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CN-121982857-A - Rare earth magnesium alloy wire material electro-plastic roller stretch breaking early warning alarm device for arc material increase

CN121982857ACN 121982857 ACN121982857 ACN 121982857ACN-121982857-A

Abstract

The invention discloses a rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase, which comprises a closed box body, a sliding guide rail module, a multidimensional detection module, a main control unit and an audible and visual warning component, wherein the sliding guide rail module adopts a modularized design, the position of a sensor can be flexibly adjusted, the multidimensional detection module collects wire operation parameters in real time, the main control unit analyzes data through a multisource information fusion algorithm, and accurately identifies broken wires and potential risks.

Inventors

  • ZHAO ZHANYONG
  • LI JINGHAO
  • BAI PEIKANG

Assignees

  • 中北大学

Dates

Publication Date
20260505
Application Date
20251225

Claims (9)

  1. 1. The rare earth magnesium alloy wire stretch-breaking early warning device for the electric arc material increase is characterized by comprising a closed box body (2), a sliding guide rail module (7), a tension detection module (11), a temperature sensor (10), an acoustic vibration sensor (4), a speed detection sensor (8), an electric parameter monitoring module (9), a torque sensor (13), a three-dimensional scanning device (5), an optical detection module, a main control unit (12), a warning lamp (1) and a buzzer (6); The box body (2) is of a metal frame structure, and the sliding guide rail module (7) is fixed at the center of the bottom of the box body (2); The tension detection module (11), the temperature sensor (10), the acoustic vibration sensor (4), the speed detection sensor (8) and the three-dimensional scanning device (5) are all arranged on the sliding guide rail module (7), the electric parameter monitoring module (9) is fixed at the lower left corner of the box body (2), the torque sensor (13) is arranged on the side wall of the box body (2), and the optical detection module is arranged at the top of the box body (2); The alarm lamp (1) is arranged at the top of the box body (2), and the buzzer (6) is arranged on the sliding guide rail module (7); The main control unit (12) is arranged outside the box body (2), is connected with the tension detection module (11), the temperature sensor (10), the acoustic vibration sensor (4), the speed detection sensor (8), the electric parameter monitoring module (9), the torque sensor (13), the three-dimensional scanning device (5), the optical detection module, the alarm lamp (1) and the buzzer (6) through electric signals, and is used for receiving detection signals of all the modules and realizing early warning and alarm control.
  2. 2. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the sliding guide rail module (7) comprises a supporting base (18), a guide rail (15), a lifting mechanism (16) and a plurality of sliding blocks (17); The supporting base (18) is fixedly connected with the bottom of the box body (2) through a high-strength bolt, the guide rail (15) is connected above the supporting base (18), and the lifting mechanism (16) is arranged between the guide rail (15) and the supporting base (18) and driven by an electric cylinder; the sliding block (17) is connected to the guide rail (15) in a sliding way, the bearing capacity of the sliding block (17) is more than or equal to 10kg, the driving stroke range of the electric cylinder is 0-300mm, and the positioning precision is +/-0.1 mm; the surface roughness Ra of the guide rail (15) is less than or equal to 1.6 mu m, and the parallelism error is less than or equal to 0.5mm/m.
  3. 3. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the three-dimensional scanning device (5) is fixed on a sliding block (17) through bolts and comprises a motor (23), a motor mounting seat (26), a screw rod (20), a guide rod (21), a synchronous support frame (19), a working backboard (24), an infrared detection positioning device (22) and an annular laser scanner (25); The motor (23) is fixed on the sliding block (17) through a motor mounting seat (26), a motor shaft is coaxially connected with the screw rod (20), the guide rods (21) are arranged on two sides of the screw rod (20) in parallel, and the synchronous support frame (19) is positioned above the guide rods (21) and matched with the guide rods (21) to form a top support assembly; the working backboard (24) is connected to the guide rod (21) in a sliding manner and is in threaded connection with the screw rod (20), the lifting stroke of the working backboard (24) is 0-200mm, and the lifting speed is 5-20mm/s; The infrared detection positioning device (22) and the annular laser scanner (25) are both arranged on the working backboard (24), the positioning accuracy of the infrared detection positioning device (22) is +/-0.5 mm, the response time is less than or equal to 10ms, the red visible laser wavelength of the annular laser scanner (25) is 650nm, the scanning line number is more than or equal to 200 lines/circle, the diameter measurement range is 5-50mm, and the measurement accuracy is +/-0.01 mm.
  4. 4. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the optical detection module comprises an annular guide rail (3), a rotating shaft seat (27), a cylinder piston (28), a camera mounting seat (29) and a high-speed camera (14); the rotating shaft seat (27) is fixed at the top of the box body (2), the cylinder piston (28) is connected between the rotating center of the annular guide rail (3) and the rotating shaft seat (27), and the lifting stroke of the cylinder piston (28) is 0-200mm; The high-speed camera (14) is fixed on a camera mounting seat (29), the camera mounting seat (29) is arranged on the annular guide rail (3), the rotation angle of the annular guide rail (3) is 0-360 degrees, and the rotation speed is 5 degrees/s; The resolution of the high-speed camera (14) is more than or equal to 200 ten thousand pixels (1920 multiplied by 1080), the frame rate is more than or equal to 1000fps, and the focal length of the lens is 12-25mm.
  5. 5. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the tension detection module (11) has a measuring range of 0-500N, the measuring precision is +/-0.5N, and the sampling frequency is more than or equal to 100Hz; the speed detection sensor (8) adopts a photoelectric encoder type speed measuring device, the resolution is more than or equal to 1000 lines/rotation, the measurement range is 0-5m/s, the measurement precision is +/-0.5%, and the sampling frequency is more than or equal to 50Hz; The temperature sensor (10) is a K-type thermocouple or an infrared temperature measuring module, the measuring range is 0-500 ℃, the measuring precision of the K-type thermocouple is +/-2.5 ℃, the response time is less than or equal to 100ms, the measuring precision of the infrared temperature measuring module is +/-1%, and the measuring distance is 100-300mm.
  6. 6. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the core of the acoustic vibration sensor (4) is a piezoelectric accelerometer, the measuring range is 0-500m/s2, the frequency response range is 10Hz-20kHz, the sensitivity is 100 mV/(m/s 2), the signal-to-noise ratio is more than or equal to 60dB, and the sampling frequency is more than or equal to 1000Hz.
  7. 7. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the electric parameter monitoring module (9) is connected in parallel between a main power supply and a roller driving circuit, adopts an isolated sampling design, and has a measuring range of 0-2000A of current, 0-50V of voltage and 0-100kW of power, and has a measuring precision of 0.5% of current, 0.2% of voltage, 1% of power, and a sampling frequency of more than or equal to 100Hz.
  8. 8. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the main control unit (12) comprises a multichannel data acquisition card, a filter circuit, an analog-to-digital conversion module and an embedded processor, and a multisource information fusion algorithm is operated in the embedded processor; the main control unit (12) is provided with an embedded touch screen and has the functions of real-time data curve display, alarm recording, parameter setting and historical data backtracking.
  9. 9. The rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc material increase according to claim 1, wherein the warning lamp (1) is a three-color LED lamp, the flashing frequency of a red lamp is 2Hz, the flashing frequency of a yellow lamp is 1Hz, and a green lamp is normally on; The alarm volume of the buzzer (6) is more than or equal to 85dB, and the buzzer has two alarm tones of intermittent sound and continuous sound, and the alarm triggering delay is less than or equal to 100ms.

Description

Rare earth magnesium alloy wire material electro-plastic roller stretch breaking early warning alarm device for arc material increase Technical Field The invention belongs to the technical field of 3D arc additive manufacturing, and particularly relates to a rare earth magnesium alloy wire electro-plastic roller stretch-breaking early warning device for arc additive. Background Arc Additive Manufacturing (WAAM) is a wire-based DED process that uses an arc as a melting source to melt a wire and deposit part preforms layer by layer. Arc additive Manufacturing technology (WAAM, wire Arc Additive Manufacturing) has been rapidly developed in recent years as an important branch of the field of metal additive Manufacturing. The technology takes electric arc as a heat source and metal wires as raw materials, and realizes the rapid forming of the three-dimensional component in a layer-by-layer deposition mode. Compared with powder bed melting processes such as laser selective melting (SLM) and Electron Beam Melting (EBM), WAAM is independent of high-cost metal powder, the material utilization rate is close to 100%, the deposition efficiency is high, the level of kilogram per hour can be reached, and the method is very suitable for manufacturing and repairing large-size and complex structural members. In addition, WAAM has flexible process path, high deposition rate and relatively low equipment cost, thus having wide application prospect in the fields of aerospace, energy equipment, rail traffic and the like. It can be said that the development of WAAM not only provides a new technical approach for the rapid manufacture of metal components, but also promotes the deep fusion of the conventional welding process and the digital manufacturing technology. In WAAM technical systems, wires are the only raw material input, and the metallurgical quality, forming precision and wire feeding stability directly determine the geometric precision and mechanical properties of the deposited layer. Particularly, for light-weight high-specific-strength metal materials such as magnesium alloy, the quality of the wire is a key for determining whether arc additive manufacturing can be stably carried out. Magnesium alloy is considered as an important material for realizing light weight structure, energy saving and consumption reduction due to low density, high specific strength and excellent vibration damping performance. However, magnesium alloys have poor plasticity and large hot cracking tendency, and the processability is far lower than that of aluminum alloys and titanium alloys, so that the preparation difficulty of welding wires is remarkably improved. In the conventional rolling and drawing preparation process, the magnesium alloy wire is easy to have defects of cracks, broken wires, uneven tissues and the like, and the popularization and the application of the magnesium alloy wire in arc additive manufacturing are limited. Therefore, how to obtain high-quality magnesium alloy wires with accurate size, uniform structure and stable components has become the premise and difficulty of WAAM to apply magnesium alloy. Aiming at the difficult forming problem in the preparation of magnesium alloy wires, the electro-plastic roller drawing technology is gradually attracting attention. The method leads pulse current into the plastic deformation process of the metal, so that the electric field and the heat and the force are mutually coupled, the flow stress of the metal can be effectively reduced, dislocation slip and dynamic recovery are promoted, and the plasticity of the magnesium alloy at room temperature or medium and low temperature is improved. Compared with the traditional roller drawing method, the electro-plastic roller drawing can obviously reduce the rolling force and improve the continuity and the yield of the wire, thereby providing a new technological means for preparing the high-quality magnesium alloy welding wire. The method not only can improve the tissue uniformity, but also can optimize the texture distribution to a certain extent and improve the stability and the forming quality of a molten pool in the subsequent arc additive manufacturing, thereby having higher research and application values in the field of magnesium alloy welding wire preparation. However, although the electro-plastic roller drawing can improve the workability of magnesium alloy, there is still a risk of wire breakage during the actual manufacturing process. This is mainly due to factors such as low ductility and grain boundary embrittlement of the magnesium alloy itself, and strain localization under the action of an electric field. Once broken wires occur, the production flow is interrupted, the material waste is increased, the equipment operation is possibly damaged, and the overall process stability and the production efficiency are reduced. Therefore, a set of wire breakage early warning and alarming device in the preparation process of the magnes