Integrated online cleaning and repairing system and method

Abstract

The invention discloses an integrated online cleaning and repairing system and method, and belongs to the technical field of integrated repairing of large parts. Comprising a transportation module, a protective repair module and a control module, the protective repair module and the control module are installed on the transportation module, the protective repair module is installed on the transportation module through a posture adjustment module, position transfer of the protective repair module is completed through the transportation module, posture adjustment of the protective repair module is completed through the posture adjustment module, and the control module is connected with the control module. Aligning to a to-be-repaired part; the protective repair module can perform protective spraying repair on the to-be-repaired part, and a spraying material is particle reinforced powder so as to enhance the mechanical property of the repaired part; and the control module is used for controlling the parameters of the protective repair module and the motion trail of the posture adjustment module. The problem that large gear parts cannot be cleaned and repaired on line in the prior art is solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of integrated repair of large parts, and in particular relates to an integrated online cleaning and repair system and method. Background Art

[0002] In the industrial field, gears with parameters, sizes, and weights that exceed the normal conditions are generally called large gears. The application scenarios of large gears are mainly some key and critical fields and important industries that affect the overall situation, such as water conservancy development points, mining industry, large engineering machinery, large ships, and missile launches. Because of its key role in the national economy and national defense, the failure of large gears is an urgent problem that needs to be solved. Like common gear parts, the tooth part of large gears is also prone to corrosion, deformation, and even fracture. However, due to their large size, replacing large gears not only has high material costs, but also complicated procedures, which will seriously delay the progress of the project. To solve the above problems, the existing solution is to perform on-site repairs on failed large gear parts.

[0003] There are two main methods for repairing large gears at present. One is the tooth-inserting repair method: for gears with small loads and low speeds, during the repair process, a trapezoidal groove is planed out at the root of the damaged gear on a planer, a new tooth blank with the same groove shape is pressed in, and it is welded firmly or bolted for processing and shaping; the other is the surfacing repair method: when the wear of a single gear or the wear on both sides of the tooth end exceeds the limit, one or several layers of metal can be surfacing on the entire or partial surface of the gear according to the gear damage. Compared with the tooth-inserting repair method, the surfacing repair of gears is simple to operate, and the repair interface is a metallurgical bond, and the bonding strength is better than the mechanical bond, so it has more application prospects.

[0004] With the development of additive manufacturing technology, process personnel have proposed laser cladding repair technology. Based on the metallurgical combination of cladding repair, laser cladding technology can repair broken teeth to original materials or repair surface wear parts to particle-reinforced composite materials to achieve surface performance enhancement effects. Compared with traditional cladding repair methods, this technology has higher molding accuracy and better bonding strength. However, more equipment is used and there are requirements for the surface finish of the gear, which limits the application of laser cladding technology in on-site repair of large gears. Therefore, the present invention provides a method and system for integrated online cleaning and repair of large transmission gears. Summary of the invention

[0005] Technical issues to be solved:

[0006] In order to avoid the shortcomings of the prior art, the present invention provides an integrated online cleaning and repair system and method. The system adopts a modular design, integrating cleaning / repair, cooling, and protection into a protective repair module with an integrated structure, and uses a transportation module and a posture adjustment module to adjust the position and posture of the protective repair module, thereby solving the problem that the prior art cannot perform online cleaning and repair of large gear parts.

[0007] The technical solution of the present invention is: an integrated online cleaning and repair system, comprising a transport module, a protective repair module and a control module installed thereon, wherein the protective repair module is installed on the transport module through a posture adjustment module, the position transfer of the protective repair module is completed through the transport module, and the posture adjustment of the protective repair module is completed through the posture adjustment module to align with the part to be repaired;

[0008] The protective repair module can perform protective spray repair on the repaired part, and the spray material is a particle reinforced powder to enhance the mechanical properties of the repaired part;

[0009] The control module is used to control the parameters of the protective repair module and the motion trajectory of the posture adjustment module.

[0010] A further technical solution of the present invention is: the protective repair module includes a main frame and a laser optical path system, a powder beam nozzle, a protective gas channel, and a cooling channel integrated thereon. The laser spot is focused on the part to be repaired through the laser optical path system, the spray powder is sprayed coaxially with the laser spot through the powder beam nozzle, and inert gas is sprayed into the molten pool through the protective gas channel to provide an inert gas atmosphere; coolant is introduced through the cooling channel to regulate the working temperature of the protective repair module.

[0011] A further technical solution of the present invention is: the protective repair module is a laser cladding head.

[0012] A further technical solution of the present invention is: the posture adjustment module is a multi-degree-of-freedom motion mechanism, a fixed end of which is installed on the transport module, and a free end of which is clamped with a protective repair module through a clamp, and the motion trajectory and posture adjustment of the multi-degree-of-freedom motion mechanism are controlled by the control module, thereby completing the position and posture adjustment of the protective repair module.

[0013] A further technical solution of the present invention is: the multi-degree-of-freedom motion mechanism is a mechanical arm or an industrial robot.

[0014] A further technical solution of the present invention is: the transport module comprises a platform and wheels installed at the bottom thereof, and the wheels are provided with a self-locking mechanism, which can lock and position the platform.

[0015] A further technical solution of the present invention is: a gas storage tank, a cooling device, a powder feeder, and a laser generator are installed on the transport module; the gas storage tank contains protective gas and is connected to the protective repair module through an air supply pipe to deliver protective gas to the protective repair module; the cooling device is connected to the protective repair module through a condenser, and the coolant is passed into the cooling channel of the protective repair module through the input condenser, and the heated coolant is returned to the cooling device through the output condenser; the powder feeder is connected to the protective repair module through a powder supply pipe, and a powder storage tank is detachably connected thereto, so that the powder storage tank of different powders can be replaced; the laser generator is connected to the protective repair module through an optical fiber, and the power of the laser is adjusted by the laser generator to complete the cleaning of the contaminated or clad powder on the part to be repaired.

[0016] A further technical solution of the present invention is: a power supply is installed on the transport module to supply power to the control module, the posture adjustment module, the cooling device, the powder feeder, the laser generator, and the protective repair module.

[0017] A further technical solution of the present invention is: it also includes a control panel, which is connected to the posture adjustment module and the control module through a data line to achieve human-computer interaction when the posture adjustment module is operated.

[0018] The integrated online cleaning and repair method, the specific steps are as follows:

[0019] Transferring the integrated online cleaning and repair system to a work site via a transport module;

[0020] Start the system power supply and adjust the working parameters of the cooling device, powder feeder and laser generator through the control module;

[0021] The laser outlet of the protective repair module is focused on the part to be repaired through the posture adjustment module;

[0022] Output work instructions to the protective repair module through the control panel to clean the contamination of the part to be repaired;

[0023] At the same time, the cooling device sends the coolant into the protective repair module through the condenser pipe, and then circulates back to the cooling device through the condenser pipe to ensure that the protective repair module will not be damaged due to excessive temperature during operation;

[0024] After cleaning, open the gas tank and powder feeder, and pass the protective gas and powder into the protective repair module. The powder is melted by the high-power laser and clad on the part to be repaired. The protective gas ensures that the molten powder will not splash and prevents oxidation of the repair area.

[0025] After the repair is complete, shut down each device and disconnect the power.

[0026] Beneficial Effects

[0027] The beneficial effects of the present invention are: the working parameters of the present invention can be adjusted through the control module, the nozzle position and angle can be adjusted through the posture adjustment module and the transportation module, and the online cleaning and repair of large gear parts are realized, the working efficiency is high, the repair effect is high, and the process flow is simple and easy to operate. The specific advantages are as follows:

[0028] 1. Large-size gears can be repaired in situ without transfer, saving time and cost.

[0029] 2. Laser cleaning is highly efficient and can remove oil stains from the fracture surface, as well as oxides produced by wear during operation, and produce a clean interface that is beneficial to additive manufacturing.

[0030] 3. Repair and strengthen the tooth surface. The wear resistance of the repaired tooth surface is improved compared to the original tooth surface, and the toughness of the core shaft position is not damaged.

[0031] 4. The integrated system can simultaneously remove surface contamination and repair defects to restore part size.

[0032] 5. Metallurgical bonding The repaired position is metallurgically bonded to the original mandrel, and the bonding strength is high. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic diagram of gear failure;

[0034] Figure 2 Microscopic diagram of the powder used for restoration;

[0035] Figure 3 The invention discloses an integrated online cleaning and repairing system for large transmission gears.

[0036] Explanation of the accompanying reference numerals: 1. laser cladding head; 2. optical fiber; 3. robotic arm; 4. condenser; 5. gas storage tank; 6. condenser; 7. powder storage tank; 8. cooling device; 9. power supply; 10. platform; 11. wheel; 12. powder feeder; 13. powder feeding pipe; 14. laser generator; 15. gas supply pipe; 16. data cable; 17. control panel. DETAILED DESCRIPTION

[0037] The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, but should not be construed as limiting the present invention.

[0038] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0039] Based on the fact that traditional cladding repair devices use a large number of equipment and have requirements for the surface finish of gears, these limit the application of laser cladding technology in on-site repair of large gears. The present invention provides an integrated online cleaning and repair system, including a transportation module and a protective repair module and a control module installed thereon. The protective repair module is installed on the transportation module through a posture adjustment module, and the position transfer of the protective repair module is completed by the transportation module. The posture adjustment module is completed to align the protective repair module with the part to be repaired; the protective repair module can perform protective spray repair on the part to be repaired, and the spraying material is a particle reinforced powder to enhance the mechanical properties of the repaired part; the control module is used to control the parameters of the protective repair module and the motion trajectory of the posture adjustment module.

[0040] Specifically, the protective repair module is a main frame and a laser optical path system, a powder beam nozzle, a protective gas channel, and a cooling channel integrated thereon. The laser spot is focused on the part to be repaired through the laser optical path system, the spray powder is sprayed coaxially with the laser spot through the powder beam nozzle, and inert gas is sprayed into the molten pool through the protective gas channel to provide an inert gas atmosphere; coolant is introduced through the cooling channel to regulate the working temperature of the protective repair module.

[0041] Specifically, the protective repair module is a laser cladding head.

[0042] Specifically, the posture adjustment module is a multi-degree-of-freedom motion mechanism, a fixed end of which is installed on the transport module, and a free end of which is clamped with a protective repair module through a fixture. The motion trajectory and posture adjustment of the multi-degree-of-freedom motion mechanism are controlled by the control module, thereby completing the position and posture adjustment of the protective repair module.

[0043] Specifically, the multi-degree-of-freedom motion mechanism is a robotic arm or an industrial robot.

[0044] Specifically, the transport module includes a platform and wheels installed at the bottom thereof, and the wheels are provided with a self-locking mechanism that can lock and position the platform.

[0045] Specifically, the transport module is equipped with a gas tank, a cooling device, a powder feeder, and a laser generator. The gas tank contains protective gas and is connected to the protective repair module through an air supply pipe to deliver protective gas to the protective repair module. The cooling device is connected to the protective repair module through a condenser, and the coolant is introduced into the cooling channel of the protective repair module through the input condenser, and the heated coolant is returned to the cooling device through the output condenser. The powder feeder is connected to the protective repair module through a powder supply pipe, and a powder tank is detachably connected to it, so that the powder tank of different powders can be replaced. The laser generator is connected to the protective repair module through an optical fiber, and the power of the laser is adjusted by the laser generator to complete the cleaning of the contaminated or melted powder on the part to be repaired.

[0046] Specifically, the transport module is equipped with a power supply for supplying power to the control module, the posture adjustment module, the cooling device, the powder feeder, the laser generator, and the protective repair module.

[0047] Specifically, it also includes a control panel, which is connected to the posture adjustment module and the control module through a data line to achieve human-computer interaction when the posture adjustment module is operated.

[0048] The above technical solution is further described below in conjunction with the accompanying drawings:

[0049] Reference Figure 3 As shown, this embodiment is an integrated online cleaning and repair system for large transmission gears, including a laser cleaning component and a laser repair component.

[0050] The laser cleaning assembly includes a laser cladding head 1, an optical fiber 2, a laser generator 14, a robotic arm 3, a condenser 4, a cooling device 8, a power supply 9, a data cable 16, a control panel 17, a platform 10, and wheels 11. A wheel 11 with a block is installed under the platform 10, which can flexibly transport the equipment to the site and ensure that the platform 10 will not move at will during the repair process; the power supply 9, the laser generator 14, the mechanical arm 3, and the cooling device 8 are all installed and fixed on the platform to ensure the stability of the equipment; the power supply 9 is connected to the laser generator 14, the mechanical arm 6, and the cooling device 8 to provide energy when the equipment is running; the laser cladding head 1 is installed on the top of the mechanical arm 3, and can move with the mechanical arm 3 to achieve cleaning and repair of parts at different positions and angles; the laser cladding head 1 is connected to the laser generator 14 through an optical fiber 2, and the laser generator 14 can adjust the power of the laser to clean the surface of the gear or clad powder; the condenser 4 and the condenser 6 are connected to the laser cladding head 1 from the cooling device 8 to ensure that the laser cladding head 1 will not overheat during operation; the control panel 17 is connected to the mechanical arm 3 through a data cable 16, and the mechanical arm 3 and the laser cladding head 1 can be manipulated to move according to the needs of the user, thereby achieving cleaning and repair of various parts.

[0051] The laser repair component additionally introduces a gas tank 5, an air delivery pipe 15, a powder tank 7, a powder feeder 12, and a powder delivery pipe 13 on the basis of the laser cleaning component. The powder tank 7 is installed on the powder feeder 12, and different powder tanks 7 can be replaced as needed to meet the needs of repairing gears of different materials; the powder feeder 12 is installed on the platform 10 and connected to the power supply 9; the powder delivery pipe 13 connects the powder feeder 12 and the laser cladding head 1. During repair, the powder material enters the powder feeder 12 from the powder tank 7, enters the laser cladding head 1 through the powder delivery pipe 13, and then is clad on the parts; the gas tank 5 is installed on the platform, and protective gas is stored inside; the gas tank 5 is connected to the laser cladding head 1 through the gas delivery pipe 15. During repair, the protective gas enters the laser cladding head 1 from the gas tank 5 through the gas delivery pipe 15, so as to reduce splashing and oxidation during the cladding process.

[0052] Reference Figure 2 As shown in the figure, the powder used for repair is particle-reinforced powder. Based on the material powder of the gear to be repaired, the powder metallurgy process is used to combine the reinforced particles with the matrix powder. Laser cladding of particle-reinforced materials on the part to be repaired can not only repair the original defects, but also enhance the mechanical properties of the repaired part, extend its service life, and ultimately achieve a composite effect of repair and reinforcement.

[0053] The following uses the cleaning and repair of large gear parts as an example to illustrate how to use the equipment. The specific usage process is as follows:

[0054] (1) Use a platform 10 equipped with wheels 11 with blocks to transport the entire device to the part that needs to be repaired on site (such as Figure 1 As shown), the wheels 11 are locked to ensure that the platform 10 is fixed to ensure the stability of the equipment during the cleaning and repair process.

[0055] (2) Turn on the power supply 9 to power the entire system, turn on the cooling device 8 and the laser generator 14, and adjust the power of the laser generator 14 so that it is within the required range for cleaning the surface of the part. After the above preparations are completed, use the control panel 17 to adjust the posture of the robot arm 3 so that the laser cladding head 1 installed on it reaches the position of the part to be cleaned. When the laser cladding head 1 reaches the specified position, use the control panel 17 to control it to start and clean the contamination of the part to be repaired. At the same time, the cooling device 8 sends the coolant into the laser cladding head 1 through the condenser 4, and then circulates back to the cooling device through the condenser 6 to ensure that the laser cladding head 1 will not be damaged due to excessive temperature during operation.

[0056] (3) After the cleaning is completed, the control panel 17 is used to control the laser cladding head 1 to temporarily stop working. The valve of the gas storage tank 5 is opened so that the protective gas therein can enter the laser cladding head 1 through the air supply pipe 15. A suitable powder storage tank 7 is selected and installed on the powder feeder 12, and the powder feeder 12 is turned on so that the powder can enter the laser cladding head 1 through the powder supply pipe 13. The power of the laser generator 14 is adjusted so that the laser power is within the required range for laser cladding, and the laser cladding head is turned on and put into working state using the control panel 17. At this time, the powder and the protective gas enter the laser cladding head 1 through the powder supply pipe 13 and the air supply pipe 15 respectively. The powder is melted by the high-power laser and clad on the part to be repaired. The protective gas ensures that the molten powder will not splash and prevents oxidation of the repair area. The cooling device 8 feeds the coolant into the laser cladding head 1 through the condenser 4, and then circulates back to the cooling device through the condenser 6 to ensure that the laser cladding head 1 will not be damaged due to excessive temperature during operation. At this time, the control panel 17 can be used to control the robot arm 3 to move relative to the part to be repaired to meet the repair requirements.

[0057] (4) After the repair is completed, shut down all equipment and cut off the power supply 9, unlock the wheels 11, and evacuate the equipment from the site.

[0058] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and intent of the present invention.

Claims

1. Integrated online cleaning and repair system, characterized by: It includes a transport module, a protective repair module and a control module installed thereon, wherein the protective repair module is installed on the transport module through a posture adjustment module, the position transfer of the protective repair module is completed through the transport module, and the posture adjustment of the protective repair module is completed through the posture adjustment module to align with the part to be repaired; The protective repair module can perform protective spray repair on the repaired part, and the spray material is a particle reinforced powder to enhance the mechanical properties of the repaired part; The control module is used to control the parameters of the protective repair module and the motion trajectory of the posture adjustment module.

2. The integrated online cleaning and repair system according to claim 1, characterized in that: The protective repair module includes a main frame and a laser optical path system, a powder beam nozzle, a protective gas channel, and a cooling channel integrated thereon. The laser spot is focused on the part to be repaired through the laser optical path system, the spray powder is sprayed coaxially with the laser spot through the powder beam nozzle, and inert gas is sprayed into the molten pool through the protective gas channel to provide an inert gas atmosphere; coolant is introduced through the cooling channel to regulate the working temperature of the protective repair module.

3. The integrated online cleaning and repair system according to claim 2, characterized in that: The protective repair module is a laser cladding head.

4. The integrated online cleaning and repair system according to claim 1, characterized in that: The posture adjustment module is a multi-degree-of-freedom motion mechanism, whose fixed end is installed on the transport module, and whose free end is clamped with a protective repair module through a fixture. The motion trajectory and posture adjustment of the multi-degree-of-freedom motion mechanism are controlled by the control module, thereby completing the position and posture adjustment of the protective repair module.

5. The integrated online cleaning and repair system according to claim 4, characterized in that: The multi-degree-of-freedom motion mechanism is a robotic arm or an industrial robot.

6. The integrated online cleaning and repair system according to claim 1, characterized in that: The transport module comprises a platform and wheels installed at the bottom thereof, wherein the wheels are provided with a self-locking mechanism, which can lock and position the platform.

7. The integrated online cleaning and repair system according to claim 6, characterized in that: The transport module is equipped with a gas tank, a cooling device, a powder feeder, and a laser generator. The gas tank contains protective gas and is connected to the protective repair module through an air supply pipe to deliver protective gas to the protective repair module. The cooling device is connected to the protective repair module through a condenser, and the coolant is introduced into the cooling channel of the protective repair module through the input condenser, and the heated coolant is returned to the cooling device through the output condenser. The powder feeder is connected to the protective repair module through a powder supply pipe, and a powder tank is detachably connected to it, so that the powder tank of different powders can be replaced. The laser generator is connected to the protective repair module through an optical fiber, and the power of the laser is adjusted by the laser generator to complete the cleaning of the contaminated or clad powder on the part to be repaired.

8. The integrated online cleaning and repair system according to claim 7, characterized in that: The transport module is equipped with a power supply for supplying power to the control module, the posture adjustment module, the cooling device, the powder feeder, the laser generator, and the protective repair module.

9. The integrated online cleaning and repair system according to claim 8, characterized in that: It also includes a control panel, which is connected to the posture adjustment module and the control module through a data line to achieve human-computer interaction when the posture adjustment module is operated.

10. An integrated online cleaning and repair method, characterized in that The specific steps are as follows: Transferring the integrated online cleaning and repair system according to any one of claims 1 to 9 to a work site by means of a transport module; Start the system power supply and adjust the working parameters of the cooling device, powder feeder and laser generator through the control module; The laser outlet of the protective repair module is focused on the part to be repaired through the posture adjustment module; Output work instructions to the protective repair module through the control panel to clean the contamination of the part to be repaired; At the same time, the cooling device sends the coolant into the protective repair module through the condenser pipe, and then circulates back to the cooling device through the condenser pipe to ensure that the protective repair module will not be damaged due to excessive temperature during operation; After cleaning, open the gas tank and powder feeder, and pass the protective gas and powder into the protective repair module. The powder is melted by the high-power laser and clad on the part to be repaired. The protective gas ensures that the molten powder will not splash and prevents oxidation of the repair area. After the repair is complete, shut down each device and disconnect the power.

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