Topological optimization high-energy-efficiency structure for connecting electromagnetic pulse tube with magnetic collector

Abstract

The utility model relates to a topological optimization high energy efficiency electromagnetic pulse tube connection magnetic collector structure, which comprises two half bodies with the same shape, the two half bodies are symmetrically arranged and spliced to form a shaft body structure with an inner cavity, each half body comprises a magnetic collector shaft part and a crimping part, and the magnetic collector shaft part is provided with an inner wall, an outer wall and a side wall; the crimping part is arranged on the inner wall, the crimping part is provided with a crimping wall, conical walls located at the two ends of the crimping wall and a connecting wall flush with the side wall, the large-caliber end of each conical wall is connected with the inner wall, and the small-caliber end of each conical wall is converged to the crimping wall; a first groove is formed in the connecting wall, a groove opening of the first groove is located in the wall surface of the connecting wall, the groove bottom of the first groove extends from the wall surface of the connecting wall in the circumferential direction of the crimping part, and the first groove penetrates through the crimping part in the axial direction of the crimping part; by arranging the first groove, the sectional area of the conductor is obviously reduced when current flows through the region, so that the current density is improved, and electromagnetic energy is concentrated and focused on the crimping working region.

Description

Technical Field

[0001] This utility model relates to the field of magnetic pulse connection technology for pipe fittings, specifically to a topology-optimized, high-efficiency electromagnetic pulse tube connection magnet collector structure. Background Technology

[0002] Electromagnetic tube joining (EMTJ) technology, as an advanced tube joining method, is widely used in fields such as automotive manufacturing due to its speed, cleanliness, and ability to achieve high-strength connections. One of the core components of this technology is the magnet collector, which concentrates and guides the time-varying electromagnetic field generated by the coil to the area of ​​the workpiece to be joined.

[0003] The efficiency of a magnet collector directly depends on the current density achievable in its operating area. According to Joule's law and the principle of electromagnetic induction, higher current density means a stronger induced magnetic field and electromagnetic force, thus driving the workpiece to undergo more effective plastic deformation for a reliable connection. However, existing integrated or split magnet collector structures typically have relatively uniform conductor cross-sectional areas, or only roughly guide the magnetic field through macroscopic shape changes. This design fails to effectively optimize and control the current path locally.

[0004] Specifically, existing technologies suffer from the following shortcomings: To improve the energy density of the connection area, the common approach is to simply increase the input current of the entire system or to use copper alloy materials, which have better conductivity but are more expensive. The former leads to a significant increase in the energy consumption of the entire device and low energy efficiency; the latter results in high manufacturing costs, and the increased weight due to high-density materials is also detrimental to the lightweighting of the equipment. The fundamental problem is that traditional magnet collector structures lack an effective means to actively and precisely increase the local current density in the critical working area (i.e., the pressing area where the interaction with the workpiece is strongest). The current distribution in the conductor is relatively dispersed and cannot be effectively "squeezed" and "focused" to the core working area that requires the most energy, which limits the efficient utilization of electromagnetic field energy.

[0005] Therefore, there is an urgent need in this field for a magnet collector structure design that can specifically enhance the current density in the crimping working area without significantly increasing overall energy consumption and manufacturing costs, thereby fundamentally improving the energy efficiency of electromagnetic pulse connection technology. Utility Model Content

[0006] This invention provides a topology-optimized, high-efficiency electromagnetic pulse tube connection magnetizer structure, which aims to solve the problem of low energy efficiency caused by insufficient current density in the working region of existing magnetizers.

[0007] To achieve the above objectives, this utility model provides a topology-optimized, high-efficiency electromagnetic pulse tube connection magnet collector structure, comprising two identical halves, which are symmetrically arranged and joined to form a shaft structure with an internal cavity. Each half includes:

[0008] A magnet collector shaft portion, the magnet collector shaft portion having an inner wall, an outer wall, and a side wall connecting the inner wall and the outer wall;

[0009] A crimping portion is disposed on the inner wall. The crimping portion has a crimping wall, conical walls located at both ends of the crimping wall, and a connecting wall flush with the side wall. The large-diameter end of the conical wall is connected to the inner wall, and the small-diameter end converges to the crimping wall.

[0010] The connecting wall has a first groove, the opening of the first groove is located on the wall surface of the connecting wall, the bottom of the first groove extends from the wall surface of the connecting wall along the circumference of the crimping part, and the first groove penetrates the crimping part in the axial direction of the crimping part.

[0011] Furthermore, a second groove is provided on the side wall of the magnet collector shaft, and the second groove passes through the magnet collector shaft.

[0012] Furthermore, a plurality of third grooves are provided on the outer wall of the magnet collecting shaft.

[0013] Furthermore, all right-angled portions of the half-body are smoothed into rounded transitions.

[0014] Furthermore, the smoothing process is applied to the edge connections of the first groove, the second groove, and / or the third groove.

[0015] Furthermore, the magnet collector structure is made of copper alloy or aluminum alloy.

[0016] Furthermore, the cross-sectional shape of the first groove is arc-shaped.

[0017] Furthermore, the plurality of the third grooves are distributed at circumferential intervals along the outer wall.

[0018] Furthermore, the depth of the second groove is greater than the depth of the first groove, and the width of the second groove is greater than the width of the first groove.

[0019] Furthermore, the second groove is positioned close to the first groove.

[0020] The beneficial effects of this utility model are:

[0021] Compared with existing technologies, this utility model provides a topology-optimized, high-efficiency electromagnetic pulse tube connection magnet collector structure. By creating an axially penetrating and circumferentially extending first groove on the connecting wall of the crimping portion, the conductor cross-sectional area is significantly reduced when current flows through this area. According to the principle of current continuity (I=J×A, where I is current, J is current density, and A is cross-sectional area), when the total current I remains constant, the reduction in cross-sectional area A inevitably leads to an increase in current density J. This geometric constraint forces the current to flow in a narrower path, thereby increasing the current density and concentrating electromagnetic energy in the crimping working area. This directly enhances the magnetic field strength and the electromagnetic force acting on the workpiece in this area, achieving the goal of improving overall energy utilization efficiency through local structural optimization. This fundamentally solves the problem of low energy efficiency caused by insufficient current density in the working area. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0023] Figure 1 This is a schematic diagram of the structure of a solid magnet collector in the prior art, as disclosed in an embodiment of this utility model.

[0024] Figure 2 This is a top view schematic diagram of a topology-optimized, high-efficiency electromagnetic pulse tube connection magnet collector structure disclosed in an embodiment of this utility model.

[0025] Figure 3 This is a three-dimensional schematic diagram of a topology-optimized, high-efficiency electromagnetic pulse tube connection magnet collector structure disclosed in an embodiment of the utility model.

[0026] Figure 4 This is a diagram of the half-body structure of the magnet collector after the smoothing process. Figure 4 (a) in the figure is a top view of the half-body structure after smoothing. Figure 4 (b) is a schematic diagram of the three-dimensional structure of the half-body after smoothing.

[0027] Reference numerals: 1. Body; 2. Magnet collector shaft; 3. Pressing part; 20. Inner wall; 21. Outer wall; 22. Side wall; 30. Pressing wall; 31. Conical wall; 32. Connecting wall; 100. Center hole; 100-1. Straight hole; 100-2. Conical hole; 100-3. Pressing hole; 201. Second groove; 202. Third groove; 301. First groove. Detailed Implementation

[0028] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. 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 should fall within the protection scope of the present invention.

[0029] In existing technologies, the magnet collector used in magnetic pulse welding is typically a solid, integral structure, such as... Figure 1 As shown, the solid magnet collector includes a body 1, in Figure 1 Only half of the structure is shown. The body 1 has a coil (not shown) wound around its outer circumference. The body 1 includes a central hole 100 extending axially. This central hole 100 consists of three parts: a smaller diameter crimping hole 100-3 located in the middle (the inner wall of the crimping hole 100-3 is described below), this area is used for welding workpieces; larger diameter straight holes 100-1 located at both ends of the body 1; and a tapered hole 100-2 connecting the straight hole 100-1 and the crimping hole 100-3 (the inner wall of the tapered hole 100-2 is described below). The larger diameter end of the tapered hole 100-2 smoothly connects to the straight hole, while the smaller diameter end converges to the crimping hole 100-3. However, this solid magnet collector structure has significant inherent drawbacks, the core problem being insufficient concentration efficiency and strength of the electromagnetic force.

[0030] To address the aforementioned problems, this invention provides a topology-optimized, high-efficiency electromagnetic pulse tube connection magnet collector structure, comprising two identical halves. Figure 2 and Figure 3 Only one half is shown. The two halves are symmetrically arranged and spliced ​​to form a shaft structure with an inner cavity. The half includes a magnet collecting shaft 2 and a pressing part 3. The magnet collecting shaft 2 has an inner wall 20, an outer wall 21, and a side wall 22 connecting the inner wall 20 and the outer wall 21. The pressing part 3 is disposed on the inner wall 20. The pressing part 3 has a pressing wall 30, conical walls 31 located at both ends of the pressing wall 30, and a connecting wall 32 flush with the side wall 22. The large-diameter end of the conical wall 31 is connected to the inner wall 20, and the small-diameter end converges to the pressing wall 30. The connecting wall 32 has a first groove 301. The groove opening of the first groove 301 is located on the wall surface of the connecting wall 32, and the bottom of the groove extends from the wall surface of the connecting wall 32 along the circumference of the pressing part 3. The first groove 301 penetrates the pressing part 3 in the axial direction.

[0031] like Figure 3As shown, the principle behind the improved magnet collector of this invention for concentrating electromagnetic force is as follows: a first groove 301 is provided on the pressing part 3, which optimizes the distribution path of the pulse current. When the coil is energized, the eddy current induced on the outer wall of the magnet collector flows towards the inner pressing wall 30, forcing the current to "bypass" the first groove 301 as much as possible. This redistributes the conductor area around the first groove 301. This current reconstruction effect concentrates the current in the remaining effective conductor area around the first groove 301 that is not slotted (i.e., this geometric constraint forces the current to flow in a narrower path). Then, the current is concentrated and guided from the inclined conical wall 31 of the pressing part 3 to the pressing wall 30. According to the principle of current continuity (I = J×A), with the total current I unchanged, the current is concentrated in a smaller effective cross-sectional area A, which inevitably leads to a significant increase in the current density J in that area. Thus, the current density and electromagnetic field strength are increased at the target location, ultimately achieving the goal of improving energy utilization and connection effect.

[0032] In this embodiment, when the magnet collector is assembled from two halves, a physical gap inevitably exists at the joint surface. This physical gap causes magnetic flux leakage. This leaked magnetic flux does not participate in the workpiece deformation, directly reducing energy efficiency. To address this, this embodiment actively processes a second groove 201 in the sidewall 22 region near the gap, i.e., in the two sidewall 22 regions. This second groove 201 penetrates the magnet collector shaft 2 in the axial direction, causing the magnetic lines of force in the edge region to tend to distribute along the path formed by the second groove 201 rather than leaking out from the joint gap.

[0033] The principle behind this is that the design of the second groove 201 utilizes the edge effect and focusing principle of the magnetic field. It partially "collects" and confines the magnetic flux that would otherwise leak from the seam within the second groove 201 area, causing it to bend and concentrate along the contour of the magnet collector, thus penetrating more effectively into the inner working area. This effectively reduces ineffective leakage and increases effective magnetic flux, thereby improving the magnetic flux density in the workpiece area. According to Faraday's law of electromagnetic induction, an increase in magnetic field strength induces a larger electromotive force, which in turn increases the induced current density, ultimately enhancing the electromagnetic forming force.

[0034] It should be noted that the magnetic field lines are generated by the pulsed current in the external coil of the magnet collector, and their direction is mainly axial from one end face to the other along the magnet collector shaft 2. When the second groove 201 is not provided, the magnetic field lines are relatively uniformly distributed, but magnetic flux leakage and magnetic field strength weakening are prone to occur at the splice seam of the two halves, resulting in insufficient induced current density in this area. However, after the second groove 201 is provided, the edge effect of the magnetic field forces the magnetic field lines to bend and concentrate in the area of ​​the second groove 201, reducing magnetic leakage and thus enhancing the magnetic field strength and induced current density in the gap area, improving the efficiency and reliability of welding.

[0035] In pursuit of high performance, current magnet collectors generally use high-density, high-cost copper alloys as materials. This results in a large overall weight and high manufacturing cost, and the inherent electrical impedance also limits further improvements in energy efficiency. To effectively address these issues while ensuring performance, it is necessary to synergistically optimize the magnet collector structure for weight reduction and electrical performance.

[0036] To this end, this application provides a plurality of third grooves 202 on the outer wall of the magnet collector shaft 2. This design directly reduces material usage, manufacturing costs, and overall weight by actively removing some material from the relatively less stressed peripheral area of ​​the magnet collector. Secondly, by changing the cross-sectional area and distribution of the current path, it effectively reduces the impedance and inductive reactance of the magnet collector structure. Thirdly, based on the principle of current continuity, with the total current remaining constant, the reduction in the equivalent impedance of the structure helps to increase the loop current, thereby indirectly improving the current density and energy utilization rate of the working area, ultimately achieving the goal of high-efficiency connection.

[0037] Preferably, all right-angled portions of the half-body are smoothly processed into rounded transitions, which can effectively avoid the tip discharge phenomenon caused by electric field concentration under high-frequency and high-current environment, and at the same time significantly reduce the stress concentration of the structure under the action of pulsed electromagnetic force, thereby improving fatigue life.

[0038] like Figure 4 As shown, this smoothing process is specifically applied to the edge connections of the first groove 301, the second groove 201, and the third groove 202 to ensure a smooth transition between current and magnetic lines of force in these critical functional areas, reducing unnecessary disturbances and losses; wherein, Figure 4 (a) in the figure is a top view of the half-body structure after smoothing. Figure 4 (b) is a schematic diagram of the three-dimensional structure of the half-body after smoothing.

[0039] In terms of materials, the magnet collector structure is preferably made of highly conductive copper alloy to ensure excellent magnet collection efficiency; in application scenarios that meet performance requirements, aluminum alloy with lower density and lower cost can also be selected to achieve a balance between lightweighting and cost control.

[0040] In terms of the specific configuration of the grooves, the size and distribution of each groove serve its specific function. The cross-section of the first groove 301 is designed to be arc-shaped, which matches its required function of smoothing the current path reconstruction.

[0041] Multiple third grooves 202 are distributed circumferentially along the outer wall of the magnet shaft portion 2 to achieve a uniform reduction in weight and impedance.

[0042] In particular, the depth and width of the second groove 201 are designed to be greater than the corresponding dimensions of the first groove 301, which gives it a stronger ability to guide and accommodate edge magnetic flux in order to more effectively combat magnetic leakage at the seam.

[0043] Meanwhile, the second groove 201 is positioned close to the first groove 301. This arrangement allows the current density enhancement area (the working area of ​​the first groove 301) and the magnetic field focusing area (the working area of ​​the second groove 201) to be spatially tightly coupled, thereby synergistically enhancing the electromagnetic pulse force acting on the workpiece and achieving overall optimization of energy utilization.

[0044] Furthermore, in this embodiment, since the first groove 301, the second groove 201, and the third groove 202 are formed, these grooves may develop cracks if subjected to repeated discharges. Therefore, the size of the grooves 301, 201, and 202 needs to be appropriately controlled to avoid excessive depth or width, which could reduce structural strength and lead to fatigue cracks under repeated discharge impacts. Considering both electromagnetic performance and mechanical durability, optimal dimensional parameters are determined through simulation analysis to ensure sufficient fatigue life while meeting magnetic flux guidance and focusing requirements, thereby improving overall operational stability and safety.

[0045] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A topology-optimized high-efficiency electromagnetic pulse tube connecting magnet structure, comprising two identical half bodies, the two half bodies are symmetrically arranged and spliced to form an axial body structure with an inner cavity, characterized in that, The half body comprises: A magnet collector shaft portion having an inner wall, an outer wall, and a side wall connecting the inner wall and the outer wall; A crimping portion provided on the inner wall, the crimping portion having a crimping wall, tapered walls at both ends of the crimping wall, and a connecting wall flush with the side wall, the large-diameter end of the tapered wall being connected to the inner wall, and the small-diameter end converging to the crimping wall; Wherein, a first groove is provided on the connecting wall, the groove opening of the first groove is located on the wall surface of the connecting wall, the groove bottom of the first groove extends from the wall surface of the connecting wall along the circumferential direction of the crimping portion, and the first groove penetrates the crimping portion in the axial direction of the crimping portion.

2. The topology-optimized, high-efficiency, electromagnetic pulse tube connection magnet- gathering structure of claim 1, wherein, A second groove is provided on the side wall of the magnet collector shaft portion, and the second groove penetrates the magnet collector shaft portion.

3. The topology-optimized, high-efficiency, electromagnetic pulse tube connection magnet- gathering structure of claim 2, wherein, A plurality of third grooves are provided on the outer wall of the magnet collector shaft portion.

4. The topology-optimized, high-efficiency, electromagnetic pulse tube connection magnet- structure of claim 3, wherein, All right-angle portions of the half body are smoothly processed as circular arc transitions.

5. The topology-optimized, high-efficiency, electromagnetic pulse tube connection magnet- structure of claim 4, wherein, The smooth processing is applied to the edge connection of the first groove, the second groove, and / or the third groove.

6. The topologically optimized high energy efficient electromagnetic pulse tube connection magnet structure of claim 1, wherein, The magnet collector structure is made of copper alloy or aluminum alloy.

7. The topologically optimized high energy efficient electromagnetic pulse tube connection magnet structure of claim 1, wherein, The cross-sectional shape of the first groove is arc-shaped.

8. The topology-optimized, high-efficiency, electromagnetic pulse tube connection magnet- structure of claim 3, wherein, The plurality of third grooves are distributed along the circumferential direction of the outer wall.

9. The topologically optimized high efficiency electromagnetic pulse tube connection magnet structure of claim 2, wherein, The depth of the second groove is greater than the depth of the first groove, and the width of the second groove is greater than the width of the first groove.

10. The topologically optimized high efficiency electromagnetic pulse tube connection magnet structure of claim 2, wherein, The second groove is provided near the first groove.

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