Water turbine flow passage component surface coating casting control method and system

Abstract

The embodiment of the invention relates to the technical field of water turbine flow passage component machining, and provides a water turbine flow passage component surface coating casting control method and system.The method comprises the steps that the thickness parameter of the next to-be-cladded position of a to-be-coated component in a water turbine flow passage component is continuously obtained; acquiring image information or identification information of the to-be-coated component, and acquiring material information of the to-be-coated component by utilizing a pre-established database based on the image information or the identification information; according to the material information and the real-time thickness parameter of the to-be-coated part, acquiring a matched laser power parameter by utilizing a database; the moving speed of the laser relative to the surface of the to-be-coated component is obtained; and based on the laser power parameters and the moving speed, power control is conducted on the laser, so that control over the casting process of the surface coating of the flow passage component of the water turbine is achieved. According to the embodiment of the invention, the quality of the laser cladding layer can be effectively improved.

Description

Technical Field

[0001] This disclosure relates to the field of turbine flow-through component processing technology, and in particular to a method and system for controlling the casting of surface coatings on turbine flow-through components. Background Technology

[0002] The flow-through components of a water turbine typically include guide vanes, top covers, and bottom rings. These components are susceptible to erosion from silt and sand carried by river water during operation, making them relatively prone to damage. Therefore, current technology involves adding a protective coating to the surface of these flow-through components to improve wear resistance and extend the equipment's service life.

[0003] Currently, existing technology provides a laser micro-melting continuous casting method. This method uses a powder feeder to deliver cladding alloy powder to the surface of the part to be processed, and then heats and melts the alloy powder and the part surface through laser irradiation to form a protective coating on the part surface. During the heating process, the powder feeding position and the heating position are moved relative to the part surface to complete the overall processing. However, although the above technical solution can cast a protective layer on the part surface, the thickness of each flow component varies and the position varies, resulting in differences in the keyholes of the cladding layer on substrates of different thicknesses. When a high-energy laser beam irradiates the material surface, the material is rapidly heated and melted, and may even evaporate. During this process, the vapor pressure pushes away the surrounding liquid material, forming a cavity where vapor and liquid coexist, the so-called keyhole. Instability of the keyhole will lead to voids in the cladding layer. Summary of the Invention

[0004] This disclosure aims to at least solve one of the problems existing in the prior art, and to provide a method and system for controlling the casting of surface coatings on turbine flow components.

[0005] One aspect of this disclosure provides a method for controlling the casting of a surface coating on a turbine flow-through component, the method comprising:

[0006] Continuously acquire the thickness parameters of the next cladding position of the component to be coated in the flow-through components of the water turbine;

[0007] Obtain image information or recognition information of the component to be coated, and based on the image information or recognition information, obtain the material information of the component to be coated using a pre-established database;

[0008] Based on the material information of the component to be coated and the real-time thickness parameters, the matching laser power parameters are obtained using the database;

[0009] Obtain the velocity of the laser relative to the surface of the component to be coated;

[0010] Based on the laser power parameters and the moving speed, the laser power is controlled to control the surface coating casting process of the turbine flow components.

[0011] Optionally, the control method further includes:

[0012] Retrieve the pre-stored 3D model of the component to be coated from the database;

[0013] The starting processing position and movement mode of the laser relative to the surface of the component to be coated are obtained, and the movement simulation is performed using the three-dimensional model based on the movement speed;

[0014] When the laser emitted by the laser enters the thickness uniformity region of the part to be coated, the laser power is stopped and the laser power is re-determined, and the adjustment of the laser power is also stopped.

[0015] Optionally, the thickness parameter is obtained by detecting the thickness at the next laser irradiation position during the motion simulation process.

[0016] Optionally, the control method further includes:

[0017] Obtain the detected distance of the laser's movement;

[0018] Before laser melting and casting, the laser is moved along a pre-selected cladding path in an off state, and the distance detection value of the laser during the movement is continuously acquired.

[0019] If the distance detection value is greater than the preset standard value, and the number of occurrences and the difference exceed the preset allowable conditions, the acquisition of the thickness parameter through the movement simulation process will be stopped, and a prompt message indicating that the part to be coated is unqualified will be output.

[0020] Another aspect of this disclosure provides a surface coating casting control system for turbine flow passage components, the control system including a control module for loading and executing a computer program corresponding to the aforementioned turbine flow passage component surface coating casting control method.

[0021] Optionally, the control system further includes an image acquisition unit, which is arranged around the workstation of the component to be coated with its acquisition end facing the component to be coated, and the image acquisition unit is electrically connected to the control module.

[0022] Optionally, the control system further includes a thickness detection unit; the thickness detection unit includes a thickness gauge and a connecting frame, the connecting frame connects the probe of the thickness gauge and a laser, an electric cylinder is mounted on the connecting frame, the probe of the thickness gauge is mounted on the rod end of the electric cylinder, the rod end of the electric cylinder faces the part to be coated, and both the thickness gauge and the electric cylinder are electrically connected to the control module.

[0023] Optionally, the control system further includes a ranging unit, which is mounted on the rod end of the electric cylinder, and the ranging path passes through the side of the thickness gauge.

[0024] Another aspect of this disclosure provides an electronic device comprising:

[0025] At least one processor; and,

[0026] A memory that is communicatively connected to at least one processor; wherein,

[0027] The memory stores instructions that can be executed by at least one processor, which enables the at least one processor to perform the aforementioned method for controlling the casting of the surface coating of the turbine flow components.

[0028] Another aspect of this disclosure provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the aforementioned method for controlling the casting of surface coatings on turbine flow components.

[0029] Compared with the prior art, this disclosure can adjust the power parameters of the welding laser according to the thickness variation of the component to be coated, so as to avoid the instability of the keyhole caused by different substrate thicknesses and fixed laser power, thereby reducing the voids generated by the cladding layer and improving the quality of the laser cladding layer. Attached Figure Description

[0030] One or more embodiments are illustrated by way of example with the corresponding pictures in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0031] Figure 1 A flowchart illustrating a method for controlling the casting of a surface coating on a turbine flow-through component, as provided in one embodiment of this disclosure;

[0032] Figure 2 A flowchart illustrating a method for controlling the casting of a surface coating on a turbine flow-through component, as provided in another embodiment of this disclosure;

[0033] Figure 3A schematic diagram of a surface coating casting control system for a turbine flow component is provided as another embodiment of this disclosure;

[0034] Figure 4 A schematic diagram of the structure of an electronic device provided in another embodiment of this disclosure. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the various embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the various embodiments of this disclosure to facilitate a better understanding of the disclosure. However, the technical solutions claimed in this disclosure can be implemented even without these technical details and with various variations and modifications based on the following embodiments. The division of the various embodiments below is for ease of description and should not constitute any limitation on the specific implementation of this disclosure. The various embodiments can be combined with and referenced by each other without contradiction.

[0036] One embodiment of this disclosure relates to a method for controlling the casting of a surface coating on a turbine flow component, the process of which is as follows: Figure 1 As shown, it includes:

[0037] Step S110: Continuously acquire the thickness parameters of the next cladding position of the component to be coated in the turbine flow component.

[0038] Specifically, the component to be coated can be any component in the turbine that requires an additional protective coating. Step S110 can continuously acquire the thickness parameters of the next cladding position of the component to be coated based on a pre-set thickness detection unit.

[0039] It is important to note that the next cladding location could be the position where the laser from the moving laser will irradiate the component in the next second. Alternatively, the coating path can be divided into small units, in which case the next cladding location refers to the next small unit.

[0040] Step S120: Obtain image information or recognition information of the part to be coated, and based on the image information or recognition information, obtain the material information of the part to be coated using a pre-established database.

[0041] Specifically, if step S120 obtains an image of the component to be coated, image recognition is performed to obtain the name or other identification information of the component to be coated. If step S120 obtains identification information of the component to be coated, such as the component name or identification code actively entered by the staff, step S120 can directly use this identification information to search the database to obtain the material information of the component to be coated.

[0042] In this embodiment, the database can store material information of each turbine flow component and laser power parameters for different thicknesses of various materials, which are pre-stored by the staff. The data and the relationship between the data can be determined by the staff through actual measurement and verification.

[0043] Step S130: Based on the material information of the part to be coated and the real-time thickness parameters, obtain the matching laser power parameters using the database.

[0044] Step S140: Obtain the moving speed of the laser relative to the surface of the part to be coated.

[0045] Specifically, the movement speed is used to determine the time required for the laser to irradiate the next cladding position. For example, if the movement speed is 2 seconds per unit, the laser will move to the next cladding position after 2 seconds, at which point the laser power parameters need to be adjusted accordingly.

[0046] Step S150: Based on the laser power parameters and moving speed, the power of the laser is controlled to control the surface coating casting process of the turbine flow components.

[0047] Specifically, when the moving speed is 2s / small unit, the calculation starts from entering the current cladding position, and after 2s, the laser power is adjusted to match the laser power parameters.

[0048] The coating casting control method for the surface of turbine flow components provided in this disclosure, compared with the prior art, can adjust the power parameters of the welding laser according to the thickness variation of the component to be coated, so as to avoid the instability of the keyhole caused by different substrate thicknesses and fixed laser power, thereby reducing the voids generated by the cladding layer and improving the quality of the laser cladding layer.

[0049] For example, the surface coating casting control method for turbine flow components further includes: retrieving a pre-stored 3D model of the component to be coated from a database; obtaining the starting processing position and movement mode of the laser relative to the surface of the component to be coated, and performing movement simulation based on the movement speed using the 3D model; when the laser irradiation position emitted by the laser enters the thickness consistency region of the component to be coated, stopping the laser power determination and simultaneously stopping the adjustment of the laser power. The thickness consistency region can be predefined manually.

[0050] Specifically, the three-dimensional model of the component to be coated refers to the three-dimensional model of the component in the turbine that needs to be coated with a protective coating, such as the three-dimensional model of the guide vane.

[0051] Assuming the laser is mounted on the robotic arm, the initial spatial position can be determined based on the feedback from the robotic arm. Based on this, combined with the initial position and posture of the component placed on the tooling or other tools, the starting processing position can be obtained.

[0052] In this embodiment, the movement method can be understood as the movement path. However, for each component, it is relatively cumbersome for the operator to input the movement path. It is more appropriate to provide a method such as the spiral relative motion of the laser to the component.

[0053] Given the initial processing position and movement method, the relative movement process of the laser can be further simulated based on the 3D model of the part to be coated, thus achieving motion simulation. It is important to note that this motion simulation process is performed synchronously. For example, the distance the robotic arm driving the laser moves is fed back and proportionally converted, and then the 3D model moves the corresponding distance.

[0054] Based on the above settings, this embodiment can reduce unnecessary thickness measurement, power parameter analysis, and adjustment steps in the implementation of the method for controlling the casting of coatings on the surface of turbine flow components.

[0055] However, the 3D model and motion simulation process of the part to be coated is not only to reduce some unnecessary analysis and control steps, but more importantly to obtain thickness parameters.

[0056] For example, the thickness parameter is obtained by detecting the thickness at the next laser irradiation position during the moving simulation process.

[0057] Specifically, the thickness parameters at various locations of the 3D model can be obtained using the measurement functions of the corresponding 3D software. The usage methods of each 3D software are existing technologies and will not be elaborated here.

[0058] Based on the above settings, this embodiment does not require simultaneous laser welding and prior physical detection of component thickness, thus making it relatively easier to implement.

[0059] For example, the surface coating casting control method for turbine flow components further includes: acquiring the distance detection value of laser movement; before laser casting, moving the laser along a pre-selected cladding path in an off state, and continuously acquiring the distance detection value of the laser during the movement; if the distance detection value is greater than a preset standard value, and the number of occurrences and the difference exceed the preset allowable conditions, then stopping the acquisition of thickness parameters through the movement simulation process, and outputting a prompt message that the component to be coated is unqualified.

[0060] For example, if the distance detection value exceeds the limit at least 3 times and the difference is greater than the allowable threshold, the process of obtaining thickness parameters through the motion simulation will be stopped, and a prompt message indicating that the part to be coated is unqualified will be output.

[0061] Based on the above settings, this embodiment can minimize the risk of laser misadjustment caused by excessive differences between the actual components and the standard 3D model, and also helps staff to identify unqualified components.

[0062] To enable those skilled in the art to better understand the above embodiments, a specific example is provided below.

[0063] like Figure 2 As shown, a method for controlling the casting of surface coatings on turbine flow components includes the following steps:

[0064] S11. Based on the pre-set thickness detection unit, continuously acquire the thickness parameters of the next cladding position of the part to be coated.

[0065] S12. Obtain the image / recognition information of the part to be coated, and search the pre-established database to obtain the material information of the part.

[0066] S13. Based on the material information of the component and the real-time thickness parameters, search the database to obtain the matching laser power parameters.

[0067] S14. Obtain the speed at which the laser moves relative to the surface of the component.

[0068] S15. Perform power control on the laser based on the moving speed and laser power parameters.

[0069] Another embodiment of this disclosure relates to a surface coating casting control system for turbine flow components, such as... Figure 3 As shown, it includes a control module. The control module is used to load and execute the computer program corresponding to the turbine flow component surface coating casting control method provided in the above embodiments.

[0070] For example, in order to meet image acquisition requirements, such as Figure 3 As shown, the surface coating casting control system for the turbine flow components also includes an image acquisition unit. The image acquisition unit is electrically connected to the control module. The image acquisition unit is positioned around the workstation of the component to be coated, with its acquisition end facing the component. The image acquisition unit can be a charge-coupled device (CCD) camera. In this embodiment, the CCD camera is fixedly installed. For example, a gantry structure is installed at the workstation of the component to be coated, with the crossbeam of the gantry spanning the workstation, and the CCD camera is mounted on the crossbeam of the gantry with its lens facing downwards.

[0071] As can be seen from the above embodiment of the surface coating casting control method for turbine flow components, the thickness parameters of the component to be coated can be obtained from the three-dimensional model of the component. However, if on-site personnel, after receiving a non-conforming warning message for the component to be coated, still need to continue the surface coating casting process for some reason, then directly relying on the thickness parameters obtained from the three-dimensional model will result in relatively poor coating quality. Therefore, the surface coating casting control system for turbine flow components can also include a thickness detection unit, which includes a thickness gauge and a connecting frame.

[0072] The connecting bracket can be a combination of Haas metal and plastic. It is bolted to the laser's mounting position, connecting the thickness gauge's probe and the laser. For example, the connecting bracket can extend to the side of the laser, where the probe is mounted.

[0073] Furthermore, an electric cylinder is installed on the connecting frame, and the probe of the thickness gauge is installed on the rod end of the electric cylinder. The rod end of the electric cylinder faces the part to be coated. Both the thickness gauge and the electric cylinder are electrically connected to the control module.

[0074] Based on the above settings, in this embodiment, when it is not necessary to use a thickness gauge to detect the thickness of the component, the electric cylinder can be controlled to move the probe of the thickness gauge away, so as to reduce the obstruction to the laser cladding process. This is because some of the components to be coated have relatively narrow areas on their surface, such as the turning part of the top cover. At the same time, it also reduces the wear of the probe, because some probes need to contact the surface of the component to measure thickness.

[0075] For example, such as Figure 3 As shown, the surface coating casting control system for the turbine flow components also includes a distance measuring unit, which is installed at the rod end of the electric cylinder, and the distance measuring path passes through the side of the thickness gauge.

[0076] Specifically, the ranging unit can be a laser ranging sensor, which is installed on the rod end of the electric cylinder. For example, the rod end is fixed with an L-plate, the lower part is fixed with the probe of the thickness gauge, and the side is fixed with the ranging unit. The ranging path of the ranging unit passes through the side of the thickness gauge.

[0077] The above-mentioned setting and setting method of the ranging unit have at least the following functions:

[0078] 1) It can determine the extension and retraction of the electric cylinder and the distance between the rod end of the electric cylinder and the surface of the component.

[0079] 2) With the length of the electric cylinder remaining constant, the change in the detection value output by the ranging unit can be compared with the standard value to assess whether the workpiece size is qualified.

[0080] The specific implementation method of the surface coating casting control system for turbine flow components provided in this disclosure can be found in the description of the surface coating casting control method for turbine flow components provided in this disclosure, and will not be repeated here.

[0081] The turbine flow component surface coating casting control system provided in this disclosure can be used to control the turbine flow component surface coating casting process and improve the quality of the cladding coating, compared with the prior art.

[0082] Another embodiment of this disclosure relates to an electronic device, such as Figure 4 As shown, it includes:

[0083] At least one processor 401; and,

[0084] Memory 402 is communicatively connected to at least one processor 401; wherein,

[0085] The memory 402 stores instructions that can be executed by at least one processor 401, which enables the at least one processor 401 to perform the turbine flow component surface coating casting control method described in the above embodiments.

[0086] The memory and processor are connected via a bus, which can include any number of interconnecting buses and bridges, connecting various circuits of one or more processors and memories. The bus can also connect various other circuits, such as peripheral devices, voltage regulators, and power management circuits, which are well known in the art and will not be described further herein. The bus interface provides an interface between the bus and the transceiver. The transceiver can be a single element or multiple elements, such as multiple receivers and transmitters, providing a unit for communicating with various other devices over a transmission medium. Data processed by the processor is transmitted over the wireless medium via an antenna, which further receives data and transmits it to the processor.

[0087] The processor manages the bus and general processing, and also provides various functions, including timing, peripheral interfaces, voltage regulation, power management, and other control functions. Memory is used to store data used by the processor during operation.

[0088] Another embodiment of this disclosure relates to a computer-readable storage medium storing a computer program that, when executed by a processor, implements the surface coating casting control method for turbine flow components described in the above embodiments.

[0089] That is, those skilled in the art will understand that all or part of the steps in the methods described in the above embodiments can be implemented by a program instructing related hardware. This program is stored in a storage medium and includes several instructions to cause a device (which may be a microcontroller, chip, etc.) or processor to execute all or part of the steps of the methods described in the various embodiments of this disclosure. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0090] Those skilled in the art will understand that the above embodiments are specific implementations of this disclosure, and in practical applications, various changes can be made in form and detail without departing from the spirit and scope of this disclosure.

Claims

1. A method for controlling the casting of coating on the surface of a flow-through component of a water turbine, characterized in that: The control method comprises: Continuously obtaining the thickness parameter of the next to-be-clad position of the to-be-coated component in the flow-through component of the turbine; Acquire image information or identification information of the component to be coated, and based on the image information or the identification information, acquire material information of the component to be coated using a pre-established database; According to the material information of the component to be coated and the real-time thickness parameter, using the database to obtain a matching laser power parameter; Acquiring the moving speed of the laser relative to the surface of the component to be coated; Based on the laser power parameter and the moving speed, the power of the laser is controlled to achieve control of the melting and casting process of the coating on the surface of the flow-through component of the turbine.

2. The control method according to claim 1, characterized in that: The control method further comprises: Retrieving a pre-stored three-dimensional model of the component to be coated from the database; Acquiring the current starting processing position and movement mode of the laser relative to the surface of the component to be coated, and performing movement simulation using the three-dimensional model based on the movement speed; When the laser irradiation position emitted by the laser enters the thickness consistency area of ​​the component to be coated, the laser power is stopped and re-determined, and the power adjustment of the laser is stopped at the same time.

3. The control method according to claim 2, characterized in that: The thickness parameter is obtained by detecting the thickness of the next laser irradiation position during the mobile simulation process.

4. The control method according to claim 3, characterized in that: The control method further comprises: Obtaining a distance detection value of the laser movement; Before laser melting and casting, the laser is moved along a preselected cladding path in an unactivated state, and a distance detection value of the laser during the movement is continuously obtained; If the distance detection value is greater than a preset standard value, and the number of occurrences and the difference exceed the preset allowable conditions, the acquisition of the thickness parameter through the mobile simulation process is terminated, and a prompt message indicating that the component to be coated is unqualified is output.

5. A coating casting control system for the surface of a turbine flow-through component, characterized in that: The control system comprises a control module, and the control module is used to load and execute a computer program corresponding to the method for controlling the casting of a surface coating on a flow-through component of a turbine according to any one of claims 1 to 4.

6. The control system according to claim 5, characterized in that: The control system further comprises an image acquisition unit, which is arranged at the periphery of the workstation of the component to be coated and has an acquisition end facing the component to be coated, and is electrically connected to the control module.

7. The control system according to claim 6, characterized in that: The control system also includes a thickness detection unit; the thickness detection unit includes a thickness gauge and a connecting frame, the connecting frame connects the probe of the thickness gauge and the laser, an electric cylinder is installed on the connecting frame, the probe of the thickness gauge is installed on the rod end of the electric cylinder, the rod end of the electric cylinder faces the part to be coated, and the thickness gauge and the electric cylinder are both electrically connected to the control module.

8. The control system according to claim 7, characterized in that: The control system further comprises a distance measuring unit, which is mounted on the rod end of the electric cylinder, and a distance measuring path passes through the side of the thickness gauge.

9. An electronic device, characterized in that: include: at least one processor; as well as, a memory communicatively connected to the at least one processor; wherein, The memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the method for controlling the casting of a surface coating on a flow-through component of a turbine according to any one of claims 1 to 4.

10. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by a processor, the method for controlling the casting of coating on the surface of a flow-through component of a turbine according to any one of claims 1 to 4 is implemented.

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