Wind power gear material addition and subtraction repair method and repair device

Abstract

The present invention relates to the technical field of wind power equipment, and in particular to a method and device for repairing wind power gears by additive and subtractive material processing, wherein the repair method comprises the following steps: S10: obtaining point cloud data of the wind power gear to be repaired; S20: constructing a three-dimensional model of the wind power gear to be repaired based on the data obtained in S10; S30: obtaining a three-dimensional model of the area to be repaired in the wind power gear to be repaired through Boolean operation; S40: obtaining material information of the wind power gear to be repaired, and selecting repair materials and arc cladding additive manufacturing process parameters accordingly; S50: thickening 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 power gear to be repaired based on the model and the arc cladding additive manufacturing process parameters; S60: performing subtractive processing on the wind power gear after arc cladding; in this way, the surface accuracy of the repaired wind power gear is close to that of the original wind power gear, so as to reduce the time required for subsequent surface treatment and improve the repair efficiency of the wind power gear.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power equipment, and in particular to a wind power gear material addition and subtraction repair method and a repair device. 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. The main forms of failure 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 material according to the material used in the wind turbine gear, and placing it 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 wind turbine gear surface 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-processing, 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 by the wind turbine gears. This increases the time required for grinding and polishing the cladding layer, resulting in a decrease in the repair efficiency of the 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, reduce the time required for processing the surface of the repaired wind turbine gear, and thus improve 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:

[0007] 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;

[0008] S20: constructing 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;

[0009] S30: constructing a three-dimensional model of the 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, to obtain a three-dimensional model of the to-be-repaired region of the wind turbine gear to be repaired;

[0010] S40: Obtain the physical and chemical properties of the wind turbine gear material to be repaired through material testing equipment, and select the repair material and arc cladding additive manufacturing process parameters accordingly;

[0011] S50: performing a thickening process on the three-dimensional model of the area to be repaired, and arc-cladding a repair material onto the area to be repaired of the wind turbine gear to be repaired according to the thickened three-dimensional model of the area to be repaired and arc cladding additive manufacturing process parameters;

[0012] 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.

[0013] Preferably, the S10 includes:

[0014] S11, pre-processing the area to be repaired of the wind turbine gear to be repaired;

[0015] S12, placing positioning marking points on the wind turbine gear to be repaired;

[0016] S13, performing a calibration operation on the handheld 3D scanner;

[0017] 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.

[0018] Preferably, the S11 includes:

[0019] S111, perform flaw detection on the tooth surface of the wind turbine gear to be repaired;

[0020] 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 no cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the process proceeds to the next step;

[0021] S113, removing pollutants on the surface of the wind turbine gear to be repaired.

[0022] Preferably, in said S14, when using a handheld three-dimensional scanner to perform data sampling, the method includes:

[0023] Data collection is performed in a stable environment with no stroboscopic light and low lighting conditions. 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 impact of reflections from the surface of the wind turbine gear to be repaired on the scanning accuracy of the handheld 3D scanner.

[0024] Preferably, the S20 includes:

[0025] S21, pre-processing the point cloud data of the wind turbine gear to be repaired saved in S14 to remove noise and redundant data therein, thereby reducing computer operation time and improving model processing accuracy;

[0026] 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;

[0027] 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;

[0028] 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;

[0029] S25, merging the three-dimensional model of the inner cylinder of the wind turbine gear to be repaired and 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.

[0030] Preferably, the S30 includes:

[0031] S31, constructing a three-dimensional model of the undamaged wind turbine gear based on the engineering drawings provided by the manufacturer or the point cloud data of the wind turbine gear to be repaired;

[0032] S32, obtaining a three-dimensional model of the to-be-repaired region of the wind turbine gear to be repaired by 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.

[0033] Preferably, the S40 includes:

[0034] S41, sampling and analyzing the wind turbine gear to be repaired by a scanning device to obtain the physical and chemical properties of the material 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, selecting the corresponding repair material and optimal arc cladding additive manufacturing process parameters based on the welding wire brand corresponding to the material, and entering S50. If the material cannot be found, proceeding to the next step;

[0036] S43, preliminarily selecting a suitable repair material based on the mechanical properties of the material used for the wind turbine gear to be repaired;

[0037] S44, conduct experiments on the repair material to determine the arc cladding additive manufacturing process parameters that enable the weld bead to be formed;

[0038] S45, continuing to experiment on the repair material to optimize the arc cladding additive manufacturing process parameters to obtain optimal arc cladding additive manufacturing process parameters for the repair material;

[0039] 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;

[0040] S47, performing various mechanical property tests on the sample to determine whether the sample meets the predetermined requirements. If so, proceed to the next step. If not, replace the repair material and repeat the test.

[0041] 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.

[0042] Preferably, the S50 includes:

[0043] S51, performing a thickening process on the external tooth profile of the three-dimensional model of the area to be repaired to reserve a reasonable amount of material shrinkage and material reduction processing allowance, thereby obtaining a three-dimensional model of the area to be repaired after the thickening process;

[0044] 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;

[0045] S53, fixing the wind turbine gear to be repaired on a work platform, and measuring the spatial coordinates of the wind turbine gear to be repaired;

[0046] 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 coordinating 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;

[0047] S55, planning a reasonable additive machining 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, replanning the additive machining trajectory;

[0048] S56, input the optimal arc cladding additive manufacturing process parameters of the repair material, and control the arc cladding additive manufacturing equipment through the control software to perform dry run. If the dry run path is correct, the repair material is placed and arc clad to the repair area of ​​the wind turbine gear to be repaired; if the dry run path is inaccurate, the additive processing trajectory is reconfirmed.

[0049] Preferably, the S60 includes:

[0050] S61, reducing the residual stress and hardness of the area to be repaired of the wind turbine gear after arc cladding;

[0051] S62, performing rough milling on the area to be repaired of the wind turbine gear after reducing the residual stress and hardness, to form a tooth shape of the wind turbine gear;

[0052] 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;

[0053] 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 meets the predetermined requirement;

[0054] S65, performing a quenching and tempering treatment on the area to be repaired of the wind turbine gear after fine milling to restore the hardness of the area;

[0055] S66, performing surface treatment by grinding 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;

[0056] 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, remanufacture the wind turbine gear 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.

[0057] 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 additive module, and a wind turbine gear subtractive module:

[0058] a three-dimensional data acquisition module configured to acquire three-dimensional data of the wind turbine gear to be repaired;

[0059] 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 based on the three-dimensional data of the wind turbine gear to be repaired;

[0060] A gear physical and chemical properties acquisition module configured to obtain material information of the wind turbine gear to be repaired;

[0061] A repair parameter acquisition module is 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;

[0062] A wind turbine gear additive module is configured to arc-clad the repair material onto the repaired area of ​​the wind turbine gear according to a three-dimensional model of the repaired area;

[0063] 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.

[0064] 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 operation 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 wind turbine gear material 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 area to be repaired of the wind turbine gear to be repaired; S60: subtractive processing is performed 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; in this way, when the wind turbine gear to be repaired is repaired, the repair material can be arc-claded to the area to be repaired of the wind turbine gear to be repaired according to the shape of the three-dimensional model of the area to be repaired and appropriate arc cladding additive manufacturing process parameters, so that the size and surface accuracy of the area to be repaired 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

[0065] Figure 1 This is a flow chart of the wind power gear material addition and subtraction repair method of the present application.

[0066] Figure 2 Schematic diagram of the repair device of the present application.

[0067] 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.

[0068] Figure 4 It is a side view of the three-dimensional model of the area to be repaired in this application.

[0069] Figure 5 It is a side view of the three-dimensional model of the area to be repaired in this application from another perspective.

[0070] Figure 6 It is a side view of the thickened three-dimensional model of the area to be repaired in this application.

[0071] Figure 7 This is the three-dimensional model of the repaired wind turbine gear of this application.

[0072] Figure 8 This is the sample after rough milling in Example 2 of the present application.

[0073] Figure 9 This is the sample after semi-finishing milling in Example 2 of the present application.

[0074] Figure 10 This is the sample after fine milling in Example 2 of the present application.

[0075] 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 addition module 60, and a wind turbine gear subtraction module 70. DETAILED DESCRIPTION

[0076] The technical solutions and technical effects of the embodiments of the present invention are further elaborated in detail below with reference to the accompanying drawings of the present invention.

[0077] 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:

[0078] 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;

[0079] S20: constructing 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;

[0080] S30: constructing a three-dimensional model of the 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, to obtain a three-dimensional model of the to-be-repaired region of the wind turbine gear to be repaired;

[0081] 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;

[0082] S50: performing a thickening process on the three-dimensional model of the area to be repaired, and arc-cladding a repair material onto the area to be repaired of the wind turbine gear to be repaired according to the thickened three-dimensional model of the area to be repaired and arc cladding additive manufacturing process parameters;

[0083] 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.

[0084] Furthermore, S10 includes:

[0085] S11, pre-processing the area to be repaired of the wind turbine gear to be repaired;

[0086] S12, placing positioning marks on the wind turbine gear to be repaired; specifically, when affixing the positioning marks, appropriate positioning mark types and positions should be selected, avoiding placing two marks in a straight line, and taking care not to press the edge of another positioning mark or cause folding to prevent incorrect splicing;

[0087] S13, calibrating the handheld 3D scanner; specifically, ensuring that the handheld 3D scanner is pointed at the center of the standard plate, and the red line is aligned with the green rectangular frame. When a window "Scanner Calibration Optimized" pops up, it indicates that the calibration of the handheld 3D scanner is complete;

[0088] 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 attached 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.

[0089] Furthermore, S11 includes:

[0090] S111, perform flaw detection on the tooth surface of the wind turbine gear to be repaired;

[0091] 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 the process returns to S111; if no cracks are detected inside the tooth surface of the wind turbine gear to be repaired, the process proceeds to the next step;

[0092] S113, removing pollutants on the surface of the wind turbine gear to be repaired, such as oxide layer, oil stains, rust impurities, etc.

[0093] Furthermore, in S14, when using a handheld 3D scanner to perform data sampling, the method includes:

[0094] Data collection is performed in a stable environment with low lighting and no stroboscopic light to avoid the impact of the collection environment on the accuracy of data collection, such as when the collection environment light is too bright, there are reflections and backlight reflections; 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 impact 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.

[0095] Furthermore, the S20 includes:

[0096] S21, preprocessing the point cloud data of the wind turbine gear to be repaired saved 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, wherein 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 and median filtering, to remove noise in the point cloud data; data simplification is to use a specific sampling method, such as a downsampling method, to reduce the amount of point cloud data and improve processing efficiency;

[0097] 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; specifically, the reverse engineering software used is Geo magic Design X, and the imported data format is STL;

[0098] 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, the steps include: 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;

[0099] S24, based on the point cloud data model of the wind turbine gear to be repaired, generates a three-dimensional model of the external teeth of the wind turbine gear to be repaired; specifically, the following steps are included: 1. Dividing the point cloud data model of the wind turbine gear to be repaired into areas, and creating multiple sections based on the damaged tooth profile in the point cloud data model of the wind turbine gear to be repaired; 2. Reversely acquiring the multiple sections created in the previous step using a sweeping method to obtain a damaged tooth profile model; 3. Using the original point cloud data model as the boundary, perform surface trimming on the portion of the damaged tooth profile model that exceeds the point cloud data model of the wind turbine gear to be repaired; 4. Performing operations such as filleting 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. Divide the domain according to the model, and create multiple sections based on a complete tooth profile in the point cloud data model of the wind turbine gear to be repaired; 6. Use the sweep 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 cropping 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;

[0100] S25, merging the three-dimensional model of the inner cylinder of the wind turbine gear to be repaired and 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; specifically, selecting the three-dimensional model of the inner cylinder of the wind turbine gear to be repaired and the three-dimensional model of the outer 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.

[0101] Furthermore, S30 includes:

[0102] S31, constructing a three-dimensional model of the undamaged wind turbine gear based on the engineering drawings provided by the manufacturer or the point cloud data of the wind turbine gear to be repaired;

[0103] In one embodiment, constructing the three-dimensional model of the undamaged wind turbine gear includes: establishing a three-dimensional model according to engineering drawings provided by a manufacturer to obtain a three-dimensional model of the undamaged wind turbine gear;

[0104] In one embodiment, constructing a 3D 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 cross sections to generate tooth profile model information of different cross sections; 2. Based on the generated tooth profile model information of different cross sections, sweeping to generate a complete 3D model of the gear;

[0105] 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 area to be repaired in the wind turbine gear to be repaired is obtained. Specifically, the steps include: 1. using reverse design software, importing the three-dimensional model of the undamaged wind turbine gear and the three-dimensional model of the wind turbine gear to be repaired that were previously constructed; 2. using the Boolean operation instructions in the reverse software, respectively obtaining the following: Figure 3 The three-dimensional model of the wind turbine gear to be repaired is shown in FIG. Figures 4 and 5 A three-dimensional model of the area to be repaired is shown;

[0106] Furthermore, S40 includes:

[0107] 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, thereby obtaining the material composition information of the wind turbine gear to be repaired, and then comparing the material composition information of the wind turbine gear to be repaired with the national standard to determine the material brand and various mechanical properties of the wind turbine gear to be repaired.

[0108] 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 optimal arc cladding additive manufacturing process parameters are selected based on 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;

[0109] S43, preliminarily selecting a suitable repair material based on the mechanical properties of the material used for the wind turbine gear to be repaired; specifically, based on 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 welding wire, preliminarily selecting a welding wire with mechanical properties slightly higher than those of the material of the wind turbine gear to be repaired as the repair material;

[0110] S44, conducting experiments on the repair material to determine arc cladding additive manufacturing process parameters that can form a weld bead; specifically, determining a range of arc cladding additive manufacturing process parameters that can form a cladding layer morphology by conducting a preliminary cladding experiment on the repair material, wherein the arc cladding additive manufacturing process parameters mainly include welding voltage, wire feed speed, filling speed, filling spacing, and layer height;

[0111] S45, continuing to perform cladding experiments on the repair material to optimize the arc cladding additive manufacturing process parameters, thereby obtaining optimal arc cladding additive manufacturing process parameters for the repair material; specifically, using the response surface methodology to perform a single-layer single-pass cladding experiment on the repair material, thereby optimizing the arc cladding additive manufacturing process parameters, wherein the 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 sequentially performed to optimize the filling spacing and layer height of the arc cladding additive manufacturing process parameters, respectively, to obtain the optimal arc cladding additive manufacturing process parameters;

[0112] 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;

[0113] S47, performing various mechanical property tests on the sample to determine whether the sample meets predetermined requirements. If the predetermined requirements are met, proceeding to the next step. If the predetermined requirements are not met, replacing the repair material and retesting. Specifically, performing various mechanical property tests on the sample, such as a Hopkinson tensile test, a hardness test, and a residual stress test, if the mechanical properties do not meet the predetermined requirements, reselecting the repair material and retesting. If the mechanical properties meet the predetermined requirements, proceeding to the next step. The predetermined requirements are determined by the material used for the wind turbine gear to be repaired.

[0114] 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.

[0115] Furthermore, S50 includes:

[0116] 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;

[0117] 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;

[0118] S53, fixing the wind turbine gear to be repaired on a work platform, and measuring the spatial coordinates of the wind turbine gear to be repaired;

[0119] 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 coordinating 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 during the welding process is consistent with the position during the simulation process;

[0120] 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, the next step is entered. If the simulation result does not meet the predetermined requirements, the additive processing trajectory is replanned. In this process, the three-dimensional model of the area to be repaired is first plane sliced, and then the additive direction is determined by selecting points and normals.

[0121] S56, input the optimal arc cladding additive manufacturing process parameters of the repair material, and control the arc cladding additive manufacturing equipment through the control software to perform an idle run. If the idle 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 idle run path is inaccurate, the additive trajectory is reconfirmed; specifically, an ABB robot teaching pendant is used as the arc cladding additive manufacturing equipment.

[0122] Furthermore, S60 includes:

[0123] 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.

[0124] S62, performing rough milling on the area to be repaired of the wind turbine gear after reducing the residual stress and hardness, to form a tooth shape of the wind turbine gear;

[0125] S63, performing semi-finishing milling on the area to be repaired of the wind turbine gear after rough milling to remove the "terraces" produced by the rough milling;

[0126] 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 meets the predetermined requirement;

[0127] S65, performing a quenching and tempering treatment on the area to be repaired of the wind turbine gear after fine milling to restore the hardness of the area;

[0128] S66, performing surface treatment by grinding 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;

[0129] 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 repair of the wind turbine gear is completed, and the following is obtained: Figure 7 The repaired wind turbine gear is shown.

[0130] 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 establishment module 30, a gear physical and chemical property 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:

[0131] A three-dimensional data acquisition module 20 is configured to acquire three-dimensional data of the wind turbine gear to be repaired;

[0132] 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 based on the three-dimensional data of the wind turbine gear to be repaired;

[0133] 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;

[0134] 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;

[0135] The wind turbine gear additive module 60 is configured to arc-clad the repair material onto the repaired area of ​​the wind turbine gear according to the three-dimensional model of the repaired area;

[0136] 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.

[0137] Example 1: Determine the cause of the fracture in the repaired area of ​​the wind turbine gear to be repaired

[0138] A ZEISS Sigma400 field emission scanning electron microscope is used to scan the area to be repaired of the wind turbine gear to be repaired, and the secondary electron image of the surface morphology of the area to be repaired of the wind turbine gear to be repaired is photographed by adjusting the positioning observation area and the filament lens barrel through the manipulator, and the reflected electron image is observed and the image is processed, so as to obtain the micro-morphological structure information of the surface of the area to be repaired of the wind turbine gear to be repaired through the processed image, and thus the cause of the fracture of the area to be repaired of the wind turbine gear to be repaired is judged according to the micro-morphological structure information of the surface of the area to be repaired of the wind turbine gear to be repaired, and then the optimization operation is performed according to the cause of the fracture, for example, improving the design defects of the wind turbine gear and improving the lubrication system in the operating environment, etc., so as to prevent the wind turbine gear from breaking again.

[0139] Example 2: Experimental description of the sample processing in step S36

[0140] In this embodiment, the material of the wind turbine gear is 18CrNiMo, and the repair material used is welding wire with the brand of SMSX900A.

[0141] 1. Using arc cladding, the welding wire is added to form a sample with the same tooth shape as the wind turbine gear to be repaired after thickening treatment;

[0142] 2. Before heat treatment to reduce the hardness of the sample, use a marker to evenly mark 10 points on the surface of the sample, ensuring 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:

[0143] Table 1

[0144]

[0145] Taking the average as the final result, it is concluded that the hardness of the sample at this time is 71HRC;

[0146] 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 with the furnace and air cool it.

[0147] 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:

[0148] Table 2

[0149]

[0150] Taking the average as the final result, it is concluded that the hardness of the sample at this time is 40HRC. Compared with the data before heating, it can be found that the hardness of the sample has decreased by 31HRC. At the same time, by observing the surface of the sample, it can be found that the oxides produced on the surface of the sample during heating fall off as the sample is taken out of the furnace, and the processing marks on the surface of the sample also disappear.

[0151] 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 specimen has obvious processing marks and is relatively smooth;

[0152] 6. Perform semi-finish 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: Figure 9 As shown, the surface of the specimen is smoother and the machining marks are lighter than those when it is rough-machined;

[0153] 7. Perform fine milling on the sample until the surface roughness reaches 0.8μm, where the process allowance is 0.1mm. The surface smoothness of the sample after processing is as follows: Figure 10 As shown, the surface of the specimen is smoother and the machining marks are lighter than those when it is rough-machined;

[0154] 8. Before performing heat treatment on the sample to restore its hardness, use a marker to evenly mark 10 points on the surface of the sample, ensuring that these points are distributed in the center and edges of the sample. Use a Rockwell hardness tester to measure the hardness of each point. The measurement results are as follows:

[0155] Table 3

[0156]

[0157] Taking the average as the final result, it is concluded that the hardness of the sample at this time is 50HRC;

[0158] 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, immediately remove the sample 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, immediately remove the sample for air cooling.

[0159] 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:

[0160] Table 4

[0161]

[0162] Taking the average as the final result, it is concluded that the hardness of the sample at this time is 70HRC. Comparing with the initial hardness value of the sample, it can be concluded that the hardness of the sample has been restored.

[0163] 11. Since the surface roughness of the sample does not reach 0.8μm after fine milling, the sample surface needs to be ground 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 of fine milling, and the machining marks are basically gone.

[0164] 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.

[0165] 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 scope of protection of the present invention.

Claims

1. A wind turbine gear repair method by adding or subtracting material, 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 based on the point cloud data of the wind turbine gear to be repaired; S30: constructing a three-dimensional model of the 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, to obtain a three-dimensional model of the to-be-repaired region of 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 the repair material and arc cladding additive manufacturing process parameters based on the physical and chemical properties, including the following steps: S41, sampling and analyzing the wind turbine gear to be repaired by a scanning device 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 optimal arc cladding additive manufacturing process parameters are selected based on 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 based on the mechanical properties of the material used for the wind turbine gear to be repaired; S44, conduct experiments on the repair material to determine the arc cladding additive manufacturing process parameters that enable the weld bead to be formed; S45, continuing to experiment on the repair material to optimize the arc cladding additive manufacturing process parameters to obtain optimal 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, performing various mechanical property tests on the sample to determine whether the sample meets the predetermined requirements. If so, proceed to the next step. If not, replace the repair material and repeat the test. 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; S50: performing a thickening process on the three-dimensional model of the area to be repaired, and arc-cladding a repair material onto the area to be repaired of the wind turbine gear to be repaired according to the thickened three-dimensional model of the area to be repaired and 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, wherein: The S10 includes: S11, pre-processing the area to be repaired of the wind turbine gear to be repaired; S12, placing positioning marking points on the wind turbine gear to be repaired; S13, performing a calibration operation on the handheld 3D 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, wherein: The S11 includes: S111, perform 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 no 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, wherein: 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 low lighting conditions. 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 impact of reflections from 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, wherein: The S20 includes: S21, pre-processing the point cloud data of the wind turbine gear to be repaired saved 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 and 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, wherein: The S30 includes: S31, constructing a three-dimensional model of the undamaged wind turbine gear based on 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 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.

7. The wind turbine gear repair method of claim 1, wherein: The S50 includes: S51, performing a thickening process on the external tooth profile of the three-dimensional model of the area to be repaired to reserve a reasonable amount of material shrinkage and material reduction processing allowance, thereby 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 a work 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 coordinating 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 machining 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, replanning the additive machining trajectory; S56, input the optimal arc cladding additive manufacturing process parameters of the repair material, and control the arc cladding additive manufacturing equipment through the control software to perform dry run. If the dry run path is correct, the repair material is placed and arc clad to the repair area of ​​the wind turbine gear to be repaired; if the dry run path is inaccurate, the additive processing trajectory is reconfirmed.

8. The wind turbine gear repair method of claim 1, wherein: 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, to form 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 "terraces" 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 meets the predetermined requirement; S65, performing a quenching and tempering treatment on the area to be repaired of the wind turbine gear after fine milling to restore the hardness of the area; S66, performing surface treatment by grinding 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, remanufacture the wind turbine gear 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.

9. A wind turbine gear repair device, used to perform the wind turbine gear additive and subtractive repair method according to any one of claims 1 to 8, 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 based on the three-dimensional data of the wind turbine gear to be repaired; A gear physical and chemical properties acquisition module configured to obtain material information of the wind turbine gear to be repaired; A repair parameter acquisition module is 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 is configured to arc-clad the repair material onto the repaired area of ​​the wind turbine gear according to a 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.

Images