The present invention relates to a
system and method for automated or “robotic” application of
hardfacing to the surface of a steel-toothed cutter of a standard earth-boring rock bit or a
hybrid-type rock bit. In particular, the
system incorporates a grounded adapter plate and chuck mounted to a
robotic arm for grasping and manipulating a rock bit cutter, particularly a
hybrid rock bit cutter, beneath an electrical or photonic energy
welding source, such as a
plasma arc welding torch manipulated by a positioner. In this configuration, the
torch is positioned substantially vertically and oscillated along a
horizontal axis as the cutter is manipulated relative along a target path for the distribution of
hardfacing. Moving the cutter beneath the
torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the
control system for identification, positioning,
welding program selection, and
welding program correction. The
control system, aided by data from the sensors, manipulates the robotically held cutter while controlling the operation and oscillation of the torch. These systems and methods can be applied to
hardfacing steel teeth of the rolling cutters of both standard tri-cone or di-cone type rolling cone bits, as well as to
hybrid-type earth boring
drill bits.