Telescopic Electron Beam Welding Arm for Small Openings
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Solution Overview
Problem
Existing electron beam welding devices face challenges in producing well-controlled electron beams with varied density distributions and precise positioning, leading to defects such as uneven heating, metal spatter, and difficulty in welding parts with small central openings due to bulky arms and frequent vacuum enclosure openings for adjustments.
Innovation Solution
An electron beam welding device with a compact arm design featuring a focusing system, transformation coils for density control, and deflection means to ensure precise beam orientation, along with a videoscope for real-time monitoring and detection electrodes for beam positioning, allowing for adjustable density distributions and precise alignment without opening the vacuum enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bulky arm is used in the welding device, then the device can be introduced through central openings of parts, but the arm cannot be introduced inside parts having a central opening of small diameter
Solution Approach 1:
The arm is divided into multiple telescopic segments that can extend and retract. The segments are arranged in series along the longitudinal axis, allowing the arm to adjust its length dynamically. This segmentation enables the arm to fit through small central openings when retracted and extend to reach welding positions when needed.
Solution Approach 2:
The arm incorporates telescopic mechanisms with movable segments that can extend and retract dynamically. The arm length is not fixed but can be adjusted based on the specific welding task and the size of the central opening, transforming a static bulky structure into a dynamic adaptable one.
2Productivity
If the arm is made long to assemble several cells, then the welding capability is extended, but a small diameter associated with a large length causes a drop in rigidity of the arm
Solution Approach 1:
The long arm is segmented into multiple rigid sections connected by telescopic mechanisms. Each segment maintains high rigidity independently, and when retracted, the segments align concentrically to minimize the overall diameter while preserving structural strength through the segmented design.
Solution Approach 2:
The telescopic segments are nested within each other when retracted, with each segment fitting inside the previous one like nested dolls. This nesting arrangement minimizes the arm's diameter when not in use while maintaining the capability to extend to the required length for assembling multiple cells, preserving rigidity through the nested structural design.
3Ease of operation
If numerous manipulations are performed for adjustment of electron beams, then the beam can be adjusted, but it is necessary to open the vacuum enclosure which deteriorates the vacuum
Solution Approach 1:
The welding device incorporates self-adjustment mechanisms including automatic beam positioning systems and self-aligning magnetic fields that eliminate the need for manual interventions. The system automatically compensates for positioning errors and adjusts beam parameters without requiring opening the vacuum enclosure, maintaining vacuum quality while providing full adjustment capability.
Solution Approach 2:
All necessary adjustments of the electron beam are performed before the vacuum enclosure is sealed. The device includes preliminary alignment mechanisms and pre-adjustment procedures that are completed while the enclosure is still accessible, after which the system operates autonomously without requiring further openings, thus preserving vacuum quality.
4Device complexity
If the electron beam density distribution is not controlled, then the welding process is simpler, but the heating area is too wide or too narrow causing weld defects
Solution Approach 1:
The device incorporates variable density distribution modes that can be selected and adjusted through control parameters. By changing the density distribution parameters of the electron beam, the system can adapt the heating area and temperature profile to match the specific welding requirements, achieving precise control without excessive complexity through parameter-based adjustment.
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 achieves precise and controlled electron beam welding with minimal deformation and heat-affected zone, enabling high-quality welds in parts with small central openings and reducing the need for frequent vacuum interruptions, enhancing industrial usability and precision.
Implementation Method 1
an electron gun capable of generating a beam of electrons
Implementation Method 2
a focusing means capable of directing the electron beam along a first axis
Implementation Method 3
a means of transforming a density distribution of the electron beam in a plane perpendicular to the first axis
Implementation Method 4
means for deflecting the electron beam along a second axis substantially perpendicular to the first axis
Implementation Method 5
Electrons launched at high speed into the vacuum impact the two parts at their interface. The significant kinetic energy of the electrons is then transformed into heat at the time of the impact, which causes the melting and then the welding of the materials
Data Source
Figure 1
Figure 2~4
Figure 5A~6
AI summary
An electron beam welding appliance (10), characterised in that it comprises: • an electron gun (11) capable of generating an electron beam (FE); • a focusing means (12) capable of orienting the electron beam along a first axis (Z); • an arm (13) extending parallel to the first axis, the arm comprising: - a means (14) for converting a density distribution of the electron beam in a plane perpendicular to the first axis (Z); and - a means (15) for bypassing the electron beam along a second axis (X) substantially perpendicular to the first axis.