An automated high speed cladding method for trt blade coatings

Abstract

The present application relates to TRT blade surface treatment technical field, specifically disclose a kind of TRT blade coating's automated high-speed cladding method, specifically comprising the following steps: step S1: for blade matrix modeling, form three-dimensional model;Step S2: to three-dimensional model is partitioned;Step S3: to blade matrix is numbered, the blade matrix stored on movable tool holder is placed into clamping tool;Step S4: cladding according to partition;After cladding is completed in a region, according to the blade matrix of cladding, adjust and optimize three-dimensional model and cladding parameter, subsequent can carry out the cladding of next region;Step S5: repeat step S4 until the cladding of whole set of blade matrix is completed.The present application is by effectively for cladding region is partitioned, and according to sequence carries out each partition cladding, can guarantee temperature and stress respectively uniformity, to make the blade cladding coating after cladding, uniform and continuous, and will not appear cracking.

Description

Technical Field

[0001] This invention relates to the field of TRT blade surface treatment technology, and more specifically, to an automated high-speed cladding method for TRT blade coating. Background Technology

[0002] TRT units, also known as blast furnace gas residual pressure turbine power generation units, are mainly used in the steel industry for the recovery and utilization of high-temperature residual gas. Their principle is to use the residual pressure of blast furnace gas to generate electricity, thereby reducing energy waste.

[0003] Because blast furnace gas contains many corrosive gases, solid particles, and water vapor, corrosion and wear of TRT turbine blades have long been a persistent problem in the industry. Conventional blades, without any protective coating, have a very short service life.

[0004] To address the aforementioned technical issues, the most reliable solution currently available is to employ a high-energy beam cladding process to treat the surface of the blades, thereby effectively extending their service life.

[0005] Theoretically, the higher the hardness of the cladding coating, the more wear-resistant it is. Therefore, high-hardness and corrosion-resistant alloy materials are generally used to form cladding coatings to improve the wear and corrosion resistance of blades, thereby extending their service life. However, high-hardness alloy cladding materials are brittle and have poor toughness due to their high hardness, and preheating is generally required to obtain a good cladding coating. But due to the special nature of blade materials, they are quite sensitive to temperature, and preheating will affect the performance of the blade materials. Therefore, conventional cladding processes are almost unable to obtain a uniform and intact cladding coating with a hardness exceeding HRC40 on blades with complex curved surface connections.

[0006] Currently, the industry lacks effective processes for surface modification and cladding of blades, resulting in issues such as numerous overlapping areas, uneven thickness, low cladding speed and efficiency, long cycles, and poor coating formation and surface quality. Furthermore, the lack of effective control over the cladding path in different areas leads to uneven heating of the blades, resulting in significant deformation and frequent cracking after treatment. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide an automated high-speed cladding method for TRT blade coating;

[0008] The solution adopted by this invention to solve the technical problem is:

[0009] An automated high-speed cladding method for TRT blade coating specifically includes the following steps:

[0010] Step S1: Model the blade matrix to form a three-dimensional model;

[0011] Step S2: Divide the 3D model into sections; specifically, divide the model into sections such as the front section of the leaf root bottom surface, the back section of the leaf root bottom surface, the front section of the root radius (R), the back section of the root radius (R), the top section of the leaf, the front section of the leaf, the back section of the leaf, the thin edge section of the leaf, and the thick edge section of the leaf.

[0012] Step S3: Number the blade substrates and place the blade substrates stored in the movable fixture onto the clamping fixture.

[0013] Step S4: Perform cladding according to the zones;

[0014] After cladding is completed in one area, the 3D model and cladding parameters are adjusted and optimized according to the blade substrate to be clad, and then the cladding of the next area can be carried out.

[0015] Step S5: Repeat step S4 until the entire blade substrate is clad.

[0016] In some possible implementations,

[0017] The cladding sequence is as follows: front area of ​​leaf root bottom surface, back area of ​​leaf root bottom surface, front area of ​​root R, back area of ​​root R, top area of ​​leaf, front area of ​​leaf, back area of ​​leaf, thin edge area of ​​leaf, and thick edge area of ​​leaf.

[0018] In some possible implementations,

[0019] When the blade substrate is placed into the clamping fixture, a robotic arm is used to transfer the blade substrate to the clamping fixture. At the same time, the robotic arm weighs and photographs the blade substrate to identify the blade number and record the blade's weight information.

[0020] If the conditions are met, the cladding operation will proceed; if not, an alarm will be triggered.

[0021] In some possible implementations,

[0022] During cladding, the cladding scanning speed is at least 30 mm / s, the laser power is 1000W-1800W, the flow rate of the protective gas is 20L / min-40L / min, and the spot size is 1.5mm-2mm.

[0023] In some possible implementations,

[0024] During cladding, each zone area adopts bidirectional reciprocating cladding.

[0025] In some possible implementations,

[0026] During cladding, the powder feeding mode is coaxial powder feeding mode, and the hardness of the cladding layer formed is ≥HRC45.

[0027] In some possible implementations,

[0028] The step S4 described in the section on adjusting and optimizing the three-dimensional model and cladding parameters specifically refers to optimizing and adjusting the cladding posture of the blade substrate, the overlap parameters of the boundary of the area to be clad, the cladding scanning speed, the laser power, the protective gas flow rate, and the spot size.

[0029] In some possible implementations,

[0030] The protective gas is argon with a purity of 99.999%.

[0031] In some possible implementations,

[0032] It also includes: after the entire set of blade substrates is clad, the robotic arm grabs the set of blade substrates and places them in the empty space of the tooling frame;

[0033] The tooling rack storing the blades to be clad automatically moves another set of blade substrates of the same model to the gripping position of the robot arm;

[0034] After the robotic arm picks up the set of blades, it places them into the clamping fixture and performs cladding.

[0035] After the cladding is completed, it is removed by the robotic arm and placed in an empty space on the tooling rack;

[0036] This process is repeated until the substrate cladding of all blades of the same type is completed.

[0037] In some possible implementations,

[0038] After cladding, the cladding thickness of each zone is the same.

[0039] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0040] This invention effectively divides the cladding area into zones and performs cladding on each zone in sequence, which ensures uniform temperature and stress distribution, thereby preventing cracking of the blade substrate after cladding.

[0041] This invention optimizes and adjusts the three-dimensional model after each cladding process to avoid excessive or insufficient overlap due to deformation of the blade substrate after cladding, thereby preventing cracking of the blade after cladding. After each cladding process, the cladding process parameters, cladding path, and cladding sequence for the next area are optimized to minimize blade deformation and reduce residual stress.

[0042] This invention effectively controls the cladding parameters, divides the cladding area into zones, and performs cladding in sequence, thereby minimizing heat input and deformation of the blade substrate. Compared with existing technologies, it features low deformation and low tendency of cladding coating to crack, achieving high-quality coating preparation for blade substrates. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the partitioning of the blades in this invention;

[0044] Among them: 1. Front area of ​​leaf root bottom; 2. Back area of ​​leaf root bottom; 3. Front area of ​​root R; 4. Back area of ​​root R; 5. Top area of ​​leaf; 6. Front area of ​​leaf; 7. Back area of ​​leaf; 8. Thin edge area of ​​leaf; 9. Thick edge area of ​​leaf. Detailed Implementation

[0045] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. The terms "first," "second," and similar terms used in this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, "a" or "one," etc., do not indicate a quantity limitation, but rather indicate the existence of at least one. In the implementation of this application, "and / or" describes the association relationship of related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. In the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more. For example, multiple positioning posts refer to two or more positioning posts. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0046] The present invention will now be described in detail.

[0047] like Figure 1 As shown:

[0048] An automated high-speed cladding method for TRT blade coating specifically includes the following steps:

[0049] Step S1: Model the blade matrix to form a three-dimensional model;

[0050] Step S2: Divide the 3D model into sections; specifically, divide the model into sections: leaf root underside front section 1, leaf root underside back section 2, root R front section 3, root R back section 4, leaf top section 5, leaf front section 6, leaf back section 7, leaf thin edge section 8, and leaf thick edge section 9.

[0051] Step S3: Number the blade substrates and place the blade substrates stored in the movable fixture onto the clamping fixture.

[0052] Specifically: When placing the blade substrate into the clamping fixture, a robotic arm is used to transfer the blade substrate onto the clamping fixture. At the same time, the robotic arm weighs and photographs the blade substrate to determine whether the blade substrate matches the 3D model. If it matches, the cladding operation is performed. If it does not match, the 3D model and cladding parameters are adjusted and optimized until they match.

[0053] The step S4 described in the section on adjusting and optimizing the three-dimensional model and cladding parameters specifically refers to optimizing and adjusting the cladding posture of the blade substrate, the boundary overlap parameters of the area to be clad, the cladding scanning speed, the laser power, the protective gas flow rate, the spot size, and the cladding path direction.

[0054] Step S4: Perform cladding according to the zones; the cladding sequence is as follows: leaf root underside front zone 1, leaf root underside rear zone 2, root R front zone 3, root R rear zone 4, blade top zone 5, blade front zone 6, blade back zone 7, blade thin edge zone 8, and blade thick edge zone 9.

[0055] After cladding is completed in one area, the 3D model and cladding parameters are adjusted and optimized according to the blade substrate to be clad, and then the cladding of the next area can be carried out.

[0056] During cladding, the cladding scanning speed is at least 30 mm / s, the laser power is 1000W-1800W, the flow rate of the protective gas is 20L / min-40L / min, and the spot size is 1.5mm-2mm; the protective gas is argon gas with a purity of 99.999%.

[0057] During cladding, each zone adopts bidirectional reciprocating cladding; the powder feeding mode is coaxial powder feeding mode; this invention adopts high-speed cladding process, adopts coaxial powder feeding mode, and combines it with the automated movement of tooling frame, which can greatly reduce the occurrence of problems such as slow robot movement speed, high cost investment of vision equipment, and recognition being easily affected by the environment.

[0058] Step S5: Repeat step S4 until the entire blade substrate is clad, and ensure that the cladding thickness of each partition after cladding is the same.

[0059] Step S6: After the entire set of blade substrates is clad, the robot arm picks up the set of blade substrates and places them in the empty space of the tooling frame;

[0060] The tooling rack storing the blades to be clad automatically moves another set of blade substrates of the same model to the gripping position of the robot arm;

[0061] After the robotic arm picks up the set of blades, it places them into the clamping fixture and performs cladding.

[0062] After the cladding is completed, it is removed by the robotic arm and placed in an empty space on the tooling rack;

[0063] This process is repeated until the substrate cladding of all blades of the same type is completed.

[0064] Example 1:

[0065] like Figure 1 As shown, the automated high-speed laser cladding of leaf roots and leaves of a certain fir tree includes the following steps:

[0066] Preparation before cladding: Clean and inspect all blades, and mark the drawing number on the side of the blade root; place all blade substrates of the same model into the tooling fixture:

[0067] Cladding zoning and programming: Open the programming software, import the three-dimensional model of the blade, and divide the blade into nine regions for cladding. Considering the blade length and weight distribution, start cladding from the root R to ensure that the heat of cladding is uniformly preheated on the entire blade.

[0068] The zones are: leaf root underside anterior zone 1, leaf root underside posterior zone 2, root R anterior zone 3, root R posterior zone 4, leaf tip zone 5, leaf front zone 6, leaf back zone 7, leaf thin edge zone 8, and leaf thick edge zone 9.

[0069] The cladding sequence is as follows: leaf root underside front area 1, leaf root underside rear area 2, root R front area 3, root R rear area 4, blade top area 5, blade front area 6, blade back area 7, blade thin edge area 8, and blade thick edge area 9.

[0070] Before cladding, dry powder with a cladding layer hardness ≥45HRC is loaded into a large-capacity powder feeder, and 99.999% high-purity argon is introduced into the gas protection channel.

[0071] A robotic arm is used to grasp a set of blade substrates. After grasping, the robotic arm checks the image interface and weighs the material to check if the grasping fixture is normal. If it is normal, the automation system is activated, the first piece is grasped and installed on the clamping fixture during trial operation. If the installation is correct, the cladding program is executed to start the cladding process.

[0072] The tooling frame moves to the gripping position, the robot arm takes a picture, identifies and stores the drawing number and the blade weight information; after gripping the blade, the robot arm sends the blade into the clamping fixture; the fixture clamps the blade root of the blade substrate; the robot arm retracts its arm extension; the cladding robot arm begins to work in coordination with the positioner to begin the cladding process;

[0073] Cladding: First, cladding is performed on the front area 1 of the blade root base. After the cladding of the front area 1 of the blade root base is completed, the three-dimensional model and cladding parameters are adjusted according to the actual situation of the blade substrate after cladding. Then, the cladding of the rear area 2 of the blade root base can be performed.

[0074] After the cladding of the leaf root underside rear zone 2 is completed, the 3D model and cladding parameters are adjusted according to the actual situation of the leaf substrate after cladding, and then the cladding of the root R front zone 3 can be carried out.

[0075] Similarly, after each cladding is completed, the three-dimensional model and cladding parameters must be adjusted according to the actual situation of the blade substrate after cladding, until the entire set of blade substrates is clad.

[0076] The main reasons for adjusting and optimizing the 3D model and cladding parameters are: firstly, considering the deformation and cumulative error of cladding welding, it is necessary to correct and optimize the actual effect of the cladding process, including the optimization of parameters such as the cladding posture of the robotic arm and the overlap of the boundary of the area to be clad; secondly, considering the change of stress after cladding, it is necessary to optimize the process parameters.

[0077] Adjusting and optimizing the 3D model and cladding parameters specifically refers to optimizing and adjusting the cladding attitude of the blade substrate, the boundary overlap parameters of the area to be clad, the cladding scanning speed, the laser power, the protective gas flow rate, the spot size, and the cladding path direction.

[0078] This method ensures the amount of overlap between the weld overlays in each area, ensuring a certain amount of overlap in all areas, thereby ensuring that the entire blade is protected without any unwelded areas; at the same time, it ensures that the attitude can be welded to produce good welds.

[0079] Cladding scanning speed: 42mm / s, laser power: 1600W; protective gas flow rate: 30L / min; the cladding path is bidirectional starting cladding, that is, cladding from point A to point B, and then from point B to point A, so that no backflow occurs during the entire cladding process, reducing the time of empty travel and improving cladding efficiency.

[0080] The cladding scanning speed is higher than that in the existing technology, which avoids the blade substrate from being heated for a long time, resulting in an increased width of the heat-affected zone and thus workpiece deformation.

[0081] After the cladding is completed, the cladding robot retracts its arm and grabs the blade, placing it in an empty space on the tooling rack. Then, the material tooling rack storing the blades to be clad automatically moves one blade, the robot grabs the blade and places it into the automatic clamping fixture for automatic cladding. After cladding is completed, the grabbed robot removes the blade and places it in an empty space on the original material tooling rack. This process is repeated until all blade substrates of the same model are clad.

[0082] In this invention, a robotic arm is used to take photos and weigh the blades to record and analyze the weight gain data before and after cladding.

[0083] The blade clad in this embodiment 1 is compared with the blade clad directly using a three-dimensional model in the prior art. Compared with the prior art, the present invention will reduce the error generated by the blade during the cladding process, and the temperature distribution of the entire blade will be uniform, which will greatly reduce the possibility of blade deformation and cracking.

[0084] This invention is not limited to the specific embodiments described above. The invention extends to any new feature or combination disclosed in this specification, as well as any new method or process step or combination disclosed herein.

Claims

1. An automated high-speed cladding method for TRT blade coating, characterized in that, Specifically, the following steps are included: Step S1: Model the blade matrix to form a three-dimensional model; Step S2: Divide the 3D model into sections; specifically, divide the model into sections such as the front section of the leaf root bottom surface, the back section of the leaf root bottom surface, the front section of the root radius (R), the back section of the root radius (R), the top section of the leaf, the front section of the leaf, the back section of the leaf, the thin edge section of the leaf, and the thick edge section of the leaf. Step S3: Number the blade substrates and place the blade substrates stored in the movable fixture onto the clamping fixture. Step S4: Perform cladding according to the zones; After cladding is completed in one area, the 3D model and cladding parameters are adjusted and optimized according to the blade substrate to be clad, and then the cladding of the next area can be carried out. Step S5: Repeat step S4 until the entire blade substrate is clad; The cladding sequence is as follows: front area of ​​leaf root bottom surface, back area of ​​leaf root bottom surface, front area of ​​root R, back area of ​​root R, top area of ​​leaf, front area of ​​leaf, back area of ​​leaf, thin edge area of ​​leaf, and thick edge area of ​​leaf. When the blade substrate is placed into the clamping fixture, the blade substrate is transferred to the clamping fixture by a robot arm. At the same time, the robot arm weighs and photographs the blade substrate to identify the blade number and record the weight information of the blade. If the conditions are met, proceed with the cladding operation; if not, issue an alarm. During cladding, the cladding scanning speed is at least 30 mm / s, the laser power is 1000W-1800W, the flow rate of the protective gas is 20L / min-40L / min, and the spot size is 1.5mm-2mm.

2. The automated high-speed cladding method for TRT blade coating according to claim 1, characterized in that, During cladding, each zone area adopts bidirectional reciprocating cladding.

3. The automated high-speed cladding method for TRT blade coating according to claim 1, characterized in that, During cladding, the powder feeding mode is coaxial powder feeding mode.

4. The automated high-speed cladding method for TRT blade coating according to claim 1, characterized in that, The step S4 described in the section on adjusting and optimizing the three-dimensional model and cladding parameters specifically refers to optimizing and adjusting the cladding posture of the blade substrate, the overlap parameters of the boundary of the area to be clad, the cladding scanning speed, the laser power, the protective gas flow rate, and the spot size.

5. The automated high-speed cladding method for TRT blade coating according to claim 4, characterized in that, The protective gas is argon with a purity of 99.999%.

6. The automated high-speed cladding method for TRT blade coating according to claim 1, characterized in that, Also includes: After the entire set of blade substrates is clad, the robotic arm picks up the set of blade substrates and places them in the empty space of the tooling frame; The tooling rack storing the blades to be clad automatically moves another set of blade substrates of the same model to the gripping position of the robot arm; After the robotic arm picks up the set of blades, it places them into the clamping fixture and performs cladding. After the cladding is completed, it is removed by the robotic arm and placed in an empty space on the tooling rack; This process is repeated until the substrate cladding of all blades of the same type is completed; Before and after cladding, the robotic arm records the weight of the blade and identifies its serial number when grasping it.

7. The automated high-speed cladding method for TRT blade coating according to claim 1, characterized in that, After cladding, the cladding thickness is the same in each cladding area.

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