Design and Numerical Simulation of Dust Removal System for Sutomotive Iongitudinal Beam Plasma Cutting

To improve the poor efficiency of the dust removal system in the plasma cutting station of automotive longitudinal beams,and reduce the cutting surface quality degradation due to dust,a bottom-side suction dust removal system is designed,and the dust removal effect is optimized through the setting of the following dampers and diversion plates.The result of numerical simulation indicates that the particle collection rate can reach 99.44%,and the field test also proves the effectiveness of the dust removal system,which is of guiding significance for the transformation of other similar dust removal systems.

A new complete model of switch-mode plasma cutting power supply

A complete model of switch-mode plasma cutting power supply and its simulation are developed. The full bridge isolated pulse width modulation (PWM) buck converter in continuous conduction mode (CCM) for high watt plasma power supply is approached. Reduced ripple current and improved power factor are achieved in the plasma power supply. With a PID control strategy, circuit responses become more stable and faster with low overshoot during load and current changing. The converter achieved high efficiency under 3 to 15kW load conditions.

Conducted EMI Suppression in Plasma Cutting Power Supply

A systematic approach to the design of the conducted electromagnetic interference （EMI） filter of high-density plasma cutting power supply has been developed. Converter components have been accurately modeled, with parasitic elements extracted to reveal their impacts on the EMI noises. Circuit simulations have been used to analyze and minimize the EMI noises. Conducted EMI noise measurement and filter design of this power supply have been achieved which successfully satisfy the FCC class B limits in the frequency range from 150 kHz to 30 MHz. The analyses and experimental results show that the designed filter guarantees that the required attenuation will be achieved.

Realization of non HF air plasma cutting power source based on a complexisolated inverter

On the basis of analyzing and testing of common inverting circuits, a new type inverter, which has a special inverting circuit called complex isolated, has been put forward. In turn, an applicable air plasma cutting machine has also been put into use. Testing results show that this kind inverter has lots of properties as high reliability, high efficiency, good EMC(electromagnetic compatibility) and easy operating. The complex isolated inverting circuit can be considered as a quite valuable reference for the research of high power welding inverter.

Specialized Numerical Control Plasma Cutting Machine

The large thermal cutting equipment——The DHG. CNC numerical control plasma cutting machine is produced by The Ha’erbin Welding & Cutting Equipment Co. It specializes in the precise formation and baiting of nonferrous boards and thin carbon steel plates at a high speed. It avoids the disadvantage of flame cutting, which cannot cut nonferrous and thin steel plates.

Study on Ceramic Cutting by Plasma Arc

Engineering ceramics are typical difficult-to-machine materials because of high hardness and brittleness. PAC (Plasma Arc Cutting) is a very important thermal cutting process and has been successfully used in cutting stainless steel and other difficult-to-machine alloys. PAC’s application in cutting ceramics, however, is still limited because the most ceramics are not good electronic conducts, and transferred plasma arc cannot be produced between cathode and work-piece. So we presented a method of plasma arc cutting engineering ceramics with additional anode. To reduce the kerf width and to improve the kerf quality, the hydro-magnetically confined plasma arc is used to cut engineering ceramic plates. By experiments and analyses the mechanism and characteristics of hydro-magnetic confined plasma are discussed and the effects of secondary confinement on cutting quality, arc properties, and optimal process parameters are presented. When the nozzle diameter is 3 mm, the kerf width of the Al 2O 3 ceramic plate with 6 mm thickness is less than 4.6 mm, and the cutting speed reaches to 0.9～1.2 m/min. Both theoretical analysis and experimental results have proved the feasibility and validity of the newly advanced hydro-magnetic plasma arc cutting, and the following conclusion can be drawn: (1)Synthesizing the advantages of both the water-constriction and magnetic constriction, the hydro-magnetic constriction of plasma arc forms a three-dimensional constriction with improved shape and uniformity of arc column, narrower kerfs, minimal beveling of cuts and higher dross-free cutting speeds than those under either water-constriction or magnetic constriction alone.(2)Hydro-magnetic constriction is capable of improving arc stability, which is reflected in the higher arc voltage at which arc-extinction occurs, than that under any single constriction. (3)For a given diameter of nozzle, quality cut can be produced by using a lower arc current than usually required in conventional plasma arc cutting, but ensuring fine arc shape and capability of cutting simply by employing hydro-magnetic constriction. Meanwhile, the heat load on nozzle could be reduced and service life of nozzle raised.

Research on a 50 kW digital inverter type plasma cutting power supply

To improve energy transfer efficiency and quality controllability of plasma cutting process of thick plate, a 50 kW digital inverter type plasma cutting power supply is developed. The power supply main circuit is composed of two similar power electronic building blocks, using full-bridge high frequency inverter topology to achieve efficient energy transformation. To realize accurate digital control of the plasma cutting power supply and cooperative work of the two power electronic building blocks, the Cortex-M4 type ARM microprocessor-TM4C123GH6PGE is used as the cybernetic core of the control system. To improve the response performance and reliability of the power system, close-loop control and peak current feedback control modes are adopted. In the end, the experimental study of the performance testing and cutting of the developed prototype is carried out. The results indicate that the design is rational and feasible, and the developed high power plnsma cutting power supply works reliably with excellent performance.

COMPARISON OF MODELING TECHNIQUES FOR SELECTING OPTIMIZED AND AUTOMATED PLASMA CUTTING PROCESS PARAMETERS

The advancement in technologies made the entire manufacturing system,to be operated with more efficient,flexible,user friendly,more productive and cost effective.One such a system to be focused for advancement is plasma cutting system,which has wider industrial applications.There are many researches pursuing at various area of plasma cutting technology,still the automated and optimized parameters value selection is challenging.The work is aimed to eliminate the manual mode of feeding the input parameters for cutting operation.At present,cutting parameters are fed by referring the past cut data information or with the assistance of experienced employers.The cutting process parameters selections will have direct impact on the quality of the material being cut,and life of the consumables.This paper is intended to automate the process parameters selection by developing the mathematical model with existing cutting process parameters database.In this,three different approaches,multiple regression,multiple polynomial regression and AI technique,are selected and analyzed with the mathematical relations developed between the different cutting process parameters.The accuracy and reliability of those methods are detailed.The advantage and disadvantage of those methods for optimal setting conditions are discussed.The appropriate method that can be preferred for automated and optimal settings are elucidated.Finally,the selected technique is checked for accuracy and reliability for the existing cut data.

Multifunction Plasma Arc Equipment

A new type of plasma arc equipment with four functions including plasma arc welding, cutting, spraying and a surfacing process was designed and manufactured. To obtain good processing stability and multifunction integration, a silicon controlled rectifier (SCR), and the programmable controller (PC) were introduced. The operation of this new machine shows that it has the advantage of simple circuit design, flexible control pattern, low fault rate and easy maintenance.