CN111014708B - Method and device for determining flame diameter of plasma arc - Google Patents
Method and device for determining flame diameter of plasma arc Download PDFInfo
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- CN111014708B CN111014708B CN201911387348.XA CN201911387348A CN111014708B CN 111014708 B CN111014708 B CN 111014708B CN 201911387348 A CN201911387348 A CN 201911387348A CN 111014708 B CN111014708 B CN 111014708B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
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- B22F9/14—Making metallic powder or suspensions thereof using physical processes using electric discharge
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Abstract
The invention discloses a method and a device for determining the flame diameter of a plasma arc, relates to the field of powder making, and is used for solving the problem that the quality of powder is influenced because the power density of the plasma arc cannot be controlled in the powder making process. The method comprises the following steps: dividing the main arc current of the plasma power supply into a plurality of equal parts according to a set numerical value; when the main arc current of the plasma power supply is increased progressively according to the numerical value corresponding to each equal part, shooting plasma arc flame diameter images by adopting an image acquisition system, and respectively corresponding the shot original images to the diameter of each plasma arc flame; when powder making is started, the plasma arc flame diameter is shot, a plurality of shot detection images are respectively compared with a plurality of original images for identification, and if the flame form of at least one detection image is the same as that of at least one original image, the plasma arc flame diameter of the original image matched with the first detection image is determined as the plasma arc flame diameter of the first detection image.
Description
Technical Field
The invention relates to the technical field of plasma rotating electrode powder making, in particular to a method and a device for determining the flame diameter of a plasma arc.
Background
The working principle of the plasma rotating electrode powder manufacturing equipment is that the high-energy plasma beam instantly generates larger heat to melt the end face of the metal bar rotating at high speed, so that molten metal droplets fly out at high speed under the action of centrifugal force, and the aim of preparing spherical powder is fulfilled.
The particle size and quality of the powder produced by the powder producing device, whether a transferred arc or a non-transferred arc, are closely related to the power density of the plasma arc, and the power density of the plasma arc is the product of the voltage U and the current I at two ends of the plasma arc divided by the cross section corresponding to the maximum diameter of the plasma arc. A certain material is melted per unit cross-sectional area, and the corresponding minimum energy density is fixed. However, when the diameter D of the metal bar corresponding to the material is changed, the required melting heat is increased, but the power density is gradually reduced.
Therefore, if the diameter D of the metal bar is kept constant, energy is wasted more if the energy density is too high, and the powder to be produced becomes coarse if the melting speed of the metal bar is too high, and the bar cannot be melted if the energy density is too low.
In summary, the existing plasma rotating electrode powder manufacturing process has the problem of influencing the powder quality due to the fact that the plasma arc power density cannot be controlled.
Disclosure of Invention
The embodiment of the invention provides a method and a device for determining the flame diameter of a plasma arc, which are used for solving the problem that the powder quality is influenced because the power density of the plasma arc cannot be controlled in the existing plasma rotating electrode powder making process.
The embodiment of the invention provides a method for determining the flame diameter of a plasma arc, which comprises the following steps:
determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value;
when the main arc current of the plasma power supply is increased progressively according to the numerical value corresponding to each equal part, an image acquisition system is adopted to shoot a plasma arc flame diameter image, the shot image is determined to be an original image, and each original image corresponds to the diameter of each plasma arc flame;
when the plasma powder making equipment starts to make powder, shooting the flame diameter of the plasma arc, and determining the shot image as a detection image;
comparing and identifying the plurality of detection images with the plurality of original images respectively, and if the flame forms of at least one detection image and at least one original image are the same, determining the determined detection image as a first detection image;
and determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image.
Preferably, the plasma arc flame diameter is determined by the following equation:
wherein D ismaxThe maximum flame diameter of the plasma arc; dminThe plasma arc minimum flame diameter; delta d is a set distance which is maximally equal to the difference between the maximum flame diameter of the plasma arc and the minimum flame diameter of the plasma arc; dxIs the diameter of the plasma arc flame and has a length of DmaxAnd DminTo (c) to (d); x is a natural number.
Preferably, each of the raw images further corresponds to each of the plasma power main arc currents respectively;
after determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image, the method further comprises:
and determining the plasma power supply main arc current corresponding to the original image matched with the first detection image as the plasma power supply main arc current of the first detection image.
Preferably, the plasma powder-making equipment comprises an atomizing chamber which is cylindrical in shape;
before adopting image acquisition system to shoot on every plasma arc flame diameter, still include:
installing a high-power light source on a central shaft of the atomizing chamber, wherein the high-power light source is positioned above the melting end face of the plasma gun and the metal bar;
and the camera is arranged on the central shaft of the atomizing chamber and is positioned above the high-power light source.
Preferably, the shooting the diameter of the plasma arc flame specifically comprises:
and according to the feeding speed of the metal bar stock, determining the shooting speed of the flame diameter of the plasma arc to be at least 5 detection images per second.
Preferably, the feeding speed of the metal bar is 1.0-2.0 mm/s, and the shooting speed of the flame diameter of the plasma arc is 10 detection images per second at most.
The embodiment of the invention also provides a device for determining the flame diameter of the plasma arc, which comprises:
the plasma arc power supply comprises a first determining unit, a second determining unit and a control unit, wherein the first determining unit is used for determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value;
the second determining unit is used for shooting a plasma arc flame diameter image by using an image acquisition system when the main arc current of the plasma power supply increases progressively according to the numerical value corresponding to each equal part, and determining an original image from the shot image, wherein each original image corresponds to the flame diameter of each plasma arc;
the third determining unit is used for shooting the flame diameter of the plasma arc when the plasma powder making equipment starts to make powder, and determining the shot image as a detection image;
the fourth determining unit is used for comparing and identifying the plurality of detection images with the plurality of original images respectively, and if the flame forms of at least one detection image and at least one original image are the same, determining the determined detection image as a first detection image;
and the fifth determining unit is used for determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image.
Preferably, the plasma arc flame diameter is determined by the following equation:
wherein D ismaxThe maximum flame diameter of the plasma arc; dminThe plasma arc minimum flame diameter; delta d is a set distance which is maximally equal to the difference between the maximum flame diameter of the plasma arc and the minimum flame diameter of the plasma arc; dxIs the diameter of the plasma arc flame and has a length of DmaxAnd DminTo (c) to (d); x is a natural number.
Preferably, each original image also corresponds to each plasma power supply main arc current;
the fifth determination unit is further configured to:
and determining the plasma power supply main arc current corresponding to the original image matched with the first detection image as the plasma power supply main arc current of the first detection image.
Preferably, the third determining unit is specifically configured to:
and according to the feeding speed of the metal bar stock, determining the shooting speed of the flame diameter of the plasma arc to be at least 5 detection images per second.
The embodiment of the invention provides a method for determining the flame diameter of a plasma arc, which comprises the following steps: determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value; when the main arc current of the plasma power supply is increased progressively according to the numerical value corresponding to each equal part, an image acquisition system is adopted to shoot a plasma arc flame diameter image, the shot image is determined to be an original image, and each original image corresponds to the diameter of each plasma arc flame; when the plasma powder making equipment starts to make powder, shooting the diameter of the plasma arc flame, and determining the shot image as a detection image; comparing and identifying the plurality of detection images with the plurality of original images respectively, and if the flame forms of at least one detection image and at least one original image are the same, determining the determined detection image as a first detection image; and determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image. The method combines an intelligent industrial camera, a high-power light source and plasma powder making equipment, and combines the detection of the length of the flame of the plasma arc and an automatic control system, so that the diameter of the plasma arc can be accurately displayed in real time. By accurately detecting the diameter of the plasma arc, the method can accurately detect the power density of the plasma arc, thereby controlling the influence of the plasma arc on the quality of the metal powder and greatly improving the powder making process; furthermore, the method can enable the automation degree of the plasma powder making equipment to enter a full-automatic era from semi-automation, and solves the problem that the plasma rotating electrode powder making process in the prior art can not control the power density of a plasma arc, so that the quality of powder is influenced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic structural diagram of a plasma milling apparatus according to the prior art;
FIG. 2 is a schematic flow chart illustrating a method for determining a flame diameter of a plasma arc according to an embodiment of the present invention;
FIG. 3 is a schematic structural diagram of a plasma milling apparatus according to an embodiment of the present invention;
FIG. 4 is a schematic view of an apparatus for determining a flame diameter of a plasma arc according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Fig. 1 is a schematic structural diagram of a plasma powder manufacturing apparatus provided in the prior art, and as shown in fig. 1, the plasma powder manufacturing apparatus includes an atomizing chamber, a plasma gun and a metal bar. The plasma arc flame is between the plasma gun and the metal bar, and can be determined according to the content recorded in the background technology, when the distance between the plasma gun and the melting end face of the metal bar is larger, the arc breakage of the plasma arc is easily caused; when the distance between the plasma gun and the melting end face of the metal bar is relatively small, the plasma gun is easily damaged, and even the plasma gun and the melting end face of the metal bar collide with each other.
Because the existing plasma powder manufacturing equipment can not realize full-automatic control, the distance between the melting end face of the plasma gun and the melting end face of the metal bar can not be detected in real time, and the main difficulty of causing the problems is as follows:
1) plasma arc generated by the plasma rotating electrode powder manufacturing equipment can reach ten thousands of degrees instantly, so that the temperature in the atomizing chamber is increased rapidly, the atomizing chamber is kept at a high temperature in the powder manufacturing process, and a temperature sensitive detection element cannot work;
2) the atomization chamber for producing the powder is filled with argon, so that the argon is easy to ionize, and most of circuit boards are short-circuited, so that the circuit boards cannot work normally; in addition, a large amount of metal dust floats in the atomizing chamber, so that the detection working condition environment is extremely complex.
In view of the above, embodiments of the present invention provide a method for determining a plasma arc flame diameter based on image processing. The method is based on an image processing device which mainly comprises a plasma arc flame diameter system, wherein the plasma arc flame diameter system comprises an industrial camera, a high-power light source, an industrial camera mounting bracket, a filter and the like. Specifically, the industrial camera is fixed on an industrial camera mounting bracket, and the industrial camera mounting bracket and the high-power light source are both fixed in an atomization chamber of the plasma powder manufacturing equipment.
In practical application, the lens of the industrial camera is installed in parallel with the plasma gun, namely the industrial camera is used for shooting plasma arc flame emitted by the plasma gun. In order to ensure that the photographed plasma arc flame has a good effect, a filter is preferably further disposed in front of the lens of the industrial camera.
FIG. 2 is a flow chart illustrating a method for determining a flame diameter of a plasma arc, which may be implemented in at least a plasma pulverizing apparatus, according to an embodiment of the present invention.
As shown in fig. 2, the method mainly includes the following steps:
step 101, determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value;
103, when the plasma powder making equipment starts to make powder, shooting the flame diameter of the plasma arc, and determining the shot image as a detection image;
and 105, determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image.
It should be noted that the method for determining the flame diameter of the plasma arc provided by the embodiment of the invention is based on the image processing device, namely the method for determining the flame diameter of the plasma arc needs to be executed depending on the image processing device.
In practical applications, the plasma arc power density can be determined using the following equation (1):
wherein rho is plasma arc power density, P is plasma arc power, S is plasma arc flame maximum section area, S ═ pi (D/2)2And D is the maximum diameter of the plasma arc flame.
The technical problem to be solved in the background of the invention is the problem of influencing the quality of powder due to the failure to control the power density of the plasma arc. It can be determined from equation (1) that plasma arc power density can be controlled by controlling the plasma arc flame diameter.
Before step 101, a high-power light source and an industrial camera included in an image processing device are arranged in an atomizing chamber, and after the high-power light source and the industrial camera are arranged in the atomizing chamber, pictures of plasma arc flames generated by a plasma gun arranged in the atomizing chamber can be collected through the industrial camera.
When the plasma gun is started to maintain the arc, it is extremely important to accurately detect the distance between the plasma gun and the melted end face of the metal bar. If the distance between the plasma gun and the melting end face of the metal bar is relatively large, the plasma arc is easy to break; if the distance between the plasma gun and the melting end face of the metal bar is relatively small, the plasma gun is easily damaged, and even the plasma gun and the melting end face of the metal bar collide with each other. In practical application, when the plasma gun is not arcing, because a piece of paint black is in the atomizing chamber, in order to enable the industrial camera to shoot the position between the plasma gun and the molten end face of the metal bar in the atomizing chamber, a light source needs to be provided in the atomizing chamber. In the embodiment of the invention, the high-power light source can be arranged in the atomizing chamber, and based on the high-power light source, the high-power light source can provide brightness for the shooting of an industrial camera.
Fig. 3 is a schematic structural diagram of a plasma powder manufacturing apparatus according to an embodiment of the present invention, and as shown in fig. 3, the plasma powder manufacturing apparatus at least includes an atomizing chamber, a high power light source, an industrial camera, a plasma gun, and a metal bar.
Specifically, the atomizing chamber is cylindrical, the high-power light source is arranged on the central shaft of the atomizing chamber, and the high-power light source is positioned above the melting end face of the plasma gun and the metal bar. Further, the industrial camera is arranged on the central shaft of the atomizing chamber, and the industrial camera is arranged above the high-power light source.
It should be noted that, because the atomizing chamber is a cylinder, the central axis of the atomizing chamber is a connection line of the centers of circles of the upper surface and the lower surface of the cylinder, that is, the high-power light source is disposed at the center of a circle of the cross section of the atomizing chamber, in practical application, the specific position of the high-power light source on the central axis is not limited (above the plasma gun and the metal bar), and only the high-power light source is ensured not to affect the plasma gun when operating, and the plasma gun does not affect the high-power light source when operating.
As shown in fig. 3, the industrial camera is arranged above the atomizing chamber, i.e. the industrial camera is arranged on the extension line of the central axis of the atomizing chamber, and the lens of the industrial camera is parallel to the plasma gun and the metal bar.
After the industrial camera and the high-power light source are arranged, the high-power light source can be started, and after the high-power light source illuminates the atomizing chamber, the industrial camera can clearly shoot the distance between the plasma gun and the molten end face of the metal bar.
In step 101, a maximum flame diameter and a minimum flame diameter of the plasma arc are determined empirically, and an adjustable flame diameter of the plasma arc may be determined based on a difference between the determined maximum flame diameter and the determined minimum flame diameter of the plasma arc, i.e. the flame diameter of the plasma arc may be between the maximum flame diameter and the minimum flame diameter.
In practical application, if the diameter of the metal bar stock is kept constant, if the energy density is too high, energy waste is more, and in addition, the melting speed of the metal bar stock is too high, the prepared powder becomes coarse, and when the energy density is too low, the bar stock cannot be melted. Since the energy density is related to the main arc current of the plasma power supply, when the adjustable value of the flame diameter of the plasma arc and the number of sections into which the adjustable value of the flame diameter of the plasma arc can be split are determined, the number of sections into which the main arc current of the plasma power supply is correspondingly divided is also determined.
Here, the number of stages into which the plasma flame diameter adjustable value is divided is equal to the number of stages into which the main arc current of the plasma power supply is divided. For example, if the main arc current of the plasma power supply is I, if I is divided into N, the main arc current of the plasma power supply sequentially is:
correspondingly, if the length value of the minimum flame diameter of the plasma arc is 1mm and the length value of the maximum flame diameter of the plasma arc is 5mm, the minimum length for dividing 4mm is determined, namely the numerical value of the minimum flame diameter of the plasma arc which is increased each time is determined, if the minimum length for dividing 4mm is 1mm, the numerical value of the maximum flame diameter of the plasma arc which is increased each time is 1mm, and the minimum flame diameters of the plasma arcs are sequentially as follows: 1mm, (1+1) mm, (1+2) mm, and (1+3) mm.
Based on this, it can be determined that the plasma arc flame diameter can be determined according to the following equation (1) in the embodiments of the present invention:
in the formula (1), DmaxThe maximum flame diameter of the plasma arc; dminThe plasma arc minimum flame diameter; delta D is a set distance which is maximally equal to the difference between the maximum flame diameter of the plasma arc and the minimum flame diameter of the plasma arc, namely delta D is not more than Dmax-Dmin；DxIs the diameter of the plasma arc flame and has a length of DmaxAnd DminTo (c) to (d); x is a natural number, when x is 0, then DxEqual to the plasma arc minimum flame diameter.
In step 102, after determining each plasma power main arc current value, each plasma arc flame diameter corresponding to each plasma arc power main arc current may be photographed, that is, each plasma arc flame diameter is photographed by using an image acquisition system, for example, if a plurality of determined each plasma power main arc current values are:
the flame diameter of each corresponding plasma arc is D in turnmin、Dmin+Δd、Dmin+2Δd、DminD.. Dmax, and accordingly, a plurality of photographs may be taken in sequence.
In the embodiment of the invention, the picture taken at the moment is determined as an original image, and the original image is matched and stored with each plasma arc flame diameter. For example, the original image 1 and the plasma power source have a main arc current value of 1 and a plasma arc flame diameter of DminThe original image 2 and the plasma power supply have the main arc current value of 2 and the plasma arc flame diameter of Dmin+ delta D is matched, the original image 3 and the plasma power supply main arc current value are 3, the plasma arc flame diameter is Dmin+2 delta D, original image 4 and plasma power main arc current value 4 plasma arc flame diameter Dmin+3 Δ d, and so on, all the original images taken can be matched to each plasma arc flame diameter.
It should be noted that, in the embodiment of the present invention, after all the original images are matched with the flame diameter of each plasma arc and the main arc current value of the plasma power supply, the matching result may be stored in a set area.
In step 103, when the plasma milling device starts milling, the diameter of the plasma arc flame can be photographed, and further, the photograph photographed when the plasma milling device starts milling is determined as the detection image.
In the embodiment of the invention, when the plasma powder-making equipment starts to make powder, the molten end surface of the metal bar stock approaches to the plasma gun according to the set feeding speed. Based on this, the shooting speed of the industrial camera for the flame diameter of the plasma arc needs to be determined to be at least 5 detection images per second.
Further, when the feeding speed of the melting end face of the metal bar is determined to be 1.0-2.0 mm/s generally, the requirement of the whole melting system on the feeding precision is not very high, and the number of pictures taken per second is 10, the shooting distance precision can reach 0.1-0.2 mm/s, and the precision can completely meet the use requirement, so that the shooting speed of the industrial camera on the flame diameter of the plasma arc can be determined to be less than 10 detection images per second.
In step 104, comparing and recognizing the plurality of shot detection images with the stored original image, in the embodiment of the present invention, the image is compared and recognized by using the existing image processing method, and the image processing is not described too much again.
When the flame form of at least one detection image is the same as that of one original image, determining a first detection image of the detection image.
In step 105, an original image matched with the first detection image is searched in the set area, the plasma arc flame diameter and the plasma power supply main arc current value matched with the original image during storage are determined, and then the determined plasma arc flame diameter and the plasma power supply main arc current value are determined as the plasma arc flame diameter corresponding to the first detection image.
In practical applications, the captured detection images may be identified and matched according to the methods provided in the above steps 104 and 105, and then the plasma arc flame diameter corresponding to each detection image is sequentially confirmed.
It should be noted that, in the embodiment of the present invention, the accuracy of the image acquired by the image acquisition system depends on Δ D and the number of pictures taken by the industrial camera per second in the pulverizing process, and theoretically, when Δ D is sufficiently small, D is calculatedmaxAnd DminThe distance between them is equally divided by ad and a continuous distance length can be formed. Then, in actual use, the flame diameter of each plasma arc is as follows in sequence: dmin、Dmin+Δd、Dmin+2Δd、Dmin+3Δd...DmaxI.e., a plurality of plasma arc flame diameters all at discrete distance points. Therefore, in the same time, when the metal bar stock is fed at the speed v (generally 1.0-2.0 mm/s), the more the shooting number of the industrial cameras is, the finer the feeding speed v is, and therefore, the more accurately the shot detection image is matched with the stored original image.
In summary, embodiments of the present invention provide a method for determining a flame diameter of a plasma arc, comprising: determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value; when the main arc current of the plasma power supply is increased progressively according to the numerical value corresponding to each equal part, an image acquisition system is adopted to shoot a plasma arc flame diameter image, the shot image is determined to be an original image, and each original image corresponds to the diameter of each plasma arc flame; when the plasma powder making equipment starts to make powder, shooting the flame diameter of the plasma arc, and determining the shot image as a detection image; comparing and identifying the plurality of detection images with the plurality of original images respectively, and if the flame forms of at least one detection image and at least one original image are the same, determining the determined detection image as a first detection image; and determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image. The method combines an intelligent industrial camera, a high-power light source and plasma powder making equipment, and combines the detection of the length of the flame of the plasma arc and an automatic control system, so that the diameter of the plasma arc can be accurately displayed in real time. By accurately detecting the diameter of the plasma arc, the method can accurately detect the power density of the plasma arc, thereby controlling the influence of the plasma arc on the quality of the metal powder and greatly improving the powder making process; furthermore, the method can enable the automation degree of the plasma powder making equipment to enter a full-automatic era from semi-automation, and solves the problem that the plasma rotating electrode powder making process in the prior art can not control the power density of a plasma arc, so that the quality of powder is influenced.
Based on the same inventive concept, the embodiment of the invention provides a device for determining the flame diameter of a plasma arc, and as the principle of solving the technical problem of the device is similar to the method for determining the flame diameter of the plasma arc, the implementation of the device can refer to the implementation of the method, and repeated parts are not repeated.
Fig. 4 is a schematic structural diagram of an apparatus for determining a flame diameter of a plasma arc according to an embodiment of the present invention, and as shown in fig. 4, the apparatus mainly includes a first determining unit 401, a second determining unit 402, a third determining unit 403, a fourth determining unit 404 and a fifth determining unit 405.
The plasma arc power supply comprises a first determining unit 401, a second determining unit and a control unit, wherein the first determining unit is used for determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value;
a second determining unit 402, configured to shoot a plasma arc flame diameter image by using an image acquisition system when the main arc current of the plasma power supply increases progressively according to the corresponding numerical value of each equal portion, determine an original image from the shot image, where each original image corresponds to each plasma arc flame diameter;
a third determining unit 403, configured to shoot the plasma arc flame diameter when the plasma powder making device starts to make powder, and determine a shot image as a detection image;
a fourth determining unit 404, configured to compare and identify the multiple detection images with the multiple original images, respectively, and determine the determined detection image as a first detection image if it is determined that the flame shape of at least one of the detection images is the same as that of at least one of the original images;
a fifth determining unit 405, configured to determine the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image.
Preferably, the plasma arc flame diameter is determined by the following equation:
wherein D ismaxThe maximum flame diameter of the plasma arc; dminThe plasma arc minimum flame diameter; delta d is a set distance which is maximally equal to the difference between the maximum flame diameter of the plasma arc and the minimum flame diameter of the plasma arc; dxIs the diameter of the plasma arc flame and has a length of DmaxAnd DminTo (c) to (d); x is a natural number.
Preferably, each original image also corresponds to each plasma power supply main arc current;
the fifth determining unit 405 is further configured to:
and determining the plasma power supply main arc current corresponding to the original image matched with the first detection image as the plasma power supply main arc current of the first detection image.
Preferably, the third determining unit 403 is specifically configured to:
and according to the feeding speed of the metal bar stock, determining the shooting speed of the flame diameter of the plasma arc to be at least 5 detection images per second.
It should be understood that the above apparatus for determining the flame diameter of a plasma arc includes only logical divisions according to the functions of the apparatus, and in practice, the above units may be stacked or separated. The function of the device for determining the diameter of the plasma arc flame provided by the embodiment corresponds to that of the method for determining the diameter of the plasma arc flame provided by the embodiment, and the more detailed processing flow realized by the device is described in the first method embodiment and is not described in detail herein.
As will be appreciated by one skilled in the art, embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (10)
1. A method of determining a plasma arc flame diameter, comprising:
determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value;
when the main arc current of the plasma power supply is increased progressively according to the numerical value corresponding to each equal part, an image acquisition system is adopted to shoot a plasma arc flame diameter image, the shot image is determined to be an original image, and each original image corresponds to the diameter of each plasma arc flame;
when the plasma powder making equipment starts to make powder, shooting the flame diameter of the plasma arc, and determining the shot image as a detection image;
respectively comparing and identifying the plurality of detection images with the plurality of original images, and if the flame forms of at least one detection image and at least one original image are the same, determining the determined detection image as a first detection image;
and determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image.
2. The method of claim 1 wherein the plasma arc flame diameter is determined by the formula:
wherein the content of the first and second substances,
the maximum flame diameter of the plasma arc;
the plasma arc minimum flame diameter;
the distance is a set distance and is maximally equal to the difference value between the maximum flame diameter of the plasma arc and the minimum flame diameter of the plasma arc;
is the diameter of the plasma arc flame and has a length between
And
to (c) to (d);
is a natural number.
3. The method of claim 1, wherein each of said raw images further corresponds to each of said plasma power main arc currents, respectively;
after determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image, the method further comprises:
and determining the plasma power supply main arc current corresponding to the original image matched with the first detection image as the plasma power supply main arc current of the first detection image.
4. The method of claim 1 wherein said plasma milling apparatus comprises an atomizing chamber having a cylindrical shape;
before the shooting is carried out on the flame diameter of each plasma arc by adopting an image acquisition system, the method further comprises the following steps:
installing a high-power light source on a central shaft of the atomizing chamber, wherein the high-power light source is positioned above the melting end face of the plasma gun and the metal bar;
the camera is arranged on the central shaft of the atomizing chamber and is positioned above the high-power light source.
5. The method of claim 1, wherein the capturing the plasma arc flame diameter comprises:
and determining the shooting speed of the flame diameter of the plasma arc to be at least 5 detection images per second according to the feeding speed of the metal bar stock.
6. The method of claim 5, wherein the metal bar is fed at a speed of 1.0 mm/s to 2.0mm/s and the plasma arc flame diameter is captured at a speed of up to 10 inspection images per second.
7. An apparatus for determining a flame diameter of a plasma arc, comprising:
the plasma arc power supply comprises a first determining unit, a second determining unit and a control unit, wherein the first determining unit is used for determining the maximum flame diameter and the minimum flame diameter of a plasma arc, segmenting the difference value between the maximum flame diameter and the minimum flame diameter of the plasma arc according to a set numerical value, and dividing the main arc current of a plasma power supply into a plurality of equal parts according to the set numerical value;
the second determining unit is used for shooting a plasma arc flame diameter image by using an image acquisition system when the main arc current of the plasma power supply increases progressively according to the numerical value corresponding to each equal part, and determining an original image from the shot image, wherein each original image corresponds to the flame diameter of each plasma arc;
the third determining unit is used for shooting the flame diameter of the plasma arc when the plasma powder making equipment starts to make powder, and determining the shot image as a detection image;
the fourth determining unit is used for comparing and identifying the plurality of detection images with the plurality of original images respectively, and if the flame forms of at least one detection image and at least one original image are the same, determining the determined detection image as a first detection image;
and the fifth determining unit is used for determining the plasma arc flame diameter corresponding to the original image matched with the first detection image as the plasma arc flame diameter of the first detection image.
8. The apparatus of claim 7 wherein the plasma arc flame diameter is determined by the formula:
wherein the content of the first and second substances,
the maximum flame diameter of the plasma arc;
minimum flame diameter for plasma arc;
the distance is a set distance and is maximally equal to the difference value between the maximum flame diameter of the plasma arc and the minimum flame diameter of the plasma arc;
is the diameter of the plasma arc flame and has a length between
And
to (c) to (d);
is a natural number.
9. The apparatus of claim 7, wherein each of said raw images further corresponds to each of said plasma power main arc currents, respectively;
the fifth determination unit is further configured to:
and determining the plasma power supply main arc current corresponding to the original image matched with the first detection image as the plasma power supply main arc current of the first detection image.
10. The apparatus of claim 7, wherein the third determining unit is specifically configured to:
and according to the feeding speed of the metal bar stock, determining the shooting speed of the flame diameter of the plasma arc to be at least 5 detection images per second.
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