A device and method for detecting radial full runout of a laser cladding round rod

Abstract

The present invention relates to a device for detecting the radial runout of a laser-clad round rod. The base of a positioner is provided with at least one laser range-finding sensor along its rotational axis, one at each end and one in the middle of the rod being clamped. Furthermore, at least one laser range-finding sensor is located at each end and one in the middle of the rod being clamped by the positioner. A robot is positioned on one side of the positioner, and a laser cladding head is mounted on the robot. The laser cladding head is connected to the laser cladding equipment. The laser range-finding sensor, the positioner, the robot, and the laser cladding equipment are each electrically connected to a controller. The present invention has the beneficial effects of replacing manual full runout measurement with automatic detection using a laser range-finding sensor and determination by a controller, thereby reducing manual labor, improving detection efficiency, and enhancing detection accuracy and stability.

Description

Technical Field

[0001] The present invention relates to the field of laser processing / additive manufacturing, and in particular to a device and method for detecting radial full runout of a laser-clad round rod. Background Art

[0002] Laser cladding technology involves placing a specialized material (such as various metal powders) as a filler on the surface of a substrate. High-power laser irradiation causes it to melt simultaneously with the substrate surface and rapidly solidify to form a coating with minimal dilution that forms a metallurgical bond with the substrate material, significantly improving the substrate's surface resistance to wear, corrosion, heat, and oxidation. Laser cladding, also known as laser additive manufacturing, has gained widespread application in recent years with the widespread use and price reduction of lasers.

[0003] The laser cladding process requires the laser head to maintain a stable distance from the workpiece surface to ensure the uniformity of the cladding material. In the cladding production of large quantities of round rods, the round rod is generally rotated, and the cladding head and the rod surface maintain a certain "distance" and uniform axial movement. Therefore, it is necessary to measure the full runout of the incoming rod to ensure the stability of the "distance" during this process. Otherwise, the cladding quality will not meet the requirements, affecting subsequent process production. Round rods that do not meet the surface requirements need to be removed and straightened in time.

[0004] The existing method for measuring the full runout of a rod is to manually punch a dial indicator (using a dial indicator to press against the surface of the rod). Three points are manually selected at both ends and the middle of the rod shaft as single-section roundness sampling points. The dial indicator, dial base, and dial stand are installed, and the dial indicator is adjusted so that the probe contacts the measured outer surface of the workpiece and there is a compression of 1 to 2 turns. The positioner drives the rod to rotate, and the fluctuation of the dial indicator pointer is observed. When the runout of any of the three sampling sections exceeds 0.2 mm, it can be determined that the rod does not meet the requirements of the cladding processing. This method is cumbersome, time-consuming, and has certain risks. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a device and method for detecting the radial full runout of a laser cladding round rod, so as to overcome the deficiencies in the above-mentioned prior art.

[0006] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A radial full runout detection device for laser cladding round rods comprises: a laser ranging sensor, a positioner, a laser cladding head, a robot and a controller, wherein at least one laser ranging sensor is arranged on the base of the positioner along the direction of its rotation center axis at both ends and the middle of the clamped round rod; the robot is arranged on one side of the positioner, the laser cladding head is set on the robot, the laser cladding head is connected to the laser cladding equipment, and the laser ranging sensor, the positioner, the robot and the laser cladding equipment are electrically connected to the controller respectively.

[0007] The beneficial effects of the present invention are:

[0008] The laser distance sensor is used to measure the distance value from the surface of the round rod, wherein the distance value includes: static distance value and dynamic distance value. The radius r of the round rod is determined based on the static distance value and the distance between the installation position of each laser distance sensor and the rotation center axis of the positioner;

[0009] Then, the runout value is determined based on the dynamic distance value, the distance between the installation position of each laser distance sensor and the rotation center axis of the positioner, and the radius r of the round rod;

[0010] Realize the full radial runout detection of round rods and judge whether the round rods meet the requirements of laser cladding based on the runout value;

[0011] Instead of manually measuring full runout, a laser rangefinder is used for automatic detection, and the controller makes the judgment. This reduces labor, improves detection efficiency, and enhances detection accuracy and stability. Automated detection can basically be completed within 1 second, significantly shortening the time compared to manual detection, which takes about 2 minutes.

[0012] It can automatically identify the radius of the round rod being loaded, determine the type of round rod based on the radius, and then automatically call the process program for laser cladding of the corresponding round rod, eliminating the need for manual parameter setting and improving production line stability.

[0013] The inspection data of each round rod can be automatically saved to make the processing quality traceable.

[0014] On the basis of the above technical solution, the present invention can also be improved as follows.

[0015] Furthermore, it also includes: multiple sensor mounting seats, the multiple sensor mounting seats are respectively installed on the base of the positioner, and the multiple laser ranging sensors are respectively installed on the multiple sensor mounting seats in a one-to-one correspondence.

[0016] A further beneficial effect of the above method is that the height position of the distance measuring point of the laser distance measuring sensor can be made flush with the rotation center axis of the positioner.

[0017] Furthermore, the sensor mounting seat can be moved on the base of the positioner along the direction of the rotation center axis of the positioner.

[0018] A further beneficial effect of the above is that the position of the laser ranging sensor in the direction of the rotation center axis of the positioner can be adjusted accordingly according to the length of the round rod to meet the detection requirements of round rods of different lengths.

[0019] Furthermore, the measurement accuracy of the laser ranging sensor is 30um.

[0020] A further beneficial effect of adopting the above method is that sufficient detection accuracy can be ensured.

[0021] Based on the above technical solution, the present invention also provides a method for detecting the radial full runout of a laser clad round rod, including a device for detecting the radial full runout of a laser clad round rod, and the specific steps are as follows:

[0022] S01, installation of round rod on positioner;

[0023] S02. Ensure that the installation position of each laser distance measuring sensor is at the same distance from the rotation center axis of the positioner;

[0024] S03, the static distance value S from the round rod surface is measured by each laser ranging sensor i0 ;

[0025] S04, according to all static distance values ​​S i0 And the distance between the installation position of each laser distance sensor and the rotation center axis of the positioner is used to calculate the radius r of the round rod;

[0026] S05, determining the round rod model according to the round rod radius r, executing the round rod full runout detection program corresponding to the model, and starting the positioner;

[0027] S06, each laser ranging sensor measures the dynamic distance value S from the round rod surface at a preset frequency ij ;

[0028] S07, combined with the distance between the installation position of each laser distance sensor and the rotation center axis of the positioner, the radius r of the round rod, and the measured dynamic distance value S ij Calculate the runout value K ij ;

[0029] S08, determine each jump value K ij Is it greater than the preset value? If any of the jump values ​​K ij If the judgment is yes, the round rod is judged to not meet the cladding requirements. If all the judgments are no, the laser cladding process program corresponding to the round rod model is executed.

[0030] The above method has the following further beneficial effects: replacing the manual measurement of full runout with a laser ranging sensor for automatic detection and determination by the controller reduces labor, improves detection efficiency, and enhances detection accuracy and stability. Automated detection can be completed in approximately 1 second, significantly shortening the time compared to manual detection, which takes approximately 2 minutes.

[0031] It can automatically identify the radius of the round rod being loaded, determine the type of round rod based on the radius, and then automatically call the process program for laser cladding of the corresponding round rod, eliminating the need for manual parameter setting and improving production line stability.

[0032] The inspection data of each round rod can be automatically saved to make the processing quality traceable.

[0033] Further, in S03, the static distance value S is measured. i0 Then, first according to the static distance value S i0 Determine whether the round rod is installed in place. If yes, enter S04. If not, re-clamp the round rod and measure the static distance value S from the round rod surface again by each laser ranging sensor. i0 .

[0034] A further beneficial effect of the above method is that by first determining whether the round rod is installed in place, subsequent detection can be avoided from being invalid.

[0035] Furthermore, in S06, the measurement frequency of the laser ranging sensor is 1000 Hz.

[0036] Furthermore, the preset value is 0.2 mm.

[0037] Furthermore, the laser cladding process in S08 includes: the motion trajectory and motion speed of the robot, and the powder feeding speed and laser power of the laser cladding head. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 This is a structural diagram of the radial full runout detection device for laser cladding round rods according to the present invention;

[0039] Figure 2 A top view of the radial full runout detection device for laser cladding round rods according to the present invention;

[0040] Figure 3 This is a first flow chart of the method for detecting radial full runout of a laser-clad round rod according to the present invention;

[0041] Figure 4 This is the second flow chart of the radial full runout detection method of the laser cladding round rod described in the present invention.

[0042] In the accompanying drawings, the components represented by the reference numerals are as follows:

[0043] 1. Laser ranging sensor, 2. Positioner, 3. Laser cladding head, 4. Robot, 5. Sensor mounting base. DETAILED DESCRIPTION

[0044] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only used to explain the present invention and are not used to limit the scope of the present invention.

[0045] Example 1

[0046] like Figure 1 、 Figure 2As shown, a radial full runout detection device for laser cladding round rods includes: a laser ranging sensor 1, a positioner 2, a laser cladding head 3, a robot 4 and a controller;

[0047] On the base of the positioner 2, at least one laser distance measuring sensor 1 is arranged at each end and the middle of the corresponding clamped round rod along the direction of its rotation center axis. Under normal circumstances, after the laser distance measuring sensors 1 are installed, the installation positions of all laser distance measuring sensors 1 are at the same distance from the rotation center axis of the positioner 2;

[0048] The robot 4 is arranged on one side of the positioner 2, the laser cladding head 3 is set on the robot 4, the laser cladding head 3 is connected to the laser cladding equipment, the signal output of the laser ranging sensor 1 is electrically connected to the signal input of the controller, the signal input of the positioner 2 is electrically connected to the signal output of the controller, the signal input of the robot 4 is electrically connected to the signal output of the controller, and the signal input of the laser cladding equipment is electrically connected to the signal output of the controller.

[0049] Example 2

[0050] like Figure 1 As shown, this embodiment is a further improvement based on Example 1, and its details are as follows:

[0051] The radial full runout detection device for laser cladding round rods also includes: multiple sensor mounting seats 5, which are respectively installed on the base of the positioner 2, and multiple laser ranging sensors 1 are respectively installed on the multiple sensor mounting seats 5 in a one-to-one correspondence, so that the height position of the ranging point of the laser ranging sensor 1 can be flush with the rotation center axis of the positioner 2.

[0052] Example 3

[0053] like Figure 1 As shown, this embodiment is a further improvement based on Example 2, and its details are as follows:

[0054] The sensor mounting seat 5 can be moved along the rotation center axis direction of the positioner 2 on the base of the positioner 2. The position of the laser ranging sensor 1 in the rotation center axis direction of the positioner 2 can be adjusted accordingly according to the length of the round rod to meet the detection requirements of round rods of different lengths.

[0055] Example 4

[0056] like Figure 1 、 Figure 2 As shown, this embodiment is a further improvement based on any one of Embodiments 1 to 3, and its details are as follows:

[0057] The measurement accuracy of the laser ranging sensor 1 is 30 μm, which can ensure sufficient detection accuracy.

[0058] Example 5

[0059] like Figure 3 As shown, a method for detecting the radial full runout of a laser clad round rod includes a device for detecting the radial full runout of a laser clad round rod, and the specific steps are as follows:

[0060] S01, round rod installation on positioner 2;

[0061] S02, ensuring that the installation position of each laser ranging sensor 1 is at the same distance from the rotation center axis of the positioner 2;

[0062] S03, the static distance value S from the round rod surface is measured by each laser ranging sensor 1 i0 , where i represents the number of the laser ranging sensor 1, i = 1, 2, 3, 4...n, and n is an integer;

[0063] S04, according to all static distance values ​​S i0 The radius r of the round rod is calculated by the distance between the installation position of each laser ranging sensor 1 and the rotation center axis of the positioner 2;

[0064] S05. Determine the rod type according to the rod radius r, execute the rod full runout detection program corresponding to the rod type, and start the positioner 2. The rod full runout detection program corresponding to each rod type is set in advance in the controller.

[0065] S06, each laser ranging sensor 1 measures the dynamic distance value S from the round rod surface at a preset frequency ij , where i represents the number of the laser ranging sensor 1, i = 1, 2, 3, 4 ... n, n is an integer, and j represents the j-th data measured by the laser ranging sensor 1, j = 1, 2, 3, 4 ... m, m is an integer, and ij represents the j-th data measured by the laser ranging sensor 1 with the number i;

[0066] S07, combining the distance between the installation position of each laser distance sensor 1 and the rotation center axis of the positioner 2, the radius r of the round rod, and the dynamic distance value S measured by each laser distance sensor 1 ij Calculate the runout value K ij ;

[0067] S08, determine each jump value K ij Is it greater than the preset value? If any of the jump values ​​K ij If the judgment is yes, the round rod is judged to not meet the cladding requirements. If all judgments are no, the laser cladding process program corresponding to the round rod model is executed. The laser cladding process program corresponding to each type of round rod is set in advance in the controller.

[0068] The calculation method of the rod radius r is as follows:

[0069] Assuming that the distance between the installation position of the laser distance sensor 1 and the rotation center axis of the positioner 2 is L, and there are i laser distance sensors 1, then the radius r = avg (LS 10 +LS 20 +LS 30 +……+LS n0 ).

[0070] The jump value K ij The calculation method of K is as follows ij =max│S ij -(Lr)│.

[0071] Example 6

[0072] like Figure 4 As shown, this embodiment is a further improvement based on embodiment 5, and its details are as follows:

[0073] After measuring the static distance value Si0 in S03, first determine whether the round rod is installed in place according to each static distance value Si0. If yes, enter S04. If not, re-clamp the round rod and measure the static distance value S from the round rod surface again by each laser distance sensor 1. i0 ; Normally, judging whether the round rod is installed in place according to each static distance value Si0 is mainly to judge whether all static distance values ​​Si0 are the same, or to judge whether the deviation between all static distance values ​​Si0 is within a predetermined range.

[0074] Example 7

[0075] This embodiment is a further improvement based on embodiment 5 or 6, and its details are as follows:

[0076] In S06 , the measurement frequency of the laser ranging sensor 1 is 1000 Hz.

[0077] Example 8

[0078] This embodiment is a further improvement based on embodiment 5, 6 or 7, and its details are as follows:

[0079] The default value is 0.2mm, that is, S08 is: to judge each runout value K ij Is it greater than 0.2mm? If any of the runout values ​​K ij If the judgment is yes, the round rod is judged to not meet the cladding requirements. If all the judgments are no, the laser cladding process program corresponding to the round rod model is executed.

[0080] Example 9

[0081] This embodiment is a further improvement based on embodiment 5, 6, 7 or 8, and its details are as follows:

[0082] The laser cladding process in S08 includes: the motion trajectory and motion speed of the robot 4 , and the powder feeding speed and laser power of the laser cladding head 3 .

[0083] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative 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.

Claims

1. A method for detecting radial full runout of a laser clad round rod, characterized in that: The adopted radial full runout detection device for laser cladding round rods comprises: a laser distance sensor (1), a positioner (2), a laser cladding head (3), a robot (4) and a controller, wherein at least one laser distance sensor (1) is arranged on the base of the positioner (2) along the direction of its rotation center axis at both ends and the middle of the corresponding clamped round rod; the robot (4) is arranged on one side of the positioner (2), the laser cladding head (3) is arranged on the robot (4), the laser cladding head (3) is connected to the laser cladding equipment, and the laser distance sensor (1), the positioner (2), the robot (4) and the laser cladding equipment are electrically connected to the controller respectively; The specific steps are as follows: S01, the round rod is installed on the positioner (2); S02, determining that the installation position of each laser distance measuring sensor (1) is at the same distance from the rotation center axis of the positioner (2); S03, the static distance value S from the round rod surface is measured by each laser distance sensor (1) i0 ; S04, according to all static distance values ​​S i0 and the distance between the installation position of each laser distance sensor (1) and the rotation center axis of the positioner (2) to calculate the radius r of the round rod; S05, determining the rod model according to the rod radius r, executing the rod full runout detection program corresponding to the rod model, and starting the positioner (2); S06, each laser distance sensor (1) measures the dynamic distance value S from the round rod surface at a preset frequency ij ; S07, combining the distance between the installation position of each laser distance sensor (1) and the rotation center axis of the positioner (2), the radius r of the round rod, and the measured dynamic distance value S ij Calculate the runout value K ij ; S08, determine each jump value K ij Is it greater than the preset value? If any of the jump values ​​K ij If the judgment is yes, the round rod is judged to not meet the cladding requirements. If all the judgments are no, the laser cladding process program corresponding to the round rod model is executed.

2. The method for detecting radial full runout of a laser clad round rod according to claim 1, characterized in that: Also includes: A plurality of sensor mounting seats (5) are respectively mounted on the base of the positioner (2); and a plurality of laser distance measuring sensors (1) are respectively mounted on the plurality of sensor mounting seats (5) in a one-to-one correspondence.

3. The method for detecting radial total runout of a laser clad round rod according to claim 2, wherein: The sensor mounting seat (5) is movable on the base of the positioner (2) along the direction of the rotation center axis of the positioner (2).

4. According to the method for detecting the radial total runout of a laser clad round rod according to claim 2, the measurement accuracy of the laser ranging sensor (1) is 30 μm.

5. The method for detecting radial total runout of a laser clad round rod according to claim 1, wherein: In S03, the static distance value S is measured. i0 Then, first according to the static distance value S i0 Determine whether the round rod is installed in place. If yes, enter S04. If not, re-clamp the round rod and measure the static distance value S from the round rod surface again by each laser distance sensor (1). i0 .

6. The method for detecting radial total runout of a laser clad round rod according to claim 1, wherein: In S06, the laser distance sensor (1) measures at a frequency of 1000 Hz.

7. The method for detecting radial total runout of a laser clad round rod according to claim 1, wherein: The default value is 0.2mm.

8. The method for detecting radial total runout of a laser clad round rod according to claim 1, wherein: The laser cladding process in S08 includes: the motion trajectory and motion speed of the robot (4), and the powder feeding speed and laser power of the laser cladding head (3).

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