A laser cladding welding device and laser cladding welding method for a shield machine cutter ring

Abstract

The invention discloses a laser cladding welding device and a laser cladding welding method for a cutter ring of a tunnel boring machine, which relate to the technical field of laser cladding welding and include a positioning mechanism, a defect visual analysis device, an automatic laser cladding mechanism and a controller based on an industrial computer; the defect visual analysis device of the invention adopts multi-angle visual images to perform three-dimensional reconstruction to realize the calculation of the wear amount of a wear area, thereby achieving a more accurate and uniform cladding effect; the laser cladding operation is realized based on the drive of a parallel robot device, so that the laser head of the laser cladding device can accurately reach the wear area, thereby realizing an accurate laser cladding process; the entire control relies on an industrial computer-based controller to realize automatic control, and can efficiently realize laser cladding repair of cutter rings of tunnel boring machines to be laser clad in different wear states, with high efficiency, uniform laser cladding, and more reliable combination of cladding material and raw material.

Description

Technical Field

[0001] The invention relates to the technical field of laser cladding welding, and in particular to a shield machine cutter ring laser cladding welding device and a laser cladding welding method. Background Art

[0002] The cutter ring of the shield machine is an important part of the shield machine cutting tool. It is in direct contact with the rock or soil on the tunnel excavation surface and is subjected to huge shear force and wear. During the tunnel construction of the shield machine, the wear of the cutter ring directly affects the construction efficiency and cost.

[0003] Laser cladding welding technology is a technology that uses high-energy laser beams to clad specific materials on the metal surface. This technology can form a coating with specific properties on the surface of the base material. This coating can have characteristics such as wear resistance, corrosion resistance, and high temperature resistance.

[0004] The application of laser cladding welding technology in the manufacturing of shield machine cutter rings has the following technical advantages: the cladding layer material usually has higher hardness and wear resistance than the base material. The wear resistance of the cutter ring is improved, thereby extending the service life of the cutter ring and reducing the replacement frequency. Different cladding materials can be selected according to different construction environments to adapt to different wear conditions. During the laser cladding process, the heat-affected zone of the base material is small and is not easily deformed. The laser cladding process is fast and has high production efficiency.

[0005] The Chinese invention patent application with publication number CN112267111A discloses a laser cladding device and method for the cutter ring of a shield machine, wherein the device includes a drive system and a cladding platform, the drive system includes an AC servo motor, the output shaft of the AC servo motor is connected to the input shaft of a planetary reducer, the output shaft of the planetary reducer is connected to the main shaft through a coupling, the main shaft and the commutator output shaft are respectively connected to two three-jaw chucks, the cutter ring of the shield machine is fixed on the three-jaw chuck, and the cladding platform includes a motion platform and a base, and the motion platform and the base are connected through a slide rail. It has a simple structure, is easy to install and operate, can clad the cutter disc in both the peripheral surface and the end surface, can reduce the cumbersome operation and programming difficulty of industrial robots, and effectively improve the problems of low cladding efficiency and low degree of automation of the cutter ring of the shield machine.

[0006] The above technical solution is more suitable for laser cladding of the cutter ring of the newly manufactured shield machine;

[0007] In actual application, the shield machine cutter ring that is replaced due to slight wear can actually continue to serve after repair. If the above-mentioned device and method are used for laser cladding, since the worn part is unpredictable, it is impossible to achieve automatic programming of the specific cladding part and thickness, and it is impossible to automatically use laser cladding to repair the worn shield machine cutter ring. Summary of the invention

[0008] In order to solve the technical problem of using laser cladding to repair the cutter ring of the shield machine after it is worn, the present invention provides a laser cladding welding device and a laser cladding welding method for the cutter ring of the shield machine. The following technical solutions are adopted:

[0009] A shield machine cutter ring laser cladding welding device, comprising a positioning mechanism, a defect visual analysis device, an automatic laser cladding mechanism and a controller based on an industrial computer;

[0010] The positioning mechanism includes a rotating support mechanism, an inner tensioning clamping mechanism and a marking mechanism. The inner tensioning clamping mechanism is installed on the rotating part of the rotating support mechanism and rotates with the rotating part. The inner ring of the cutter ring of the shield machine to be laser clad is clamped on the clamping part of the inner tensioning clamping mechanism and is in a horizontal state. The marking mechanism is installed on one side of the rotating support mechanism and is used to engrave a visual mark on the cutter ring of the shield machine to be laser clad.

[0011] The defect visual analysis device includes a visual camera component and a visual analysis module. The visual camera component is installed directly above the inner tension clamping mechanism through a bracket. The visual camera component captures the visual image of the upper surface of the cutter ring of the shield machine to be laser clad. The visual analysis module communicates with the visual camera component to exchange the upper surface visual image, establishes a coordinate system based on the visual mark as the origin, and obtains the regional wear amount and the corresponding coordinates of the wear area based on the upper surface visual image analysis;

[0012] The automatic laser cladding mechanism comprises a parallel robot device and a laser cladding device, wherein the parallel robot device is installed above the inner tension clamping mechanism through a bracket, and the laser cladding device is installed on the movable part of the parallel robot device, and the upper surface of the cutter ring of the shield machine to be laser clad is laser clad and welded under the drive of the movable part of the parallel robot device;

[0013] The controller is communicatively connected with the visual analysis module, and based on the regional wear amount and the corresponding coordinates of the wear area, the wear area is divided into multiple wear levels according to the wear amount. The controller controls the action of the automatic laser cladding mechanism, and adjusts the cladding amount of the laser cladding device each time in the order of wear amount from large to small, and concentrates on laser cladding repair of multiple wear areas of the same wear level.

[0014] Optionally, the rotary support mechanism is a servo-electric rotary platform.

[0015] Optionally, the internal tensioning clamping mechanism includes a two-finger servo electric claw and a pair of support blocks, the bottom of the two-finger servo electric claw can be detachably mounted on the rotating part of the rotating support mechanism, and the pair of support blocks can be detachably mounted on the two movable blocks of the two-finger servo electric claw. When the inner ring of the cutter ring of the shield machine to be laser clad is placed on a pair of support blocks, the controller controls the two-finger servo electric claw to move, and the two movable blocks move outward to clamp the cutter ring of the shield machine to be laser clad.

[0016] By adopting the above technical solution, the rotating support mechanism can provide rotating clamping support, which is convenient for assembly. During laser cladding, the controller can control the servo electric rotating platform to provide a slight amplitude to the left and right. For example, the cutter ring of the shield machine to be laser clad is first rotated forward by 0.5°, and then rotated in the opposite direction by 0.5° within 0.1 seconds. The servo electric rotating platform can achieve the above control accuracy and achieve a more uniform laser cladding effect.

[0017] The inner tension clamping mechanism can realize the inner ring tension clamping of the cutter ring of the laser cladding shield machine, for example, using a two-finger servo electric claw or a two-finger air claw, a three-finger electric claw, a three-finger air claw, etc.; with the support block, the inner tension clamping of the cutter ring of the laser cladding shield machine can be quickly completed, because the inner ring is generally not worn, and the inner tension clamping can provide better clamping positioning;

[0018] The marking mechanism can be a laser marking, which can automatically mark the upper surface of the cutter ring of the shield machine to be laser clad. The purpose of the marking is to provide the origin of the coordinate system for subsequent vision, so as to facilitate the establishment of a coordinate system with the geometric center of the mark as the origin, thereby realizing the coordinate indication of the wear area;

[0019] The defect visual analysis device realizes defect analysis based on the visual images taken by the visual camera component. The defect analysis mainly involves visual recognition of the wear area and the use of multi-angle visual images for three-dimensional reconstruction to calculate the wear amount of the wear area. The calculation of the wear amount is actually the volume of the wear area, thereby providing a suitable amount of cladding material for subsequent laser cladding and achieving a more accurate and uniform cladding effect.

[0020] The specific laser cladding operation is realized based on the drive of the parallel robot device. The parallel robot device can provide driving force above the clamped shield machine cutter ring to be laser clad, and drive the laser cladding device to move to the specified position, so that the laser head of the laser cladding device can accurately reach the wear area and realize the precise laser cladding process;

[0021] The entire control relies on an industrial computer-based controller to achieve automated control, which can efficiently realize laser cladding repair of shield machine cutter rings in different wear states. It has high efficiency, uniform laser cladding, and a more reliable combination of cladding material and raw material.

[0022] Optionally, the marking mechanism includes a support member, a lifting mechanism, an electric linear slide, a connecting plate and a laser marking machine, the support member is located on one side of the internal expansion clamping mechanism, the bottom of the lifting mechanism is installed on the top of the support member, the linear track of the electric linear slide is detachably installed on the top of the piston rod of the lifting mechanism, one end of the connecting plate is detachably installed on the slider of the electric linear slide, the shell of the laser marking machine is detachably installed on the other end of the connecting plate, and the laser head faces downward, and the controller controls the execution actions of the lifting mechanism, the electric linear slide and the laser marking machine respectively.

[0023] By adopting the above technical solution, since the marking mechanism needs to be marked just after the installation is completed, and needs to be removed after the marking is completed to avoid interfering with the laser cladding operation, a liftable and translatable structure is adopted. The action sequence of the lifting mechanism and the electric linear slide is not prioritized. The lifting mechanism can be a servo electric cylinder or a servo air cylinder, and the lifting stroke can be greater than one hundred millimeters. The laser marking machine can realize laser marking on the upper surface of the cutter ring of the shield machine to be laser clad, and the marking is clearer and more accurate. Of course, other marking forms can also be used.

[0024] Optionally, the visual camera assembly includes a camera bracket and two visual cameras, the camera bracket is mounted on the movable part of the parallel robot device, and the two visual cameras are respectively mounted on the camera bracket, one of the visual camera lenses faces downward to capture the visual image of the upper surface of the shield machine cutter ring to be laser clad, and the other visual camera lens has an obtuse angle with the upper surface of the shield machine cutter ring to be laser clad, and the visual analysis module includes a memory 2 and a visual analysis chip, the memory 2 is respectively communicated with the two visual cameras to exchange the visual images of the upper surface, the visual analysis chip is communicated with the memory 2, a coordinate system is first established based on the visual mark engraved by the laser marking machine as the origin, a visual feature matching algorithm is used to identify the contour of the wear area, and the wear amount of the wear area is calculated based on the visual three-dimensional reconstruction algorithm, and the visual analysis chip stores the wear area coordinate data and the wear amount data of the wear area in the memory 2.

[0025] By adopting the above technical solution, a visual acquisition solution with two visual cameras is adopted. Of course, in order to achieve more accurate visual detection results, multiple cameras can be used, one of which collects the visual image directly above, and the other collects the visual image at a certain angle. Usually, the angle between the lens of the other visual camera and the upper surface of the cutter ring of the shield machine to be laser clad is an obtuse angle, such as 50° to 70°, which can realize subsequent three-dimensional reconstruction. Since it is a fixed-point shooting without other interference, fill light can be used to improve the shooting effect during shooting. The measurement accuracy of the regional volume corresponding to the wear amount can reach a calculation accuracy of 0.1 cubic millimeter. For the cutter ring of the shield machine, this accuracy can meet the repair requirements of laser cladding.

[0026] Optionally, the parallel robot device includes a gantry frame and a delta robot, the delta robot is installed on the gantry frame, and the laser cladding device is installed on the movable part of the delta robot, and follows the movable part to perform laser cladding welding on the upper surface of the cutter ring of the shield machine to be laser clad;

[0027] The laser cladding device comprises a cladding material bin 3, a laser cladding head and a laser cladding controller. The cladding material bin 3 and the laser cladding head are respectively mounted on the movable part of the delta robot. The controller controls the execution action of the laser cladding head through the laser cladding controller.

[0028] By adopting the above technical solution, the Delta robot is generally used as a supporting manipulator for the visual sorting solution and is adapted to the field of laser cladding. It can efficiently and accurately move the laser cladding device to the specified position. The laser cladding device adopts the cladding silo 3 to connect the laser cladding head, and adopts the laser cladding controller to receive the control instructions of the controller to realize the precise control of the laser cladding amount.

[0029] Optionally, the controller includes an industrial control computer and a display screen, and the industrial control computer communicates with the memory 2 to exchange wear area coordinate data and wear area wear amount data, and controls the execution actions of the positioning mechanism and the automatic laser cladding mechanism respectively.

[0030] By adopting the above technical solutions, the industrial control computer can realize efficient data analysis and command control of industrial actuators, and can also cooperate with the display screen to realize real-time monitoring of the laser cladding process. The visual source can be the visual signal of the Delta robot.

[0031] A shield machine cutter ring laser cladding welding method, using a shield machine cutter ring laser cladding welding device to perform laser cladding repair on the shield machine cutter ring to be laser clad, comprising the following steps:

[0032] Step 1, placing the inner ring of the shield machine cutter ring to be laser clad on the inner tension clamping mechanism, and the industrial control computer controls the inner tension clamping mechanism to clamp the shield machine cutter ring to be laser clad, with one side of the shield machine cutter ring facing upward;

[0033] Step 2: The industrial control computer controls the lifting mechanism to drive the laser marking machine to descend, controls the electric linear slide to drive the laser marking machine to move horizontally, makes the laser head of the laser marking machine contact the upper surface of the cutter ring of the shield machine to be laser clad, and controls the laser marking machine to mark the upper surface of the cutter ring of the laser clad shield machine;

[0034] Step 3: the industrial control computer controls the visual camera assembly to take pictures of the top view and side view of the upper surface of the cutter ring of the shield machine to be laser clad;

[0035] Step 4: The visual analysis module first analyzes the top-down image, extracts the marked position, takes the geometric center point of the mark as the origin of the coordinate system, uses the visual feature matching algorithm to extract the visual features of the wear area, and contours the visual features of the wear area, calculates the geometric center of the contoured wear area, and marks the geometric center coordinates of the contoured wear area based on the origin of the coordinate system;

[0036] Step 5: The visual analysis module analyzes the top-view image and the side-view image, performs three-dimensional reconstruction of the wear area, and calculates the wear of each wear area based on the three-dimensional reconstructed three-dimensional model;

[0037] Step 6: Based on the regional wear amount and the corresponding coordinates of the wear area, the industrial control computer divides the wear area into multiple wear levels according to the wear amount, with 1 cubic millimeter as the wear amount level difference. The industrial control computer controls the action of the automatic laser cladding mechanism, and adjusts the cladding amount of the laser cladding device each time in the order of wear amount from large to small, and concentrates multiple wear areas of the same wear level for laser cladding repair.

[0038] By adopting the above technical solution, the wear area is divided into multiple wear levels according to the wear amount, with every 1 cubic millimeter as the wear amount level difference. For example, the wear area with a wear amount greater than 1 cubic millimeter and less than or equal to 2 cubic millimeters is marked as a wear area of ​​level A, and the wear area with a wear amount greater than 2 cubic millimeters and less than or equal to 3 cubic millimeters is marked as a wear area of ​​level B. By analogy, in the specific laser cladding, the first batch of laser cladding can be performed on multiple wear areas with the maximum wear amount. For example, the level marked on multiple wear areas with the maximum wear amount is C, and the wear amount is greater than 3 cubic millimeters and less than or equal to 4 cubic millimeters. At this time, the laser cladding amount of the automatic laser cladding mechanism controlled by the industrial control computer is corresponding to 3 cubic millimeters. After laser cladding operations are performed on multiple wear areas of level C respectively, based on vision, a small amount of cladding operations are required for those that do not meet the repair requirements (for example, the surface flatness does not reach the set value). After laser cladding is completed on multiple wear areas of level C, the same operation is performed on multiple wear areas of level B.

[0039] This repair process of performing laser cladding in batches according to the amount of wear can avoid the laser cladding head from constantly adjusting the cladding amount over a large range, and can increase the uniformity of the laser cladding.

[0040] Optionally, the mark in step 2 is a hollow circle.

[0041] By adopting the above technical solution, the use of hollow circles can better calculate the geometric center of the circle, which is convenient for visual processing.

[0042] In summary, the present invention includes at least one of the following beneficial technical effects:

[0043] The present invention can provide a shield machine cutter ring laser cladding welding device and a laser cladding welding method. The defect visual analysis device realizes defect analysis based on the visual picture taken by the visual camera component. The defect analysis is mainly the visual recognition of the wear area, and the multi-angle visual picture is used to perform three-dimensional reconstruction to realize the calculation of the wear amount of the wear area. The calculation of the wear amount is actually the volume of the wear area, so as to provide a suitable amount of cladding material for subsequent laser cladding, and achieve a more accurate and uniform cladding effect.

[0044] The specific laser cladding operation is realized based on the drive of the parallel robot device. The parallel robot device can provide driving force above the clamped shield machine cutter ring to be laser clad, and drive the laser cladding device to move to the specified position, so that the laser head of the laser cladding device can accurately reach the wear area and realize the precise laser cladding process;

[0045] The entire control relies on an industrial computer-based controller to achieve automated control, which can efficiently realize laser cladding repair of shield machine cutter rings in different wear states. It has high efficiency, uniform laser cladding, and a more reliable combination of cladding material and raw material. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 It is a structural schematic diagram of a shield machine cutter ring laser cladding welding device of the present invention;

[0047] Figure 2 It is a structural schematic diagram of an automatic laser cladding mechanism of a shield machine cutter ring laser cladding welding device of the present invention;

[0048] Figure 3 It is a structural schematic diagram of a marking mechanism of a shield machine cutter ring laser cladding welding device of the present invention;

[0049] Figure 4 The present invention is a schematic diagram of the connection principle of electrical components of a shield machine cutter ring laser cladding welding device.

[0050] Explanation of the reference numerals: 11. Rotating support mechanism; 12. Internal tensioning clamping mechanism; 121. Two-finger servo electric claw; 122. Support block; 13. Marking mechanism; 131. Support member; 132. Lifting mechanism; 133. Electric linear slide; 134. Connecting plate; 135. Laser marking machine; 21. Visual camera assembly; 211. Camera bracket; 212. Visual camera; 22. Visual analysis module; 221. Memory; 222. Visual analysis chip; 31. Parallel robot device; 311. Gantry frame; 312. Delta robot; 32. Laser cladding device; 321. Cladding silo; 322. Laser cladding head; 323. Laser cladding controller; 4. Controller; 41. Industrial computer; 42. Display screen; 100. Cutting ring of shield machine to be laser clad; 101. Frame. DETAILED DESCRIPTION

[0051] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0052] The embodiments of the present invention disclose a shield machine cutter ring laser cladding welding device and a laser cladding welding method.

[0053] Reference Figure 1 - Figure 4 , Embodiment 1, a shield machine cutter ring laser cladding welding device, including a positioning mechanism, a defect visual analysis device, an automatic laser cladding mechanism and a controller 4 based on an industrial computer;

[0054] The positioning mechanism includes a rotating support mechanism 11, an inner tensioning clamping mechanism 12 and a marking mechanism 13. The inner tensioning clamping mechanism 12 is installed on the rotating part of the rotating support mechanism 11 and rotates with the rotating part. The inner ring of the shield machine cutter ring 100 to be laser clad is clamped on the clamping part of the inner tensioning clamping mechanism 12 and is in a horizontal state. The marking mechanism 13 is installed on one side of the rotating support mechanism 11 and is used to engrave a visual mark on the shield machine cutter ring 100 to be laser clad.

[0055] The defect visual analysis device includes a visual camera component 21 and a visual analysis module 22. The visual camera component 21 is installed directly above the inner tension clamping mechanism 12 through a bracket. The visual camera component 21 captures the visual image of the upper surface of the shield machine cutter ring 100 to be laser clad. The visual analysis module 22 communicates with the visual camera component 21 to exchange the upper surface visual image, establishes a coordinate system based on the visual mark as the origin, and obtains the regional wear amount and the corresponding coordinates of the wear area based on the upper surface visual image analysis;

[0056] The automatic laser cladding mechanism includes a parallel robot device 31 and a laser cladding device 32. The parallel robot device 31 is installed above the inner tension clamping mechanism 12 through a bracket, and the laser cladding device 32 is installed on the movable part of the parallel robot device 31. The laser cladding device 32 is driven by the movable part of the parallel robot device 31 to perform laser cladding welding on the upper surface of the shield machine cutter ring 100 to be laser clad.

[0057] The controller 4 is in communication connection with the visual analysis module 22, and based on the regional wear amount and the corresponding coordinates of the wear area, the wear area is divided into multiple wear levels according to the wear amount. The controller 4 controls the action of the automatic laser cladding mechanism, and adjusts the cladding amount of the laser cladding device 32 each time in the order of wear amount from large to small, and concentrates the laser cladding repair on multiple wear areas of the same wear level.

[0058] In the second embodiment, the rotation support mechanism 11 is a servo-electric rotation platform.

[0059] Embodiment 3, the internal tension clamping mechanism 12 includes a two-finger servo electric claw 121 and a pair of support blocks 122, the bottom of the two-finger servo electric claw 121 can be detachably mounted on the rotating part of the rotating support mechanism 11, and the pair of support blocks 122 can be detachably mounted on the two movable blocks of the two-finger servo electric claw 121. When the inner ring of the shield machine cutter ring 100 to be laser clad is placed on the pair of support blocks 122, the controller 4 controls the two-finger servo electric claw 121 to move, and the two movable blocks move outward to clamp the shield machine cutter ring 100 to be laser clad.

[0060] The rotating support mechanism 11 can provide a rotating clamping support for easy assembly. During laser cladding, the controller 4 can control the servo electric rotating platform to provide a slight amplitude to the left and right. For example, the cutter ring 100 of the shield machine to be laser clad is first rotated forward by 0.5°, and then rotated in the opposite direction by 0.5° within 0.1 seconds. The servo electric rotating platform can achieve the above control accuracy and achieve a more uniform laser cladding effect.

[0061] The inner tension clamping mechanism 12 can realize the inner ring tension clamping of the laser cladding shield machine cutter ring 100, for example, by using a two-finger servo electric claw 121 or a two-finger air claw, a three-finger electric claw, a three-finger air claw, etc.; in conjunction with the support block, the inner tension clamping of the laser cladding shield machine cutter ring 100 can be quickly completed, because the inner ring is generally free of wear, and the inner tension clamping can provide better clamping positioning;

[0062] The marking mechanism 13 can be a laser marking, which can automatically realize the marking on the upper surface of the shield machine cutter ring 100 to be laser clad. The purpose of the marking is to provide the origin of the coordinate system for subsequent vision, so as to facilitate the establishment of a coordinate system with the geometric center of the mark as the origin, thereby realizing the coordinate indication of the wear area;

[0063] The defect visual analysis device realizes defect analysis based on the visual images captured by the visual camera assembly 21. The defect analysis mainly involves visual recognition of the wear area and three-dimensional reconstruction using multi-angle visual images to calculate the wear amount of the wear area. The calculation of the wear amount is actually the volume of the wear area, thereby providing a suitable amount of cladding material for subsequent laser cladding and achieving a more accurate and uniform cladding effect.

[0064] The specific laser cladding operation is driven by the parallel robot device 31. The parallel robot device 31 can provide driving force above the clamped shield machine cutter ring 100 to be laser clad, and drive the laser cladding device 32 to move to the specified position, so that the laser head of the laser cladding device 32 can accurately reach the wear area, realizing a precise laser cladding process;

[0065] The entire control relies on the controller 4 based on the industrial computer to realize automatic control, which can efficiently realize the laser cladding repair of the shield machine cutter ring 100 to be laser clad in different wear states, with high efficiency, uniform laser cladding, and more reliable combination of cladding material and raw material.

[0066] Embodiment 4, the marking mechanism 13 includes a support member 131, a lifting mechanism 132, an electric linear slide 133, a connecting plate 134 and a laser marker 135, the support member 131 is located on one side of the internal tension clamping mechanism 12, the bottom of the lifting mechanism 132 is installed on the top of the support member 131, the linear track of the electric linear slide 133 is detachably installed on the top of the piston rod of the lifting mechanism 132, one end of the connecting plate 134 is detachably installed on the slider of the electric linear slide 133, the shell of the laser marker 135 is detachably installed on the other end of the connecting plate 134, and the laser head faces downward, and the controller 4 controls the execution actions of the lifting mechanism 132, the electric linear slide 133 and the laser marker 135 respectively.

[0067] Since the marking mechanism 13 needs to be marked right after the installation is completed and needs to be removed after the marking is completed to avoid interfering with the laser cladding operation, a liftable and translatable structure is adopted. The action sequence of the lifting mechanism 132 and the electric linear slide 133 is not prioritized. The lifting mechanism 132 can be a servo electric cylinder or a servo air cylinder, and the lifting stroke can be greater than one hundred millimeters. The laser marking machine 135 can realize laser marking on the upper surface of the shield machine cutter ring 100 to be laser clad, and the marking is clearer and more accurate. Of course, other marking forms can also be used.

[0068] Embodiment 5, the visual camera assembly 21 includes a camera bracket 211 and two visual cameras 212. The camera bracket 211 is installed on the movable part of the parallel robot device 31, and the two visual cameras 212 are respectively installed on the camera bracket 211. The lens of one of the visual cameras 212 faces downward to shoot the visual image of the upper surface of the shield machine cutter ring 100 to be laser clad, and the angle between the lens of the other visual camera 212 and the upper surface of the shield machine cutter ring 100 to be laser clad is an obtuse angle. The visual analysis module 22 includes a memory 221 and a visual analysis chip 222. The memory 221 is communicated with the two visual cameras 212 to exchange the visual images of the upper surface, and the visual analysis chip 222 is communicated with the memory 221. First, a coordinate system based on the visual mark engraved by the laser marking machine 135 as the origin is established, and a visual feature matching algorithm is used to identify the contour of the wear area, and the wear amount of the wear area is calculated based on the visual three-dimensional reconstruction algorithm. The visual analysis chip 222 stores the wear area coordinate data and the wear amount data of the wear area in the memory 221.

[0069] A visual acquisition solution using two visual cameras 212 is used. Of course, in order to achieve more accurate visual detection results, multiple cameras can be used, one of which captures the visual image directly above, and the other captures the visual image at a certain angle. Usually, the angle between the lens of the other visual camera 212 and the upper surface of the shield machine cutter ring 100 to be laser clad is an obtuse angle, such as 50° to 70°, which can achieve subsequent three-dimensional reconstruction. Since it is a fixed-point shooting without other interference, fill light can be used during shooting to improve the shooting effect. The measurement accuracy of the regional volume corresponding to the wear amount can reach a calculation accuracy of 0.1 cubic millimeter. For the shield machine cutter ring, this accuracy can meet the repair requirements of laser cladding.

[0070] When installing the two visual cameras 212 , the interference problem of the parallel robot device 31 should be considered. In specific implementation, the two visual cameras 212 can be installed on the movable part of the parallel robot device 31 through the camera bracket 211 , and can be kept a certain distance away from the laser cladding device 32 .

[0071] Embodiment 6, the parallel robot device 31 includes a gantry frame 311 and a delta robot 312, the delta robot 312 is installed on the gantry frame 311, the laser cladding device 32 is installed on the movable part of the delta robot 312, and follows the movable part to perform laser cladding welding on the upper surface of the shield machine cutter ring 100 to be laser clad;

[0072] The laser cladding device 32 includes a cladding material bin 321 , a laser cladding head 322 and a laser cladding controller 323 . The cladding material bin 321 and the laser cladding head 322 are respectively installed on the movable part of the delta robot 312 . The controller 4 controls the execution action of the laser cladding head 322 through the laser cladding controller 323 .

[0073] The delta robot 312 is generally used as a supporting manipulator for visual sorting solutions and is adapted to the field of laser cladding. It can efficiently and accurately move the laser cladding device 32 to a specified position. The laser cladding device 32 is implemented by connecting the cladding silo 321 to the laser cladding head 322, and a laser cladding controller 323 is used to receive control instructions from the controller 4 to achieve precise control of the laser cladding amount.

[0074] In embodiment 7, the controller 4 includes an industrial control computer 41 and a display screen 42. The industrial control computer 41 communicates with the memory 221 to exchange wear area coordinate data and wear area wear amount data, and controls the execution actions of the positioning mechanism and the automatic laser cladding mechanism respectively.

[0075] The industrial control computer 41 can realize efficient data analysis and command control of industrial actuators, and can also cooperate with the display screen 42 to realize real-time monitoring of the laser cladding process. The visual source can be the visual signal of the delta robot 312.

[0076] Embodiment 8, a shield machine cutter ring laser cladding welding method, using a shield machine cutter ring laser cladding welding device to perform laser cladding repair on the shield machine cutter ring 100 to be laser clad, comprising the following steps:

[0077] Step 1, placing the inner ring of the shield machine cutter ring 100 to be laser clad on the inner tension clamping mechanism 12, the industrial control computer 41 controls the inner tension clamping mechanism 12 to clamp the shield machine cutter ring 100 to be laser clad, and one side of the shield machine cutter ring 100 to be laser clad faces upward;

[0078] Step 2, the industrial control computer 41 controls the lifting mechanism 132 to move, drives the laser marking machine 135 to descend, controls the electric linear slide 133 to drive the laser marking machine 135 to move horizontally, makes the laser head of the laser marking machine 135 contact the upper surface of the shield machine cutter ring 100 to be laser clad, and controls the laser marking machine 135 to move to carve marks on the upper surface of the shield machine cutter ring 100 to be laser clad;

[0079] Step 3, the industrial control computer 41 controls the visual camera assembly 21 to take pictures of the top view and the side view of the upper surface of the shield machine cutter ring 100 to be laser clad;

[0080] Step 4, the visual analysis module 22 first analyzes the top-view image, extracts the marked position, takes the geometric center point of the mark as the origin of the coordinate system, uses the visual feature matching algorithm to extract the visual features of the wear area, and contours the visual features of the wear area, calculates the geometric center of the contoured wear area, and marks the geometric center coordinates of the contoured wear area based on the origin of the coordinate system;

[0081] Step 5, the visual analysis module 22 analyzes the top view and the side view, performs three-dimensional reconstruction of the wear area, and calculates the wear of each wear area based on the three-dimensional reconstructed three-dimensional model;

[0082] Step 6: The industrial control computer 41 divides the wear area into multiple wear levels based on the regional wear amount and the corresponding coordinates of the wear area, with 1 cubic millimeter as the wear level difference. The industrial control computer 41 controls the action of the automatic laser cladding mechanism, and adjusts the cladding amount of the laser cladding device 32 each time in the order of wear amount from large to small, and concentrates multiple wear areas of the same wear level for laser cladding repair.

[0083] The wear area is divided into multiple wear levels according to the wear amount, with every 1 cubic millimeter as the wear amount level difference. For example, the wear area with a wear amount greater than 1 cubic millimeter and less than or equal to 2 cubic millimeters is marked as a wear area of ​​level A, and the wear area with a wear amount greater than 2 cubic millimeters and less than or equal to 3 cubic millimeters is marked as a wear area of ​​level B. By analogy, during specific laser cladding, the first batch of laser cladding can be performed on multiple wear areas with the maximum wear amount. For example, the level marked on multiple wear areas with the maximum wear amount is C, and the wear amount is greater than 3 cubic millimeters and less than or equal to 4 cubic millimeters. At this time, the industrial control computer 41 controls the automatic laser cladding mechanism to correspond to 3 cubic millimeters of laser cladding amount. After laser cladding operations are performed on multiple wear areas of level C respectively, a small amount of cladding operations are required for those that do not meet the repair requirements (for example, the surface flatness does not reach the set value) based on vision. After laser cladding is completed on multiple wear areas of level C, the same operation is performed on multiple wear areas of level B.

[0084] This repair process of performing laser cladding in batches according to the amount of wear can avoid the laser cladding head from constantly adjusting the cladding amount over a large range, and can increase the uniformity of the laser cladding.

[0085] In Example 9, the mark in step 2 is a hollow circle.

[0086] Using hollow circles can better calculate the geometric center and facilitate visual processing.

[0087] The following methods can be used to calculate the wear amount:

[0088] Use an edge detection algorithm, such as Canny edge detection, to identify the edges of the worn areas.

[0089] According to the edge detection results, the worn area is segmented from the entire knife circle image.

[0090] The top view and side view images are stereo matched to obtain the position information of the same wear area at different viewing angles.

[0091] Using the results of stereo matching, the three-dimensional model of the worn area is reconstructed through the principle of triangulation.

[0092] The following are the steps to calculate the wear volume (depression area volume) based on the reconstructed 3D model:

[0093] Perform surface fitting on the unworn cutter ring surface to obtain a reference plane or surface.

[0094] Compare the 3D model of the worn area to a reference surface to determine the depth and extent of the wear.

[0095] The 3D model of the worn area is divided into many small volume units (eg voxels).

[0096] The volume of each voxel is calculated and summed to get the total wear volume.

[0097] The following is the specific calculation method:

[0098] a. Meshing

[0099] The wear area is divided into grids, and the volume of each grid cell can be calculated by the following formula:

[0100] ;

[0101] in are the sizes of the grid cells in the x, y, and z directions, respectively;

[0102] b. Volume sum

[0103] For each grid cell, if it is below the reference surface, its volume is calculated and accumulated:

[0104] ;

[0105] in, is the total wear amount, is the volume of the i-th voxel.

[0106] Through the above steps, the wear amount of the wear area on the surface of the shield machine cutter ring can be calculated.

[0107] The above are all preferred embodiments of the present invention, and are not intended to limit the protection scope of the present invention. Therefore, any equivalent changes made based on the structure, shape, and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A shield machine cutter ring laser cladding welding device, characterized in that: It includes a positioning mechanism, a defect visual analysis device, an automatic laser cladding mechanism and a controller based on an industrial computer (4); The positioning mechanism comprises a rotating support mechanism (11), an internal tensioning clamping mechanism (12) and a marking mechanism (13); the internal tensioning clamping mechanism (12) is mounted on a rotating portion of the rotating support mechanism (11) and rotates with the rotating portion; the inner ring of the shield machine cutter ring (100) to be laser clad is clamped on the clamping portion of the internal tensioning clamping mechanism (12) and is in a horizontal state; the marking mechanism (13) is mounted on one side of the rotating support mechanism (11) and is used to engrave a visual mark on the shield machine cutter ring (100) to be laser clad; The defect visual analysis device comprises a visual camera component (21) and a visual analysis module (22), wherein the visual camera component (21) is installed directly above the inner tensioning clamping mechanism (12) via a bracket, the visual camera component (21) captures a visual image of the upper surface of the shield machine cutter ring (100) to be laser clad, the visual analysis module (22) communicates and interacts with the visual camera component (21) to exchange the upper surface visual image, establishes a coordinate system based on the visual mark as the origin, and obtains the regional wear amount and the corresponding coordinates of the wear area based on the upper surface visual image analysis; The automatic laser cladding mechanism comprises a parallel robot device (31) and a laser cladding device (32), wherein the parallel robot device (31) is mounted above the inner tensioning clamping mechanism (12) via a bracket, and the laser cladding device (32) is mounted on the movable part of the parallel robot device (31) and performs laser cladding welding on the upper surface of a shield machine cutter ring (100) to be laser clad under the drive of the movable part of the parallel robot device (31); The controller (4) is in communication connection with the visual analysis module (22), and based on the regional wear amount and the corresponding coordinates of the wear area, the wear area is divided into multiple wear levels according to the wear amount. The controller (4) controls the operation of the automatic laser cladding mechanism, and adjusts the cladding amount of the laser cladding device (32) each time according to the order of wear amount from large to small, so that multiple wear areas of the same wear level are collectively laser clad and repaired.

2. A shield machine cutter ring laser cladding welding device according to claim 1, characterized in that: The rotating support mechanism (11) is a servo-electric rotating platform.

3. A shield machine cutter ring laser cladding welding device according to claim 2, characterized in that: The internal tension clamping mechanism (12) comprises a two-finger servo electric claw (121) and a pair of support blocks (122); the bottom of the two-finger servo electric claw (121) is detachably mounted on the rotating part of the rotating support mechanism (11); the pair of support blocks (122) are detachably mounted on two movable blocks of the two-finger servo electric claw (121); when the inner ring of the shield machine cutter ring (100) to be laser clad is placed on the pair of support blocks (122), the controller (4) controls the two-finger servo electric claw (121) to move, and the two movable blocks move outward to clamp the shield machine cutter ring (100) to be laser clad.

4. A shield machine cutter ring laser cladding welding device according to claim 3, characterized in that: The marking mechanism (13) comprises a support member (131), a lifting mechanism (132), an electric linear slide (133), a connecting plate (134) and a laser marking machine (135), wherein the support member (131) is located on one side of the inner tension clamping mechanism (12), the bottom of the lifting mechanism (132) is mounted on the top of the support member (131), the linear track of the electric linear slide (133) is detachably mounted on the top of the piston rod of the lifting mechanism (132), one end of the connecting plate (134) is detachably mounted on the slider of the electric linear slide (133), the housing of the laser marking machine (135) is detachably mounted on the other end of the connecting plate (134), and the laser head faces downward, and the controller (4) controls the execution actions of the lifting mechanism (132), the electric linear slide (133) and the laser marking machine (135) respectively.

5. A shield machine cutter ring laser cladding welding device according to claim 4, characterized in that: The visual camera assembly (21) comprises a camera support (211) and two visual cameras (212), wherein the camera support (211) is mounted on a movable part of the parallel robot device (31), and the two visual cameras (212) are respectively mounted on the camera support (211), wherein the lens of one of the visual cameras (212) faces downward to capture a visual image of the upper surface of a shield machine cutter ring (100) to be laser clad, and the angle between the lens of the other visual camera (212) and the upper surface of the shield machine cutter ring (100) to be laser clad is an obtuse angle, and the visual analysis module (22) comprises a memory (221) and a visual analysis chip (222), the memory (221) is respectively connected to the two visual cameras (212) for communicating with each other to display the visual images on the surface, the visual analysis chip (222) is connected to the memory (221) for communicating with each other, firstly a coordinate system is established based on the visual mark carved by the laser marking machine (135) as the origin, a visual feature matching algorithm is used to identify the contour of the wear area, and the wear amount of the wear area is calculated based on the visual three-dimensional reconstruction algorithm, and the visual analysis chip (222) stores the coordinate data of the wear area and the wear amount data of the wear area in the memory (221).

6. A shield machine cutter ring laser cladding welding device according to claim 5, characterized in that: The parallel robot device (31) comprises a gantry frame (311) and a delta robot (312), wherein the delta robot (312) is mounted on the gantry frame (311), and the laser cladding device (32) is mounted on the movable part of the delta robot (312) and follows the movable part to perform laser cladding welding on the upper surface of a shield machine cutter ring (100) to be laser clad; The laser cladding device (32) comprises a cladding material bin (321), a laser cladding head (322) and a laser cladding controller (323); the cladding material bin (321) and the laser cladding head (322) are respectively mounted on the movable part of the delta robot (312); and the controller (4) controls the execution action of the laser cladding head (322) through the laser cladding controller (323).

7. A shield machine cutter ring laser cladding welding device according to claim 6, characterized in that: The controller (4) comprises an industrial control computer (41) and a display screen (42); the industrial control computer (41) communicates with the memory (221) to exchange wear area coordinate data and wear area wear amount data, and respectively controls the execution actions of the positioning mechanism and the automatic laser cladding mechanism.

8. A shield machine cutter ring laser cladding welding method, characterized in that: The shield machine cutter ring laser cladding welding device according to claim 7 is used to perform laser cladding repair on the shield machine cutter ring (100) to be laser clad, comprising the following steps: Step 1, placing the inner ring of the shield machine cutter ring (100) to be laser clad on the inner tension clamping mechanism (12), and the industrial control computer (41) controls the inner tension clamping mechanism (12) to clamp the shield machine cutter ring (100) to be laser clad, with one side of the shield machine cutter ring (100) facing upwards; Step 2, the industrial control computer (41) controls the lifting mechanism (132) to move, drives the laser marking machine (135) to descend, controls the electric linear slide (133) to move, drives the laser marking machine (135) to move horizontally, makes the laser head of the laser marking machine (135) contact the upper surface of the shield machine cutter ring (100) to be laser clad, and controls the laser marking machine (135) to move to carve a mark on the upper surface of the shield machine cutter ring (100) to be laser clad; Step 3, the industrial control computer (41) controls the visual camera assembly (21) to capture a top-view image and a side-view image of the upper surface of the shield machine cutter ring (100) to be laser clad; Step 4, the visual analysis module (22) first analyzes the top-view image, extracts the marked position, takes the geometric center point of the mark as the origin of the coordinate system, uses a visual feature matching algorithm to extract the visual features of the wear area, and contours the visual features of the wear area, calculates the geometric center of the contoured wear area, and marks the geometric center coordinates of the contoured wear area based on the origin of the coordinate system; Step 5, the visual analysis module (22) analyzes the top-view image and the side-view image, performs three-dimensional reconstruction of the wear area, and calculates the wear of each wear area based on the three-dimensional reconstructed three-dimensional model; Step 6, the industrial control computer (41) divides the wear area into multiple wear levels according to the wear amount based on the regional wear amount and the corresponding coordinates of the wear area, with every (1) cubic millimeter as the wear amount level difference. The industrial control computer (41) controls the operation of the automatic laser cladding mechanism, and adjusts the cladding amount of the laser cladding device (32) each time according to the order of wear amount from large to small, so that multiple wear areas of the same wear level are concentratedly laser clad and repaired.

9. A shield machine cutter ring laser cladding welding method according to claim 8, characterized in that: The mark in step 2 is a hollow circle.

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