台灣光子源鋁合金超高真空腔自動銲接系統之研究

Development of Automatic Welding System for Taiwan Photon Source Aluminium Bending Chambers

陳慶隆(Ching-Lung Chen) ； 許憲能(Shen-Nung Hsu) ； 張進春(Chin-Chun Chang) ； 陳彥斌(Yen-Bin Chen) ； 楊佳螢(Chia-Ying Yang) ； 熊高鈺(Gao-Yu Hsiung) ； 陳俊榮(June-Rong Chen)

《真空科技》 21卷3&4期 (2008/12) Pp. 27-33

https://doi.org/10.29808/JVSROC.200812.0004

摘要

針對台灣光子源(TPS)的鋁合金超高真空腔，國家同步輻射研究中心已發展兩套自動TIG銲接系統。其中一套系統設計為兩支銲槍可以同時銲接真空腔的兩側，另一套系統為利用工業等級之六軸機器手臂應用於銲接比較複雜的幾何構造，例如圓形的真空管件或是圓弧真空腔。此兩套自動銲接系統不但可應付大部分的鋁合金真空腔銲接需求和節省人力成本，並可以提供穩定且最佳的銲道品質。經過許多測試並確保此自動銲接系統可以提供無裂縫且無漏氣之真空腔。此篇將會介紹此兩套自動銲接系統並敘述即時監測實驗系統。針對溫度分布與熱變形在銲接前、銲接當下、和銲接之後皆有完整敘述。真空腔所受銲接熱量的影響，產生的溫度將會影響熱變形量。此次的實驗，真空腔銲接之後所測之漏率為＜1×10^(-9)mbar•1/s，而最大的變形量為300μm。另外，並將此數據與有限元素的電腦模擬(ANSYS)做比較。

並列摘要

Two novel automatic Gas Tungsten Arc Welding (GTAW) systems have been developed at National Synchrotron Radiation Research Center for welding Taiwan Photon Source (TPS) aluminium bending chambers. One automatic system is designed by using two welding torches to implement two parallel welds on each side of an aluminium chamber simultaneously. The other is to use an industrial 6-axis robot with a unique welding configuration. This robot can be used to weld some complicated geometries, such as circular weld of pumping ports or curvature weld near dipole magnet portion. These two automatic TIG welding systems are designed to use in a various range of welding geometries to save labour costs and to provide high quality welds. Several experiments have been conducted to obtain optimum welding parameters for leakage-free bending chambers. In this paper, a real-time thermal and deformation monitoring measurements will be introduced for analyzing the temperature distribution along the chamber surface and the thermal deformation during and after the welding processes. A maximum temperature on the chamber surface is controlled to minimize the thermal deflection due to the high energy heating loads. The welded chambers are checked with leakage-free (leakage rate ＜1×10^(-9) mbar•1/s) and the maximum deformation is controlled under 300μm. Moreover, these measurements are also used to validate computational simulation results, done by finite element analysis software (ANSYS).