CN111673246B - Compact large-melting-depth plasma arc welding gun - Google Patents
Compact large-melting-depth plasma arc welding gun Download PDFInfo
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- CN111673246B CN111673246B CN201911205342.6A CN201911205342A CN111673246B CN 111673246 B CN111673246 B CN 111673246B CN 201911205342 A CN201911205342 A CN 201911205342A CN 111673246 B CN111673246 B CN 111673246B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
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Abstract
The invention relates to a compact large-melting-depth plasma arc welding gun, which belongs to the technical field of plasma arc welding, and comprises a tungsten electrode, a gas guide porcelain bushing, a water-cooling copper nozzle, a gas protection cover and a gas cover head, wherein the end part of the welding gun sequentially comprises the tungsten electrode, the gas guide porcelain bushing, the water-cooling copper nozzle, the gas protection cover and the gas cover head from inside to outside, ion gas passes through the gas guide porcelain bushing and the water-cooling copper nozzle, and protective gas passes through the water-cooling copper nozzle, the gas protection cover and the gas cover head; the tungsten utmost point outside is equipped with insulation support, and the insulation support outside sets up the nozzle holder, and nozzle holder tip sets up water-cooling copper nozzle, and the nozzle holder outside sets up gaseous safety cover, and gaseous safety cover one end tip sets up the gas cover head. The water-cooled copper nozzle is in a circular truncated cone shape, and the shape inclination angle of the air guide porcelain sleeve is the same as the inclination angle of the water-cooled copper nozzle. The upper part is thick and the lower part is thin, the nozzle is uniformly inclined, and a sudden change structure is avoided, so that the smooth passing of air flow can be ensured, the air flow is gradually compressed in the flowing process along the inner wall of the nozzle, and the ion air can keep higher speed at the moment of exiting from the gun, thereby having stronger penetrating power.
Description
Technical Field
The invention relates to a compact large-melting-depth plasma arc welding gun, belonging to the technical field of plasma arc welding.
Background
The development of efficient, low-energy-consumption and high-reliability welding technology is the development direction of advanced welding technology and is also the sustainable development requirement of modern manufacturing industry. Because the penetration capacity of the welding arc of the traditional arc welding process is limited, for the connection of medium-thick wall metal structural parts, the base metal is often required to be beveled on one side or two sides for multi-layer welding, so that the problems of cost increase, production efficiency reduction, expansion of a heat affected zone, welding defects and the like are caused.
Plasma arc welding is a high-energy-density arc welding process, plasma arcs are used as heat sources, welding arcs form plasma beams with strong restraint after three compression actions of thermal compression, mechanical compression and electromagnetic compression, the plasma beams have very strong penetrating power, and the thickness of weldable parent metal can reach 12 mm. However, when the thickness of the base material is larger, the penetration ability of the arc is limited, the stability of the piercing process is insufficient or the penetration cannot be realized, and the application of the plasma arc welding in the welding of large thick plates is limited.
In the welding process, in order to improve the welding quality and debug process parameters, the state of a molten pool and the behavior of an electric arc need to be monitored, even in a welding control system taking images as control factors, the electric arc or the molten pool needs to be shot in real time, but a gas hood of a welding gun usually comprises a water cooling system and other complex structures, so that the diameter of a gun head is increased, and in order to ensure the penetration force and the arc stiffness of the electric arc, the welding height of a plasma arc is small and is generally controlled within 10mm, so that the visual field of a welding area is narrow, and the monitoring of the state of the molten pool and the behavior of the electric arc in the welding process is seriously influenced.
The conventional water-cooling gas hood is directly contacted with an ultrahigh-temperature electric arc, even if water cooling is used, burning loss still occurs in long-term use, and even the water-cooling structure of the gas hood is damaged, so that unexpected dangerous conditions are caused.
In conclusion, the existing plasma arc welding gun can not meet the requirement of improving the process quality.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a compact large-melting-depth plasma arc welding gun.
The technical scheme of the invention is as follows:
a compact large-melting-depth plasma arc welding gun comprises a tungsten electrode, a gas guide porcelain bushing, a water-cooling copper nozzle, a gas protection cover and a gas hood head from inside to outside, wherein ionic gas passes through the gas guide porcelain bushing and the water-cooling copper nozzle, and protective gas passes through the water-cooling copper nozzle, the gas protection cover and the gas hood head;
the tungsten pole is connected with the electrode clamp through the chuck, an insulating sleeve is arranged on the outer side of the tungsten pole, a nozzle seat is arranged on the outer side of the insulating sleeve, a water-cooling copper nozzle is arranged at the end part of the nozzle seat, a gas protection cover is arranged outside the nozzle seat, and a gas cover head is arranged at one end part of the gas protection cover.
Preferably, the inner wall of the water-cooling copper nozzle is of a hollow circular truncated cone shape, and the inclination angle of the inner wall and the axial direction is 5-15 degrees. The nozzle is thick at the top and thin at the bottom, the inner wall is uniformly inclined, and a sudden change structure is avoided, so that the smooth passing of the air flow can be ensured, the air flow is gradually compressed in the flowing process along the inner wall of the nozzle, and the ion gas is kept at a higher speed at the moment of being discharged from the gun, so that the penetration force is stronger.
After the ion gas is discharged from the gun, the ion gas is converged towards the center of the electric arc at a certain angle under the action of inertia to form a conical electric arc, the focus is determined by the inclination angle of the inner wall of the nozzle, and the ion gas cannot flow along the axis direction of the welding gun or disperse towards the periphery at once, so that the stiffness of the welding electric arc is ensured.
Preferably, the vertical projection of the air guide porcelain sleeve is in a circular truncated cone shape, the inclination angle of the air guide porcelain sleeve is the same as that of the water-cooling copper nozzle, the air guide porcelain sleeve is tightly attached to the inner wall of the copper nozzle, and the outer surface of the air guide porcelain sleeve is vertically provided with a diversion trench. The dip angle of the diversion trench is consistent with that of the porcelain bushing, the ionic gas flows between the diversion trench of the porcelain bushing and the inner wall of the nozzle, and due to the special shapes of the diversion trench and the nozzle, the ionic gas is compressed, and the ionic gas passes through the gas guide porcelain bushing at a higher flow speed.
Further preferably, the number of the guide grooves is 3-15.
Further preferably, the cross section of the guide groove is semicircular.
Further preferably, the arc radius of the upper diversion trench is larger than that of the lower diversion trench. A semicircular diversion trench with a wide upper part and a narrow lower part is adopted.
Further preferably, the arc radius of the upper diversion trench is 5-8 mm.
Preferably, the gas hood head comprises a cylinder end and a circular table end, the cylinder end is connected with the gas hood, the inclination angle of the circular table end is 5-15 degrees, and spiral ribs are arranged on the inner wall of the circular table end. The round table end is designed to be thick at the top and thin at the bottom in appearance, and the spiral ribs are adopted for air guiding inside the round table end.
Further preferably, the spiral rib angle is 30-60 degrees, and the number is 3-15. This design can carry out abundant induced swirl to the protective gas along welder axial flow with higher speed, and the protective gas receives spiral inertia effect after going out the rifle, adds the inclination of gas hood head to the compression and the direction of spiral air current, so after this device of protective gas outflow, can continue to flow along welder axis fast, can not produce the diffusion of bursting form, carries out gas protection and compression effect to the electric arc that the parcel lived.
Preferably, the end of the hood head is above the end of the water-cooled copper nozzle. Compared with the conventional gas hood, the gas hood head provided by the invention has the advantages that the length of the gas hood can be shortened on the premise that the same protection effect is realized by the shielding gas, the lower end part of the gas hood head is higher than the end part of the welding gun, so that the welding gun nozzle does not need to be completely wrapped, and a molten pool and an electric arc in the welding process can be conveniently observed. And the length of the gas protection cover is short, the gas protection cover is not contacted with high-temperature plasma in the welding process, burning loss is avoided, and a complex cooling system of the protection cover is omitted.
Preferably, a gas protection diffuser is arranged inside the other end of the gas protection cover. The gas shield is used for guiding gas to enter the gas shield and dispersing the gas to the whole circumference from only two paths of gas at the upper end.
The invention mainly aims at the design of an ion gas channel and a protective gas channel, the ion gas channel adopted by the invention is non-spiral, is different from a spiral structure, and the purpose of using the spiral structure is to generate vortex, thereby achieving a certain purpose. In the spiral structure, the compression action on the gas is not existed, and the compression action is realized by the additionally designed abrupt structure at the front end part of the nozzle. The whole ion gas channel adopts a circular truncated cone-shaped linear gas passage with a thick upper part and a thin lower part, the structure comprises an internal structure of the nozzle and a diversion trench structure of the outer wall of the gas guide porcelain sleeve, the ion gas is compressed and accelerated in the whole process of passing through the nozzle, and the whole process has no structure of sudden change of the front section of the nozzle, so that the ion gas channel is smoother. The ion gas is different from the shielding gas, the flow stability of the ion gas is a very large influence factor of welding quality, and particularly when a large thick plate is welded, the turbulent flow of the gas can cause the oscillation of a molten pool to generate splashing. The spiral acceleration of the ion gas can achieve a vortex effect, so that the gas has a better forward movement effect, but the gas flow can be unstable. The channel of the invention is a linear channel, and the air flow is stable.
The protective gas channel spirally induces and accelerates the whole protective gas at the end part gas cover head, the gas flow channel is smooth and continuous, no structure mutation exists, ion gas is converged towards the center, and the protective gas is ensured to be discharged from the gun and is spiral gas flow converged towards the axis of the welding gun. The gas shield head can be used for fully and spirally accelerating the protective gas, so that the protective gas can realize the functions of protecting and restraining the electric arc without wrapping the gun head, the electric arc is not contacted with the gas shield, the burning loss is not generated, the gas shield does not need to be replaced, and the production cost is reduced.
The invention has the beneficial effects that:
1. the novel nozzle structure is adopted, the novel nozzle structure comprises a circular truncated cone-shaped nozzle inner wall with a thick upper part and a thin lower part, the air guide porcelain bushing and the air guide groove on the air guide porcelain bushing outer wall, the flow track of the ion gas in the welding gun is changed, and the common movement along the axis is changed into the gathering towards the axis. Compared with a conventional nozzle, the ionic gas with the same gas flow is restrained by the nozzle in the flowing process, the flowing speed is higher after the ionic gas is discharged from the arc gun, the integral straightness of the electric arc is better, and the welding gun has stronger penetrating power.
2. By utilizing the device, the plasma beam after being discharged moves towards the axial direction of the welding gun within a certain time, the electric arc is sprayed in an approximately conical shape, and is different from the conventional cylindrical electric arc and not easy to disperse, so that the welding gun can be allowed to have a larger welding height which is increased from 3-10mm to more than 10 mm.
3. The air hood head designed by the invention is in a circular truncated cone shape, the spiral ribs are used for guiding air, the shielding air is spirally induced and accelerated in the air hood head, and the shielding air discharged out of the gun moves along the outer wall of the nozzle and cannot be immediately dispersed to the periphery. Compare with conventional water-cooling gas hood, the novel gas hood of design can realize the same effect of restraining the protection gas, need not the water-cooling, length and the tip diameter of gas hood under obviously shortening, make welder tip structure compacter, welder tip can not have the gas hood cover, electric arc produces the back at tungsten tip promptly and produces the rifle, guarantee the maximum utilization of electric arc energy, the straightness nature of straightening of electric arc has been improved, can guarantee still can weld at bigger weld height, further enlarge welding area's field of vision scope, be convenient for to the monitoring of electric arc form and the molten bath action among the welding process.
4. The end part of the gas hood head is higher than the end part of the nozzle and is not contacted with the ion gas, so that a complex water cooling structure is omitted, and burning loss is avoided.
Drawings
FIG. 1 is a partial cross-sectional view of an end of a plasma torch;
FIG. 2 is a schematic view of a prior art nozzle;
FIG. 3 is a cross-sectional view of a nozzle of the present invention;
FIG. 4 is a schematic view of a conventional porcelain bushing;
FIG. 5 is a schematic view of the structure of the porcelain bushing of the present invention;
FIG. 6 is a schematic view of the appearance of a conventional gas hood
FIG. 7 is a top view of the gas shield head of the present invention
FIG. 8 is a schematic cross-sectional view of a mask head according to the present invention
In the above drawings: 1. a gas-tight enclosure; 2. a gas protection diffuser; 3. a nozzle holder; 4. an insulating sleeve; 5. an electrode holder; 6. a chuck; 7. a tungsten electrode; 8. an air hood head; 9. a copper nozzle; 10. a porcelain bushing; 11. and a nozzle cover.
Detailed Description
The present invention will be further described by way of examples, but not limited thereto, with reference to the accompanying drawings.
As shown in fig. 1-8.
Example 1:
a compact large-melting-depth plasma arc welding gun is shown in figure 1, wherein the end part of the welding gun sequentially comprises a tungsten electrode, a gas guide porcelain bushing, a water-cooling copper nozzle, a gas protection cover and a gas hood head from inside to outside, ion gas passes through the gas guide porcelain bushing and the water-cooling copper nozzle, and protection gas passes through the water-cooling copper nozzle, the gas protection cover and the gas hood head.
The tungsten utmost point passes through the chuck and links to each other with the electrode holder, and the tungsten utmost point outside is equipped with insulation support, and the insulation support outside sets up the nozzle holder, and the nozzle holder tip sets up water-cooling copper nozzle, and the nozzle holder outside sets up gaseous safety cover, and gaseous safety cover one end tip sets up the gas cover head, and the inside gas protection diffuser that is equipped with of the gaseous safety cover other end.
The inner wall of the water-cooling copper nozzle is of a hollow circular truncated cone shape, and the inclination angle of the inner wall is 15 degrees. The nozzle is thick at the top and thin at the bottom, the inner wall is uniformly inclined, and a sudden change structure is avoided, so that the smooth passing of the air flow can be ensured, the air flow is gradually compressed in the flowing process along the inner wall of the nozzle, and the ion gas is kept at a higher speed at the moment of being discharged from the gun, so that the penetration force is stronger.
After the ion gas is discharged from the gun, the ion gas is converged towards the center of the electric arc at a certain angle under the action of inertia to form a conical electric arc, the focus is determined by the inclination angle of the inner wall of the nozzle, and the ion gas cannot flow along the axis direction of the welding gun or disperse towards the periphery at once, so that the stiffness of the welding electric arc is ensured.
The vertical projection of air guide insulator appearance is round platform form, and the appearance inclination of air guide insulator is the same with the inclination of water-cooling copper nozzle and is 15, the copper nozzle inner wall of closely laminating, the vertical guiding gutter that is equipped with of air guide insulator surface, the quantity of guiding gutter is 8, upper portion air guide insulator periphery diameter 10mm, the circular arc diameter 3mm of upper portion guiding gutter, lower part air guide insulator periphery diameter 5mm, lower part guiding gutter diameter 1.5mm, air guide insulator length 20 mm. The cross section of the diversion trench is semicircular, and the arc radius of the upper diversion trench is larger than that of the lower diversion trench. A semicircular diversion trench with a wide upper part and a narrow lower part is adopted. The dip angle of the diversion trench is consistent with that of the porcelain bushing, the ionic gas flows between the diversion trench of the porcelain bushing and the inner wall of the nozzle, and due to the special shapes of the diversion trench and the nozzle, the ionic gas is compressed, and the ionic gas passes through the gas guide porcelain bushing at a higher flow speed.
The gas hood head comprises a cylinder end and a circular table end, the diameter of the cylinder end is 30mm, the cylinder end is connected with the gas hood, the inclination angle of the circular table end is 12 degrees, the diameter of the lower end of the circular table end is 22mm, and spiral ribs are arranged on the inner wall of the circular table end. The round table end is designed to be thick at the top and thin at the bottom in appearance, and the spiral ribs are adopted for air guiding inside the round table end. The spiral rib angle is 30 degrees, and the number is 12. This design can carry out abundant induced swirl to the protective gas along welder axial flow with higher speed, and the protective gas receives spiral inertia effect after going out the rifle, adds the inclination of gas hood head to the compression and the direction of spiral air current, so after this device of protective gas outflow, can continue to flow along welder axis fast, can not produce the diffusion of bursting form, carries out gas protection and compression effect to the electric arc that the parcel lived.
The end of the gas hood head is above the end of the water-cooled copper nozzle. Compared with the conventional gas hood, the gas hood head provided by the invention has the advantages that the length of the gas hood can be shortened on the premise that the same protection effect is realized by the shielding gas, the lower end part of the gas hood head is higher than the end part of the welding gun, so that the welding gun nozzle does not need to be completely wrapped, and a molten pool and an electric arc in the welding process can be conveniently observed. And the length of the gas protection cover is short, the gas protection cover is not contacted with high-temperature plasma in the welding process, burning loss is avoided, and a complex cooling system of the protection cover is omitted.
Example 2:
a compact high penetration plasma arc torch constructed as described in example 1, except that the number of flow channels is 3.
Example 3:
a compact high penetration plasma arc torch constructed as described in example 1, except that the number of flow channels is 15.
Example 4:
a compact high penetration plasma arc torch constructed as described in example 1, except that the helical ribs are angled at 30 ° and 3 in number.
Example 5:
a compact high penetration plasma arc torch constructed as described in example 1, except that the helical ribs are angled at 60 ° and 15 in number.
Example 6:
the compact large penetration plasma arc welding gun is as described in embodiment 1, except that the inner wall of the water cooled copper nozzle has an inclination angle of 5 ° with the axial direction and the gas shield head has an inclination angle of 5 ° with the circular table end.
Example 7:
a compact large penetration plasma arc torch is constructed as described in embodiment 1, except that the inner wall of the water-cooled copper nozzle is inclined at 15 degrees to the axial direction, and the inclination of the circular table end of the gas shield head is inclined at 15 degrees.
Examples of the experiments
By utilizing the structure of the embodiment 1 of the invention, the welding plate is subjected to plasma welding, when the ion gas passes through the gas guide ceramic sleeve and the water-cooling copper nozzle, the ion gas is restrained by the inner wall of the nozzle and the gas guide ceramic sleeve guide groove, the ion gas can move towards the axis center of the welding gun in an accelerating way, after arcing, the ion gas continues to flow along the original direction under the action of inertia, cohesion can continue within a certain distance after the arc is discharged, the focus of the cohesion depends on the taper of the inner wall of the welding gun, so that the ion beam can not be dispersed within the range of the focus, and the welding height can be properly adjusted. The protective gas passes through the water-cooling copper nozzle, the gas protective cover and the gas cover head, is accelerated through the spiral and is compressed, and flows along the spiral direction of the nozzle after being discharged from the gun, so that the protective gas surrounds the electric arc to play a role in protection and compression. Compared with the existing design welding test, the welding test is shown in table 1, in the existing design, the air guide porcelain bushing is in a straight cylinder type, and the inner wall of the air hood is in a cylinder type. As is clear from table 1, in the present application, parameter 1 is identical to the conventional design in welding parameters, and the weldable sheet thickness is increased by 33.3%. Compared with the existing design, the parameter 2 of the application has the same other welding parameters, the thickness of the weldable plate is the same, and the welding height is improved by 50%.
Table 1 comparison of this application with existing design weld tests
Claims (4)
1. A compact large-melting-depth plasma arc welding gun is characterized in that the end part of the welding gun sequentially comprises a tungsten electrode, a gas guide porcelain bushing, a water-cooling copper nozzle, a gas protection cover and a gas hood head from inside to outside, wherein ion gas passes through the gas guide porcelain bushing and the water-cooling copper nozzle, and protective gas passes through the water-cooling copper nozzle, the gas protection cover and the gas hood head;
the tungsten electrode is connected with the electrode clamp through the chuck, an insulating sleeve is arranged on the outer side of the tungsten electrode, a nozzle seat is arranged on the outer side of the insulating sleeve, a water-cooling copper nozzle is arranged at the end part of the nozzle seat, a gas protection cover is arranged outside the nozzle seat, and a gas cover head is arranged at one end part of the gas protection cover;
the inner wall of the water-cooling copper nozzle is of a hollow circular truncated cone shape, and the inclination angle of the inner wall and the axial direction is 5-15 degrees;
the vertical projection of the air guide porcelain sleeve is in a round table shape, the inclination angle of the air guide porcelain sleeve is the same as that of the water-cooling copper nozzle, and the outer surface of the air guide porcelain sleeve is vertically provided with a diversion trench;
the number of the flow guide grooves is 3-15;
the cross section of the diversion trench is semicircular;
the arc radius of the upper diversion trench is larger than that of the lower diversion trench;
the gas hood head comprises a cylinder end and a circular table end, the cylinder end is connected with the gas hood, the inclination angle of the circular table end is 5-15 degrees, and spiral ribs are arranged on the inner wall of the circular table end.
2. The compact large penetration plasma arc torch as in claim 1 wherein the helical ribs are angled at 30 ° to 60 ° and numbered 3 to 15.
3. The compact large penetration plasma arc torch as in claim 1 wherein the tip of the gas shield head is above the water cooled copper nozzle tip.
4. The compact large penetration plasma arc torch as set forth in claim 1 wherein a gas shield diffuser is disposed within the other end of the gas shield.
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| CN201911205342.6A CN111673246B (en) | 2019-11-29 | 2019-11-29 | Compact large-melting-depth plasma arc welding gun |
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| CN111673246B true CN111673246B (en) | 2021-08-31 |
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| CN115070181B (en) * | 2021-03-16 | 2024-01-05 | 上海梅山钢铁股份有限公司 | Method for improving plasma welding quality |
| CN114012220A (en) * | 2021-11-19 | 2022-02-08 | 北京电子科技职业学院 | Aluminum alloy consumable electrode arc welding equipment and welding method |
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| CN109483031A (en) * | 2018-12-14 | 2019-03-19 | 山东大学 | A kind of big depth-to-width ratio plasma arc welding device of big fusion penetration and welding method |
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| JPS6228084A (en) * | 1985-07-30 | 1987-02-06 | Akira Kanekawa | Plasma jet torch |
| JP2000197974A (en) * | 1998-12-25 | 2000-07-18 | Tanaka Engineering Works Ltd | Nozzle for plasma torch |
| CN101084701A (en) * | 2004-11-16 | 2007-12-05 | 人工发热机有限公司 | Plasma arc torch having an electrode with internal passages |
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