with workpieces with complex geometries, existing systems are often unable to achieve uniform current distribution or precise magnetic field control, thereby affecting the coverage and sensitivity of the detection area. In addition, the magnetic suspension spray device and coil design in the existing technology generally have problems with poor adaptability and slow response speed, which further restricts the improvement of detection efficiency.
[0004] More importantly, current technical solutions have significant shortcomings in real-time feedback and adaptive adjustment capabilities. For example, when faced with unexpected situations or changes in the workpiece surface condition, the system struggles to quickly adjust parameters to maintain optimal working conditions. This not only increases operational difficulty but can also lead to waste of resources and increased production costs. Therefore, developing a comprehensive technical solution that can achieve efficient contour electrode clamping, uniform current distribution, precise magnetic field control, and real-time feedback adjustment has become a key issue that the industry urgently needs to address. This technology will significantly improve the accuracy, efficiency, and stability of the welding and inspection processes, providing strong support for further development in the industrial manufacturing sector. Summary of the Invention
[0005] The present invention provides a welding and testing process and related equipment, including a welding gun, a workpiece, an electrode, a coil, a magnetic suspension spray device, a contoured electrode chuck body and a brass backing plate, wherein: The welding gun is positioned above the workpiece, performing welding operations on the workpiece surface. The workpiece surface is provided with a grid of markings and circular raised structures. The grid markings are used to precisely locate the welding area, while the circular raised structures serve as key welding points or reinforcements. Furthermore, the layout of the grid markings is optimized through geometric calculations to ensure that they correspond to the movement trajectory of the welding gun during welding, thereby improving welding positioning accuracy. The height and diameter of the circular raised structures are designed based on the thickness and thermal conductivity of the welding material to form a stable heat conduction path during welding, reducing thermal stress concentration.
[0006] Furthermore, electrodes are positioned on either side of the workpiece to apply the welding current. The current density distribution is optimized by adjusting the electrode positions and introducing auxiliary measures. These auxiliary measures include placing a brass backing plate between the electrode and the workpiece. This plate has specific electrical and thermal conductivity, ensuring it evenly distributes the current and absorbs excess heat during welding, preventing damage to the workpiece due to localized overheating. Specifically, the thickness range of the brass backing plate has been experimentally verified to ensure it provides sufficient conductivity while maintaining mechanical strength during welding.
[0007] Furthermore, the coil is positioned around the workpiece to generate a magnetic field, the direction and distribution of which are determined by the electrodes and coil. The number of turns and winding method of the coil are designed based on the geometry and material properties of the workpiece to ensure uniform distribution of the magnetic field on and within the workpiece. In particular, the distribution characteristics of the magnetic field are simulated and optimized using finite element analysis, enabling the magnetic field to form a closed loop within the workpiece, thereby improving the sensitivity of defect detection.
[0008] Furthermore, the magnetic suspension spray device is arranged near the surface of the workpiece and is used to spray the magnetic suspension onto the surface of the workpiece. The nozzle angle and spraying pressure of the magnetic suspension spray device are precisely adjusted to ensure that the magnetic suspension can evenly cover the surface of the workpiece and reveal defects inside the workpiece under the action of the magnetic field. In particular, the components of the magnetic suspension include ferromagnetic particles and fluorescent dyes, the particle size of the ferromagnetic particles ranges from 10 microns to 50 microns, and the emission wavelength of the fluorescent dye ranges from 400 nanometers to 600 nanometers, to ensure that it can clearly display the defect location under ultraviolet light. Furthermore, the contoured electrode chuck body, used to clamp the electrode, is designed to conform to the workpiece's geometry, ensuring stable and uniform current transmission. The inner surface of the contoured electrode chuck body is provided with an elastic conductive layer, with a thickness ranging from 0.5 mm to 2 mm, to accommodate minor surface irregularities during clamping while maintaining good electrical conductivity. Specifically, the elastic conductive layer is made of a nickel-chromium alloy, whose electrical conductivity and high-temperature resistance have been experimentally verified to meet the current transmission requirements during welding.
[0009] The technical solution of the present invention realizes the welding and testing process through the following steps: S1: Place the workpiece on the work platform and accurately position it using the grid markings and circular raised structures; S2: Start the welding gun to perform welding operations on the workpiece surface, and monitor the current density distribution to ensure welding quality; S3: After welding is completed, the contoured electrode chuck body is installed and current is applied through the electrode; S4: Start the coil to generate a magnetic field, and use the magnetic suspension spray device to spray the magnetic suspension onto the surface of the workpiece; S5: Observe the changes in magnetic lines of force and, combined with the magnetic suspension development effect, determine whether there are defects inside the workpiece.
[0010] Compared with the existing technology, the beneficial effects of the present invention are: through the design of grid-shaped marks and circular protrusion structures, precise positioning of the welding area is achieved, and welding errors are reduced; by optimizing the current density distribution, thermal stress concentration in the welding process is reduced and welding quality is improved; through the application of magnetic field distribution and magnetic suspension spraying device, the sensitivity and accuracy of defect detection are significantly improved; through the design of the contoured electrode chuck body and the brass pad, the stability of current transmission is ensured and the service life of the equipment is extended.
[0011] In particular, the technical solution of this invention is applicable to welding and nondestructive testing needs in a variety of industrial scenarios, demonstrating exceptional performance in the processing of difficult-to-weld materials such as high-strength steel and aluminum alloys. Through implementation, welding efficiency and testing accuracy are significantly improved, providing reliable technical support for industrial production. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 A schematic diagram of the welding operation of the present invention; Figure 2 Schematic diagram of current density distribution of the present invention; Figure 3 Schematic diagram of uniform current distribution of the present invention; Figure 4 This is a structural diagram of the magnetic suspension spraying device of the present invention; Figure 5 Schematic diagram of the magnetic field detection principle of the present invention; Figure 6 Schematic diagram of the coil detection principle of the present invention.
[0013] Figure: 1. Welding gun; 2. Workpiece; 3. Grid-shaped marking; 4. Circular raised structure; 5. Electrode; 6. Coil; 7. Magnetic field; 8. Magnetic lines of force; 9. Defect; 10. Current density distribution; 11. Uniform current distribution; 15. Magnetic suspension spray device; 16. Contoured electrode chuck body; 17. Brass backing plate. DETAILED DESCRIPTION
[0014] The present invention provides a welding and detection process and related equipment. Figure 1 To the attached Figure 6 Detailed description is given. In actual operation, the workpiece 2 is first placed on the work platform, and precise positioning is achieved through the grid mark 3 and the circular raised structure 4. The design of the grid mark 3 is based on geometric calculation optimization to ensure that the motion trajectory of the welding gun 1 forms a one-to-one correspondence with the marking point, thereby improving the accuracy of the positioning of the welding area. The height and diameter of the circular raised structure 4 are designed according to the thickness and thermal conductivity of the welding material. Its purpose is to form a stable heat conduction path during the welding process and reduce welding defects caused by thermal stress concentration. For example, in the welding of high-strength steel, the height of the circular raised structure 4 can be set to 2 mm and the diameter to 5 mm to adapt to the thermal conductivity requirements of the material and improve the welding quality.
[0015] Before welding, it is necessary to install the electrode 5 and adjust its position to ensure the uniformity of current density distribution. Figure 2 As shown, the electrodes 5 are arranged on both sides of the workpiece 2 to apply the current required for welding. In order to further optimize the current density distribution, the present invention introduces a brass pad 17 as an auxiliary measure. The brass pad 17 is located between the electrode 5 and the workpiece 2, and its thickness range has been verified by experiments to ensure that it can provide sufficient conductivity and maintain mechanical strength during the welding process. For example, in aluminum alloy welding, the thickness of the brass pad 17 is preferably 1.5 mm, the conductivity is not less than 58MS / m, and the thermal conductivity is not less than 100W / (m·K). Through the above design, the brass pad 17 disperses the current and absorbs excess heat, avoiding local overheating and damage to the workpiece 2. Appendix Figure 3 The optimized current density distribution is shown, in which the uniform current distribution11 significantly improves the stability of the welding process.
[0016] After welding is completed, the coil 6 is started to generate the magnetic field 7, and the magnetic suspension spraying device 15 is used to spray the magnetic suspension onto the surface of the workpiece 2. The number of turns and the winding method of the coil 6 are designed according to the geometric shape and material properties of the workpiece 2 to ensure that the magnetic field 7 is evenly distributed on the surface and inside the workpiece 2. For example, for a steel plate with a thickness of 10 mm, the number of turns of the coil 6 is set to 50 turns, and the winding method adopts double-layer spiral winding to improve the penetration ability of the magnetic field. The magnetic field distribution is simulated and optimized by the finite element analysis method to ensure that the magnetic field 7 can form a closed loop inside the workpiece 2, thereby improving the sensitivity of defect detection. Appendix Figure 5 and attached Figure 6 The specific situations of magnetic field generation and coil arrangement are respectively shown, wherein the magnetic field lines 8 clearly show the distribution characteristics of the magnetic field 7. The nozzle angle and spraying pressure of the magnetic suspension spraying device 15 are precisely adjusted to ensure that the magnetic suspension can evenly cover the surface of the workpiece 2. The components of the magnetic suspension include ferromagnetic particles and fluorescent dyes, wherein the particle size of the ferromagnetic particles ranges from 10 microns to 50 microns, and the emission wavelength of the fluorescent dye ranges from 400 nanometers to 600 nanometers. In actual application, ferromagnetic particles with a particle size of 30 microns and fluorescent dyes with a emission wavelength of 500 nanometers are selected to ensure that the location of the defect 9 can be clearly displayed under ultraviolet light. Figure 4 The working state of the magnetic suspension spraying device 15 and the development effect of the surface defects 9 of the workpiece 2 are demonstrated.
[0017] The contoured electrode chuck body 16 is designed to conform to the geometry of the workpiece 2, ensuring stable and uniform current transmission. The inner surface of the contoured electrode chuck body 16 is provided with an elastic conductive layer with a thickness ranging from 0.5 mm to 2 mm. In practical applications, for curved workpieces, the thickness of the elastic conductive layer is set to 1 mm, and a nickel-chromium alloy is used as the material. Nickel-chromium alloy has excellent electrical conductivity and high-temperature resistance. Experimental verification has shown that it can meet the current transmission requirements during welding and adapt to minor surface irregularities of the workpiece. The design of the contoured electrode chuck body 16 further improves welding efficiency and detection accuracy.
[0018] The specific implementation process of the present invention is as follows: S1 places the workpiece 2 on the work platform and accurately positions it through the grid-shaped mark 3 and the circular raised structure 4; S2 starts the welding gun 1 to perform the welding operation on the surface of the workpiece 2, and monitors the current density distribution 10 to ensure the welding quality; S3 After the welding is completed, install the contoured electrode chuck body 16 and apply current through the electrode 5; S4 starts the coil 6 to generate the magnetic field 7, and uses the magnetic suspension spray device 15 to spray the magnetic suspension onto the surface of the workpiece 2; S5 observes the changes in the magnetic lines of force 8, and combines the magnetic suspension development effect to determine whether there are defects inside the workpiece 2 9. In actual operation, the above steps can be applied to welding and non-destructive testing needs in a variety of industrial scenarios. For example, in the field of aerospace, for the welding of high-strength steel and aluminum alloys, the technical solution of the present invention can significantly reduce welding errors, improve welding quality, and extend the service life of equipment.
[0019] The present invention is also applicable to welding and detection needs in the fields of automobile manufacturing, shipbuilding, etc. In automobile manufacturing, for the welding of door frames, the design of the grid-shaped mark 3 and the circular raised structure 4 can achieve precise positioning of the welding area and reduce welding errors. By optimizing the current density distribution 10, the thermal stress concentration during the welding process can be reduced and the welding quality can be improved. In shipbuilding, for the welding of hull steel plates, the application of the magnetic field 7 distribution and the magnetic suspension spray device 15 can significantly improve the sensitivity and accuracy of defect detection. The design of the contoured electrode chuck body 16 and the brass pad 17 can ensure the stability of current transmission and extend the service life of the equipment.
[0020] In summary, the present invention achieves precise positioning of the welding area through the design of the grid-shaped markings 3 and the circular raised structures 4. Thermal stress concentration during welding is reduced by optimizing the current density distribution 10. The distribution of the magnetic field 7 and the application of the magnetic suspension spray device 15 significantly improve the sensitivity and accuracy of defect detection. The design of the contoured electrode chuck body 16 and the brass backing plate 17 ensures the stability of current transmission. The technical solution of the present invention has demonstrated excellent performance in a variety of industrial scenarios, providing reliable technical support for industrial production.
[0021] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.
Claims
1. A magnetic particle inspection device for a rocking seat product for a railway freight car, comprising a welding gun (1), a workpiece (2), an electrode (5), a coil (6), a magnetic suspension spray device (15), a contoured electrode chuck body (16) and a brass backing plate (17), characterized in that: The welding gun (1) is located above the workpiece (2) and is used to perform a welding operation on the surface of the workpiece (2); the surface of the workpiece (2) is provided with a grid-shaped mark (3) and a circular protrusion structure (4); the electrode (5) is arranged on both sides of the workpiece (2) and is used to apply the current required for welding; the coil (6) is arranged around the workpiece (2) and is used to generate a magnetic field (7); the magnetic suspension spraying device (15) is arranged near the surface of the workpiece (2) and is used to spray the magnetic suspension onto the surface of the workpiece (2); the contoured electrode chuck body (16) is used to clamp the electrode (5); and the brass pad (17) is arranged between the electrode (5) and the workpiece (2).
2. The magnetic particle detection device for a rocking seat product for a railway freight car according to claim 1, characterized in that: The grid-shaped markings (3) are arranged in an optimized manner through geometric calculation, ensuring that they form a corresponding relationship with the motion trajectory of the welding gun (1) during the welding process.
3. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 2, characterized in that: The height and diameter of the circular protrusion structure (4) are designed according to the thickness and thermal conductivity of the welding material to form a stable heat conduction path during welding.
4. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 1, characterized in that: The brass backing plate (17) has a thickness ranging from 1 mm to 2 mm, an electrical conductivity not less than 58 MS / m, and a thermal conductivity not less than 100 W / (m·K).
5. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 1, characterized in that: The number of turns and the winding method of the coil (6) are designed according to the geometric shape and material properties of the workpiece (2) to ensure that the magnetic field (7) is evenly distributed on the surface and inside the workpiece (2).
6. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 5, characterized in that: The distribution characteristics of the magnetic field (7) are simulated and optimized using a finite element analysis method, so that the magnetic field (7) can form a closed loop inside the workpiece (2).
7. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 1, characterized in that: The nozzle angle and spraying pressure of the magnetic suspension spraying device (15) are adjusted to ensure that the magnetic suspension can evenly cover the surface of the workpiece (2).
8. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 1, characterized in that: An elastic conductive layer is provided on the inner surface of the contoured electrode chuck body (16), and the thickness of the elastic conductive layer ranges from 0.5 mm to 2 mm.
9. The magnetic particle inspection device for a rocking seat for a railway freight car according to claim 8, characterized in that: The elastic conductive layer is made of nickel-chromium alloy, whose electrical conductivity and high temperature resistance meet the current transmission requirements during welding.