Abstract
With the rapid advancement of metal 3D printing technology, there is a growing demand for spherical metal powder as a primary material for 3D printing. The process technology that ensures the production of high-quality spherical metal powder has become a focal area of research for numerous enterprises and research institutions globally. In the conventional plasma rotating electrode method for powder production, the feed speed of the servo feeding mechanism is manually predetermined, leading to potential variations in the distance between the end face of the metal rod and the plasma gun that generates the plasma arc. Such inconsistency can compromise the quality of the metal powder produced and pose safety hazards if the gap between the metal rod and the plasma gun is too narrow. To address these issues, this study presents a novel plasma arc length detection system based on the concept of the region of interest. The proposed system leverages image processing technology for efficiently detecting the plasma arc length. By incorporating image detection within the region of interest alongside an arc length correction function, the system enhances real-time performance and detection precision. Additionally, real-time monitoring of the detection site is enabled through KingView. Experimental findings indicate that the image target area post plasma arc detection exhibits well-defined edges, clear brightness, and minimal noise, thereby meeting the prerequisites for subsequent image processing and monitoring tasks. The corrected plasma arc length averages around 40mm, with a detection error of less than 1mm when compared to the desired controlled plasma arc length. Moreover, the length variation remains relatively stable, thus fulfilling the measurement criteria. Over time, the detected plasma arc length exhibits negligible fluctuations, suggesting consistent proximity between the plasma gun and the end face of the metal rod during the melting process. The controller can dynamically control the feed speed of the servo feeding mechanism according to the detected plasma arc length, ensuring a constant distance between the plasma arc and the end face of the metal rod throughout the powder production process, thus aligning with practical industrial requirements.