磁控电弧传感器有限元分析及优化设计
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摘要
焊接作为一种先进制造技术,广泛应用于能源、造船、电子、交通与航天工程等领域,要解决实际生产中生产效率不高、工人劳动强度较大等问题,则必须实现焊接的自动化。而焊缝的自动化跟踪是实现自动化焊接所需解决的关键问题,在整个焊缝跟踪系统当中,传感器是最为重要的部分。本文旨在对磁控电弧传感器进行研究,并且进行优化设计,改善其性能,使其制造成本更低,焊缝跟踪精度更高。
首先,研究了磁控电弧传感器的原理和结构,结合磁控电弧传感器的设计,建立了磁控电弧传感器的有限元分析模型。
第二,对磁控电弧传感器进行了谐波磁场分析。分别改变线圈匝数、空气隙长度、铁芯磁导率、铁芯直径、激磁频率等因素,得出了其对应的磁力线图和磁场矢量图,并得出了各个因素对磁控电弧传感器的磁场分布和磁感应强度大小的影响规律。
第三,验证了有限元分析的可行性。通过高斯计分别测量线圈匝数、空气隙长度、激磁频率等为一固定值时,磁控电弧传感器电弧区域内10个节点的磁感应强度的大小,并与有限元分析得出的对应的数据进行对比。
第四,验证了有限元分析得出的结论的正确性。分别改变线圈匝数、空气隙长度、激磁频率等因素,通过高斯计测量对应的因素发生改变时,选定的固定节点的磁感应强度的大小,从而得出线圈匝数、空气隙长度、激磁频率等改变时,对应的磁感应强度的变化规律,然后与通过有限元分析得出的变化规律进行比较。
最后,对磁控电弧传感器进行了优化设计。以降低磁控电弧传感器的制造成本为目标函数,通过有限元软件ANSYS对其进行优化设计,并比较优化前后的焊缝跟踪精度等性能。
As a kind of advanced manufacturing technology, welding is widely used in energy, shipbuilding, electronics, transportation and aerospace engineering, etc.But the production efficiency is low, and the level of labor intensity is high.So it is necessary to realize welding automation. Its key problem is seam tracking,and the sensor is the most important part in the seam tracking system. This paper attempts to research and optimize the magnetic-control arc sensor, improve its performance, reduce the cost of manufacture,and enhance the seam tracking precision .
Firstly, researched the principle and structure of the magnetic-control arc sensor, combined with the magnetic-control arc sensor, builded the finite element modeling of the magnetic-control arc sensor.
Secondly, analysised the magnetic-control arc sensor. Separately changed coil turns, air gap length, core magnetic conductance, core diameter, excitation frequency, concluded the corresponding magnetic maps and magnetic vector diagram.And concluded its influence law of the magnetic field distribution and the magnetic induction.
Thirdly, verified feasibility of finite element analysis.In the arc region ,measured the magnetic induction of 10 nodes by guass meter when coil turns, air gap length, excitation frequency as a fixed value, and compared with the data gained by finite element analysis.
Fourthly, verified correctness of the conclusion by the finite element analysis. Separately changed coil turns, air gap length, excitation frequency and so on, measured the magnetic induction of the selected node by guass meter, concluded the corresponding rules of magnetic induction when separately changed coil turns, air gap length, excitation frequency, then compared with the rules by finite element analysis. Finally, optimized the magnetic-control arc sensor. In order to reduce its cost of manufacture, optimization designed the magnetic-control arc sensor by ANSYS ,and compared with the seam tracking precision of the magnetic-control arc sensor before optimized.
首先,研究了磁控电弧传感器的原理和结构,结合磁控电弧传感器的设计,建立了磁控电弧传感器的有限元分析模型。
第二,对磁控电弧传感器进行了谐波磁场分析。分别改变线圈匝数、空气隙长度、铁芯磁导率、铁芯直径、激磁频率等因素,得出了其对应的磁力线图和磁场矢量图,并得出了各个因素对磁控电弧传感器的磁场分布和磁感应强度大小的影响规律。
第三,验证了有限元分析的可行性。通过高斯计分别测量线圈匝数、空气隙长度、激磁频率等为一固定值时,磁控电弧传感器电弧区域内10个节点的磁感应强度的大小,并与有限元分析得出的对应的数据进行对比。
第四,验证了有限元分析得出的结论的正确性。分别改变线圈匝数、空气隙长度、激磁频率等因素,通过高斯计测量对应的因素发生改变时,选定的固定节点的磁感应强度的大小,从而得出线圈匝数、空气隙长度、激磁频率等改变时,对应的磁感应强度的变化规律,然后与通过有限元分析得出的变化规律进行比较。
最后,对磁控电弧传感器进行了优化设计。以降低磁控电弧传感器的制造成本为目标函数,通过有限元软件ANSYS对其进行优化设计,并比较优化前后的焊缝跟踪精度等性能。
As a kind of advanced manufacturing technology, welding is widely used in energy, shipbuilding, electronics, transportation and aerospace engineering, etc.But the production efficiency is low, and the level of labor intensity is high.So it is necessary to realize welding automation. Its key problem is seam tracking,and the sensor is the most important part in the seam tracking system. This paper attempts to research and optimize the magnetic-control arc sensor, improve its performance, reduce the cost of manufacture,and enhance the seam tracking precision .
Firstly, researched the principle and structure of the magnetic-control arc sensor, combined with the magnetic-control arc sensor, builded the finite element modeling of the magnetic-control arc sensor.
Secondly, analysised the magnetic-control arc sensor. Separately changed coil turns, air gap length, core magnetic conductance, core diameter, excitation frequency, concluded the corresponding magnetic maps and magnetic vector diagram.And concluded its influence law of the magnetic field distribution and the magnetic induction.
Thirdly, verified feasibility of finite element analysis.In the arc region ,measured the magnetic induction of 10 nodes by guass meter when coil turns, air gap length, excitation frequency as a fixed value, and compared with the data gained by finite element analysis.
Fourthly, verified correctness of the conclusion by the finite element analysis. Separately changed coil turns, air gap length, excitation frequency and so on, measured the magnetic induction of the selected node by guass meter, concluded the corresponding rules of magnetic induction when separately changed coil turns, air gap length, excitation frequency, then compared with the rules by finite element analysis. Finally, optimized the magnetic-control arc sensor. In order to reduce its cost of manufacture, optimization designed the magnetic-control arc sensor by ANSYS ,and compared with the seam tracking precision of the magnetic-control arc sensor before optimized.
引文
[1]毛鹏军,黄石生,薛家祥,等.弧焊机器人焊缝跟踪系统研究现状及发展趋势[J].电焊机,Vol131,2001 10 :9～12,22.
[2]张轲,吕学勤,吴毅雄,等.移动焊接机器人的研究现状及发展趋势[J].焊接,2004(8):5-9.
[3] YOO W S. A study on sensors for automatic welding of 3-D seam in ship hull asembly[D].Korea:Korea Advanced Institute of Science and Technology,2004
[4] Lee S K.A study on automatic seam tracking in pulsed laseredgewelding by using a vision sensor without an auxiliary light source. Journal ofManufacturing Systems, 2002, 21 (4) : 302～315.
[5]王加友,朱征宇,任彦胜,等.窄间隙焊缝跟踪电弧传感方法及特性研究[J].江苏科技大学学报(自然科学版),2007,21(6):17-20.
[6]洪波等.一种用于焊缝跟踪的磁控电弧传感器[J].焊接学报,2008,29(5):1-4.
[7]曾松盛,石永华,王国荣.基于电弧传感器的焊缝跟踪技术现状与展望[J].焊接技术,37(2),2008,4 :1-4
[8]王元良.高效节能的细丝双丝自动焊接研究[J].焊接技术,2000,29(10):39-42.
[9] Kimura S.et al. The twist arc welding process. Conference Proceedings. Advances in welding Processes, May, 1987.
[10]潘际銮.现代弧焊控制[M].北京:机械工业出版社,2000:171-188.
[11]李志彬.日本NKK焊接机器人和自动化焊接设备[J].造船技术,1995,( 2):1-7.
[12]秦国梁.Nd:YAG激光薄钢板深熔焊接小孔特征及同轴视觉传感[D].哈尔滨:哈尔滨工业大学,2004.
[13]陈善本.焊接过程现代控制技术[M].哈尔滨:哈尔滨工业大学出版社, 2001.1.
[14]陈武柱,王勇,林青松.焊缝自动跟踪技术的现状及新发展[J].焊管. 1992, 15(5):1-10.
[15]吴世德.电弧传感器焊缝跟踪的信息处理技术[D].清华大学博士论文.1997:10-110.
[16] Nomura H.et al. Automatic real-time bead height control with arc sensor in TIG welding, IIW Doc XII-884-85.
[17]吴世德,廖宝剑.高速旋转电弧传感器[J].焊接学报,1997,18(1):61-66.
[18] Hiller,F.s.,and Lieberman,G.J.Introduction to Operations Research,6thed.New Yorl: Mc-Graw.1995:225-229
[19] Rekaitis,G.V.,Racindran a.,and Ragsdell,K.M.Engineering Optimization-Methods and Applications.New York:Tohn Wiley andSons.1983:321-324
[20]姜廷玺,宋根宗.力学与电磁学[M].沈阳:东北大学出版社.2006,1.
[21] Yamamoto T, Takeda K. Distribution of heat flux transported by a magnetically driven arc[J]. Thin Solid Film, 2007(3): 4228-4233.
[22]常云龙,陈德善,肖纪云.磁控等离子弧的基本特性[J].焊接技术,2001,30(4):29-30.
[23]吴林,陈善本.智能化焊接技术[M].国防工业出版社.2000:2-18.
[24]嘉木工作室编著.ANSYS5.7有限元实例分析教程[M].机械工业出版社.2002
[25]唐兴伦,范群波,张朝辉等.ANSYS工程应用教程(热与电磁学篇)[M].北京:中国铁道出版社,2003
[26]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西安:西北工业大学出版社,1999
[27]金建铭著,王建国译.电磁场有限元分析[M].西安:西安电子科技大学出版社,1998
[28]张榴晨,徐松.有限元法在电磁计算中德应用[M].北京:中国铁道出版社,1996
[29]龚曙光.ANSYS基础应用及范例解析[M].北京:机械工业出版社,2003
[30] J.A.埃德米尼斯特尔著,雷银照,吴静译.工程电磁场基础[M].北京:科学出版社,2002
[31]王军.磁场控制高效MAG焊接旋转射流过渡稳定性的研究[D].北京:北京工业大学,2003.
[32]费跃农.电弧传感器焊缝自动跟踪系统及电弧传感器基础理论研究[D].北京:清华大学,1990.
[33]陈树君,王学震,华爱兵,等.磁控电弧旋转磁场发生装置的设计[J].电焊机,2006,36(5):47-50.
[34]祁贵云.旋转磁场作用下电弧特性和电弧行为的研究[D].北京:北京工业大学,2004.
[35]孙明礼,胡仁喜,崔海蓉,等.ANSYS 10.0电磁学有限元分析实例指导教程[M].北京:机械工业出版社,2007
[36]张倩,胡仁喜,康士廷等.ANSYS 12.0电磁学有限元分析从入门到精通[M].北京:机械工业出版社,2007
[37]任重.ANSYS实用分析教程[M].北京:北京大学出版社,2003
[38]李红云,赵社戌,孙雁. ANSYS 10.0基础及工程应用[M].北京:机械工业出版社,2008
[39]莫维尼,Moaveni.有限元分析: ANSYS理论与应用[M].北京:电子工业出版社,2003
[40]张朝晖. Ansys 11.0有限元分析理论与工程应用[M].北京:电子工业出版社,2008
[41]刘国庆,杨庆东. ANSYS工程应用教程.机械篇[M].北京:中国铁道出版社,2003
[42]高耀东.ANSYS机械工程应用精华30例[M].北京:电子工业出版社,2010
[43]张洪信,赵清海. ANSYS有限元分析完全自学手册[M].北京:机械工业出版社,2008
[44]秦宇. ANSYS 11.0基础与实例教程[M].北京:化学工业出版社,2009
[45]周长城,胡仁喜,熊文波. ANSYS 11.0基础与典型范例[M].北京:电子工业出版社,2007
[46]邢静忠,王永岗.有限元基础与ANSYS入门[M].北京:机械工业出版社,2005
[47]余伟炜,高炳军. ANSYS在机械与化工装备中的应用[M].北京:中国水利水电出版社,2004
[48]邓凡平. ANSYS10.0有限元分析自学手册[M].北京:人民邮电出版社,2007
[49]王庆五,左昉,胡仁喜ANSYS10.0机械设计高级应用实例[M].北京:机械工业出版社,2006
[50]郝文化. ANSYS 7.0实例分析与应用[M].北京:清华大学出版社,2004
[51]姜勇,张波. ANSYS 7.0实例精解[M].北京:清华大学出版社,2004
[2]张轲,吕学勤,吴毅雄,等.移动焊接机器人的研究现状及发展趋势[J].焊接,2004(8):5-9.
[3] YOO W S. A study on sensors for automatic welding of 3-D seam in ship hull asembly[D].Korea:Korea Advanced Institute of Science and Technology,2004
[4] Lee S K.A study on automatic seam tracking in pulsed laseredgewelding by using a vision sensor without an auxiliary light source. Journal ofManufacturing Systems, 2002, 21 (4) : 302～315.
[5]王加友,朱征宇,任彦胜,等.窄间隙焊缝跟踪电弧传感方法及特性研究[J].江苏科技大学学报(自然科学版),2007,21(6):17-20.
[6]洪波等.一种用于焊缝跟踪的磁控电弧传感器[J].焊接学报,2008,29(5):1-4.
[7]曾松盛,石永华,王国荣.基于电弧传感器的焊缝跟踪技术现状与展望[J].焊接技术,37(2),2008,4 :1-4
[8]王元良.高效节能的细丝双丝自动焊接研究[J].焊接技术,2000,29(10):39-42.
[9] Kimura S.et al. The twist arc welding process. Conference Proceedings. Advances in welding Processes, May, 1987.
[10]潘际銮.现代弧焊控制[M].北京:机械工业出版社,2000:171-188.
[11]李志彬.日本NKK焊接机器人和自动化焊接设备[J].造船技术,1995,( 2):1-7.
[12]秦国梁.Nd:YAG激光薄钢板深熔焊接小孔特征及同轴视觉传感[D].哈尔滨:哈尔滨工业大学,2004.
[13]陈善本.焊接过程现代控制技术[M].哈尔滨:哈尔滨工业大学出版社, 2001.1.
[14]陈武柱,王勇,林青松.焊缝自动跟踪技术的现状及新发展[J].焊管. 1992, 15(5):1-10.
[15]吴世德.电弧传感器焊缝跟踪的信息处理技术[D].清华大学博士论文.1997:10-110.
[16] Nomura H.et al. Automatic real-time bead height control with arc sensor in TIG welding, IIW Doc XII-884-85.
[17]吴世德,廖宝剑.高速旋转电弧传感器[J].焊接学报,1997,18(1):61-66.
[18] Hiller,F.s.,and Lieberman,G.J.Introduction to Operations Research,6thed.New Yorl: Mc-Graw.1995:225-229
[19] Rekaitis,G.V.,Racindran a.,and Ragsdell,K.M.Engineering Optimization-Methods and Applications.New York:Tohn Wiley andSons.1983:321-324
[20]姜廷玺,宋根宗.力学与电磁学[M].沈阳:东北大学出版社.2006,1.
[21] Yamamoto T, Takeda K. Distribution of heat flux transported by a magnetically driven arc[J]. Thin Solid Film, 2007(3): 4228-4233.
[22]常云龙,陈德善,肖纪云.磁控等离子弧的基本特性[J].焊接技术,2001,30(4):29-30.
[23]吴林,陈善本.智能化焊接技术[M].国防工业出版社.2000:2-18.
[24]嘉木工作室编著.ANSYS5.7有限元实例分析教程[M].机械工业出版社.2002
[25]唐兴伦,范群波,张朝辉等.ANSYS工程应用教程(热与电磁学篇)[M].北京:中国铁道出版社,2003
[26]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西安:西北工业大学出版社,1999
[27]金建铭著,王建国译.电磁场有限元分析[M].西安:西安电子科技大学出版社,1998
[28]张榴晨,徐松.有限元法在电磁计算中德应用[M].北京:中国铁道出版社,1996
[29]龚曙光.ANSYS基础应用及范例解析[M].北京:机械工业出版社,2003
[30] J.A.埃德米尼斯特尔著,雷银照,吴静译.工程电磁场基础[M].北京:科学出版社,2002
[31]王军.磁场控制高效MAG焊接旋转射流过渡稳定性的研究[D].北京:北京工业大学,2003.
[32]费跃农.电弧传感器焊缝自动跟踪系统及电弧传感器基础理论研究[D].北京:清华大学,1990.
[33]陈树君,王学震,华爱兵,等.磁控电弧旋转磁场发生装置的设计[J].电焊机,2006,36(5):47-50.
[34]祁贵云.旋转磁场作用下电弧特性和电弧行为的研究[D].北京:北京工业大学,2004.
[35]孙明礼,胡仁喜,崔海蓉,等.ANSYS 10.0电磁学有限元分析实例指导教程[M].北京:机械工业出版社,2007
[36]张倩,胡仁喜,康士廷等.ANSYS 12.0电磁学有限元分析从入门到精通[M].北京:机械工业出版社,2007
[37]任重.ANSYS实用分析教程[M].北京:北京大学出版社,2003
[38]李红云,赵社戌,孙雁. ANSYS 10.0基础及工程应用[M].北京:机械工业出版社,2008
[39]莫维尼,Moaveni.有限元分析: ANSYS理论与应用[M].北京:电子工业出版社,2003
[40]张朝晖. Ansys 11.0有限元分析理论与工程应用[M].北京:电子工业出版社,2008
[41]刘国庆,杨庆东. ANSYS工程应用教程.机械篇[M].北京:中国铁道出版社,2003
[42]高耀东.ANSYS机械工程应用精华30例[M].北京:电子工业出版社,2010
[43]张洪信,赵清海. ANSYS有限元分析完全自学手册[M].北京:机械工业出版社,2008
[44]秦宇. ANSYS 11.0基础与实例教程[M].北京:化学工业出版社,2009
[45]周长城,胡仁喜,熊文波. ANSYS 11.0基础与典型范例[M].北京:电子工业出版社,2007
[46]邢静忠,王永岗.有限元基础与ANSYS入门[M].北京:机械工业出版社,2005
[47]余伟炜,高炳军. ANSYS在机械与化工装备中的应用[M].北京:中国水利水电出版社,2004
[48]邓凡平. ANSYS10.0有限元分析自学手册[M].北京:人民邮电出版社,2007
[49]王庆五,左昉,胡仁喜ANSYS10.0机械设计高级应用实例[M].北京:机械工业出版社,2006
[50]郝文化. ANSYS 7.0实例分析与应用[M].北京:清华大学出版社,2004
[51]姜勇,张波. ANSYS 7.0实例精解[M].北京:清华大学出版社,2004