Plasma gun air bearing system and air bearing

Abstract

The invention provides a plasma gun air bearing system and an air bearing, and relates to the technical field of air bearings, the plasma gun air bearing system comprises a rotor system, the rotor system comprises a design level, a process level and a control level, the design level is responsible for rotor dynamics design, a hollow shaft structure is adopted for reducing weight and inertia, and the process level is responsible for controlling the process level; a connecting interface is integrally eliminated through interference fit, the working rotating speed is adjusted through rigid rotor design, the design level covers shaft system design at the same time, and the specific modification mode of the shaft system design is as follows: cutting off a bearing position under the condition that an original shaft system is kept as much as possible, newly adding an air floating shaft section, adopting transition design for a conical surface, and adopting a thrust ring for an end face. Finally, the magnetic balance ring and the air floating journal section need to belong to a radial bearing surface, a mechanical bearing is replaced by the air floating bearing, a continuous air film is formed through a radial air path (12 holes are uniformly distributed in the circumferential direction) and a thrust air path (8 fan-shaped cavities are formed in the end face), non-contact supporting is achieved, and metal dust generated by mechanical friction is effectively eliminated.

Description

Technical Field

[0001] This invention relates to the field of air bearing technology, specifically to a plasma gun air bearing system and an air bearing. Background Technology

[0002] The plasma gun air bearing system and air bearings are a high-precision rotational support technology specifically designed for plasma rotating electrode atomization powder production (PREP) equipment. It aims to achieve stable rotation of the rod at high speeds (e.g., 50,000 RPM) using a non-contact air bearing, while ensuring low contamination and high sphericity during powder preparation. PREP technology is widely used in aerospace, additive manufacturing, and medical devices, utilizing a plasma arc to melt a high-speed rotating rod and atomize it into high-purity metal powder. However, in traditional plasma gun equipment, the bearing system faces significant technical challenges when the rod rotates at high speeds, directly affecting powder quality, equipment lifespan, and operational stability.

[0003] In existing technologies, the rotor system of plasma guns (such as the SLPA-V type horizontal PREP device) typically uses mechanical bearings to support the rotation of the bar stock. Mechanical bearings provide radial and axial support through metal-to-metal contact, combined with lubricating grease or oil grooves to reduce friction. However, this design exposes a series of problems in the high-temperature, high-speed operating environment of plasma guns:

[0004] Mechanical friction leads to metal dust contamination: Taking a solid titanium alloy shaft with a diameter of 70mm and a length of 150mm as an example, when running at 50,000 RPM, its moment of inertia is extremely large, and a microgram-level imbalance mass can generate several kilograms of centrifugal force. This force exacerbates the wear of mechanical bearings, causing metal dust to mix into the working chamber, contaminating the alloy powder, reducing powder purity and sphericity, and directly affecting the quality of 3D printing or high-temperature alloy manufacturing.

[0005] High temperatures lead to lubrication failure and seal damage: The working chamber temperature of the plasma gun can reach over 1500℃, causing lubricating grease to fail and even carbonize and peel off. Dynamic seals are prone to wear or ablation under high temperature and high-speed friction, leading to seal failure and allowing external oxygen and impurities to penetrate, causing powder oxidation contamination. Furthermore, bearing heating further accelerates seal aging, increasing maintenance frequency and costs.

[0006] Vibration-induced resonance and powder quality degradation: High-speed rotating rotor systems have natural frequencies. When the rotational speed approaches the low-order critical speed, resonance occurs, leading to a sharp amplification of the amplitude. The high rotational inertia of the titanium alloy shaft requires enormous torque for acceleration or deceleration. Even minor imbalances at high speeds generate significant centrifugal forces, squeezing the bearings and amplifying vibrations. This not only results in uneven powder particle morphology and reduced sphericity but can also cause devastating damage, threatening equipment safety.

[0007] Therefore, a plasma gun air bearing system and an air bearing are needed to solve the above problems. Summary of the Invention

[0008] Technical problems to be solved

[0009] To address the shortcomings of existing technologies, this invention provides a plasma gun air bearing system and an air bearing, thus solving the problems of existing technologies.

[0010] Technical solution

[0011] To achieve the above objectives, the present invention provides the following technical solution: a plasma gun air-bearing system, characterized in that it includes a rotor system, comprising a design level, a process level, and a control level. The design level is responsible for rotor dynamics design, employing a hollow shaft structure to reduce weight and inertia, eliminating connection interfaces through interference fit integration, and using a rigid rotor design to adjust the operating speed. The design level also covers shaft system design, specifically modified as follows: the bearing position is removed while preserving the original shaft system as much as possible. The newly added air-bearing shaft section features a transition design on the tapered surface, a thrust ring on the end face, and a magnetic balance ring. The air-bearing journal section is a radial bearing surface. The thrust surface uses a single thrust bearing sleeve to bear unilateral axial and radial forces. This design employs a bidirectional thrust surface to withstand the bidirectional axial force generated during bar stock clamping. Two thrust bearing sleeves are used in conjunction to restrict axial movement. After ventilation, an air film forms on the inner wall and raised surface of the sleeve, facilitating shaft engagement. The thrust surface design creates a central thrust structure in the middle of the journal, simplifying the shaft system. The thrust surface is achieved through ultra-precision surface grinding. The process involves a guide cone angle designed at the front end to facilitate the installation and introduction of the air bearing. A rounded unloading groove is machined at the transition between the journal and the non-fitting section to reduce stress concentration. The process layer is responsible for ultra-precision manufacturing and assembly, divided into integral manufacturing, ultra-precision dynamic balancing, and thermal assembly processes. The control layer implements intelligent monitoring and control, employing an active vibration suppression system and collision prediction and deceleration logic to maintain stability. The active vibration suppression system includes air film thickness monitoring and thermal management design, and is equipped with a K-type thermocouple on the graphite bearing surface and an infrared thermometer at the bar root, along with an infrared monitoring system. This system collects the bar offset position in real time and transmits the data to the PID controller for analysis. The active vibration suppression system aims to monitor vibration parameters in real time and actively adjust the air film thickness and air pressure distribution to suppress vibration amplification. The collision prediction and deceleration logic analyzes vibration trends, predicts potential collision risks, and automatically reduces the rotational speed to avoid catastrophic damage. This logic includes a prediction algorithm module that integrates sensor data for trend analysis.

[0012] Preferably, the rotor dynamics design uses finite element analysis to simulate the rotor's natural frequency distribution to determine the rigid rotor structure parameters. Then, an interference fit is used to connect the shaft and the fixture to eliminate looseness at the connection interface, and the rotor structure is formed by laser welding. Finally, the operating speed is adjusted to avoid the low-order critical speed region.

[0013] Preferably, the shaft system design retains the original shaft system foundation by removing the bearing position, then adds an air-bearing journal section to create a radial bearing surface, and connects the journal section with other parts through a conical transition design. The shaft end position is then fixed with an end face thrust ring, and the dynamic balance is adjusted with the help of a magnetic balance ring. A bidirectional thrust surface and a thrust sleeve are configured to bear axial force. An air film is formed on the inner wall and the convex surface air film to cooperate with the shaft through ventilation. A thrust surface is placed in the middle of the journal in the middle thrust structure. The shaft is guided into the air-bearing sleeve by a guide cone angle. Finally, the transition corner is rounded to reduce stress concentration by unloading groove treatment.

[0014] Preferably, the process is configured to be manufactured as a whole through the following steps: the rotor structure is formed by machining the forging blank as a whole, the shaft surface is then treated by ultra-precision machining, the journal is smoothed by mirror polishing diamond turning tool, a thermal expansion gap is reserved to prevent thermal deformation, a floating shaft end design is adopted to adapt to temperature changes, and a ceramic coating channel is used to protect against metal dust contamination. At the same time, argon positive pressure and titanium getter are used to prevent oxygen permeation.

[0015] Preferably, the process involves configuring ultra-precision dynamic balancing through the following steps: detecting residual imbalance by multi-plane correction using a vacuum balancing machine, removing excess mass by laser micro-weight removal, adding balancing mass by counterweight screws, verifying the balancing effect by vibration speed detection, and finally achieving interference fit by heating the shaft and fixture using a heat fitting process.

[0016] Preferably, the control layer is configured with an active vibration suppression system through the following steps: infrared sensors are used to collect bar offset data, combined with eddy current probes to collect radial runout data, vibration sensors to collect equipment status data, pressure sensors to collect air chamber pressure data, and infrared monitoring systems to collect bar offset positions. K-type thermocouples are used to collect the surface temperature of the graphite bearings, and infrared thermometers are used to collect the temperature at the bar root. Finally, a laser oxygen analyzer is used to collect oxygen content changes. All the above data are transmitted to a PID controller for analysis. The PID controller then calculates the compensation amount and transmits it to a piezoelectric ceramic actuator to fine-tune the air film thickness. A four-quadrant independent pressure regulating structure is used to adjust the air path pressure to stabilize the air film. Finally, a feedback loop transmits the execution results back to the PID controller to repeat the monitoring and adjustment process to ensure vibration suppression.

[0017] Preferably, the control layer is configured to monitor the air film thickness through the following steps: real-time acquisition of the bar offset position using an infrared sensor, acquisition of axial and radial displacement changes using an eddy current probe, acquisition of air film pressure fluctuations using a pressure sensor, acquisition of overall vibration amplitude using a vibration sensor, and acquisition of the bar offset position using an infrared monitoring system. The above data are transmitted to a PID controller for integration and real-time analysis. Subsequently, a compensation signal is generated based on the analysis results and transmitted to a piezoelectric ceramic actuator to perform axial fine adjustment. Then, the air pressure distribution is adjusted through a four-quadrant independent pressure regulating structure to maintain air film uniformity. Finally, the adjustment results are transmitted back to the PID controller through a feedback mechanism to continuously optimize the monitoring process.

[0018] Preferably, the control layer is configured with thermal management design through the following steps: K-type thermocouples are used to collect the surface temperature of the graphite bearing, combined with an infrared thermometer to collect the temperature at the root of the bar stock, and a laser oxygen analyzer is used to collect changes in oxygen content. The temperature and oxygen content data are then transmitted to an intelligent feedback controller for analysis. Subsequently, based on the temperature threshold, a temperature-based control logic generates an adjustment signal and transmits it to the argon cooling curtain to activate the inner argon curtain. The insulation ring water cooling structure is then activated for water cooling. In case of an anomaly, liquid nitrogen is injected through a liquid nitrogen injection structure. Simultaneously, the chamber pressure gradient is adjusted to a positive pressure gradient design. Oxygen is captured using a titanium-molybdenum alloy honeycomb structure, and the laser monitoring structure provides real-time feedback to adjust the gas supply pressure. Finally, the adjustment results are transmitted back to the intelligent feedback controller through a feedback mechanism to continuously optimize the thermal environment control.

[0019] Preferably, the control layer configures the collision prediction and deceleration logic through the following steps: A vibration sensor is used to collect the rotor vibration frequency, an eddy current probe is used to collect the shaft displacement trajectory, a pressure sensor is used to collect abnormal air film pressure, and an infrared monitoring system is used to collect the bar offset position. The above data is transmitted to the prediction algorithm module for analysis. The prediction algorithm module then analyzes the vibration and displacement trends and compares them with the natural frequencies to predict resonance risk, generating an early warning signal. This signal is then transmitted through the collision prediction logic. Subsequently, the deceleration logic receives the early warning signal, adjusts the rotational speed, switches the dual-air path automatic switching structure to the backup air path, and activates the vacuum negative pressure protection structure to form a temporary air film. Finally, a feedback mechanism transmits the deceleration result back to the prediction algorithm module to verify the effect and repeat the monitoring process to prevent catastrophic damage.

[0020] Preferably, the air bearing, as the core component of the plasma gun air bearing system, is externally equipped with a graphite bushing with a porosity of 30%2%, and has an 8-channel evenly distributed air supply structure on its surface. The air pressure is regulated by the thrust air chamber with independent PID control of the pressure in each zone. At the same time, a pressure sensor with an accuracy of 0.1%FS is installed for real-time pressure monitoring, and a silicon carbide ceramic sliding bearing is used as an emergency support. The air bearing forms a continuous air film through a radial air path and a circumferential 12-hole evenly distributed design. The anti-overturning moment is enhanced by the thrust air path and the 8-fan-shaped cavity design on the end face. The inner wall air film and the convex surface air film cooperate with the journal section to bear radial and axial forces.

[0021] Beneficial effects

[0022] This invention provides a plasma gun air bearing system and an air bearing. It has the following beneficial effects:

[0023] 1. This invention uses air-bearing bearings instead of mechanical bearings. A continuous air film is formed through radial air channels (12 evenly distributed holes circumferentially) and thrust air channels (8 sector-shaped cavities on the end face), achieving contactless support and effectively eliminating metal dust generated by mechanical friction. Furthermore, the system uses argon positive pressure (pressure gradient in the chamber 0.25MPa→0.15MPa→0.05MPa) and titanium getter protection to control oxygen permeability below 0.5ppm / h. Combined with ceramic-coated flow channels (roughness Ra0.05μm), oxygen and impurity contamination is prevented. Oxygen content control (≤8ppm) and positive pressure gradient design further ensure high-purity powder preparation, significantly improving powder sphericity and quality, meeting the stringent requirements of the aerospace and medical device fields.

[0024] 2. This invention uses a porous graphite bushing with a porosity of 30%±2%, combined with an argon cooling curtain (spray angle 30°, airflow speed 120m / s, Reynolds number >4000) and a heat insulation ring water cooling structure (flow rate 5L / s) to achieve a drastic temperature drop from 1500℃ to 200℃, effectively protecting the bearing from high-temperature damage.

[0025] 3. The plasma gun air bearing system, through four core innovations—"non-contact purification, high speed and high precision, low consumption and environmental protection, and intelligent reliability"—not only solves the inherent defects of traditional mechanical bearings in PREP equipment, but also promotes the upgrade of powder making equipment from "intermittent low precision" to "continuous high precision"—meeting the additive manufacturing requirements for fine powder (15-53μm), high purity (oxygen content ≤50ppm), and high sphericity (≥90%) powder. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the rotor system composition of the present invention;

[0027] Figure 2This is a schematic diagram of the triple protection against pollution sources according to the present invention;

[0028] Figure 3 This is a schematic diagram of the shaft system structure reconstruction design of the present invention;

[0029] Figure 4 This is a schematic diagram of the air bearing turntable model of the present invention;

[0030] Figure 5 This is a schematic diagram of the thrust bearing model of the present invention;

[0031] Figure 6 This is a diagram of the anti-penetration system architecture of the present invention. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Specific Implementation Example 1:

[0034] like Figures 1 to 6 As shown, the plasma gun air bearing system is a high-precision rotary support system designed for plasma gun applications. It achieves contactless, high-speed rotary support through air bearings, ensuring rotor stability, vibration suppression, and collision avoidance during high-speed operation. The system integrates three major aspects: structural design optimization, precision manufacturing and assembly, and intelligent monitoring and control. These work together to support the rotor against radial and axial forces (such as the bidirectional axial force generated by bar clamping). The following details the complete working process of the system from startup to stable operation, including details of the mixed structural design, manufacturing process, and control layers. It focuses on clarifying the dynamic interaction between data flow (sensor acquisition, transmission, and analysis) and control flow (analysis results to command execution and feedback). In particular, the control layer will detail each analysis, threshold, command generation, execution mechanism, and feedback verification to ensure a clear and complete data and control flow.

[0035] Before system startup, the rotor is prepared through precision manufacturing and assembly. It is machined from a single forging blank into a unibody structure, with a hollow shaft design to reduce weight and inertia. The shaft surface undergoes ultra-precision machining, and the journal section is mirror-polished using a diamond turning tool to ensure surface smoothness supporting air film formation. A small thermal expansion gap is reserved to prevent thermal deformation, a floating shaft end design adapts to temperature changes, a ceramic coating protects the flow channel from metal dust contamination, and argon positive pressure and titanium getter prevent oxygen penetration, improving high-temperature durability. Ultra-precision dynamic balancing uses a vacuum balancing machine for multi-plane calibration, laser micro-weight removal to remove excess mass, counterweight screws to add balancing mass, and vibration velocity testing to verify the balancing effect, ensuring minimal rotational vibration. A heat-fitting process heats the shaft and fixture to achieve an interference fit, eliminating looseness at the connection interface, and laser welding seals and solidifies the structure. The shaft system design retains the original shaft system foundation, with the bearing position removed and a new air-floating journal section added as a radial bearing surface. A tapered transition connects the journal section to other parts, an end-face thrust ring fixes the shaft end, and a magnetic balance ring adjusts the dynamic balance. The bidirectional thrust surface (two thrust bushings mating in opposite directions) bears bidirectional axial force, the central thrust structure (the thrust surface is located in the middle of the journal and is machined by ultra-precision surface grinding) simplifies the shaft system, the guide cone angle (front end design) facilitates the insertion of the shaft into the air bearing, and the unloading groove (the transition between the journal and the non-fitting section is machined with a rounded corner) reduces stress concentration.

[0036] During startup, the rotor is positioned within an air-bearing environment, externally using a graphite bushing with 30% porosity and an 8-channel evenly distributed air supply structure. Air pressure is regulated by a thrust chamber with independent PID control for each zone, and a pressure sensor (accuracy 0.1%FS) monitors the chamber pressure in real time. A radial air path and a circumferentially distributed 12-hole design form a continuous air film, while the thrust air path and an 8-fan-shaped cavity design on the end face enhance anti-overturning moment. The inner wall air film and the raised surface air film cooperate with the journal section to bear radial and axial forces, with a silicon carbide ceramic sliding bearing providing emergency support. Once the air supply structure is activated, air pressure regulation forms a uniform air film (target thickness 0.01mm), and the rotor accelerates to its operating speed (avoiding low-order critical speed regions, such as 6000rpm, based on finite element analysis). A magnetic balance ring adjusts the dynamic balance in real time, and a thrust ring fixes the shaft end. The sensor array (infrared sensor, eddy current probe, vibration sensor, pressure sensor, K-type thermocouple, infrared thermometer, laser oxygen analyzer) begins collecting data and transmitting it to the PID controller or intelligent feedback controller to check the initial vibration (e.g., vibration velocity <0.1 mm / s is normal). If the threshold is exceeded, preliminary adjustments are triggered, such as increasing the air pressure by 5 kPa or reducing the rotation speed by 10%.

[0037] During stable operation, the hollow shaft and interference fit ensure the high-speed rotational stability of the rigid rotor. The air-bearing shaft journal section supports radial force through an air film, while the central thrust surface bears axial force. A magnetic balance ring continuously adjusts the dynamic balance to prevent vibration amplification. Sensors collect data in real time, providing a basis for the control layer. The control layer includes an active vibration suppression system (air film thickness monitoring, thermal management design) and collision prediction and deceleration logic, equipped with infrared sensors (bar offset), eddy current probes (radial runout and axial displacement), vibration sensors (equipment status and vibration amplitude), pressure sensors (air chamber pressure and air film fluctuation), K-type thermocouples (graphite bearing surface temperature), infrared thermometers (bar root temperature), and laser oxygen analyzers (oxygen content). Actuation components include piezoelectric ceramic actuators, a four-quadrant independent pressure regulation structure, a dual-air-path automatic switching structure, and a vacuum negative pressure protection structure. The closed-loop control process is: sensor data acquisition → transmission to controller → analysis and command generation → actuator execution → feedback verification → repeated optimization.

[0038] The active vibration suppression system monitors vibration parameters and adjusts the air film thickness and air pressure distribution. Sensors collect data every second (bar offset, radial runout, vibration amplitude, air chamber pressure), transmitting it to the PID controller via RS-485 or Ethernet. Data is timestamped to avoid delays. The controller filters (using a low-pass filter to remove high-frequency noise) and integrates the data (fusing offset and runout to calculate the vibration vector), comparing thresholds (vibration amplitude > 0.05 mm or air film pressure fluctuation > 5 kPa indicates instability). A PID algorithm (Kp=2.0, Ki=0.5, Kd=1.0) calculates compensation, generating commands such as "axial fine-tuning 0.001 mm" and "increase front quadrant air pressure by 10%". These commands are sent as voltage signals to the piezoelectric ceramic actuator (applying 5V for deformation fine-tuning of the shaft position) and the four-quadrant pressure regulating structure (solenoid valve adjusting pressure to 55 kPa). After execution, the sensors collect new data (e.g., vibration reduced to 0.03 mm) and transmit it back to the controller to verify compliance (target < 0.04 mm). If the deviation is >0.01mm, optimize the PID parameters (adjust Kp to 2.1), and repeat the adjustment until it stabilizes.

[0039] The air film thickness monitoring system collects data on bar offset (infrared sensor), axial and radial displacement (eddy current probe), air film pressure fluctuation (pressure sensor), and vibration amplitude (vibration sensor), transmitting this data to a PID controller (including CRC checksum) via a CAN bus. The controller calculates the thickness deviation (target 0.01mm, deviation >0.002mm triggers adjustment), and combines this with model predictive control analysis of displacement trends (increase rate >0.001mm / s indicates deterioration), generating commands such as "axial movement 0.001mm" and "air pressure adjustment 5kPa". A piezoelectric ceramic actuator applies a voltage pulse (elongation 0.001mm), and a four-quadrant pressure regulating structure adjusts the pressure via a proportional valve (increasing pressure in one quadrant from 45kPa to 50kPa). Feedback data verifies the thickness (deviation <0.001mm is considered successful); if the target is not met, the prediction window is optimized (increasing from 1s to 2s), and the process is repeated cyclically.

[0040] Thermal management design ensures high-temperature stability. K-type thermocouples (millivolt signals), infrared thermometers (infrared radiation), and laser oxygen analyzers (laser absorption spectra) collect temperature and oxygen content data, transmitting this information to an intelligent feedback controller. The controller compares thresholds (bearing surface >150°C or oxygen content >0.1%), calculates the thermal gradient (>5°C / s indicates overheating), and generates commands such as "argon curtain flow rate 10L / min" and "water cooling flow rate 0.5L / s". Argon gas is injected into the argon cooling curtain via a solenoid valve, and the water cooling structure activates the pump circulation water flow; liquid nitrogen is injected at 0.1L / min if necessary. A titanium-molybdenum alloy honeycomb structure traps oxygen, maintaining a positive pressure of 0.2 bar in the chamber. Laser monitoring provides feedback on the gas supply pressure, and the controller verifies the temperature (<140°C) and oxygen content (<0.05%). If these parameters are not met, cooling is enhanced (e.g., liquid nitrogen is increased to 0.2L / min), and the circulation is optimized.

[0041] Collision prediction and deceleration logic prevent damage. Vibration sensors, eddy current probes, pressure sensors, and infrared monitoring systems collect vibration frequency, shaft displacement trajectory, abnormal air film pressure, and bar stock deviation, transmitting this data to the prediction algorithm module via a multiplexer. The module integrates trend vectors (frequency close to natural frequency ±5%, displacement >0.03mm) and uses a Kalman filter to predict the collision probability (>80% triggers an early warning). The deceleration logic reduces the rotational speed (from 6000rpm to 5400rpm), switches to the backup air path, and activates vacuum negative pressure protection (pressure drop of 0.1bar). Feedback verifies the risk probability (<20% is considered successful); if not eliminated, further deceleration or pause is implemented, with cyclical monitoring. The target oxygen content control in the bearing cavity is ≤8ppm (volume fraction), and oxygen permeability is controlled at ≤0.5ppm / h; when the detected oxygen content exceeds 50ppm, emergency venting and replenishment logic is triggered.

[0042] The air bearing forms an air film through an 8-channel air supply and a 12-hole radial air path. An 8-sector thrust air path enhances anti-overturning moment. Pressure sensors and a PID controller regulate the pressure in each zone (increasing air supply if the deviation exceeds 3 kPa). If the air film fails, a silicon carbide ceramic bearing provides support. Through the synergy of structural design, precision manufacturing, and intelligent control, the system ensures efficient and safe operation. Specific Implementation Example 2:

[0044] like Figures 1 to 6 As shown, the entire system design first considers reducing the weight of the bar stock from the source. However, due to rigid performance requirements that cannot be modified, the only solution is to focus on the fit. To eliminate loosening of the mating surfaces and potential sources of imbalance caused by detachable connections, structures such as bolted connections, which would generate secondary imbalances, are eliminated. The bar stock clamp and rotor shaft adopt an interference fit, and the end faces are sealed with laser welding to form a rigid integral rotor. For the 50,000 RPM operating condition, a rigid rotor must be designed to avoid crossing the critical speed range during start-up and shutdown; otherwise, the vibration will be uncontrollable. Secondly, ultra-precision manufacturing and assembly are employed to minimize residual imbalance. The rotor (shaft + clamp) is machined from a single forging blank as much as possible to avoid assembly errors. Ultra-precision dynamic balancing is not ordinary dynamic balancing but must achieve G0.4 level (aerospace standard). It requires fine balancing on a vacuum balancing machine across multiple planes (at least two correction planes). After balancing, at a speed of 50,000 RPM, the vibration velocity caused by the residual imbalance should be less than 0.4 mm / s. This may require precise calibration using laser micro-weight reduction or the addition of counterweight screws.

[0045] The system modification scheme adopts a thermo-mechanical decoupled air-bearing bearing. Material selection requires a high-temperature and oxidation-resistant porous graphite matrix. This modification necessitates increasing the rod rotation speed to 50,000 rpm; therefore, a combined radial and axial air-bearing bearing structure is used to enhance vibration resistance, providing extremely high radial and axial rotational accuracy. If this bearing design still does not meet the actual modification requirements, a backup scheme combining the air-bearing bearing with auxiliary mechanical supports can be used to provide additional stiffness under extreme loads. For airflow distribution, a double-layer argon gas system forms a dynamic barrier. The inner layer of low-pressure argon gas forms an argon curtain. The specific thermal management logic is as follows: when the plasma gun is activated, the inner argon curtain is activated and maintained at a pressure of 0.1 MPa, then the heat-insulating ring water cooling is activated at a flow rate of 5 L / s. If the bearing temperature exceeds 180℃, the inner argon gas is pressurized to 0.12 MPa; if the temperature exceeds 220℃ and an abnormality is detected, liquid nitrogen emergency injection is triggered.

[0046] It should be noted that the pollution sources encountered in actual situations mainly fall into three categories. To prevent mechanical friction, the bearing housing of the air bearing is eliminated, and the shaft is directly inserted into the air bearing sleeve. To prevent thermal deformation of the shaft components, a thermal expansion clearance is required, and a floating shaft end design is adopted. Lubrication is changed from grease lubrication to a completely dry operation, using a sealing structure that eliminates the oil groove. The bearing stiffness is changed from the original bearing metal stiffness to air film pressure stiffness, and the journal surface requires ultra-precision machining, followed by mirror polishing with a diamond turning tool. Simultaneously, protection against oxygen permeation is implemented using argon positive pressure and titanium getter to ensure an oxygen content below 8 ppm. Considering the possibility of metal dust pollution, a ceramic-coated flow channel will be used during the modification process to ensure a surface roughness Ra0.05 μm. Specific Implementation Example 3:

[0048] like Figures 1 to 6 As shown, the specific modifications to the shaft system involve the following steps: removing the bearing positions while preserving the original shaft system as much as possible, adding an air-bearing shaft section, using a transition design for the tapered surface, using a thrust ring on the end face, and finally requiring a magnetic balance ring. The specific steps are as follows... Figure 4 As shown. The air-bearing journal section is a radial bearing surface. The thrust surface uses a thrust bearing. A single thrust bushing can bear unilateral axial and radial forces. This design uses a bidirectional thrust surface to withstand the bidirectional axial forces that may be generated during bar stock clamping. Two thrust bushings are used in conjunction to restrict axial movement. After air is introduced, an air film is formed on the inner wall of the bushing and the raised surface. It is used in conjunction with the shaft. The thrust surface is designed in the middle of the journal, forming a central thrust structure, simplifying the shaft system structure and improving stability. The thrust surface machining requires a flatness of ≤0.5μm and a perpendicularity to the journal of ≤0.005mm, requiring ultra-precision surface grinding. A 15° guide cone angle with a length of 5mm is designed at the front end to facilitate the installation and introduction of the air-bearing bearing. An R2 fillet unloading groove is machined at the transition between the journal and the non-fitting section, significantly reducing stress concentration and improving fatigue life.

[0049] The air bearing mainly consists of four components: a graphite bushing with a porosity of 30%±2%, an 8-channel evenly distributed air supply, a thrust air chamber with independent PID control of pressure in each zone, a pressure sensor with an accuracy of 0.1%FS, and a silicon carbide ceramic sliding bearing as an emergency bearing. The air circuit interface design is divided into radial and thrust air circuits. The radial air circuit has 12 evenly distributed holes circumferentially, with dimensions to ensure the formation of a continuous air film. The thrust air circuit has 8 sector-shaped cavities on the end face, spaced at 15° intervals, primarily to generate anti-overturning moment. The air bushing bears radial force through the air film on its inner wall and thrust surface air film through the "protruding surface." Customizing an air bearing requires determining its air supply pressure and flow rate. The air supply pressure and flow rate of the air bearing need to be comprehensively determined based on load requirements (radial / axial force), bearing structural parameters (size, throttling method), and operating conditions (speed). The core is to ensure that the air film can stably bear the load and that the pressure / flow rate is matched, avoiding air film rupture, excessive vibration, or excessive energy consumption. Specific Implementation Example 4:

[0051] like Figures 1 to 6 As shown, the following is a supplement to the above content:

[0052] Determining the gas supply pressure:

[0053] Air supply pressure is the core determining factor of air film load capacity. It must simultaneously meet load capacity and stability requirements. The load capacity of air bearings is directly related to air supply pressure, and the actual radial and axial loads must be determined first.

[0054] The minimum air supply pressure is calculated based on the load. The load is divided into radial load and axial load. The radial load mainly consists of gravity and centrifugal force, as represented by Equation 1.

[0055] Formula 1

[0056] In the formula: , For the quality of the bar stock, It is the radius of the bar stock. It is the rotational angular velocity of the bar stock under actual loading.

[0057] The axial load mainly comes from the feed thrust of the bar stock or rotational eccentricity, and can be ignored compared with the radial load. Therefore, only the radial load is considered when calculating the minimum air supply pressure. The minimum air supply pressure is shown in Equation 2. Formula 2

[0058] In the formula: It is the radial load during bar stock operation. It is the effective area of ​​the air film. This is the flow coefficient, which is taken as 0.7 when the material is porous graphite. This is the pipeline pressure loss load, taken as 0.05MPa.

[0059] Based on the above values, the radial load is calculated to be 4.134 kN, and the minimum air supply pressure is calculated to be 0.2687 MPa.

[0060] Shaft-air bearing sleeve fit:

[0061] This design features a double-sided air film with a total diameter of 50µm. The journal diameter is designed to be the bar diameter minus 0.10mm, resulting in a journal diameter of 69.90mm. To meet the air film stability requirements, the surface roughness Ra is [not specified]. 0.05µm, to prevent air film rupture, the journal cylindricity must be maintained. 1µm, ensuring the uniformity of its thrust film and the flatness of the axial positioning surface. 0.5µm. To prevent its thermal deformation, not only are solution treatment and aging heat treatment required to improve fatigue strength, but also journal-direction compensation design is needed to maintain the axial float at a certain level. The radial clearance is 0.5 mm, and the formula for calculating it is shown in Equation 3.

[0062] =D +0.02 Equation 3

[0063] Formula 3: =8.6 (Titanium alloy shaft) , .

[0064] The radial clearance was found to be 0.08 mm.

[0065] Air film thickness monitoring:

[0066] This solution utilizes a triple technology of physical isolation (argon positive pressure), chemical capture (titanium getter), and intelligent feedback (closed-loop control of oxygen content) to suppress oxygen permeability to below 0.5 ppm / h, thus completely solving the oxygen contamination problem in the preparation of high-purity powders.

[0067] Positive pressure gradient design: The pressure in the chamber decreases in stages from the inside out, from 0.25MPa to 0.15MPa to 0.05MPa, reducing energy consumption by 35%; Titanium-molybdenum alloy honeycomb structure, which improves adsorption efficiency by 5 times compared to traditional titanium wire; TDLAS laser monitoring: Real-time feedback to adjust the gas supply pressure.

[0068] Thermal management solution design:

[0069] The argon cooling curtain is the core of this thermal management system. Its function is to construct a dynamic gaseous barrier between the high-temperature plasma arc and the air-bearing system, efficiently blocking thermal radiation and removing heat through forced convection heat transfer. Its parameters were determined through a combination of theoretical calculations and fluid dynamics (CFD) simulation optimization. A detailed thermal management scheme was designed to address the extreme heat load problem faced by the air-bearing system in the PREP equipment. First, by optimizing key parameters such as the argon cooling curtain's injection angle and airflow velocity, a reliable gaseous barrier capable of efficiently isolating high temperatures and achieving a dramatic temperature drop from 1500℃ to 200℃ was designed. Second, a multi-layered thermal monitoring system consisting of contact thermocouples and non-contact infrared thermometers was constructed, and a temperature-based intelligent feedback control logic was designed to achieve adaptive adjustment and precise temperature control of the cooling system. This comprehensive thermal management scheme effectively ensures the thermal stability of the air-bearing system at a high speed of 50,000 RPM, laying a solid foundation for its long-term reliable operation and ultimately achieving the goal of low-pollution powder preparation.

[0070] Cooling curtain structure design and parameter optimization:

[0071] The argon cooling curtain designed in this system adopts an annular slit design. Its core parameter optimization is mainly divided into three parts. The first is the injection angle, optimized to a 30° cone angle. This angle allows the argon gas flow to fully cover more than 80% of the heated surface of the air bearing, forming a uniform protective air curtain and avoiding localized overheating dead zones. The second is the airflow velocity, optimized to 120 m / s. The Reynolds number (Re) calculated from this velocity is much greater than 4000, ensuring the airflow is in a highly turbulent state. Turbulence greatly enhances the convective heat transfer efficiency between the airflow and the hot wall surface, thereby maximizing its cooling capacity. The third is the temperature attenuation gradient, reduced from 1500℃ to 200℃. Based on actual temperature measurement data, after the airflow exits the cooling curtain and travels a distance of 10 mm, the temperature of the high-temperature area it encloses (simulating a plasma arc environment) can be rapidly reduced from 1500℃ to below 200℃, effectively protecting the downstream air bearing.

[0072] The heat insulation effect of the cooling curtain is mainly achieved through the following mechanisms: convective heat transfer is achieved by high-speed, low-temperature argon gas (usually pre-cooled to below 20°C) undergoing forced convective heat transfer with the high-temperature area, directly carrying away a large amount of heat; gas film shielding is ensured by the continuous and stable argon gas curtain forming a relatively static insulating gas film between the high-temperature heat source and the bearing surface. This gas film has low thermal conductivity and can effectively attenuate thermal radiation energy; and environmental replacement is achieved by the high-speed airflow continuously sweeping away and replacing trace amounts of oxygen and water vapor that may penetrate into the bearing area, maintaining the purity of the inert atmosphere.

[0073] Graphite bearing surface (K-type thermocouple): A high-temperature resistant armored K-type thermocouple is used, with its measuring end in close contact with the bearing load area surface through pre-embedding. K-type thermocouples are low in cost, stable in performance, and have a wide measurement range (-200℃ to +1250℃). They can accurately and quickly reflect the actual operating temperature of the bearing body and are the core input signal of the control logic.

[0074] Bar root (infrared thermometer): A high-precision infrared thermometer is used to monitor the temperature near the bar end non-contactly. This is intended to indirectly assess fluctuations in the plasma arc heat load and serves as an important redundant backup and trend warning for thermocouple measurements, preventing grain growth or melting deformation due to overheating of the bar. Specific Implementation Example 5:

[0076] like Figures 1 to 6 As shown, the following is the implementation plan for the plasma gun air bearing system:

[0077] stage cycle Key Mission Old system removal and foundation preparation 3 days Safely disconnect power and isolate, remove old mechanical bearing components, assess and treat the installation foundation. Air bearing assembly installation 15 days Install a porous graphite bearing (PT-30 model) and a double-layer water-cooling jacket (Inconel 718 base), adjusting the bearing coaxiality to ≤0.01mm. Argon gas sealed circulation system installation 20 days Lay argon gas pipelines (including high-pressure / low-pressure dual gas paths) and install exhaust gas purification devices (cyclone separator + molecular sieve dryer), with a leakage rate test result of ≤0.05L / min. Construction technology and quality control of vibration reduction platform 8 days Excavation of foundation pit, foundation treatment, waterproofing construction, laying of base layer vibration damping pads, reinforcement binding and installation of embedded parts, concrete pouring and curing, installation of vibration dampers, and construction of edge vibration damping trenches.

[0078] Because the air film has relatively low stiffness, it is easily affected by external loads and vibrations. Infrared sensors are used to monitor bar offset, a PID controller calculates the compensation amount, and piezoelectric ceramic actuators allow for fine-tuning. Independent pressure adjustment in four quadrants enables response speed and compensation accuracy within a specified range, ultimately achieving dynamic balance of the air film thickness. The parameters of the air bearing after subsequent operation require long-term monitoring. Specific Implementation Example Six:

[0080] like Figures 1 to 6 As shown, the following is a further supplement to this technical solution:

[0081] (1) Non-contact support design to ensure the ultimate purity of powder:

[0082] Traditional mechanical bearings rotate through metal-to-metal contact, easily generating wear debris (Fe / Cr / Ni elements) and lubricant carbon deposits, leading to excessive non-metallic inclusions in the powder (≥50 particles / 1000g) and an increase in oxygen content exceeding 80ppm. This system utilizes porous graphite non-contact air film support to achieve "zero friction and zero pollution."

[0083] Gas film seal replaces mechanical seal: Using 0.4-0.6MPa high-purity argon gas as the medium, a 40±5μm uniform gas film is formed between the bearing and the rod material through a German PT-30 porous graphite matrix with a porosity of 30%±2%. The gas film not only bears radial / axial load (radial load ≥344N, axial load ≥5000N), but also forms a dynamic sealing barrier to prevent external air from seeping in and internal powder from overflowing.

[0084] Significant pollution control results: no metal contact wear (no new wear debris detected by SEM-EDS), no lubricant carbonization (all-dry operation), ultimately achieving an oxygen content of ≤10ppm in the chamber, an oxygen content increase of ≤50ppm in high-temperature alloy powder, and <10 non-metallic inclusions per 1000g of powder under a 20x magnifying glass, meeting the requirements for aerospace-grade high-purity powder (oxygen content increase ≤50ppm).

[0085] Enhanced material purity: The bearing substrate surface is sprayed with a 99.99% Al2O3 ceramic layer (Ra≤0.05μm) to eliminate the risk of trace amounts of graphite substrate falling off, further ensuring powder purity.

[0086] (2) Low friction and high rigidity, supporting stable high-speed rotation at 50,000 rpm:

[0087] Traditional mechanical bearings suffer from high frictional resistance, limiting their maximum speed to only 20,000 rpm, resulting in low fine powder yield (TC4 < 30%) and excessive vibration (acceleration 0.8g). Air-bearing bearings achieve non-contact support through their core mechanism, and air-bearing spindles possess precision unattainable by traditional rolling bearings. With only one moving part and zero contact, sub-micron synchronous error is standard, and asynchronous error is almost completely eliminated. Unlike the complex magnetic levitation or high-pressure oil lubrication systems used in other precision spindle designs, air-bearing spindles suspend the rotor on a rigid layer of compressed air, providing frictionless motion without adding complexity, and completely eliminating mechanical wear because the parts never come into contact. This enables faster speeds and higher precision rotational motion, thereby reducing interruptions or downtime.

[0088] This system achieves high-speed and high-precision operation through a synergistic design of air film characteristics and vibration damping:

[0089] Low friction and high speed capability: The gas viscosity is only 1 / 5000 of that of machine oil, the gas film friction coefficient is <0.001, and it can stably support φ70mm / 14kg bar stock to rotate at 50000rpm with an angular velocity of 5236rad / s and centrifugal force controlled within 3839N (gas film stiffness ≥200N / μm, radial runout ≤10μm).

[0090] The yield of fine powder is greatly improved: the high speed brings sufficient centrifugal force, which fully breaks up the molten liquid film, and the yield of 15-53μm fine powder is significantly improved - titanium alloy TC4≥40%, high temperature alloy IN718≥60%, which is 30%~50% higher than traditional equipment, and the powder sphericity is ≥90% (traditional mechanical bearings only 85%).

[0091] Vibration and noise control: With the basement-type layered vibration reduction platform (rubber pads + combined shock absorbers + polyurethane vibration damping trenches), the equipment operating amplitude is ≤0.1mm and the noise is ≤75dB, which is far lower than that of traditional mechanical bearings (amplitude >0.5mm, noise 85~90dB), meeting the environmental protection and equipment precision requirements of the workshop.

[0092] (3) Argon gas closed-loop circulation, low consumption, environmental protection and cost reduction

[0093] Traditional equipment lacks argon recovery, resulting in a loss of ≥1L per kilogram of powder. The air-bearing spindle, however, consumes very little air and does not rely on the air required by orifice-type air-bearing bearings. If the airflow is disrupted in some way, the gradual decompression of the porous medium can lead to a lack of air supply. This lack of air supply does not damage the bearing or rotor surface, unlike orifice-type air-bearing spindles, which typically require complete rebuilding after such failures.

[0094] (4) Intelligent monitoring and safety redundancy ensure continuous and stable production:

[0095] The system integrates intelligent control with "real-time monitoring + dynamic compensation + emergency protection" to reduce manual intervention and adapt to continuous batch production requirements.

[0096] High-precision real-time monitoring: The system uses an eddy current probe (resistant to 400℃, resolution 0.5μm) to monitor radial runout, a laser oxygen analyzer (accuracy ±1ppm) to monitor oxygen content in the chamber, and a vibration sensor (frequency response 11000Hz) to monitor equipment status. Data is uploaded to the PLC in real time.

[0097] Dynamic accuracy compensation: Equipped with a piezoelectric ceramic actuator (response ≤1ms, compensation accuracy ±1μm), it corrects the gas film thickness deviation in real time, counteracts the micron-level chatter of the high-speed rotation of the bar, and ensures the stability of the gas film (thickness fluctuation ≤±3μm / 10min).

[0098] Safety redundancy design: Dual gas path automatic switching (response ≤10ms), vacuum negative pressure protection is activated within 0.1 seconds when argon gas is interrupted (forming a temporary gas film) to prevent rotor seizure; foolproof function (switching to manual mode in case of automation failure) to ensure production continuity, equipment MTBF (mean time between failures) ≥2000 hours.

[0099] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising a reference structure" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0100] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A plasma gun gas float bearing system characterized by: The rotor system comprises a design level, a process level and a control level, wherein the design level is responsible for rotor dynamics design, adopts hollow shaft structure to reduce weight and inertia, eliminates connection interface through interference fit integration, adopts rigid rotor design to adjust working speed, and simultaneously covers shafting design, and the shafting design is specifically changed as follows: bearing positions are cut off while the original shafting is kept, gas floating shaft section is newly added, taper surface adopts transition design, end surface uses thrust ring, finally magnetic force balance ring is needed, gas floating shaft journal section belongs to radial bearing surface, thrust surface uses single thrust bearing to bear unilateral axial and radial force, double thrust surface is used to bear bidirectional axial force generated by bar clamping, two thrust sleeves are used in cooperation to limit axial movement, air is passed to form a layer of gas film on the inner wall of the sleeve and the convex surface to cooperate with the shaft, the thrust surface is designed to form a central thrust structure in the shaft journal to simplify the shafting structure, the thrust surface is processed by ultra-precision plane grinding, the guide taper angle is designed at the front end to facilitate the installation of the guide taper angle to guide the insertion of the gas floating bearing, and the unloading groove is processed with a round corner at the transition of the shaft journal and the non-cooperating section to reduce stress concentration. The process level is responsible for ultra-precision manufacturing and assembly, and is divided into integral manufacturing, ultra-precision dynamic balancing and hot mounting process. The control level realizes intelligent monitoring and control, and the control level uses active vibration suppression system and collision prediction and speed reduction logic to keep stable, wherein the active vibration suppression system comprises gas film thickness monitoring, thermal management design, is equipped with graphite bearing surface K-type thermocouple and bar root infrared temperature instrument, and has infrared monitoring system, the infrared monitoring system is used for real-time acquisition of bar displacement position and transmission of data to PID controller for analysis, the active vibration suppression system is used for real-time monitoring of vibration parameters and active adjustment of gas film thickness and air pressure distribution to suppress vibration amplification, the collision prediction and speed reduction logic aims to analyze vibration trend to predict potential collision risk and automatically reduce speed to avoid destructive damage, and the collision prediction and speed reduction logic internally comprises a prediction algorithm module for trend analysis by integrating sensor data.

2. A plasma gun gas float bearing system as claimed in claim 1, wherein: The rotor dynamics design determines the rigid rotor structure parameters by simulating the inherent frequency distribution of the rotor through finite element analysis, then eliminates the connection interface looseness by connecting the shaft and the clamp through interference fit, and forms an integrated rotor structure by laser welding, and finally adjusts the working speed to avoid the low-order critical speed area.

3. A plasma gun gas float bearing system as defined in claim 1 wherein: The shafting design retains the original shafting basis by cutting off the bearing position, then creates a radial bearing surface by adding a gas floating shaft journal section, connects the shaft journal section and other parts through taper transition design, fixes the shaft end position with an end surface thrust ring, adjusts the dynamic balance with the help of a magnetic force balance ring, bears the axial force with a double thrust surface and a thrust sleeve, cooperates the shaft with the inner wall gas film and the convex surface gas film by air passing, and places the thrust surface in the middle of the shaft journal in the central thrust structure, uses the guide taper angle to guide the insertion of the gas floating sleeve, and finally processes the transition round corner with an unloading groove to reduce stress concentration.

4. A plasma gun gas float bearing system as defined in claim 1 wherein: The process level is configured by the following steps: the rotor structure is formed by integral machining from a forging blank, the shaft surface is then processed by superfinishing, the journal is smoothed by mirror polishing diamond turning tools, a thermal expansion gap is reserved to prevent thermal deformation, a floating design of the shaft end is adopted to adapt to temperature changes, and metal dust pollution is prevented by a ceramic coating flow channel, while oxygen penetration is prevented by argon overpressure and titanium getter.

5. A plasma gun gas float bearing system as defined in claim 1 wherein: The process level is configured by the following steps: the rotor structure is formed by integral machining from a forging blank, the shaft surface is then processed by superfinishing, the journal is smoothed by mirror polishing diamond turning tools, a thermal expansion gap is reserved to prevent thermal deformation, a floating design of the shaft end is adopted to adapt to temperature changes, and metal dust pollution is prevented by a ceramic coating flow channel, while oxygen penetration is prevented by argon overpressure and titanium getter.

6. A plasma gun gas float bearing system as defined in claim 1 wherein: The control level is configured by the following steps: the piezoelectric ceramic actuator is used to collect rod offset data using an infrared sensor, combined with eddy current probe radial runout data, vibration sensor equipment state data, pressure sensor air cavity pressure data, infrared monitoring system rod offset position, K-type thermocouple graphite bearing surface temperature, infrared thermometer rod root temperature, and laser oxygen analyzer oxygen content changes, and the above data is transmitted to the PID controller for analysis, then the PID controller calculates the compensation and transmits it to the piezoelectric ceramic actuator to execute fine adjustment of the gas film thickness, then the four-quadrant independent pressure regulating structure adjusts the gas path pressure to stabilize the gas film, and finally the feedback loop transmits the execution results back to the PID controller to repeat the monitoring and adjustment process to ensure vibration suppression.

7. A plasma gun gas float bearing system as defined in claim 1 wherein: The control level is configured by the following steps: the piezoelectric ceramic actuator is used to collect rod offset data using an infrared sensor, combined with eddy current probe radial runout data, vibration sensor equipment state data, pressure sensor air cavity pressure data, infrared monitoring system rod offset position, K-type thermocouple graphite bearing surface temperature, infrared thermometer rod root temperature, and laser oxygen analyzer oxygen content changes, and the above data is transmitted to the PID controller for analysis, then the PID controller calculates the compensation and transmits it to the piezoelectric ceramic actuator to execute fine adjustment of the gas film thickness, then the four-quadrant independent pressure regulating structure adjusts the gas path pressure to stabilize the gas film, and finally the feedback loop transmits the execution results back to the PID controller to repeat the monitoring and adjustment process to ensure vibration suppression.

8. A plasma gun gas float bearing system as defined in claim 1 wherein: The control level is provided with an intelligent feedback controller, and the heat management design is configured by the following steps: collecting the surface temperature of the graphite bearing by using a K-type thermocouple, collecting the temperature at the root of the bar by using an infrared thermometer, collecting the oxygen content change by using a laser oxygen analyzer, transmitting the above-mentioned temperature and oxygen content data to the intelligent feedback controller for analysis, then generating an adjustment signal based on the temperature threshold value through the temperature-based control logic and transmitting it to the argon cooling curtain to activate the inner argon curtain, then starting the water cooling of the heat insulation ring structure, and in the case of abnormality, injecting liquid nitrogen through the liquid nitrogen injection structure, at the same time, adjusting the pressure gradient of the chamber body to the positive pressure gradient design, capturing oxygen by means of the titanium molybdenum alloy honeycomb body, and adjusting the gas supply pressure in real time by using the laser monitoring structure, and finally transmitting the adjustment result back to the intelligent feedback controller through the feedback mechanism to continuously optimize the heat environment control.

9. A plasma gun gas float bearing system as defined in claim 1 wherein: The control level is provided with a prediction algorithm module, and the collision prediction and speed reduction logic is configured by the following steps: collecting the rotor vibration frequency by using a vibration sensor, collecting the shaft displacement trajectory by using an eddy current probe, collecting the gas film pressure anomaly by using a pressure sensor, and collecting the bar displacement position by using an infrared monitoring system, transmitting the above-mentioned data to the prediction algorithm module for analysis, then analyzing the vibration and displacement trend by the prediction algorithm module and comparing the inherent frequency to predict the risk of resonance, generating a warning signal through the collision prediction logic, then the speed reduction logic receives the warning signal to adjust the speed, switches the double-gas-path automatic switching structure to the standby gas path, and activates the vacuum negative pressure protection structure to form a temporary gas film, and finally the speed reduction result is transmitted back to the prediction algorithm module through the feedback mechanism to verify the effect and repeat the monitoring process to prevent catastrophic damage.

10. A gas floatation bearing for a plasma gun, characterized by: The gas bearing is the core component of the plasma gun gas bearing system in claims 1-9, and the outer part is provided with a graphite sleeve with a porosity of 30%±2%, and the surface is equipped with 8-channel uniform gas supply structure, the gas pressure is adjusted by the independent PID control of the thrust gas cavity of each zone, at the same time, the pressure sensor with an accuracy of 0.1%FS is installed for real-time pressure monitoring, and the silicon carbide ceramic sliding bearing is used as the emergency support, the gas bearing forms a continuous gas film through the radial gas path and the circumferential 12-hole uniform design, and enhances the anti-overturning moment through the thrust gas path and the end face 8-fan-shaped cavity design, the inner wall gas film and the convex surface gas film cooperate to bear the radial and axial force of the shaft neck segment.

Images