Anti-deformation intelligent welding control system for port machine matching kit

Abstract

The application discloses a kind of anti-deformation intelligent welding control systems for port machine supporting parts, it is related to welding intelligent control technical field, including: predictive controller, rotating magnetic field generator, welding execution module and sensing feedback module;Predictive controller is used to calculate welding heat input according to the input welding process parameter, and according to the preset angle deformation inhibition rate, back-calculation rotating magnetic field parameter, generates control instruction and is sent to rotating magnetic field generator and welding execution module respectively;Rotating magnetic field generator is used to generate adjustable magnetic induction intensity and adjustable rotating frequency rotating magnetic field in welding pool area according to the control instruction sent by predictive controller;Welding execution module is used to execute welding operation according to the control instruction sent by predictive controller;Sensing feedback module is used to measure the angle deformation amount of completed weld and feedback to predictive controller in real time.The application actively regulates and controls the solidification shrinkage direction of molten pool by rotating magnetic field, and inhibits the angle deformation from the root of welding deformation.

Description

Technical Field

[0001] This invention relates to the field of intelligent welding control technology, specifically an anti-deformation intelligent welding control system for port machinery components. Background Technology

[0002] Port machinery components (such as hinge supports, balance beams, box girders, etc.) are key load-bearing structural components of port lifting equipment. They are usually assembled by welding multiple parts such as bottom plates, ear plates, and stiffening plates. The welding quality directly affects the structural safety and service life of port equipment.

[0003] Port machinery components are generally characterized by large structural dimensions, thick plates, numerous welds, and concentrated heat input. The complex stress-strain field generated by uneven heat input during welding can easily lead to various welding deformations such as angular deformation, bending deformation, and torsional deformation, which seriously affect the dimensional accuracy and assembly quality of the components. For components such as hinge supports that require precise pin fitting, excessive welding deformation may even prevent normal installation.

[0004] Currently, the industry mainly adopts the following technical methods to control welding deformation of port machinery components and other large structural parts:

[0005] 1. Rigid fixing method: This method will significantly increase welding stress, and the design and manufacture of large fixtures are complex and costly, and clamping and disassembling are time-consuming and labor-intensive;

[0006] 2. The reverse deformation method mainly relies on the operator's experience and lacks precise quantitative calculation basis. It has poor applicability to different plate thicknesses, different joint types and different materials, and it is difficult to accurately predict the structure of port machinery components with complex structures.

[0007] 3. Post-weld straightening method: This method is a passive remedial measure, which adds extra steps and costs, and flame straightening may have an adverse effect on the microstructure and mechanical properties of the material.

[0008] 4. Process parameter optimization method: This method has limited adjustment space and is difficult to fundamentally eliminate angular deformation and bending deformation.

[0009] In summary, there is an urgent need in this field for an intelligent welding control system that can actively suppress deformation from the source of the welding process, has quantitative prediction capabilities, and is applicable to large components of port machinery. Summary of the Invention

[0010] The purpose of this invention is to overcome the above-mentioned deficiencies in existing welding deformation control technologies for port machinery components, and to provide an anti-deformation intelligent welding control system that can actively suppress deformation from the source of the welding process, has quantitative prediction capabilities, and is applicable to large structural components.

[0011] To achieve the above objectives, the present invention provides the following technical solution: an anti-deformation intelligent welding control system for port machinery components, comprising: a predictive controller, a rotating magnetic field generator, a welding execution module, and a sensing feedback module;

[0012] The predictive controller is communicatively connected to the rotating magnetic field generator, the welding execution module, and the sensing feedback module, respectively.

[0013] The predictive controller is used to calculate the welding heat input based on the input welding process parameters, and to back-calculate the required rotating magnetic field parameters based on the preset angular deformation suppression rate target value, and generate control commands to be sent to the rotating magnetic field generator and the welding execution module respectively.

[0014] The rotating magnetic field generator is fixedly mounted on the welding torch and moves synchronously with the welding torch. It is used to generate a rotating magnetic field with adjustable magnetic induction intensity and adjustable rotation frequency in the welding pool area according to the control command sent by the predictive controller.

[0015] The welding execution module is used to perform welding operations according to the control instructions sent by the predictive controller;

[0016] The sensing feedback module is located behind the welding torch and is used to measure the angular deformation of the completed weld in real time and feed it back to the predictive controller.

[0017] Furthermore, the predictive controller determines the rotating magnetic field parameters based on the quantitative relationship between the angular deformation suppression rate and the magnetic field energy input;

[0018] The predictive controller calculates the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the quantitative relationship and the target suppression rate, and selects a combination of magnetic induction intensity and rotation frequency that satisfies the lower limit and outputs it to the rotating magnetic field generator.

[0019] It should be noted that the quantitative relationship is that the angular deformation suppression rate increases exponentially with the increase of the product of the square of the magnetic induction intensity of the rotating magnetic field and the rotation frequency. In this exponential relationship, the numerator of the exponent is the product of the square of the magnetic induction intensity, the rotation frequency and the thickness of the workpiece plate being welded, and the denominator is the product of the welding heat input and the material empirical coefficient.

[0020] Furthermore, the prediction controller includes:

[0021] The parameter input unit is used to receive welding process parameters input by the operator. The welding process parameters include at least welding current, welding voltage, welding speed, workpiece thickness and material grade.

[0022] The storage unit is used to store material empirical coefficient values ​​corresponding to different material grades and historical welding data;

[0023] The calculation unit is used to calculate the welding heat input based on the welding process parameters received by the parameter input unit, and to calculate the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the quantitative relationship and the target suppression rate, and to select a feasible combination of magnetic induction intensity and rotation frequency.

[0024] The instruction output unit is used to convert the magnetic induction intensity and rotation frequency determined by the calculation unit into corresponding drive current amplitude instructions and frequency instructions, send them to the rotating magnetic field generator, and send the welding parameters to the welding execution module;

[0025] An adaptive correction unit, which is communicatively connected to the sensing feedback module, is used to receive the actual angular deformation amount fed back by the sensing feedback module, calculate the actual suppression rate, and compare it with the target suppression rate. When the deviation exceeds a preset threshold, the material empirical coefficient in the storage unit is corrected online.

[0026] Furthermore, the rotating magnetic field generator includes:

[0027] Multi-pole excitation coils are 4-pole or 6-pole coils arranged in a ring symmetrical arrangement, which are wrapped around the outside of the welding torch to generate a rotating magnetic field;

[0028] The iron core, made of stacked high-permeability silicon steel sheets, is placed inside the multi-pole excitation coil to enhance the magnetic induction intensity;

[0029] The driving power supply is communicatively connected to the command output unit of the predictive controller, and is used to receive current amplitude commands and frequency commands, and output AC power with corresponding amplitude and frequency to the multi-pole excitation coil.

[0030] A magnetic field strength adjustment unit is used to change the magnetic induction intensity by adjusting the output current amplitude of the drive power supply;

[0031] A frequency adjustment unit is used to change the rotation frequency by adjusting the inverter switching frequency of the drive power supply.

[0032] A cooling unit is located outside the multipole excitation coil and is used to cool the coil.

[0033] Furthermore, the welding execution module includes:

[0034] The welding power source is communicatively connected to the command output unit of the predictive controller to receive welding start, stop, and process parameter commands.

[0035] Welding torch and motion mechanism, used to achieve uniform movement of the welding torch along the weld seam;

[0036] A synchronous triggering unit is connected to the welding power source and the rotating magnetic field generator respectively, and is used to ensure that the rotating magnetic field generator starts and stops synchronously with the welding power source.

[0037] Furthermore, the sensing feedback module includes:

[0038] An angular deformation measurement unit includes at least two laser displacement sensors, which are fixedly installed 100 mm to 200 mm behind the welding torch to measure the vertical displacement difference between the two sides of the weld in real time and calculate the angular deformation.

[0039] The signal conditioning unit, connected to the angular deformation measurement unit, is used to convert the sensor signal into a standard industrial signal and transmit it to the adaptive correction unit of the predictive controller.

[0040] Furthermore, it also includes a human-computer interaction module, which is communicatively connected to the predictive controller, and includes:

[0041] The touch screen is used for operators to input welding process parameters, set target suppression rates, and display the current rotating magnetic field parameters and measured angular deformation curves in real time.

[0042] An emergency stop button is used to disconnect the welding execution module and the rotating magnetic field generator in an emergency.

[0043] Alternatively, a method is provided that includes the following steps:

[0044] Step S1: Input the material grade, plate thickness, welding current, welding voltage and welding speed of the workpiece to be welded through the human-computer interaction module;

[0045] Step S2: The predictive controller retrieves the corresponding material empirical coefficient from the storage unit according to the material grade, and calculates the welding heat input by dividing the product of welding voltage and welding current by the welding speed;

[0046] Step S3: The predictive controller calculates the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the preset target suppression rate and the quantitative relationship, and selects the rotation frequency from the preset frequency table to calculate the required magnetic induction intensity.

[0047] Step S4: The predictive controller determines whether the magnetic induction intensity calculated in step S3 exceeds the maximum output capability of the rotating magnetic field generator. If it does, the target suppression rate is reduced or the rotation frequency is increased and the calculation is repeated until the magnetic induction intensity is within a feasible range.

[0048] Step S5: The predictive controller converts the determined magnetic induction intensity and rotation frequency into drive current amplitude and frequency commands and sends them to the rotating magnetic field generator, while simultaneously sending a welding start command to the welding execution module;

[0049] Step S6: The rotating magnetic field generator generates a rotating magnetic field that acts on the weld pool area. The welding execution module performs the welding operation, and the rotating magnetic field generator moves synchronously with the welding torch.

[0050] Step S7: The sensing feedback module measures the angular deformation of the completed weld in real time and feeds it back to the predictive controller;

[0051] Step S8: The adaptive correction unit of the predictive controller calculates the actual suppression rate based on the actual angular deformation amount fed back. If the deviation between the actual suppression rate and the target suppression rate exceeds the preset threshold, the rotating magnetic field parameters are adjusted and resent to the rotating magnetic field generator.

[0052] Step S9: After welding is completed, the predictive controller sends a stop command to the welding execution module and the rotating magnetic field generator. The sensor feedback module measures the final angular deformation and saves all process data.

[0053] Compared with the prior art, the beneficial effects of the present invention are:

[0054] 1. This invention actively controls the direction of solidification shrinkage of the molten pool by rotating a magnetic field, thereby suppressing angular deformation at the root cause of welding deformation;

[0055] 2. This invention establishes a quantitative relationship between magnetic field parameters and the effect of welding deformation suppression, and realizes predictive feedforward calculation of magnetic field parameters. It does not require repeated trial and error based on operator experience, and is applicable to port machinery components with different plate thicknesses, materials and joint types, with strong adaptability.

[0056] 3. Compared with the traditional rigid fixing method, the present invention does not require large and complex fixtures and does not significantly increase welding stress; compared with the post-weld straightening method, the present invention is an active prevention rather than a passive remedy, does not add extra processes, and does not damage the microstructure and mechanical properties of the material; compared with conventional magnetic welding technology, the present invention is the first to expand the magnetic field from a means of improving the structure to a means of controlling deformation, and its function and application fields have undergone fundamental changes.

[0057] 4. This invention measures angular deformation in real time and corrects it online through a sensor feedback module, forming an intelligent control closed loop of prediction-execution-feedback-correction. At the same time, the adaptive correction unit continuously learns from the empirical coefficients, enabling the system to adapt to material batch differences and environmental changes, and its accuracy continues to improve over long-term use. Attached Figure Description

[0058] Figure 1This is a structural schematic diagram of an anti-deformation intelligent welding control system for port machinery components according to the present invention. Detailed Implementation

[0059] 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.

[0060] Example: Figure 1 As shown, the present invention provides a technical solution, an anti-deformation intelligent welding control system for port machinery components, comprising: a predictive controller, a rotating magnetic field generator, a welding execution module, and a sensing feedback module;

[0061] The predictive controller is communicatively connected to the rotating magnetic field generator, the welding execution module, and the sensing feedback module, respectively.

[0062] The predictive controller is used to calculate the welding heat input based on the input welding process parameters, and to back-calculate the required rotating magnetic field parameters based on the preset angular deformation suppression rate target value, and generate control commands to be sent to the rotating magnetic field generator and the welding execution module respectively.

[0063] The rotating magnetic field generator is fixedly mounted on the welding torch and moves synchronously with the welding torch. It is used to generate a rotating magnetic field with adjustable magnetic induction intensity and adjustable rotation frequency in the welding pool area according to the control command sent by the predictive controller.

[0064] The welding execution module is used to perform welding operations according to the control instructions sent by the predictive controller;

[0065] The sensing feedback module is located behind the welding torch and is used to measure the angular deformation of the completed weld in real time and feed it back to the predictive controller.

[0066] Furthermore, the predictive controller determines the rotating magnetic field parameters based on the quantitative relationship between the angular deformation suppression rate and the magnetic field energy input;

[0067] The predictive controller calculates the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the quantitative relationship and the target suppression rate, and selects a combination of magnetic induction intensity and rotation frequency that satisfies the lower limit and outputs it to the rotating magnetic field generator.

[0068] It should be noted that the quantitative relationship is that the angular deformation suppression rate increases exponentially with the increase of the product of the square of the magnetic induction intensity of the rotating magnetic field and the rotation frequency. In this exponential relationship, the numerator of the exponent is the product of the square of the magnetic induction intensity, the rotation frequency and the thickness of the workpiece plate being welded, and the denominator is the product of the welding heat input and the material empirical coefficient.

[0069] In one embodiment of the present invention, the default value of the standard inhibition rate is 0.90, which can be adjusted to the range of 0.70-0.98 according to the actual situation.

[0070] In one embodiment of the present invention, the material empirical coefficient ranges from 0.5 to 2.0 and is obtained by fitting calibrated welding experiments under 3 to 5 sets of different rotating magnetic field parameters.

[0071] Furthermore, the prediction controller includes:

[0072] The parameter input unit is used to receive welding process parameters input by the operator. The welding process parameters include at least welding current, welding voltage, welding speed, workpiece thickness and material grade.

[0073] The storage unit is used to store material empirical coefficient values ​​corresponding to different material grades and historical welding data;

[0074] The calculation unit is used to calculate the welding heat input based on the welding process parameters received by the parameter input unit, and to calculate the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the quantitative relationship and the target suppression rate, and to select a feasible combination of magnetic induction intensity and rotation frequency.

[0075] The instruction output unit is used to convert the magnetic induction intensity and rotation frequency determined by the calculation unit into corresponding drive current amplitude instructions and frequency instructions, send them to the rotating magnetic field generator, and send the welding parameters to the welding execution module;

[0076] An adaptive correction unit, which is communicatively connected to the sensing feedback module, is used to receive the actual angular deformation amount fed back by the sensing feedback module, calculate the actual suppression rate, and compare it with the target suppression rate. When the deviation exceeds a preset threshold, the material empirical coefficient in the storage unit is corrected online.

[0077] Furthermore, the rotating magnetic field generator includes:

[0078] Multi-pole excitation coils are 4-pole or 6-pole coils arranged in a ring symmetrical arrangement, which are wrapped around the outside of the welding torch to generate a rotating magnetic field;

[0079] The iron core, made of stacked high-permeability silicon steel sheets, is placed inside the multi-pole excitation coil to enhance the magnetic induction intensity;

[0080] The driving power supply is communicatively connected to the command output unit of the predictive controller, and is used to receive current amplitude commands and frequency commands, and output AC power with corresponding amplitude and frequency to the multi-pole excitation coil.

[0081] A magnetic field strength adjustment unit is used to change the magnetic induction intensity by adjusting the output current amplitude of the drive power supply;

[0082] A frequency adjustment unit is used to change the rotation frequency by adjusting the inverter switching frequency of the drive power supply.

[0083] A cooling unit is located outside the multipole excitation coil and is used to cool the coil.

[0084] In one embodiment of the present invention, the inner diameter of the multipole excitation coil is 40 mm to 80 mm, the rotating magnetic field generator is fixed to the welding torch holder by an adjustable bracket, the adjustable distance of the adjustable bracket along the welding direction is 10 mm to 30 mm, and the axis of the multipole excitation coil coincides with the axis of the welding torch.

[0085] Furthermore, the welding execution module includes:

[0086] The welding power source is communicatively connected to the command output unit of the predictive controller to receive welding start, stop, and process parameter commands.

[0087] Welding torch and motion mechanism, used to achieve uniform movement of the welding torch along the weld seam;

[0088] A synchronous triggering unit is connected to the welding power source and the rotating magnetic field generator respectively, and is used to ensure that the rotating magnetic field generator starts and stops synchronously with the welding power source.

[0089] Furthermore, the sensing feedback module includes:

[0090] An angular deformation measurement unit includes at least two laser displacement sensors, which are fixedly installed 100 mm to 200 mm behind the welding torch to measure the vertical displacement difference between the two sides of the weld in real time and calculate the angular deformation.

[0091] The signal conditioning unit, connected to the angular deformation measurement unit, is used to convert the sensor signal into a standard industrial signal and transmit it to the adaptive correction unit of the predictive controller.

[0092] Furthermore, it also includes a human-computer interaction module, which is communicatively connected to the predictive controller, and includes:

[0093] The touch screen is used for operators to input welding process parameters, set target suppression rates, and display the current rotating magnetic field parameters and measured angular deformation curves in real time.

[0094] An emergency stop button is used to disconnect the welding execution module and the rotating magnetic field generator in an emergency.

[0095] In this invention, the predictive controller and the rotating magnetic field generator are connected via RS485 bus or Modbus protocol; the predictive controller and the welding execution module are connected via CAN bus or analog interface; and the predictive controller and the sensing feedback module are connected via 4 to 20 mA current loop or Ethernet.

[0096] Alternatively, a method is provided that includes the following steps:

[0097] Step S1: Input the material grade, plate thickness, welding current, welding voltage and welding speed of the workpiece to be welded through the human-computer interaction module;

[0098] Step S2: The predictive controller retrieves the corresponding material empirical coefficient from the storage unit according to the material grade, and calculates the welding heat input by dividing the product of welding voltage and welding current by the welding speed;

[0099] Step S3: The predictive controller calculates the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the preset target suppression rate and the quantitative relationship, and selects the rotation frequency from the preset frequency table to calculate the required magnetic induction intensity.

[0100] Step S4: The predictive controller determines whether the magnetic induction intensity calculated in step S3 exceeds the maximum output capability of the rotating magnetic field generator. If it does, the target suppression rate is reduced or the rotation frequency is increased and the calculation is repeated until the magnetic induction intensity is within a feasible range.

[0101] Step S5: The predictive controller converts the determined magnetic induction intensity and rotation frequency into drive current amplitude and frequency commands and sends them to the rotating magnetic field generator, while simultaneously sending a welding start command to the welding execution module;

[0102] Step S6: The rotating magnetic field generator generates a rotating magnetic field that acts on the weld pool area. The welding execution module performs the welding operation, and the rotating magnetic field generator moves synchronously with the welding torch.

[0103] Step S7: The sensing feedback module measures the angular deformation of the completed weld in real time and feeds it back to the predictive controller;

[0104] Step S8: The adaptive correction unit of the predictive controller calculates the actual suppression rate based on the actual angular deformation amount fed back. If the deviation between the actual suppression rate and the target suppression rate exceeds the preset threshold, the rotating magnetic field parameters are adjusted and resent to the rotating magnetic field generator.

[0105] Step S9: After welding is completed, the predictive controller sends a stop command to the welding execution module and the rotating magnetic field generator. The sensor feedback module measures the final angular deformation and saves all process data.

[0106] In one embodiment of the present invention, the preset frequency table includes five levels: 50 Hz, 80 Hz, 100 Hz, 120 Hz and 150 Hz. The predictive controller preferentially selects the highest frequency level that ensures the required magnetic induction intensity does not exceed the maximum output capability of the rotating magnetic field generator.

[0107] In one embodiment of the present invention, the method for the adaptive correction unit to perform online correction of the material empirical coefficients is as follows:

[0108] After a predetermined number of welds are completed, the welding heat input, plate thickness, magnetic induction intensity, rotation frequency and actual suppression rate of each weld are stored as a set of samples in the database; linear regression is performed on the quantitative relationship to calculate new material empirical coefficients; the original material empirical coefficients in the storage unit are replaced with the new material empirical coefficients.

[0109] In one embodiment of the present invention, the operator inputs the base material grade, plate thickness h (in mm), and welding process parameters (I, U, v) through a human-machine interface; wherein, welding current I (in A), voltage U (in V), and welding speed v (in mm / s);

[0110] The system automatically retrieves the empirical coefficient of the material from the storage unit as the material empirical coefficient α;

[0111] Set the target suppression rate η_target; the calculation unit calculates the thermal input E=U·I / v.

[0112] Calculate the minimum required B 2 f:B 2 f_min=-(E / αh)ln(1-η_target); where B is the magnetic induction intensity of the rotating magnetic field and f is the frequency of the rotating magnetic field;

[0113] The frequency f is selected from a pre-set frequency table within the system, prioritizing frequencies that ensure the required frequency B does not exceed the coil's maximum capacity. For example, if f = 100Hz, then Breq = (B 2 f_min / 100) 1 / 2 ;Breq represents the expected magnetic flux density of the rotating magnetic field;

[0114] If Breq exceeds the upper limit of the coil, η_target will be automatically reduced or f will be increased and recalculated.

[0115] The final (Breq,f) is converted into the current amplitude command of the drive power supply, I_mag=Breq / k_B; where k_B is the coil constant, which is factory calibrated.

[0116] When the operator presses the start button, the predictive controller simultaneously sends an arc-ignition command to the welding power source, a movement command to the motion mechanism, and an output command to the rotating magnetic field drive power source.

[0117] The rotating magnetic field generator produces a rotating magnetic field with set f and I_mag, which acts on the molten pool region.

[0118] The angular deformation measurement unit of the sensor feedback module samples the weld angular deformation φ_actual every 50ms.

[0119] The adaptive correction unit calculates the current actual suppression rate η_actual = 1 - φ_actual / φ0; where φ0 is the standard angular deformation of the same process without a magnetic field, which is pre-stored in the system; if |η_actual - η_target| > 0.05, then the correction is performed according to the following rules:

[0120] If η_actual is too small, then increase (B) 2 The value of f_min should be increased preferentially, either f or B.

[0121] After correction, the command is resent to the rotating magnetic field drive power supply; at the same time, the deviation is recorded and the α value is updated by recursive least squares method.

[0122] After the welding motion mechanism reaches the end point, the predictive controller issues a stop command, the welding power supply extinguishes the arc, and the rotating magnetic field stops outputting.

[0123] The sensor feedback module measures the angular deformation of the last weld segment. If it exceeds the allowable threshold of 0.5°, the system will issue an alarm and suggest local correction.

[0124] All process data is automatically saved to the storage unit for subsequent process optimization.

[0125] For each weld completed, the system stores (E,h,B,f,η_actual) as a set of samples in the database.

[0126] Every time 10 new samples are accumulated, the adaptive correction unit refits the formula: ln(1-η_actual)=-α·(B 2 fh / E);

[0127] This involves replacing the original α value with the slope calculated using linear regression. This continuously enhances the system's adaptability to different batches of materials and varying environmental temperatures.

[0128] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A deformation-resistant intelligent welding control system for port machinery components, characterized in that: It includes a predictive controller, a rotating magnetic field generator, a welding execution module, and a sensor feedback module; The predictive controller is communicatively connected to the rotating magnetic field generator, the welding execution module, and the sensing feedback module, respectively. The predictive controller is used to calculate the welding heat input based on the input welding process parameters, and to back-calculate the required rotating magnetic field parameters based on the preset angular deformation suppression rate, and generate control commands to be sent to the rotating magnetic field generator and the welding execution module respectively. The rotating magnetic field generator is fixedly mounted on the welding torch and moves synchronously with the welding torch. It is used to generate a rotating magnetic field with adjustable magnetic induction intensity and adjustable rotation frequency in the welding pool area according to the control command sent by the predictive controller. The welding execution module is used to perform welding operations according to the control instructions sent by the predictive controller; The sensor feedback module is located behind the welding torch and is used to measure the angular deformation of the completed weld in real time and feed it back to the predictive controller.

2. The anti-deformation intelligent welding control system for port machinery components according to claim 1, characterized in that: The predictive controller determines the rotating magnetic field parameters based on the quantitative relationship between the angular deformation suppression rate and the magnetic field energy input; The predictive controller calculates the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the quantitative relationship and the target suppression rate, and selects a combination of magnetic induction intensity and rotation frequency that satisfies the lower limit and outputs it to the rotating magnetic field generator.

3. The anti-deformation intelligent welding control system for port machinery components according to claim 2, characterized in that: The prediction controller includes: The parameter input unit is used to receive welding process parameters input by the operator. The welding process parameters include at least welding current, welding voltage, welding speed, workpiece thickness and material grade. The storage unit is used to store material empirical coefficient values ​​corresponding to different material grades and historical welding data; The calculation unit is used to calculate the welding heat input based on the welding process parameters received by the parameter input unit, and to calculate the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the quantitative relationship and the target suppression rate, and to select a feasible combination of magnetic induction intensity and rotation frequency. The instruction output unit is used to convert the magnetic induction intensity and rotation frequency determined by the calculation unit into corresponding drive current amplitude instructions and frequency instructions, send them to the rotating magnetic field generator, and send the welding parameters to the welding execution module; An adaptive correction unit, which is communicatively connected to the sensing feedback module, is used to receive the actual angular deformation amount fed back by the sensing feedback module, calculate the actual suppression rate, and compare it with the target suppression rate. When the deviation exceeds a preset threshold, the material empirical coefficient in the storage unit is corrected online.

4. The anti-deformation intelligent welding control system for port machinery components according to claim 3, characterized in that: The rotating magnetic field generator includes: Multi-pole excitation coils are 4-pole or 6-pole coils arranged in a ring symmetrical arrangement, which are wrapped around the outside of the welding torch to generate a rotating magnetic field; The iron core, made of stacked high-permeability silicon steel sheets, is placed inside the multi-pole excitation coil to enhance the magnetic induction intensity; The driving power supply is communicatively connected to the command output unit of the predictive controller, and is used to receive current amplitude commands and frequency commands, and output AC power with corresponding amplitude and frequency to the multi-pole excitation coil. A magnetic field strength adjustment unit is used to change the magnetic induction intensity by adjusting the output current amplitude of the drive power supply; A frequency adjustment unit is used to change the rotation frequency by adjusting the inverter switching frequency of the drive power supply. A cooling unit is located outside the multipole excitation coil and is used to cool the coil.

5. The anti-deformation intelligent welding control system for port machinery components according to claim 4, characterized in that: The welding execution module includes: The welding power source is communicatively connected to the command output unit of the predictive controller to receive welding start, stop, and process parameter commands. Welding torch and motion mechanism, used to achieve uniform movement of the welding torch along the weld seam; A synchronous triggering unit is connected to the welding power source and the rotating magnetic field generator respectively, and is used to ensure that the rotating magnetic field generator starts and stops synchronously with the welding power source.

6. The anti-deformation intelligent welding control system for port machinery components according to claim 5, characterized in that: The sensing feedback module includes: An angular deformation measurement unit includes at least two laser displacement sensors, which are fixedly installed behind the welding torch to measure the vertical displacement difference between the two sides of the weld in real time and calculate the angular deformation. The signal conditioning unit, connected to the angular deformation measurement unit, is used to convert the sensor signal into a standard industrial signal and transmit it to the adaptive correction unit of the predictive controller.

7. The anti-deformation intelligent welding control system for port machinery components according to claim 6, characterized in that: It also includes a human-computer interaction module, which is communicatively connected to the predictive controller, and includes: The touch screen is used for operators to input welding process parameters, set target suppression rates, and display the current rotating magnetic field parameters and measured angular deformation curves in real time. An emergency stop button is used to disconnect the welding execution module and the rotating magnetic field generator in an emergency.

8. The anti-deformation intelligent welding control system for port machinery components according to claim 2, characterized in that: The quantitative relationship is that the angular deformation suppression rate increases exponentially with the increase of the product of the square of the magnetic induction intensity of the rotating magnetic field and the rotation frequency. In this exponential relationship, the numerator of the exponent is the product of the square of the magnetic induction intensity, the rotation frequency and the thickness of the workpiece plate being welded, and the denominator is the product of the welding heat input and the material empirical coefficient.

9. A method for applying an anti-deformation intelligent welding control system for port machinery components as described in any one of claims 1-8, characterized in that: Includes the following steps: Step S1: Input the material grade, plate thickness, welding current, welding voltage and welding speed of the workpiece to be welded through the human-computer interaction module; Step S2: The predictive controller retrieves the corresponding material empirical coefficient from the storage unit according to the material grade, and calculates the welding heat input by dividing the product of welding voltage and welding current by the welding speed; Step S3: The predictive controller calculates the lower limit of the product of the square of the magnetic induction intensity and the rotation frequency that needs to be satisfied based on the preset target suppression rate and the quantitative relationship, and selects the rotation frequency from the preset frequency table to calculate the required magnetic induction intensity. Step S4: The predictive controller determines whether the magnetic induction intensity calculated in step S3 exceeds the maximum output capability of the rotating magnetic field generator. If it does, the target suppression rate is reduced or the rotation frequency is increased and the calculation is repeated until the magnetic induction intensity is within a feasible range. Step S5: The predictive controller converts the determined magnetic induction intensity and rotation frequency into drive current amplitude and frequency commands and sends them to the rotating magnetic field generator, while simultaneously sending a welding start command to the welding execution module; Step S6: The rotating magnetic field generator generates a rotating magnetic field that acts on the weld pool area. The welding execution module performs the welding operation, and the rotating magnetic field generator moves synchronously with the welding torch. Step S7: The sensing feedback module measures the angular deformation of the completed weld in real time and feeds it back to the predictive controller; Step S8: The adaptive correction unit of the predictive controller calculates the actual suppression rate based on the actual angular deformation amount fed back. If the deviation between the actual suppression rate and the target suppression rate exceeds the preset threshold, the rotating magnetic field parameters are adjusted and resent to the rotating magnetic field generator. Step S9: After welding is completed, the predictive controller sends a stop command to the welding execution module and the rotating magnetic field generator. The sensor feedback module measures the final angular deformation and saves all process data.

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