大功率电子束焊机高频高压油箱关键技术研究与实现

发布时间：2018-07-15 07:34

【摘要】：大功率电子束焊机高压电源是给电子束焊机提供电能的装置。当电子枪中的阴极灯丝加热到一定温度时会产生电子,电子在高压电场中被加速至光速或接近光速,散射的电子通过电磁透镜聚焦后,形成能量密度超高的电子束,当电子束轰击焊件表面时,电子的强大动能瞬间转变为热能,使金属熔融,待冷却后自然凝固,达到焊接的目的。大功率高频高压油箱作为电子束焊机高压电源的核心组成部分,其主要由高频高压变压器、高压整流电路、高压采样电路、高压滤波电路组成。油箱在设计的过程中需要考虑很多因素,涉及到各个方面的学科知识。首先机械机构方面的设计决定了整个油箱体积的尺寸大小,同时也直接影响着油箱中各个部分如何固定和支撑。其次每个部分的材料选型不仅需要考虑机械强度问题,而且也要明确油箱中的绝缘问题。绝缘问题是油箱设计过程中的难点之一,绝缘是整个油箱能够稳定正常工作的前提,各部分之间的绝缘距离和绝缘材料的选取对绝缘都有非常大的影响。所以这些难点之间又是相互影响、相互制约的。本文对油箱中的绝缘技术进行了研究后,接下来又对油箱中高频高压变压器的分布参数、温度等方面进行了理论公式的推导。利用Ansoft Maxwell 16仿真软件对高频高压变压器进行建模仿真,首先建立高频高压变压器的2D和3D模型,接着根据所要分析的参数选择不同的场求解器,使用ANSYS Workbench 15.0仿真软件对高频高压变压器进行温度仿真,最后采用Ansoft Maxwell 16软件自带的Ansoft Maxwell Circuit Editor功能对高频高压油箱中的整体电路进行仿真分析,证明了仿真结果对油箱的设计具有指导意义。利用LCR电桥测量高频高压变压器的漏感值,用阻抗分析仪测量高频高压变压器的分布电容值。最后与理论计算结果、仿真值进行对比,准确计算出了高频高压变压器的分布参数值。最后通过Solidworks机械软件对油箱内部和整体的结构进行了优化设计,制作出了一台大功率高频高压油箱样机,并应用在电子束焊机焊接实验中。
[Abstract]:High-voltage power supply for high-power electron beam welder is a device for supplying electric energy to electron beam welding machine. When the cathode filament in the electron gun is heated to a certain temperature, electrons will be produced. The electrons will be accelerated to the speed of light or near the speed of light in a high voltage electric field, and the scattered electrons will be focused through an electromagnetic lens to form an ultra-high energy density electron beam. When the electron beam bombardes the surface of the welded piece, the strong kinetic energy of the electron is transformed into heat energy in an instant, which melts the metal and solidifies naturally after cooling, so that the purpose of welding is achieved. As the core part of high voltage power supply for electron beam welder, high power high frequency and high voltage oil tank is mainly composed of high frequency and high voltage transformer, high voltage rectifier circuit, high voltage sampling circuit and high voltage filter circuit. There are many factors to be taken into account in the design of fuel tank. First, the design of mechanical mechanism determines the size of the whole tank volume, and also directly affects how the various parts of the tank are fixed and supported. Secondly, the material selection of each part should not only consider the mechanical strength, but also clarify the insulation problem in the fuel tank. Insulation is one of the most difficult problems in the design of oil tank. Insulation is the precondition for the whole tank to work stably and normally. The insulation distance between different parts and the selection of insulating materials have a great influence on the insulation. So these difficulties affect each other and restrict each other. After the study of insulation technology in oil tank, the distribution parameters and temperature of high frequency and high voltage transformer in oil tank are deduced. Using Ansoft Maxwell 16 software to model and simulate the high-frequency high-voltage transformer, the 2D and 3D models of the high-frequency high-voltage transformer are first established, and then different field solvers are selected according to the parameters to be analyzed. The temperature of high frequency high voltage transformer is simulated by ANSYS Workbench 15.0. Finally, the whole circuit of high frequency high voltage oil tank is simulated and analyzed by Ansoft Maxwell Circuit Editor function of Ansoft Maxwell 16 software. It is proved that the simulation results are instructive to the design of fuel tank. The leakage inductance of high frequency high voltage transformer is measured by LCR bridge and the distribution capacitance of high frequency high voltage transformer is measured by impedance analyzer. Finally, the distribution parameters of high frequency high voltage transformer are calculated by comparing with the theoretical calculation results and the simulation results. Finally, the internal and integral structure of the fuel tank is optimized by Solidworks mechanical software, and a high-power high-frequency and high-pressure oil tank prototype is made and applied in the welding experiment of the electron beam welding machine.
【学位授予单位】：北方工业大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG439.3

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