Electromagnetic Laser Cladding Head With Adjustable Field Coupling
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Solution Overview
Problem
Existing laser processing technologies face challenges in achieving synchronous coupling of electromagnetic composite fields, particularly for large industrial parts, leading to limited improvement in molten pool quality and restricted application due to limited magnetic field intensity and adjustability.
Innovation Solution
A flexible self-adaptive composite carbon brush type electromagnetic composite field synchronous laser cladding device is developed, featuring a mechanical arm-driven electromagnetic field coupling module with adjustable magnetic and electric fields, utilizing U-shaped iron cores and electromagnetic coils for enhanced magnetic field distribution and a scissor fork lifting platform for dynamic electric field generation, ensuring stable and adjustable field synchronization with the laser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If permanent magnets are used to supply magnetic field in electro-magnetic composite field cooperative laser cladding device, then magnetic field can be generated, but magnetic field intensity is limited and adjustment capability is restricted
Solution Approach 1:
The patent replaces permanent magnets with electromagnetic coils that can generate magnetic fields with continuously adjustable intensity and direction by changing electrical parameters (current, voltage, frequency). This allows the magnetic field parameters to be dynamically adjusted according to different processing requirements, resolving the limitation of fixed magnetic field intensity from permanent magnets.
Solution Approach 2:
The patent introduces dynamic control of magnetic field generation through electromagnetic coils that can be activated and adjusted in real-time during the laser cladding process. The magnetic field strength and orientation can be dynamically changed to match different processing stages and material requirements, unlike static permanent magnets.
2Temperature
If strict requirements are imposed on sample shape for magnetic field generation, then magnetic field can be generated, but application conditions are limited
Solution Approach 1:
The patent designs the electromagnetic coil system to be universally applicable to different sample shapes and sizes. The coils can be positioned and oriented to generate appropriate magnetic fields for various geometries, making the system adaptable to diverse industrial parts without requiring specific sample shape constraints.
Solution Approach 2:
The patent uses multiple electromagnetic coils that can be independently controlled and positioned. This segmentation allows the magnetic field to be tailored for different regions and shapes of workpieces, providing flexibility to handle various sample geometries rather than requiring a single fixed configuration.
3Productivity
If synchronous coupling of electromagnetic composite field is attempted for large industrial parts, then processing capability is enhanced, but implementation difficulty increases
Solution Approach 1:
The patent extends the electromagnetic field generation from small-scale 2D configurations to large-scale 3D industrial part processing. By using multiple electromagnetic coils arranged in three-dimensional space around the workpiece, the system achieves synchronous coupling capability for large industrial components while maintaining controllable complexity through modular coil arrangements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides continuous adjustable magnetic field intensity, improved magnetic field linearity, and self-adaptive electric field contact, enabling effective synchronous coupling of electromagnetic fields with the laser, enhancing processing quality and adaptability for various industrial applications.
Implementation Method 1
the magnetic field portion comprises two magnetic field generating modules which are arranged on the front side and the rear side of the output tube in the radial direction of the output tube respectively, the magnetic field generating module comprises a U-shaped iron core with a downward opening, the two ends of the U-shaped iron core correspond to a set of coil parts respectively; and the coil part comprises an electromagnetic coil
Implementation Method 2
a laser that generates laser
Implementation Method 3
the electric field portion comprises two sets of electric field generating modules which are oppositely arranged on the left side and the right side of the output tube in the y-axis direction
Data Source
AI summary
A flexible self-adaptive composite carbon brush-type electromagnetic composite field synchronous laser cladding device, comprising an electromagnetic field synchronous coupling module that processes a part to be processed, a mechanical arm that drives the electromagnetic field synchronous coupling module to move, and a laser that generates laser; the electromagnetic field synchronous coupling module comprises a laser head, an electric field portion and a magnetic field portion; the magnetic field portion comprises two magnetic field generating modules, and the electric field portion comprises two electric field generating modules, the magnetic field portion and the electric field portion both being fixedly erected at the periphery of the laser head by means of a supporting structure. This invention adopts four sets of coil parts arranged in the annular circumference, and continuous adjustment of the magnetic field size can be realized with the external magnetic field power supply, and the size meets the use requirement; the design of the pointed part of the iron core head improves the magnetic field intensity and linearity of the processing surface. The supporting structure ensures simultaneous follow-up coupling of the electric and magnetic fields.