一种抑制外界磁场干扰的氩弧焊装置研究
摘要
目前国内大型冶金行业电磁环境较为复杂,比如电解车间普遍采用大电流强度的电解槽,其母线运行电流达数万安培以上,在空间产生的磁场使焊接电弧明显偏移甚至不能起弧,只能采取切断母线停止电解冶炼来对其进行维修与护理,严重影响了生产效率。本课题针对此问题,设计了一种抑制磁场干扰的氩弧焊装置,采用磁头装置与焊枪结合的设计方式,将产生的纵向磁场完全导入电弧区域用来控制电弧形态并对外界磁场干扰进行抑制,从而提高焊接准确性和稳定性,大大提高了生产效率。此装置具有附加装置简单、投入成本低、耗能少等特点,易于工程实现。目前国内关于通过外加磁场抑制干扰磁场对焊接电弧的位置、形状和运行状态的影响,从而提高焊接质量,改善焊接工艺方面的研究和设计未曾见到任何文章和报道。
首先,基于ANSYS为研究手段,对影响磁场分布和磁场强度的各种因素进行了有限元分析和计算,为设计科学合理的外加磁场发生装置提供理论基础。设计了一台恒流稳压励磁电源,该电源通过半桥逆变和同步整流对磁头装置进行供电。本装置通过氩弧焊焊接试验,有效抑制了外界干扰磁场对电弧的影响,验证了该装置的正确性及合理性。
Electromagnetic circumstance of domestic large-scale metallurgy industry is very complex at present, for example, the electrolysis tank with great current is generally used in Electrolysis workshop which uses the bus bar current amount to above several thousand amperes. The magnetic field which produced in the space enables the welding electric arc obviously displacement, and even cannot have the electric arc. Only to cut off bus bar to stop electrolysis smelting before maintenance and care was done, which seriously influence production efficiency. In view of this question, one kind of electric welding installment is designed in this paper to suppress the magnetic field disturbance which selects design method of the magnetic head working with the welding torch, so longitudinal magnetic field is completely made into the regional arc area to control electric arc shape and suppress the outside magnetic disturbance, thus welding accuracy and stability is enhanced, and the production efficiency is greatly raised. This device is used for it's characteristics of simple additional installations and cheaper investment and fewer energy consumes and so on. There is little literature or report about restraining interfere magnetic field from affecting welding arc position and shape through outside magnetic field, so the welding quality and craftwork are improved.
Firstly, FEA about factors which affects magnetic field distributing and intensity was researched based on ANSYS, and theoretic base was provided to design scientific magnetic device. A constant-current and steady-voltage power supply was designed which use half-bridge inverter and synchronized rectification. Through the experimentation of argon-arc welding, influence of arc from outside interferential magnetic field was restrained .Correctness and rationality of the device was proved.
首先,基于ANSYS为研究手段,对影响磁场分布和磁场强度的各种因素进行了有限元分析和计算,为设计科学合理的外加磁场发生装置提供理论基础。设计了一台恒流稳压励磁电源,该电源通过半桥逆变和同步整流对磁头装置进行供电。本装置通过氩弧焊焊接试验,有效抑制了外界干扰磁场对电弧的影响,验证了该装置的正确性及合理性。
Electromagnetic circumstance of domestic large-scale metallurgy industry is very complex at present, for example, the electrolysis tank with great current is generally used in Electrolysis workshop which uses the bus bar current amount to above several thousand amperes. The magnetic field which produced in the space enables the welding electric arc obviously displacement, and even cannot have the electric arc. Only to cut off bus bar to stop electrolysis smelting before maintenance and care was done, which seriously influence production efficiency. In view of this question, one kind of electric welding installment is designed in this paper to suppress the magnetic field disturbance which selects design method of the magnetic head working with the welding torch, so longitudinal magnetic field is completely made into the regional arc area to control electric arc shape and suppress the outside magnetic disturbance, thus welding accuracy and stability is enhanced, and the production efficiency is greatly raised. This device is used for it's characteristics of simple additional installations and cheaper investment and fewer energy consumes and so on. There is little literature or report about restraining interfere magnetic field from affecting welding arc position and shape through outside magnetic field, so the welding quality and craftwork are improved.
Firstly, FEA about factors which affects magnetic field distributing and intensity was researched based on ANSYS, and theoretic base was provided to design scientific magnetic device. A constant-current and steady-voltage power supply was designed which use half-bridge inverter and synchronized rectification. Through the experimentation of argon-arc welding, influence of arc from outside interferential magnetic field was restrained .Correctness and rationality of the device was proved.
引文
[1]王军.磁场控制高效MAG焊接旋转射流过渡稳定性的研究:[博士学位论文][D].北京:北京工业大学,2003
[2]祁贵云.旋转磁场作用下电弧特性和电弧行为的研究:[硕士学位论文][D].北京:北京工业大学,2004
[3]贾昌申,殷咸青.纵向磁场中的焊接电弧行为[J].西安交通大学学报,1994(4):7-12
[4]王军,陈树君,卢振洋,殷树言.横向磁场控制MAG焊接焊缝成型工艺的研究[J].北京工业大学学报.2003,Vol.29(2):147-150
[5]Boldyrev A.M.,etal.Special features of Melting the Electrode Metal when Welding in an external Magnetic Field[J].Welding Production,2002(5):28-30
[6]Iofinaov P.A.,etal.Effect of an external Electromagnetic Field on the Melting Rate of Electrode Wire in automatic Submerged Arc Surfacing[J].Welding Production,1991(1):34-35
[7]Manabe,etal.Investigation on TIG welding using 2 filler wires with Electromagnetically Controlled Molten Pool process in horizontal position[J].Quarterly Journal of the Japan Welding Society,2000(1):40-50
[8]Yukio,etal.Basic Concept and Viability of Electromagnetically Controlled Molten Pool Welding Process [J].IIW Doc.XII-1668-0,2003:63-77
[9]韦尚戟.载流无限长螺线管磁场的分析[J].河池师专学报,1994,Vol.14(3):39-41
[10]郎成,丁力,路大勇.任意形状螺线管磁场的研究[J].吉林化工学院学报,1997,Vol.11(4):79-80
[11]唐兴伦,范群波,张朝辉,等.ANSYS工程应用教程(热与电磁学篇)[M].中国铁道出版社,2003
[12]王国强.实用工程数值模拟技术及在ANSYS上的实践[M].西北工业大学出版社,1999
[13]阿勃拉格夫MA.电磁作用焊接技术[M].韦福水译.机械工业出版社,1998
[14]Dr Philip J Blakeley,etal.Magnetism a Blow to Welding[J].Welding and Metal Fabrication,2002:22-26
[15]D Hilton.Shielding Gases for Gas Metal Arc Welding[J].Welding and Metal Fabrication,1990:332-334
[16]吴丰顺.纵向磁场作用下电弧的运动机制[J].武汉汽车工业大学学报,1997,Vol.19(1):43-46
[17]罗键.外加纵向磁场GTAW焊接熔池流体流动与传热行为的研究:[博士学位论文][D].西安:西安交通大学,1999
[18]赵彭生等.双尖角磁场再压缩等离子弧切割fJ].机械工程学报,1991(5):23-62
[19]Keigo Hoshikwa,Xinming Huang.Oxygen transportation during Czochralski silicon crystal growth[J].Materials Science and Engineering,2000:73-79
[20]Saseed Moaveni.有限元分析—ANSYS理论与应用[M].王松等译.电子厂业出版社,2005
[21]柯松.常用钢材磁特性曲线速查手册[M].机械工业出版社,2003
[22]Olivier Trescases,Wai Tung Ng,Shuo Chen.Precision Gate Drive Timing in a Zero- Voltage-Switching DC-DC Converter[J].IEEE Power Semiconductor Devices and ICs,2004,16:55-58
[23]Dragan Maksimovic.Design of the Zero-Voltage-Switching Quasi-Square-Wave Resonant Switch[J].IEEE Annual Power Electronics Specialists Conference,1993:323-329
[24]Wei chen,F.C.Lee,Xunwei Zhou,etal.Integrated planar inductor scheme for Multi-module interleaved Quasi-Square-Wave(QSW)DC/DC converter[J].IEEE Annual Power Electronics Specialists Conference,1999,2:759-762
[25]张长征.现代高频软开关功率变化研究:[硕士学位论文][D].西安:西北工业大学,2003
[26]庞永强,梁冠安.低压大电流DC/DC变换器拓扑分析[J].电力电子技术,2002,36(4):47-50
[27]周辉杰,何志伟.开关电源倍流同步整流器的研究[J].电力电子技术,2006,8:6-9
[28]张海源,吴卉,邹祖冰等.同步整流下对称半桥倍流变换器的建模与分析[J].电机工程学报,2003,23(8):66-70
[29]Nasser H.Kutkut.A Full Bridge Switch Telecom Power Supply with A Current Doubler Rectifier[J].IEEE,1997,7:344-351
[30]蔡拥军,叶欣.倍流同步整流在DC/DC变换器中工作原理分析[J].电源技术应用,2005,8:15-18
[31]李龙文.同步整流技术在DC-DC中的应用[C].第十五届全国电源技术年会论文集,2005:81-85
[32]张占松,蔡宣三.开关电源的原理与设计[M].电子工业出版社,2002
[33]王兆安,黄俊.电力电子技术[M].机械工业出版社,2004
[34]王雅生.横向磁场对TIG焊不锈钢焊缝成型影响[J].压力容器,1990(2):73-75
[35]张治军.电弧电磁摆动装置自动钨极氩弧焊焊枪研究[J].焊接,1994(4):30-32
[36]常云龙,陈德善.磁控等离子弧的基本特性[J].焊接设备与材料杂志,2001(3):24-25
[37]P.Xu,Q.Wu,P.Wong,etal.A novel integrated current double rectifier[J].IEEE APEC,2000:735-740
[38]Ennis,M.G,etal.Rotaing Arc Interrupter with Independent Field Excitation[J].IEE Proceedings:Science,Measurement and Technology,1996,2:113-118
[39]郑峰,杨旭,王兆安.同步整流管的损耗分析[C].第十五届全国电源技术年会论文集,2005:40-66
[40]宋辉淇,林维明.同步整流技术的特点与分析比较[J].开关电源技术,2006,1:11-13
[41]金建铭著,王建国译.电磁场有限元分析[M].西安电子科技大学出版社,1998
[42]宫野,张林.旋转磁场作用下电弧螺旋不稳定性的数值研究[J].大连理工大学学报,2004(1):30-32
[43]江淑园.外磁场对CO2焊飞溅的控制机理[J].焊接学报,2004(2):50-53
[44]秦海鸿,朱军卫,王慧贞,等.一种新颖的单绕组自驱动同步整流方案的研究[J].电工电能新技术,2003,22(2):60-75
[45]任光,苗建龙,高潮.同步整流器自驱动方式及其典型整流电路分析[J].电源技术,2003(9):68-71
[2]祁贵云.旋转磁场作用下电弧特性和电弧行为的研究:[硕士学位论文][D].北京:北京工业大学,2004
[3]贾昌申,殷咸青.纵向磁场中的焊接电弧行为[J].西安交通大学学报,1994(4):7-12
[4]王军,陈树君,卢振洋,殷树言.横向磁场控制MAG焊接焊缝成型工艺的研究[J].北京工业大学学报.2003,Vol.29(2):147-150
[5]Boldyrev A.M.,etal.Special features of Melting the Electrode Metal when Welding in an external Magnetic Field[J].Welding Production,2002(5):28-30
[6]Iofinaov P.A.,etal.Effect of an external Electromagnetic Field on the Melting Rate of Electrode Wire in automatic Submerged Arc Surfacing[J].Welding Production,1991(1):34-35
[7]Manabe,etal.Investigation on TIG welding using 2 filler wires with Electromagnetically Controlled Molten Pool process in horizontal position[J].Quarterly Journal of the Japan Welding Society,2000(1):40-50
[8]Yukio,etal.Basic Concept and Viability of Electromagnetically Controlled Molten Pool Welding Process [J].IIW Doc.XII-1668-0,2003:63-77
[9]韦尚戟.载流无限长螺线管磁场的分析[J].河池师专学报,1994,Vol.14(3):39-41
[10]郎成,丁力,路大勇.任意形状螺线管磁场的研究[J].吉林化工学院学报,1997,Vol.11(4):79-80
[11]唐兴伦,范群波,张朝辉,等.ANSYS工程应用教程(热与电磁学篇)[M].中国铁道出版社,2003
[12]王国强.实用工程数值模拟技术及在ANSYS上的实践[M].西北工业大学出版社,1999
[13]阿勃拉格夫MA.电磁作用焊接技术[M].韦福水译.机械工业出版社,1998
[14]Dr Philip J Blakeley,etal.Magnetism a Blow to Welding[J].Welding and Metal Fabrication,2002:22-26
[15]D Hilton.Shielding Gases for Gas Metal Arc Welding[J].Welding and Metal Fabrication,1990:332-334
[16]吴丰顺.纵向磁场作用下电弧的运动机制[J].武汉汽车工业大学学报,1997,Vol.19(1):43-46
[17]罗键.外加纵向磁场GTAW焊接熔池流体流动与传热行为的研究:[博士学位论文][D].西安:西安交通大学,1999
[18]赵彭生等.双尖角磁场再压缩等离子弧切割fJ].机械工程学报,1991(5):23-62
[19]Keigo Hoshikwa,Xinming Huang.Oxygen transportation during Czochralski silicon crystal growth[J].Materials Science and Engineering,2000:73-79
[20]Saseed Moaveni.有限元分析—ANSYS理论与应用[M].王松等译.电子厂业出版社,2005
[21]柯松.常用钢材磁特性曲线速查手册[M].机械工业出版社,2003
[22]Olivier Trescases,Wai Tung Ng,Shuo Chen.Precision Gate Drive Timing in a Zero- Voltage-Switching DC-DC Converter[J].IEEE Power Semiconductor Devices and ICs,2004,16:55-58
[23]Dragan Maksimovic.Design of the Zero-Voltage-Switching Quasi-Square-Wave Resonant Switch[J].IEEE Annual Power Electronics Specialists Conference,1993:323-329
[24]Wei chen,F.C.Lee,Xunwei Zhou,etal.Integrated planar inductor scheme for Multi-module interleaved Quasi-Square-Wave(QSW)DC/DC converter[J].IEEE Annual Power Electronics Specialists Conference,1999,2:759-762
[25]张长征.现代高频软开关功率变化研究:[硕士学位论文][D].西安:西北工业大学,2003
[26]庞永强,梁冠安.低压大电流DC/DC变换器拓扑分析[J].电力电子技术,2002,36(4):47-50
[27]周辉杰,何志伟.开关电源倍流同步整流器的研究[J].电力电子技术,2006,8:6-9
[28]张海源,吴卉,邹祖冰等.同步整流下对称半桥倍流变换器的建模与分析[J].电机工程学报,2003,23(8):66-70
[29]Nasser H.Kutkut.A Full Bridge Switch Telecom Power Supply with A Current Doubler Rectifier[J].IEEE,1997,7:344-351
[30]蔡拥军,叶欣.倍流同步整流在DC/DC变换器中工作原理分析[J].电源技术应用,2005,8:15-18
[31]李龙文.同步整流技术在DC-DC中的应用[C].第十五届全国电源技术年会论文集,2005:81-85
[32]张占松,蔡宣三.开关电源的原理与设计[M].电子工业出版社,2002
[33]王兆安,黄俊.电力电子技术[M].机械工业出版社,2004
[34]王雅生.横向磁场对TIG焊不锈钢焊缝成型影响[J].压力容器,1990(2):73-75
[35]张治军.电弧电磁摆动装置自动钨极氩弧焊焊枪研究[J].焊接,1994(4):30-32
[36]常云龙,陈德善.磁控等离子弧的基本特性[J].焊接设备与材料杂志,2001(3):24-25
[37]P.Xu,Q.Wu,P.Wong,etal.A novel integrated current double rectifier[J].IEEE APEC,2000:735-740
[38]Ennis,M.G,etal.Rotaing Arc Interrupter with Independent Field Excitation[J].IEE Proceedings:Science,Measurement and Technology,1996,2:113-118
[39]郑峰,杨旭,王兆安.同步整流管的损耗分析[C].第十五届全国电源技术年会论文集,2005:40-66
[40]宋辉淇,林维明.同步整流技术的特点与分析比较[J].开关电源技术,2006,1:11-13
[41]金建铭著,王建国译.电磁场有限元分析[M].西安电子科技大学出版社,1998
[42]宫野,张林.旋转磁场作用下电弧螺旋不稳定性的数值研究[J].大连理工大学学报,2004(1):30-32
[43]江淑园.外磁场对CO2焊飞溅的控制机理[J].焊接学报,2004(2):50-53
[44]秦海鸿,朱军卫,王慧贞,等.一种新颖的单绕组自驱动同步整流方案的研究[J].电工电能新技术,2003,22(2):60-75
[45]任光,苗建龙,高潮.同步整流器自驱动方式及其典型整流电路分析[J].电源技术,2003(9):68-71