An automated laser cladding process for tube screens

Abstract

This invention relates to the field of tube screen cladding technology, specifically disclosing an automated laser cladding process for tube screens. First, bolts are welded to the back of the tube screen. Then, the tube screen is installed on a rotary worktable, and the tube screen is divided into sections for processing. A new process program is established, and an automated trajectory monitoring device is used to detect and acquire the cladding trajectory. A height detection device determines the Z0 position, and a set of three-dimensional coordinates is obtained. Based on the three-dimensional coordinates and parameters in the process program, the first section of each single tube is clad sequentially. After the first section of all single tubes is clad, the second section of each single tube is clad sequentially, until all sections of all single tubes are clad. This method requires only one detection per section, eliminating the need to detect all single tubes in each section separately, thus reducing detection time and improving the efficiency of tube screen cladding.

Description

Technical Field

[0001] This invention belongs to the field of tube screen cladding technology, specifically relating to an automated laser cladding process for tube screens. Background Technology

[0002] A pipe screen is made by welding several identical single pipes and connecting fins. The construction of a pipe screen can be broken down into making one single pipe and its connecting fins, and then replicating this process to all single pipes. During pipeline use, damage or defects may appear on the pipe surface due to factors such as wear and corrosion. If these problems are not repaired in time, they may lead to safety hazards such as pipeline leaks. Laser technology is typically used to repair the pipe surface through cladding. A laser beam melts the pipe surface at high temperature, and then a special alloy material is sprayed onto the molten area to form a new coating. This coating has high hardness, wear resistance, and corrosion resistance, effectively repairing damage to the pipe surface and extending its service life.

[0003] However, existing technologies require separate detection of the cladding trajectory for each individual tube during tube cladding, which consumes a lot of time and affects the cladding efficiency of the tube screen. Therefore, we need to propose an automated laser cladding process for tube screens to solve the above-mentioned problems. Summary of the Invention

[0004] The purpose of this invention is to provide an automated laser cladding process for tube screens, which only requires one detection for each zone, eliminating the need to detect all individual tubes in each zone separately. This reduces detection time to a certain extent, thereby improving the tube screen cladding efficiency and solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An automated laser cladding process for tube screens includes the following steps:

[0007] S1. First, rivet and weld bolts on the back of the tube screen, then install the tube screen on the rotary worktable, so that the left side of the tube screen is tightly attached to the positioning block of the rotary table, and rotate the adjusting bolts to make the left side of the tube screen be in a straight line.

[0008] S2. Perform partitioning on the tube panel and then create a new process program. The parameters in the process program include product data, equipment operation data, and process data for the tube panel partitions. The number of tube panel partitions is determined according to actual production needs.

[0009] S3. Manually move the laser cladding gun head to the origin position of the workpiece in the tube screen, start the detection button, and use the automated trajectory monitoring device to detect and obtain the cladding trajectory;

[0010] S4. Press the height detection button to determine the Z0 position using the height detection device;

[0011] S5. Press the start button to initiate the cladding process, detect the cladding trajectory of the first zone, and obtain a set of three-dimensional coordinate data.

[0012] S6. Move the cladding gun head to the cladding starting point position, and perform cladding on the first section of the first tube according to the parameters of the process program and the three-dimensional coordinate data. Then perform cladding on the second section of the first tube, and so on until all sections of the first tube of each tube are clad.

[0013] S7. According to the cladding sequence in the final cladding sequence table, perform the second zone cladding. Before cladding each zone, conduct a probe and record a set of three-dimensional coordinates. Repeat S5-S7 until all zones of all single tubes are clad.

[0014] S8. Remove the tube panel, remove the riveted bolts, clean the cladding surface and grind the weld scars.

[0015] Preferably, in step S1, M12 bolts are used when riveting the tube screen. The welding data of the M12 bolts are determined according to the size of the tube screen. The distance between two adjacent horizontal bolts is 300mm, and the distance between two adjacent vertical bolts is 1000mm.

[0016] Preferably, after the tube screen is installed on the rotary worktable, the bolts are tightened with corresponding nuts to completely fix the tube screen on the rotary worktable and prevent large deformation of the tube screen during the cladding process.

[0017] Preferably, in step S2, when the process program is established, the process name is first set, and the product data of single tube diameter, single tube quantity, single tube center distance and single tube length in the tube panel are input into the program; then the equipment operation data of cladding speed, y-axis running speed, non-cladding y-axis length at the beginning and end and detection distance are input; then the process data of single tube partition number, rotary table angle corresponding to each partition, welding torch angle, partition start point X, Z coordinates, partition weld number, partition weld offset, cladding direction and cladding angle are input.

[0018] Preferably, in step S3, the position of the origin of the tube screen workpiece refers to the position X of the highest point of the first single tube of the tube screen and the starting point Y of the tube screen in the Y direction. X and Y are the origin.

[0019] Preferably, the automated trajectory monitoring device includes: a rotary table for mounting and fixing the tube screen;

[0020] Support frame, on which a Y-axis robotic arm is mounted;

[0021] An X-axis robotic arm mounted on a Y-axis robotic arm;

[0022] A Z-axis robotic arm installed at one end of an X-axis robotic arm;

[0023] The laser cladding gun head and trajectory detector are installed at the lower end of the Z-axis robotic arm.

[0024] Preferably, during detection, the automated trajectory monitoring device moves the robotic arm in the X direction a fixed distance in the negative Y direction to begin monitoring, determines the precise X origin position, and moves in the positive X direction. The moving distance is the set center distance of a single tube, and the actual center distance value and Z coordinate difference of each tube are detected. Then, it moves in the positive Y direction a distance equal to the length of the tube screen, and the X position and Z difference of the ends of all single tubes are measured.

[0025] Preferably, in step S4, the Z0 position is the center position of the single tube, which is the detected Z-point coordinates minus the single tube radius value.

[0026] Preferably, in step S5, after the cladding start button is pressed, the first zone of cladding begins. The rotary table and welding torch move to the set angle, and the robotic arm in the X direction moves to the negative Y direction, so that the probe is at the X0Y0 position and probes in the positive Y direction. The probe is probed once at fixed intervals to obtain a three-dimensional coordinate. After the entire probe is completed, a set of three-dimensional coordinate data is obtained.

[0027] Preferably, in step S6, the cladding torch head moves to the cladding starting point position, and according to the input process parameters and referring to the detected three-dimensional coordinates, it follows a spatial polyline to the endpoint, offsets by the input offset, returns along the original path, offsets by one offset, and continues cladding until the cladding of the zone is completed. The number of weld beads clad is determined by the input process parameters. During this process, the probe is raised and not working, the X-axis robotic arm moves to the negative Y-axis, and the Z-axis robotic arm moves to the positive X-axis, so that the probe is detected in the positive Y-axis direction at the center of the second single tube, at position Y0. After detection, cladding is performed to complete the cladding of the first zone of the second single tube; this step is continued until the first zone of all single tubes is completely clad.

[0028] The automated laser cladding process for tube screens proposed in this invention has the following advantages compared with existing technologies:

[0029] 1. This invention first rivets bolts onto the back of the tube panel, then installs the tube panel on a rotary worktable, divides the tube panel into sections, establishes a new process program, and then uses an automated trajectory monitoring device to detect and obtain the cladding trajectory. A height detection device then determines the Z0 position and obtains a set of three-dimensional coordinates. Based on the three-dimensional coordinates and parameters in the process program, the first section of each single tube is clad sequentially. After the first section of all single tubes is clad, the second section of each single tube is clad sequentially, until all sections of all single tubes are clad. This method requires only one detection per section, eliminating the need to detect all single tubes in each section separately, thus reducing detection time and improving the tube panel cladding efficiency. Attached Figure Description

[0030] Figure 1 This is a flowchart of the present invention. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] This invention provides, for example Figure 1 The automated laser cladding process for tube screens shown includes the following steps:

[0033] S1. First, rivet and weld bolts on the back of the tube screen, then install the tube screen on the rotary worktable, so that the left side of the tube screen is tightly attached to the positioning block of the rotary table, and rotate the adjusting bolts to make the left side of the tube screen be in a straight line.

[0034] When riveting the tube screen, M12 bolts are used. The welding data of the M12 bolts are determined according to the size of the tube screen. The distance between two adjacent horizontal bolts is 300mm, and the distance between two adjacent vertical bolts is 1000mm. After the tube screen is installed on the rotary worktable, the bolts are tightened with the corresponding nuts to completely fix the tube screen on the rotary worktable and prevent large deformation of the tube screen during the cladding process.

[0035] S2. Perform partitioning on the tube panel and then create a new process program. The parameters in the process program include product data, equipment operation data, and process data for the tube panel partitions. The number of tube panel partitions is determined according to actual production needs.

[0036] When establishing the process procedure, first set the process name, then input the product data of single tube diameter, single tube quantity, single tube center distance and single tube length in the tube panel; then input the equipment operation data of cladding speed, y-axis running speed, non-cladding y-axis length at the start and end and detection distance; then input the process data of single tube partition number, rotary table angle corresponding to each partition, welding torch angle, partition start point X, Z coordinates, partition weld number, partition weld offset, cladding direction and cladding angle.

[0037] S3. Manually move the laser cladding gun head to the origin position of the workpiece in the tube screen, start the detection button, and use the automated trajectory monitoring device to detect and obtain the cladding trajectory;

[0038] The origin of the tube panel workpiece refers to the position X of the highest point of the first single tube of the tube panel and the starting point Y of the tube panel in the Y direction. X and Y are the origin.

[0039] The automated trajectory monitoring device includes: a rotary table for mounting and fixing the tube screen;

[0040] Support frame, on which a Y-axis robotic arm is mounted;

[0041] An X-axis robotic arm mounted on a Y-axis robotic arm;

[0042] A Z-axis robotic arm installed at one end of an X-axis robotic arm;

[0043] The laser cladding gun head and trajectory detector are installed at the lower end of the Z-axis robotic arm.

[0044] When the automated trajectory monitoring device is detecting, the robotic arm moves a fixed distance in the negative Y direction in the X direction to start monitoring, determine the precise X origin position, and then moves in the positive X direction. The moving distance is the set center distance of the single tube, and the actual center distance value and Z coordinate difference of each tube are detected. Then it moves in the positive Y direction, and the distance is the length of the tube screen, and the X position and Z difference of the end of all single tubes are measured.

[0045] S4. Press the height detection button to determine the Z0 position using the height detection device; the Z0 position is the center position of the single tube, which is the coordinate of the detected Z point minus the radius of the single tube.

[0046] S5. Press the start button to initiate the cladding process, detect the cladding trajectory of the first zone, and obtain a set of three-dimensional coordinate data.

[0047] After pressing the start button for cladding, the first section of cladding begins. The rotary table and welding torch move to the set angle, and the robotic arm moves in the negative Y direction, so that the probe is at the X0Y0 position and probes in the positive Y direction. Every fixed distance (e.g., 300mm, specific data depends on the input), a three-dimensional coordinate (X1YXZ1) is obtained. After the entire probe is completed, a set of three-dimensional coordinate data is obtained.

[0048] S6. Move the cladding gun head to the cladding starting point position, and perform cladding on the first section of the first tube according to the parameters of the process program and the three-dimensional coordinate data. Then perform cladding on the second section of the first tube, and so on until all sections of the first tube of each tube are clad.

[0049] The cladding torch moves to the starting point of the cladding process. Based on the input process parameters and referring to the detected 3D coordinates, it follows a spatial polyline to the endpoint. It then offsets by the input offset and returns along the original path, offsetting by one offset, continuing the cladding process until the cladding of the zone is complete. The number of weld beads is determined by the input process parameters. During this process, the probe is raised and not working. The robotic arm moves in the negative Y direction in the X direction and in the positive X direction in the Z direction, so that the probe, at the center of the second single tube, at position Y0, probes in the positive Y direction. After the probe probes, cladding is performed, completing the cladding of the first zone of the second single tube. This process is repeated until the first zone of all single tubes is cladding.

[0050] S7. According to the cladding sequence in the final cladding sequence table, perform the second zone cladding. Before cladding each zone, conduct a probe and record a set of three-dimensional coordinates. Repeat S5-S7 until all zones of all single tubes are clad.

[0051] S8. Remove the tube panel, remove the riveted bolts, clean the cladding surface and grind the weld scars.

[0052] Instructions for laser cladding of tube screens:

[0053] 1. The basic principle for tube screen cladding is to turn on the powder first, then the laser; turn off the laser first, then the powder. After turning on the powder feeder switch, the powder feeding will stabilize after 15 seconds, and cladding can then be performed. Turning on the laser can be considered to have no delay.

[0054] 2. When the equipment is cladding, turn on the powder feeder, delay for 15 seconds, and then move it in the Y direction.

[0055] 3. Assume there are 500mm uncladized areas at both ends of the tube screen. When the laser gun head moves to the 500mm dividing line at the beginning, the laser is turned on, and the equipment performs normal cladding. When it moves to the 500mm dividing line at the end, the laser is turned off. (At this time, the gun head continues to move forward Xmm, stops, and moves in the opposite direction. This process is because the gun head vibrates during the reversal, and continuing to move forward keeps the vibrating area outside the cladding area. It can be considered to uniformly decelerate and stop at the 500mm dividing line, and then uniformly accelerate in the opposite direction.) After the reversal, the laser is turned on again at the 500mm end, and cladding continues. The movement relationship at the beginning is a mirror image. When performing N cladding passes in a certain area, only the laser is turned on and off, while the powder feeder is always on.

[0056] 4. After cladding is completed in a certain area, turn off the laser and then turn off the powder feeder after a 3-second delay. The equipment's rotary table will rotate (the same section of different tubes will not rotate). When performing individual detection, both the powder feeder and the laser will be off. After detection, return to the starting position, turn on the powder feeder, and after a 15-second delay, move in the new Y direction. When it reaches the 500mm dividing line, turn on the laser.

[0057] 5. Repeat steps three and four.

[0058] 6. After all cladding is completed, turn off the powder feeder and the laser.

[0059] In summary, by first riveting bolts onto the back of the tube panel, then installing the tube panel on a rotary table, dividing the tube panel into sections, establishing a new process, and then using an automated trajectory monitoring device to detect and obtain the cladding trajectory, followed by determining the Z0 position using a height detection device, and then obtaining a set of three-dimensional coordinates, the first section of each single tube is clad sequentially according to the three-dimensional coordinates and the parameters in the process program. After the first section of all single tubes is clad, the second section of each single tube is clad sequentially, until all sections of all single tubes are clad. This method requires only one detection per section, eliminating the need to detect all single tubes in each section separately, thus reducing detection time to a certain extent and improving the tube panel cladding efficiency.

[0060] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A tube panel automated laser cladding process characterized by: It comprises the following steps: S1, rivet and weld bolts on the back of the tube panel first, then install the tube panel on the rotary workbench, make the left side of the tube panel close to the positioning block of the rotary table, rotate the adjusting bolt, make the left side of the tube panel a straight line; the tube panel adopts M12 bolts when riveting and welding the bolts, the welding data of the M12 bolts is determined according to the size of the tube panel, the distance between the adjacent two horizontal bolts is 300mm, and the distance between the adjacent two vertical bolts is 1000mm; S2, divide the tube panel into zones, and then establish a new process program, the parameters in the process program include product data, equipment operation data and process data of tube panel zoning, wherein the number of tube panel zoning is divided according to actual production requirements; When the process program is established, first set the process name, input the product data of the single tube diameter, single tube quantity, single tube center distance and single tube length in the tube panel in the program; then input the equipment operation data of the cladding speed, y-axis running speed, starting end and end non-cladding y-direction length and detection distance; then input the process data of single tube zoning quantity, corresponding rotary table angle of each zone, welding gun angle, zoning starting point X, Z coordinate, zoning number of welding passes, zoning welding pass offset, cladding direction and cladding angle; S3, manually move the laser cladding gun head to the origin position of the tube panel workpiece, start the detection button, and detect through the automatic trajectory monitoring device to obtain the cladding trajectory; S4, press the height detection button, and determine the Z0 position through the height detection device; S5, start the cladding start button, detect the cladding trajectory of the first zone, and obtain a set of three-dimensional coordinate data; S6, move the cladding gun head to the cladding starting point position, and perform cladding on the first zone of the first tube according to the parameters of the process program and the three-dimensional coordinate data, then perform cladding on the first zone of the second tube, and so on until the cladding of all single tubes in the first zone is completed; S7, according to the cladding sequence in the final cladding sequence table, perform second zone cladding, and before cladding in each zone, detect and record a set of three-dimensional coordinates, repeat S5-S7 until the cladding of all zones of all single tubes is completed; S8, remove the tube panel, remove the riveted and welded bolts, and clean the cladding surface and polish the welding scar.

2. The automated laser cladding process for tube sheets according to claim 1, wherein: After the tube panel is installed on the rotary workbench, the corresponding nut is tightened on the bolt to make the tube panel completely fixed on the rotary workbench, so as to prevent large deformation of the tube panel during cladding.

3. The tube panel automated laser cladding process of claim 2, wherein: In step S3, the position of the tube panel workpiece origin is the position of the highest point of the first single tube of the tube panel, and the position of the Y direction starting point of the tube panel is Y, and X and Y are the origin.

4. The tube panel automated laser cladding process of claim 3, wherein: The automatic trajectory monitoring device comprises: a rotary table workbench for installing and fixing the tube panel; A support frame, a Y-direction mechanical arm is installed on the support frame; An X-direction mechanical arm installed on the Y-direction mechanical arm; A Z-direction mechanical arm installed at one end of the X-direction mechanical arm; A laser cladding gun head and a trajectory detector installed at the lower end of the Z-direction mechanical arm.

5. The tube panel automated laser cladding process of claim 4, wherein: The automatic track monitoring device moves the X direction mechanical arm to the Y negative direction by a fixed distance when detecting, starts monitoring, determines the accurate X origin position, and moves to the X positive direction by a distance of the set single tube center distance, detects the actual center distance value and Z coordinate difference value of each tube, moves to the Y positive direction by the tube screen length, and measures the X position and Z difference value of all single tube ends.

6. The tube panel automated laser cladding process of claim 5, wherein: In step S4, the Z0 position is the single tube center position, and the Z point coordinate is subtracted by the single tube radius value.

7. The tube panel automated laser cladding process of claim 6, wherein: In step S5, after the cladding start button is started, the first subarea is cladded, the rotary table and the welding gun are operated to the set angle, the X direction mechanical arm moves to the Y negative direction, the probe is at the X0Y0 position, the Y positive direction is detected, the three-dimensional coordinate is obtained by detecting every fixed distance, a group of three-dimensional coordinate data is obtained after the whole detection.

8. The tube panel automated laser cladding process of claim 7, wherein: In step S6, the cladding gun head moves to the cladding start point position, the space polyline is walked according to the input process parameters and the detected three-dimensional coordinate, the offset input offset is offset, the original path is returned, an offset is offset, the cladding is continuously cladded, the cladding of the subarea is completed, the number of cladded welds is determined by the input process parameters, the probe is lifted and not worked in the process, the X direction mechanical arm moves to the Y negative direction, the Z direction mechanical arm moves to the X positive direction, the probe is at the second single tube center Y0 position, the Y positive direction is detected, the second single tube first subarea is cladded after the detection is completed, and the first subarea of all single tubes is completely cladded by continuously performing the step.

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