Finite Element Analysis And Optimum Design For Magnetic-control Arc Sensor

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.