Additive and subtractive material repairing method and repairing device for wind power gear

Abstract

The invention relates to the technical field of wind power equipment, in particular to a wind power gear additive and subtractive material repairing method and device, and the repairing method comprises the following steps: S10, obtaining point cloud data of a to-be-repaired wind power gear; s20, constructing a three-dimensional model of the wind power gear to be repaired according to the data obtained in the step S10; s30, a three-dimensional model of a to-be-repaired area in the to-be-repaired wind power gear is obtained through Boolean operation; s40, material information of the wind power gear to be repaired is obtained, and a repairing material and electric arc cladding additive manufacturing process parameters are selected according to the material information; s50, thickening treatment is conducted on the three-dimensional model of the to-be-repaired area, and according to the model and electric arc cladding additive manufacturing process parameters, electric arc cladding is conducted on a repairing material to the to-be-repaired area of the to-be-repaired wind power gear; s60, the wind power gear subjected to electric arc cladding is subjected to material reduction machining; therefore, the surface precision of the repaired wind power gear is close to that of the original wind power gear, so that the time required by subsequent surface treatment is shortened, and the repair efficiency of the wind power gear is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power equipment, and in particular to a method and a device for repairing wind power gears by adding or subtracting material. Background Art

[0002] Wind turbine gears are important components in wind power generation equipment. Their main function is to transmit the power generated by the wind wheel under the action of wind to the engine so that the engine can obtain the corresponding speed. At the same time, wind turbine gears are also one of the components with the highest failure rate in wind power generation equipment. Their main failure forms include gear wear, gear breakage, tooth surface pitting, tooth surface bonding and plastic deformation.

[0003] Laser cladding technology is currently the most commonly used wind turbine gear repair technology. Its repair process includes the following steps: 1. Pretreatment, cleaning and treating the surface of the wind turbine gear to make its surface free of oil and impurities to ensure good bonding between the cladding material and the wind turbine gear; 2. Material addition, selecting suitable cladding materials according to the materials used in the wind turbine gear, and placing them on the surface of the wind turbine gear to be repaired; 3. Laser irradiation, irradiating a high-energy laser beam on the cladding material and the surface of the wind turbine gear to melt them at the same time; 4. Rapid cooling, so that the molten material quickly cools and solidifies to form a cladding layer with metallurgical bonding between the wind turbine gear and the cladding material; 5. Post-treatment, grinding and polishing the cladding layer and other subsequent treatments to ensure that the repaired wind turbine gear has a smooth surface and stable performance.

[0004] However, the stability of laser cladding technology is poor. When using laser cladding technology to repair wind turbine gears, the surface error of the repaired wind turbine gears is large, which is far from the precision required for wind turbine gears. This increases the time required for grinding and polishing the cladding layer, resulting in a decrease in the repair efficiency of wind turbine gears. Summary of the invention

[0005] In view of this, it is necessary to provide a wind turbine gear additive and subtractive material repair method and repair device, which can improve the accuracy of the repaired wind turbine gear, so as to reduce the time required for processing the surface of the repaired wind turbine gear, thereby improving the repair efficiency of the wind turbine gear.

[0006] In a first aspect, the present invention provides a method for repairing wind turbine gears by adding or subtracting materials, comprising the following steps: S10: Scanning the wind turbine gear to be repaired using a three-dimensional scanning device to obtain point cloud data of the wind turbine gear to be repaired; S20: constructing a three-dimensional model of the wind turbine gear to be repaired according to the point cloud data of the wind turbine gear to be repaired; S30: constructing a three-dimensional model of an undamaged wind turbine gear, and performing a Boolean operation on the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired, so as to obtain a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired; S40: obtaining the physical and chemical properties of the wind turbine gear material to be repaired through material testing equipment, and selecting the repair material and arc cladding additive manufacturing process parameters accordingly; S50: performing thickening processing on the three-dimensional model of the area to be repaired, and arc-cladding the repair material to the area to be repaired of the wind turbine gear to be repaired according to the three-dimensional model of the area to be repaired after the thickening processing and the arc cladding additive manufacturing process parameters; S60: performing subtractive processing on the area to be repaired of the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear.

[0007] Preferably, the S10 includes: S11, pre-processing the repair area of ​​the wind turbine gear to be repaired; S12, placing a positioning mark point on the wind turbine gear to be repaired; S13, calibrating the handheld three-dimensional scanner; S14, using a handheld 3D scanner to scan the wind turbine gear to be repaired and the positioning mark points from various angles, obtaining a point cloud data model of the wind turbine gear to be repaired, and exporting and saving the point cloud data of the wind turbine gear to be repaired.

[0008] Preferably, the S11 includes: S111, performing flaw detection on the tooth surface of the wind turbine gear to be repaired; S112, if cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the tooth surface of the wind turbine gear to be repaired is subjected to crack removal processing, and then the process returns to S111; if cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the process proceeds to the next step; S113, removing pollutants on the surface of the wind turbine gear to be repaired.

[0009] Preferably, in S14, when using a handheld three-dimensional scanner to perform data sampling, the method includes: Data collection is performed in a stable environment with no stroboscopic light and weak lighting; and when the collected point cloud data is not effective, a layer of white developer is evenly sprayed on the surface of the wind turbine gear to be repaired to eliminate the influence of the reflection of the surface of the wind turbine gear to be repaired on the scanning accuracy of the handheld 3D scanner.

[0010] Preferably, the S20 includes: S21, preprocessing the point cloud data of the wind turbine gear to be repaired stored in S14 to remove noise and redundant data therein, thereby reducing computer operation time and improving model processing accuracy; S22, importing the pre-processed point cloud data of the wind turbine gear to be repaired into reverse engineering software to generate a point cloud data model of the wind turbine gear to be repaired; S23, generating a three-dimensional model of the internal cylinder of the wind turbine gear to be repaired based on the point cloud data model of the wind turbine gear to be repaired; S24, generating a three-dimensional model of the external teeth of the wind turbine gear to be repaired based on the point cloud data model of the wind turbine gear to be repaired; S25, merging the three-dimensional model of the inner cylinder of the wind turbine gear to be repaired with the three-dimensional model of the outer teeth of the wind turbine gear to be repaired to obtain the three-dimensional model of the wind turbine gear to be repaired.

[0011] Preferably, the S30 includes: S31, constructing a three-dimensional model of the undamaged wind turbine gear according to the engineering drawings provided by the manufacturer or the point cloud data of the wind turbine gear to be repaired; S32, obtaining a three-dimensional model of the to-be-repaired region of the wind turbine gear to be repaired by performing Boolean operations on the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired.

[0012] Preferably, the S40 includes: S41, sampling and analyzing the wind turbine gear to be repaired by scanning equipment to obtain the physical and chemical properties of the material of the wind turbine gear to be repaired; S42, searching for the material used for the wind turbine gear to be repaired in a pre-set base material library. If the material can be found, the corresponding repair material and the optimal arc cladding additive manufacturing process parameters are selected according to the welding wire brand corresponding to the material, and the process goes to S50. If the material cannot be found, the process goes to the next step; S43, preliminarily selecting a suitable repair material according to the mechanical properties of the material used for the wind turbine gear to be repaired; S44, conducting experiments on the repair material to determine the arc cladding additive manufacturing process parameters that enable the weld bead to be formed; S45, continue to experiment on the repair material to optimize the arc cladding additive manufacturing process parameters to obtain the best arc cladding additive manufacturing process parameters for the repair material; S46, processing the repair material into a sample having the same tooth shape as the wind turbine gear to be repaired according to the three-dimensional model of the wind turbine gear to be repaired and the optimal arc cladding additive manufacturing process parameters of the repair material; S47, various mechanical property tests are performed on the sample to determine whether the sample meets the predetermined requirements. If the sample meets the predetermined requirements, the next step is performed. If the sample does not meet the predetermined requirements, the repair material is replaced and the test is repeated. S48, adding the material used for the wind turbine gear to be repaired, the corresponding repair material and the optimal arc cladding additive manufacturing process parameters to the substrate library.

[0013] Preferably, the S50 includes: S51, performing a thickening process on the external tooth shape of the three-dimensional model of the area to be repaired to reserve a reasonable amount of material addition shrinkage and material subtraction processing allowance, and obtaining a three-dimensional model of the area to be repaired after the thickening process; S52, importing the three-dimensional model of the wind turbine gear to be repaired and the three-dimensional model of the area to be repaired after the thickening treatment into the control software; S53, fixing the wind turbine gear to be repaired on the working platform, and measuring the spatial coordinates of the wind turbine gear to be repaired; S54, inputting the spatial coordinates into the control software, ensuring that the placement position of the three-dimensional model of the wind turbine gear to be repaired in the software is consistent with the position of the actual wind turbine gear to be repaired, and matching the three-dimensional model of the wind turbine gear to be repaired and the three-dimensional model of the area to be repaired in the control software; S55, planning a reasonable additive processing trajectory, and performing simulation optimization on the process of adding the three-dimensional model of the area to be repaired to the area to be repaired in the three-dimensional model of the wind turbine gear to be repaired in the control software, if the simulation result meets the predetermined requirements, proceeding to the next step, if the simulation result does not meet the predetermined requirements, re-planning the additive trajectory; S56, input the optimal arc cladding additive manufacturing process parameters of the repair material, and control the arc cladding additive manufacturing equipment to perform dry run through the control software. If the dry run path is correct, put the repair material and arc clad it to the repair area of ​​the wind turbine gear to be repaired; if the dry run path is inaccurate, reconfirm the additive processing trajectory.

[0014] Preferably, the S60 includes: S61, reducing the residual stress and hardness of the area to be repaired of the wind turbine gear after arc cladding; S62, performing rough milling on the area to be repaired of the wind turbine gear after reducing the residual stress and hardness, so as to obtain a tooth shape of the wind turbine gear; S63, performing semi-finishing milling on the area to be repaired of the wind turbine gear after the rough milling process, to remove the "terrace" steps formed during the rough milling process; S64, performing finish milling on the area to be repaired of the wind turbine gear after the semi-finish milling, so that its dimensional accuracy reaches a predetermined requirement; S65, performing a quenching and tempering treatment on the area to be repaired of the wind turbine gear after fine milling, so as to restore the hardness of the area; S66, performing grinding surface treatment on the area to be repaired of the wind turbine gear after quenching and tempering treatment, so that the tooth surface accuracy, surface quality and performance meet the design requirements; S67, perform performance testing on the wind turbine gear after grinding to confirm whether its various performances meet the performance requirements of the original wind turbine gear. If the various performances do not meet the performance requirements of the original wind turbine gear, the wind turbine gear is remanufactured until the various performances meet the performance requirements of the original wind turbine gear; if the various performances meet the performance requirements of the original wind turbine gear, the repair of the wind turbine gear is completed.

[0015] In a second aspect, the present invention provides a wind turbine gear repair device, which includes: a three-dimensional data acquisition module, a three-dimensional model building module, a gear physical and chemical properties acquisition module, a repair parameter acquisition module, a wind turbine gear material addition module and a wind turbine gear material reduction module: A three-dimensional data acquisition module, configured to acquire three-dimensional data of the wind turbine gear to be repaired; A three-dimensional model building module, configured to obtain a three-dimensional model of the wind turbine gear to be repaired and a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired according to the three-dimensional data of the wind turbine gear to be repaired; A gear physical and chemical properties acquisition module, configured to acquire material information of the wind turbine gear to be repaired; A repair parameter acquisition module, configured to select appropriate repair materials and arc cladding additive manufacturing process parameters according to material information of the wind turbine gear to be repaired; A wind turbine gear additive module, configured to arc-clad the repair material onto the repaired area of ​​the wind turbine gear to be repaired according to the three-dimensional model of the repaired area; The wind turbine gear subtractive module is configured to perform subtractive processing on the area to be repaired of the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear.

[0016] The above-mentioned wind turbine gear additive and subtractive material repair method is provided with the following steps: S10: Use a three-dimensional scanning device to scan the wind turbine gear to be repaired to obtain point cloud data of the wind turbine gear to be repaired; S20: Construct a three-dimensional model of the wind turbine gear to be repaired based on the point cloud data of the wind turbine gear to be repaired; S30: Construct a three-dimensional model of the undamaged wind turbine gear, and perform Boolean operations on it and the three-dimensional model of the wind turbine gear to be repaired to obtain a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired; S40: Obtain the physical and chemical properties of the material of the wind turbine gear to be repaired through the detection equipment, and select the repair material and arc cladding additive manufacturing process parameters accordingly; S50: Based on the three-dimensional model of the area to be repaired and the arc cladding additive manufacturing process Parameters are used to arc-clad the repair material to the repair area of ​​the wind turbine gear to be repaired; S60: subtractive processing is performed on the repair area of ​​the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear; in this way, when the wind turbine gear to be repaired is repaired, the repair material can be arc-claded to the repair area of ​​the wind turbine gear to be repaired according to the shape of the three-dimensional model of the repair area and suitable arc cladding additive manufacturing process parameters, so that the size and surface accuracy of the repair area of ​​the wind turbine gear after arc cladding are similar to those of the original wind turbine gear, thereby improving the accuracy of the repaired wind turbine gear and reducing the time required for processing the surface of the repaired wind turbine gear, thereby improving the repair efficiency of the wind turbine gear. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a flow chart of the wind power gear adding and subtracting material repair method of the present application.

[0018] Figure 2 It is a schematic diagram of the repair device of the present application.

[0019] Figure 3 This is an oblique bird's-eye view of the three-dimensional model of the wind turbine gear to be repaired in the present application.

[0020] Figure 4 It is a side view of the three-dimensional model of the area to be repaired in the present application.

[0021] Figure 5 It is a side view of the three-dimensional model of the area to be repaired in the present application from another perspective.

[0022] Figure 6 It is a side view of the thickened three-dimensional model of the area to be repaired in the present application.

[0023] Figure 7 It is a three-dimensional model of the repaired wind turbine gear of the present application.

[0024] Figure 8 This is the sample after rough milling in Example 2 of the present application.

[0025] Fig. 9 This is the sample after semi-finishing milling in Example 2 of the present application.

[0026] Fig.10 This is the sample after fine milling in Example 2 of the present application.

[0027] In the figure: a wind turbine gear repair device 10, a three-dimensional data acquisition module 20, a three-dimensional model building module 30, a gear material acquisition module 40, a repair parameter acquisition module 50, a wind turbine gear material addition module 60, and a wind turbine gear material reduction module 70. DETAILED DESCRIPTION

[0028] The technical solutions and technical effects of the embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings of the present invention.

[0029] Please refer to Figure 1 In a first aspect, the present invention provides a method for repairing wind turbine gears by adding or subtracting materials, comprising the following steps: S10: Scanning the wind turbine gear to be repaired using a three-dimensional scanning device to obtain point cloud data of the wind turbine gear to be repaired; S20: constructing a three-dimensional model of the wind turbine gear to be repaired according to the point cloud data of the wind turbine gear to be repaired; S30: constructing a three-dimensional model of an undamaged wind turbine gear, and performing a Boolean operation on the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired, so as to obtain a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired; S40: Obtain the physical and chemical properties of the wind turbine gear material to be repaired through material testing equipment, and select appropriate repair materials and arc cladding additive manufacturing process parameters accordingly; S50: performing thickening processing on the three-dimensional model of the area to be repaired, and arc-cladding the repair material to the area to be repaired of the wind turbine gear to be repaired according to the three-dimensional model of the area to be repaired after the thickening processing and the arc cladding additive manufacturing process parameters; S60: performing subtractive processing on the area to be repaired of the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear.

[0030] Furthermore, S10 includes: S11, pre-processing the repair area of ​​the wind turbine gear to be repaired; S12, placing positioning marks on the wind turbine gear to be repaired; specifically, when pasting the positioning marks, a suitable positioning mark type and position should be selected to avoid placing two marks in a straight line, and be careful not to press the edge of another positioning mark or cause folding to prevent incorrect splicing; S13, calibrating the handheld 3D scanner; specifically, ensuring that the handheld 3D scanner points to the center of the standard plate, and the red line is aligned with the green rectangular frame, and when a window of "Scanner calibration optimized" pops up, it indicates that the calibration of the handheld 3D scanner is completed; S14, use a handheld 3D scanner to scan the wind turbine gear to be repaired and the positioning mark points from various angles, obtain the point cloud data model of the wind turbine gear to be repaired, and export and save the point cloud data of the wind turbine gear to be repaired; specifically, the built-in software system of the handheld 3D scanner will automatically identify the point cloud data and automatically splice it according to the fixed positioning mark points to obtain the point cloud data model of the wind turbine gear to be repaired, and then export and save the point cloud data of the wind turbine gear to be repaired in STL format, completing the point cloud data collection operation of the wind turbine gear to be repaired.

[0031] Furthermore, S11 includes: S111, performing flaw detection on the tooth surface of the wind turbine gear to be repaired; S112, if cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the tooth surface of the wind turbine gear to be repaired is subjected to crack removal treatment, for example, grinding, and then returns to S111; if no cracks are detected inside the tooth surface of the wind turbine gear to be repaired, proceed to the next step; S113, removing pollutants on the surface of the wind turbine gear to be repaired, such as oxide layer, oil stains, rust impurities, etc.

[0032] Furthermore, in S14, when using a handheld 3D scanner to perform data sampling, the method includes: Data collection is performed in a stable environment with low light and no stroboscopic light to avoid the influence of the collection environment on the accuracy of data collection, for example, the light in the collection environment is too bright, there are reflections and backlight reflections, etc.; and when the collected point cloud data is not good, a layer of white developer is evenly sprayed on the surface of the wind turbine gear to be repaired to eliminate the influence of the reflection on the surface of the wind turbine gear to be repaired on the scanning accuracy of the handheld 3D scanner, thereby improving the accuracy of the acquired point cloud data.

[0033] Furthermore, S20 includes: S21, preprocessing the point cloud data of the wind turbine gear to be repaired stored in S14 to remove noise and redundant data therein, thereby reducing computer operation time and improving model processing accuracy; specifically, preprocessing includes data filtering, data denoising and data simplification, among which data filtering is to remove invalid data such as outliers and duplicate points by setting a threshold; data denoising is to use a filtering algorithm, such as Gaussian filtering, median filtering, etc., to remove noise in the point cloud data; data simplification is to reduce the amount of point cloud data and improve processing efficiency through a specific sampling method, such as a downsampling method; S22, importing the pre-processed point cloud data of the wind turbine gear to be repaired into the reverse engineering software to generate a point cloud data model of the wind turbine gear to be repaired; specifically, the reverse engineering software used is Geo magic Design X, and the imported data format is STL; S23, based on the point cloud data model of the wind turbine gear to be repaired, generating a three-dimensional model of the internal cylinder of the wind turbine gear to be repaired; specifically, comprising the following steps: 1. creating a reference plane based on multiple points at the bottom of the point cloud data model of the wind turbine gear to be repaired; 2. drawing the inner diameter contour of the wind turbine gear to be repaired on the reference plane; 3. stretching the inner diameter contour to obtain a three-dimensional model of the internal cylinder of the wind turbine gear to be repaired; S24, based on the point cloud data model of the wind turbine gear to be repaired, generate a three-dimensional model of the external teeth of the wind turbine gear to be repaired; specifically, it includes the following steps: 1. Divide the point cloud data model of the wind turbine gear to be repaired into fields, and create multiple sections based on the damaged tooth profile in the point cloud data model of the wind turbine gear to be repaired; 2. Use the sweeping method to reversely obtain the multiple sections created in the previous step to obtain the damaged tooth profile model; 3. Use the original point cloud data model as the boundary to perform surface trimming on the part of the damaged tooth profile model that exceeds the point cloud data model of the wind turbine gear to be repaired; 4. Perform operations such as rounding on the damaged tooth profile model to obtain a three-dimensional model of the damaged teeth of the wind turbine gear to be repaired; 5. 6. Use the sweeping method to reversely obtain the multiple sections created in the previous step to obtain the tooth profile model before damage; 7. Use the original point cloud data model as the boundary to perform surface trimming on the part of the tooth profile model before damage that exceeds the point cloud data model of the wind turbine gear to be repaired; 8. Perform operations such as filleting on the tooth profile model before damage to obtain a three-dimensional model of the complete teeth of the wind turbine gear to be repaired; 9. Select a suitable position to create a reference line based on the point cloud data model of the repaired wind turbine gear; 10. Perform a circular array on the three-dimensional model of the complete teeth of the wind turbine gear to be repaired based on the reference line to obtain a three-dimensional model of the external teeth of the wind turbine gear to be repaired; S25, merging the three-dimensional model of the internal cylinder of the wind turbine gear to be repaired and the three-dimensional model of the external teeth of the wind turbine gear to be repaired to obtain the three-dimensional model of the wind turbine gear to be repaired; specifically, selecting the three-dimensional model of the internal cylinder of the wind turbine gear to be repaired and the three-dimensional model of the external teeth of the wind turbine gear to be repaired, and performing a Boolean merge operation to merge them into a whole, thereby obtaining the three-dimensional model of the wind turbine gear to be repaired.

[0034] Furthermore, S30 includes: S31, constructing a three-dimensional model of the undamaged wind turbine gear according to the engineering drawings provided by the manufacturer or the point cloud data of the wind turbine gear to be repaired; In one embodiment, constructing the three-dimensional model of the undamaged wind turbine gear includes: establishing a three-dimensional model according to an engineering drawing provided by a manufacturer to obtain a three-dimensional model of the undamaged wind turbine gear; In one embodiment, constructing a three-dimensional model of an undamaged wind turbine gear includes the following steps: 1. Based on a complete tooth in a point cloud data model of the wind turbine gear to be repaired, creating multiple sections to generate tooth profile model information of different sections; 2. Based on the generated tooth profile model information of different sections, sweeping to generate a complete gear three-dimensional model; S32, by performing Boolean operations on the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired, a three-dimensional model of the to-be-repaired area of ​​the wind turbine gear to be repaired is obtained. Specifically, the following steps are included: 1. Using reverse design software, the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired are respectively imported; 2. Using the Boolean operation instructions in the reverse software, the following three-dimensional models are respectively obtained: Figure 3 The three-dimensional model of the wind turbine gear to be repaired is shown in FIG. Figures 4 to 5 A three-dimensional model of the area to be repaired is shown; Furthermore, S40 includes: S41, sampling and analyzing the wind turbine gear to be repaired by scanning equipment to obtain the physical and chemical properties of the materials used in the wind turbine gear to be repaired; specifically, using a ZEISS Sigma400 field emission scanning electron microscope at a low acceleration voltage to observe the structure of the wind turbine gear to be repaired at the nanoscale, and performing qualitative, semi-quantitative and quantitative analysis on the micro-area elements on the surface of the wind turbine gear to be repaired, so as to obtain the material composition information of the wind turbine gear to be repaired, and then compare the material composition information of the wind turbine gear to be repaired with the national standard to determine the material grade and various mechanical properties of the wind turbine gear to be repaired.

[0035] S42, searching for the material used for the wind turbine gear to be repaired in a pre-set base material library. If the material can be found, the corresponding repair material and the optimal arc cladding additive manufacturing process parameters are selected according to the welding wire brand corresponding to the material, and the process proceeds to S50. If the material cannot be found, the process proceeds to the next step; S43, preliminarily selecting a suitable repair material according to the mechanical properties of the material used for the wind turbine gear to be repaired; specifically, according to the brand and various mechanical properties of the material of the wind turbine gear to be repaired, and referring to the corresponding mechanical property table of the welding wire, preliminarily selecting a welding wire with a mechanical property slightly higher than that of the material of the wind turbine gear to be repaired as the repair material; S44, conducting experiments on the repair material to determine arc cladding additive manufacturing process parameters that can form a weld bead; specifically, by conducting a cladding pre-experiment on the repair material, determining the range of arc cladding additive manufacturing process parameters that can form the morphology of the cladding layer, wherein the arc cladding additive manufacturing process parameters mainly include welding voltage, wire feeding speed, filling speed, filling spacing and layer height; S45, continuing to perform cladding experiments on the repair material to optimize the arc cladding additive manufacturing process parameters, thereby obtaining the best arc cladding additive manufacturing process parameters for the repair material; specifically, using the response surface method to perform a single-layer single-pass cladding experiment on the repair material, thereby optimizing the arc cladding additive manufacturing process parameters, and its response value is a pre-set weld residual stress and heat-affected zone residual stress, and on this basis, single-layer multi-pass and multi-layer multi-pass cladding experiments are performed in sequence, and the filling spacing and layer height of the arc cladding additive manufacturing process parameters are optimized respectively, and the best arc cladding additive manufacturing process parameters are obtained; S46, processing the repair material into a sample having the same tooth shape as the wind turbine gear to be repaired according to the three-dimensional model of the wind turbine gear to be repaired and the optimal arc cladding additive manufacturing process parameters of the repair material; S47, various mechanical property tests are performed on the sample to determine whether the sample meets the predetermined requirements. If the predetermined requirements are met, the next step is performed. If the predetermined requirements are not met, the repair material is replaced and the test is repeated. Specifically, various mechanical property tests are performed on the sample, such as Hopkinson tensile test, hardness test, residual stress test, etc. If the various mechanical properties cannot meet the predetermined requirements, the repair material is reselected and the test is repeated. If the various mechanical properties meet the predetermined requirements, the next step is performed, wherein the predetermined requirements are determined according to the materials used for the wind turbine gear to be repaired. S48, adding the material used for the wind turbine gear to be repaired, the corresponding repair material and the optimal arc cladding additive manufacturing process parameters to the base material library.

[0036] Furthermore, S50 includes: S51, the external tooth shape of the three-dimensional model of the repaired area is thickened to reserve a reasonable amount of material shrinkage and material reduction processing allowance, and the following is obtained: Figure 6 The three-dimensional model of the area to be repaired after the thickening treatment is shown; S52, importing the three-dimensional model of the wind turbine gear to be repaired and the three-dimensional model of the area to be repaired after the thickening treatment into the control software; S53, fixing the wind turbine gear to be repaired on the working platform, and measuring the spatial coordinates of the wind turbine gear to be repaired; S54, inputting the spatial coordinates into the control software to ensure that the placement position of the three-dimensional model of the wind turbine gear to be repaired in the software is consistent with the position of the actual wind turbine gear to be repaired; and matching the three-dimensional model of the wind turbine gear to be repaired and the three-dimensional model of the area to be repaired in the control software to ensure that the repair position in the welding process is consistent with the position in the simulation process; S55, planning a reasonable additive processing trajectory, and simulating and optimizing the process of adding the three-dimensional model of the area to be repaired to the area to be repaired in the three-dimensional model of the wind turbine gear to be repaired in the control software, if the simulation result meets the predetermined requirements, then proceeding to the next step, if the simulation result does not meet the predetermined requirements, then replanning the additive trajectory; wherein, firstly plane slicing the three-dimensional model of the area to be repaired, and then determining the additive direction by selecting points and normals; S56, input the optimal arc cladding additive manufacturing process parameters of the repair material, and control the arc cladding additive manufacturing equipment to perform dry run through the control software. If the dry run path is correct, the repair material is arc clad to the repair area of ​​the wind turbine gear to be repaired to perform the repair operation; if the dry run path is inaccurate, the additive trajectory is reconfirmed; specifically, an ABB robot teaching pendant is used as the arc cladding additive manufacturing equipment.

[0037] Furthermore, S60 includes: S61, reducing the residual stress and hardness of the area to be repaired of the wind turbine gear after arc cladding; specifically, since the surface residual stress and hardness of the cladding layer formed by the repair material cladding on the area to be repaired are relatively high, it is difficult for the tool to mill it, so it is necessary to first reduce the residual stress and hardness of the area to be repaired of the wind turbine gear to be repaired, for example, heating the cladding layer in the area to be repaired of the wind turbine gear to facilitate subsequent processing.

[0038] S62, performing rough milling on the area to be repaired of the wind turbine gear after reducing the residual stress and hardness, so as to obtain a tooth shape of the wind turbine gear; S63, performing semi-finishing milling on the area to be repaired of the wind turbine gear after rough milling to remove the "terraced" steps of the rough milling; S64, performing finish milling on the area to be repaired of the wind turbine gear after the semi-finish milling, so that its dimensional accuracy reaches a predetermined requirement; S65, performing a quenching and tempering treatment on the area to be repaired of the wind turbine gear after fine milling, so as to restore the hardness of the area; S66, performing grinding surface treatment on the area to be repaired of the wind turbine gear after quenching and tempering treatment, so that the tooth surface accuracy, surface quality and performance meet the design requirements; S67, performing a performance test on the wind turbine gear after the grinding process to confirm whether its various performances meet the performance requirements of the original wind turbine gear. If the various performances do not meet the performance requirements of the original wind turbine gear, the wind turbine gear is remanufactured until the various performances meet the performance requirements of the original wind turbine gear; if the various performances meet the performance requirements of the original wind turbine gear, the wind turbine gear is repaired, and the following is obtained: Figure 7 The repaired wind turbine gear is shown.

[0039] Please refer to Figure 2 In a second aspect, the present invention provides a wind turbine gear repair device 10, which includes: a three-dimensional data acquisition module 20, a three-dimensional model building module 30, a gear physical and chemical properties acquisition module 40, a repair parameter acquisition module 50, a wind turbine gear material addition module 60 and a wind turbine gear material reduction module 70: A three-dimensional data acquisition module 20, configured to acquire three-dimensional data of the wind turbine gear to be repaired; A three-dimensional model building module 30 is configured to obtain a three-dimensional model of the wind turbine gear to be repaired and a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired according to the three-dimensional data of the wind turbine gear to be repaired; The gear physical and chemical properties acquisition module 40 is configured to acquire physical and chemical properties information of the wind turbine gear to be repaired; A repair parameter acquisition module 50 is configured to select appropriate repair materials and arc cladding additive manufacturing process parameters according to the material information of the wind turbine gear to be repaired; The wind turbine gear additive module 60 is configured to arc-clad the repair material to the repaired area of ​​the wind turbine gear to be repaired according to the three-dimensional model of the repaired area; The wind turbine gear subtractive module 70 is configured to perform subtractive processing on the area to be repaired of the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear.

[0040] Example 1: Determining the cause of the fracture of the area to be repaired in the wind turbine gear to be repaired A ZEISS Sigma400 field emission scanning electron microscope is used to scan the repair area of ​​the wind turbine gear to be repaired, and the secondary electron image of the surface morphology of the repair area of ​​the wind turbine gear to be repaired is photographed by adjusting the positioning observation area and the filament lens tube through the manipulator, and the reflected electron image is observed and processed, so as to obtain the micro-morphological structure information of the surface of the repair area of ​​the wind turbine gear to be repaired through the processed image, so as to judge the fracture cause of the repair area of ​​the wind turbine gear according to the micro-morphological structure information of the surface of the repair area of ​​the wind turbine gear to be repaired, so as to perform optimization operations according to the fracture cause, for example, improving the design defects of the wind turbine gear and improving the lubrication system in the operating environment, so as to prevent the wind turbine gear from breaking again.

[0041] Example 2: Experimental description of the sample processing in step S36 In this embodiment, the material of the wind turbine gear is 18CrNiMo, and the repair material used is welding wire with a brand of SMSX900A.

[0042] 1. Using arc cladding to add welding wire to a specimen with the same tooth shape as the wind turbine gear to be repaired after thickening treatment; 2. Before heat treatment of the sample to reduce the hardness, use a marker to evenly draw 10 points on the surface of the sample, and ensure that these points are distributed in the center and edge of the sample. Use a Rockwell hardness tester to measure the hardness of each point. The measurement results are as follows: Table 1

[0043] Taking the average as the final result, it is concluded that the hardness of the sample is 71HRC; 3. Place the sample in a muffle furnace at room temperature, start the instrument, and heat it to 830°C at a rate of 5°C per minute. After keeping it warm for one hour, take out the sample that has cooled to 200°C in the furnace and air cool it. 4. Draw ten points on the surface of the sample that match the positions before heating, and use a Rockwell hardness tester to measure the hardness of each point. The measurement results are as follows: Table 2

[0044] Taking the average as the final result, it is concluded that the hardness of the sample is 40HRC. Compared with the data before heating, it can be found that the hardness of the sample is reduced by 31HRC. At the same time, by observing the surface of the sample, it can be found that the oxide produced on the surface of the sample during heating falls off as the sample is taken out of the furnace, and the processing marks on the surface of the sample also disappear. 5. Rough milling is performed on the sample until the machining allowance reaches 0.5mm and the corresponding tooth shape is machined. The process allowance is 0.6mm. The surface smoothness of the sample after machining is as follows: Figure 8 As shown, the tooth shape is formed, and the surface of the sample has obvious processing marks and is relatively smooth; 6. Perform semi-finishing milling on the sample until the machining allowance reaches 0.1mm and remove the "terraces" formed during rough milling. The process allowance is 0.3mm. The surface smoothness of the sample after machining is as follows: Fig. 9 As shown, the surface of the specimen is smoother than that of the rough machining, and the machining marks become lighter; 7. Perform fine milling on the sample until the surface roughness of the sample reaches 0.8μm, where the process allowance is 0.1mm. The surface smoothness of the sample after processing is as follows: Fig.10As shown, the surface of the specimen is smoother than that of the rough machining, and the machining marks become lighter; 8. Before performing heat treatment on the sample to restore its hardness, use a marker to evenly draw 10 points on the surface of the sample, and ensure that these points are distributed in the center and edge of the sample. Use a Rockwell hardness tester to measure the hardness of each point. The measurement results are as follows: Table 3

[0045] The average value is taken as the final result, and the hardness of the sample is 50HRC; 9. Place the sample in a muffle furnace at room temperature, start the instrument, and heat it to 940°C at a rate of 5°C per minute. After keeping it warm for one hour, take out the sample immediately for air cooling. When the furnace temperature drops to 200°C, place the sample in the muffle furnace again for low-temperature tempering. After keeping it warm for one and a half hours, take out the sample immediately for air cooling. 10. Draw ten points on the surface of the sample that match the positions before heating, and use a Rockwell hardness tester to measure the hardness of each point. The measurement results are as follows: Table 4

[0046] Taking the average as the final result, it is concluded that the hardness of the sample is 70HRC. Comparing with the initial hardness value of the sample, it can be concluded that the hardness of the sample has been restored.

[0047] 11. Since the surface roughness of the sample after fine milling does not reach 0.8μm, it is necessary to grind the surface of the sample to make its surface roughness reach 0.8μm, where the machining allowance is 0.3mm. After machining, the surface smoothness of the sample shape is smoother than that during fine milling, and the machining marks are basically gone.

[0048] The process of processing the sample in this embodiment is consistent with the step of "performing subtractive processing on the area to be repaired of the wind turbine gear after arc cladding" in S50. The purpose is to make the state of the sample the same as the state of the repaired wind turbine gear, so that the results of various mechanical tests on the sample are the same as the results of various mechanical tests on the repaired wind turbine gear.

[0049] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A wind power gear repair method by adding or subtracting materials. It is characterized in that The following steps are involved: S10: Scanning the wind turbine gear to be repaired using a three-dimensional scanning device to obtain point cloud data of the wind turbine gear to be repaired; S20: constructing a three-dimensional model of the wind turbine gear to be repaired according to the point cloud data of the wind turbine gear to be repaired; S30: constructing a three-dimensional model of an undamaged wind turbine gear, and performing a Boolean operation on the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired, so as to obtain a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired; S40: obtaining the physical and chemical properties of the wind turbine gear material to be repaired through material testing equipment, and selecting the repair material and arc cladding additive manufacturing process parameters accordingly; S50: performing thickening processing on the three-dimensional model of the area to be repaired, and arc-cladding the repair material to the area to be repaired of the wind turbine gear to be repaired according to the three-dimensional model of the area to be repaired after the thickening processing and the arc cladding additive manufacturing process parameters; S60: performing subtractive processing on the area to be repaired of the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear.

2. The wind turbine gear repair method of claim 1, It is characterized in that The S10 includes: S11, pre-processing the repair area of ​​the wind turbine gear to be repaired; S12, placing a positioning mark point on the wind turbine gear to be repaired; S13, calibrating the handheld three-dimensional scanner; S14, using a handheld 3D scanner to scan the wind turbine gear to be repaired and the positioning mark points from various angles, obtaining a point cloud data model of the wind turbine gear to be repaired, and exporting and saving the point cloud data of the wind turbine gear to be repaired.

3. The wind turbine gear repair method of claim 2, It is characterized in that The S11 includes: S111, performing flaw detection on the tooth surface of the wind turbine gear to be repaired; S112, if cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the tooth surface of the wind turbine gear to be repaired is subjected to crack removal processing, and then the process returns to S111; if cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the process proceeds to the next step; S113, removing pollutants on the surface of the wind turbine gear to be repaired.

4. The wind turbine gear repair method of claim 2, It is characterized in that In the S14, when using a handheld three-dimensional scanner to perform data sampling, the method includes: Data collection is performed in a stable environment with no stroboscopic light and weak lighting; and when the collected point cloud data is not effective, a layer of white developer is evenly sprayed on the surface of the wind turbine gear to be repaired to eliminate the influence of the reflection of the surface of the wind turbine gear to be repaired on the scanning accuracy of the handheld 3D scanner.

5. The wind turbine gear repair method of claim 2, It is characterized in that The S20 includes: S21, preprocessing the point cloud data of the wind turbine gear to be repaired stored in S14 to remove noise and redundant data therein, thereby reducing computer operation time and improving model processing accuracy; S22, importing the pre-processed point cloud data of the wind turbine gear to be repaired into reverse engineering software to generate a point cloud data model of the wind turbine gear to be repaired; S23, generating a three-dimensional model of the internal cylinder of the wind turbine gear to be repaired based on the point cloud data model of the wind turbine gear to be repaired; S24, generating a three-dimensional model of the external teeth of the wind turbine gear to be repaired based on the point cloud data model of the wind turbine gear to be repaired; S25, merging the three-dimensional model of the inner cylinder of the wind turbine gear to be repaired with the three-dimensional model of the outer teeth of the wind turbine gear to be repaired to obtain the three-dimensional model of the wind turbine gear to be repaired.

6. The wind turbine gear repair method of claim 1, It is characterized in that The S30 includes: S31, constructing a three-dimensional model of the undamaged wind turbine gear according to the engineering drawings provided by the manufacturer or the point cloud data of the wind turbine gear to be repaired; S32, obtaining a three-dimensional model of the to-be-repaired region of the wind turbine gear to be repaired by performing Boolean operations on the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired.

7. The wind turbine gear repair method of claim 1, It is characterized in that The S40 includes: S41, sampling and analyzing the wind turbine gear to be repaired by scanning equipment to obtain the physical and chemical properties of the material of the wind turbine gear to be repaired; S42, searching for the material used for the wind turbine gear to be repaired in a pre-set base material library. If the material can be found, the corresponding repair material and the optimal arc cladding additive manufacturing process parameters are selected according to the welding wire brand corresponding to the material, and the process goes to S50. If the material cannot be found, the process goes to the next step; S43, preliminarily selecting a suitable repair material according to the mechanical properties of the material used for the wind turbine gear to be repaired; S44, conducting experiments on the repair material to determine the arc cladding additive manufacturing process parameters that enable the weld bead to be formed; S45, continue to experiment on the repair material to optimize the arc cladding additive manufacturing process parameters to obtain the best arc cladding additive manufacturing process parameters for the repair material; S46, processing the repair material into a sample having the same tooth shape as the wind turbine gear to be repaired according to the three-dimensional model of the wind turbine gear to be repaired and the optimal arc cladding additive manufacturing process parameters of the repair material; S47, various mechanical property tests are performed on the sample to determine whether the sample meets the predetermined requirements. If the sample meets the predetermined requirements, the next step is performed. If the sample does not meet the predetermined requirements, the repair material is replaced and the test is repeated. S48, adding the material used for the wind turbine gear to be repaired, the corresponding repair material and the optimal arc cladding additive manufacturing process parameters to the substrate library.

8. The wind turbine gear repair method of claim 1, It is characterized in that The S50 includes: S51, performing a thickening process on the external tooth shape of the three-dimensional model of the area to be repaired to reserve a reasonable amount of material addition shrinkage and material subtraction processing allowance, and obtaining a three-dimensional model of the area to be repaired after the thickening process; S52, importing the three-dimensional model of the wind turbine gear to be repaired and the three-dimensional model of the area to be repaired after the thickening treatment into the control software; S53, fixing the wind turbine gear to be repaired on the working platform, and measuring the spatial coordinates of the wind turbine gear to be repaired; S54, inputting the spatial coordinates into the control software, ensuring that the placement position of the three-dimensional model of the wind turbine gear to be repaired in the software is consistent with the position of the actual wind turbine gear to be repaired, and matching the three-dimensional model of the wind turbine gear to be repaired and the three-dimensional model of the area to be repaired in the control software; S55, planning a reasonable additive processing trajectory, and performing simulation optimization on the process of adding the three-dimensional model of the area to be repaired to the area to be repaired in the three-dimensional model of the wind turbine gear to be repaired in the control software, if the simulation result meets the predetermined requirements, proceeding to the next step, if the simulation result does not meet the predetermined requirements, re-planning the additive trajectory; S56, input the optimal arc cladding additive manufacturing process parameters of the repair material, and control the arc cladding additive manufacturing equipment to perform dry run through the control software. If the dry run path is correct, put the repair material and arc clad it to the repair area of ​​the wind turbine gear to be repaired; if the dry run path is inaccurate, reconfirm the additive processing trajectory.

9. The wind power gear repair method of claim 1, It is characterized in that The S60 includes: S61, reducing the residual stress and hardness of the area to be repaired of the wind turbine gear after arc cladding; S62, performing rough milling on the area to be repaired of the wind turbine gear after reducing the residual stress and hardness, so as to obtain a tooth shape of the wind turbine gear; S63, performing semi-finishing milling on the area to be repaired of the wind turbine gear after the rough milling process, to remove the "terrace" steps formed during the rough milling process; S64, performing finish milling on the area to be repaired of the wind turbine gear after the semi-finish milling, so that its dimensional accuracy reaches a predetermined requirement; S65, performing a quenching and tempering treatment on the area to be repaired of the wind turbine gear after fine milling, so as to restore the hardness of the area; S66, performing grinding surface treatment on the area to be repaired of the wind turbine gear after quenching and tempering treatment, so that the tooth surface accuracy, surface quality and performance meet the design requirements; S67, perform performance testing on the wind turbine gear after grinding to confirm whether its various performances meet the performance requirements of the original wind turbine gear. If the various performances do not meet the performance requirements of the original wind turbine gear, the wind turbine gear is remanufactured until the various performances meet the performance requirements of the original wind turbine gear; if the various performances meet the performance requirements of the original wind turbine gear, the repair of the wind turbine gear is completed.

10. A wind turbine gear repair device, It is characterized in that The wind turbine gear repair device includes: a three-dimensional data acquisition module, a three-dimensional model building module, a gear physical and chemical properties acquisition module, a repair parameter acquisition module, a wind turbine gear material addition module and a wind turbine gear material reduction module: A three-dimensional data acquisition module, configured to acquire three-dimensional data of the wind turbine gear to be repaired; A three-dimensional model building module, configured to obtain a three-dimensional model of the wind turbine gear to be repaired and a three-dimensional model of the area to be repaired in the wind turbine gear to be repaired according to the three-dimensional data of the wind turbine gear to be repaired; A gear physical and chemical properties acquisition module, configured to acquire material information of the wind turbine gear to be repaired; A repair parameter acquisition module, configured to select appropriate repair materials and arc cladding additive manufacturing process parameters according to material information of the wind turbine gear to be repaired; A wind turbine gear additive module, configured to arc-clad the repair material onto the repaired area of ​​the wind turbine gear to be repaired according to the three-dimensional model of the repaired area; The wind turbine gear subtractive module is configured to perform subtractive processing on the area to be repaired of the wind turbine gear after arc cladding, so that the repaired wind turbine gear meets the performance requirements of the original wind turbine gear.

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