Submerged arc additive printing equipment and method for large metal component

Abstract

The invention discloses a large metal component submerged arc additive printing device and method, a welding gun is installed on a Z-axis movement system in a multi-axis movement mechanism, one end of a welding flux feeding pipeline is located on one side of the welding gun, and the other end of the welding flux feeding pipeline is connected with the output end of a feeding mechanism. An inlet of the welding flux recycling pipeline is located on the other side of the welding gun and fixed to the first R-axis movement system. The other end of the welding flux recycling pipeline is connected with one end of the collecting device, the other end of the collecting device is connected with the input end of the welding flux and welding slag screening device, and the output end of the welding flux and welding slag screening device is connected with the input end of the feeding mechanism. The welding slag cleaning device and the welding flux recovery pipeline are located on the same side of the welding gun, the welding slag cleaning device is fixed to the second R-axis movement system, and the CCD camera monitoring system is installed on the third R-axis movement system. According to the invention, the functions of automatic welding flux laying and welding slag cleaning are combined, automatic printing, welding flux recovery and slag cleaning are realized, the welding flux waste is reduced, the labor cost is saved, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention belongs to the field of additive manufacturing, and in particular to a submerged arc additive printing device and method for large metal components. Background Art

[0002] Due to its incomparable efficiency and cost advantages over other additive technologies, the submerged arc additive manufacturing process is particularly suitable for low-cost, efficient and rapid near-net shaping of large-scale complex metal components. In existing arc additive manufacturing technologies, the mainstream heat source form of additive manufacturing equipment is cold metal transfer (CMT) arc welding heat source, and its printing efficiency for steel materials is about 3kg / h. Single-gun submerged arc additive manufacturing technology can successfully increase the printing efficiency of steel materials to 8kg / h.

[0003] In the 1970s, German scholars proposed the use of submerged arc welding for cladding. However, due to the need to lay flux before welding and remove slag after welding, and the heavy submerged arc welding gun, the degree of automation is limited, and there are no reports on engineering applications. In recent years, with the development of technology, technologies related to submerged arc cladding and additive manufacturing have begun to appear again. Foshan Yuren Intelligent Technology Co., Ltd. provides a fully automated metal additive submerged arc printing equipment and method based on the concept of laser powder bed technology, and specifically describes the laying auxiliary device for submerged arc additive (application number: 202010260537.7, 202020479735.8). In this scheme, the laying flux, welding gun, flux recovery, slag removal and other devices are all installed on the motion mechanism. The workflow draws on the process of laser powder bed melting (SLM). The main process flow is: laying flux-movement mechanism reset-submerged arc printing-movement mechanism reset-flux removal-movement mechanism reset-cleaning welding slag-movement mechanism reset cycle operation. The original single-pass submerged arc welding work of laying welding, cladding, flux recovery and slag cleaning is broken down into 8 steps. Although submerged arc additive manufacturing can be achieved, too many movement steps reduce printing efficiency, flux filling cannot be automated, and slag after welding cannot be automatically cleaned. At the same time, the extra flux consumption also increases costs. Summary of the invention

[0004] The purpose of the present invention is to solve the problems in the prior art and to provide a submerged arc additive printing device and method for large metal components to solve the problems of existing submerged arc welding in which flux filling cannot be automated, welding slag after welding cannot be automatically cleaned, and production efficiency is low.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A submerged arc additive printing device for large metal components, comprising a multi-axis motion mechanism, a flux recovery pipeline, a welding slag cleaning device, a welding gun, a flux feeding pipeline, a feeding mechanism, a flux slag screening device, a collecting device and a CCD camera monitoring system;

[0007] One end of the flux recovery pipeline is fixed on the first R-axis motion system in the multi-axis motion mechanism, the other end of the flux recovery pipeline is connected to one end of the collecting device, the other end of the collecting device is connected to the input end of the flux slag screening device, the output end of the flux slag screening device is connected to the input end of the feeding mechanism, the output end of the feeding mechanism is connected to one end of the flux feeding pipeline, the other end of the flux feeding pipeline is located on one side of the welding gun, the other side of the welding gun is the flux recovery pipeline, the welding gun is installed on the Z-axis motion system in the multi-axis motion mechanism, the welding slag cleaning device is fixed on the second R-axis motion system in the multi-axis motion mechanism, the welding slag cleaning device is located on one side of the flux recovery pipeline, and the CCD camera monitoring system is installed on the third R-axis motion system in the multi-axis motion mechanism.

[0008] Furthermore, the first R-axis motion system, the second R-axis motion system and the third R-axis motion system are all installed on the Z-axis motion system in the multi-axis motion mechanism.

[0009] Furthermore, the motion trajectories of the first R-axis motion system, the second R-axis motion system and the third R-axis motion system are all the same as the motion trajectory of the welding gun.

[0010] Furthermore, the welding gun is fixedly connected to a flux feeding pipeline.

[0011] Furthermore, the feeding mechanism includes a feed inlet cover, a scraper plate, a coupling and a feeding body;

[0012] The feed inlet cover is connected to the feeding body through screws and sealing strips, the scraper plate is arranged in the feeding body, and the scraper plate is connected to the feeding drive motor through a coupling.

[0013] Furthermore, the scraper plate is provided with a plurality of first grooves, the feeding body is provided with a second groove, and the second groove is connected to the flux feeding pipeline.

[0014] Furthermore, the device for screening flux and welding slag comprises a feed inlet, a screen and a discharge port;

[0015] The feed port is connected to the material collecting device through a pipeline, the discharge port is connected to the feeding mechanism through a pipeline, and the screen is detachably arranged in the device for screening flux and welding slag.

[0016] Furthermore, a fan is provided in the material collecting device, one side of the material collecting device is fixedly connected to the ventilation duct via a clamp sealing strip, a filter box is provided on the ventilation duct, and the filter box and the ventilation duct are fixedly connected via a clamp sealing strip.

[0017] Furthermore, the material collecting device is fixedly connected to the flux recovery pipeline via a clamp sealing strip.

[0018] A submerged arc additive printing method for large metal components of the device comprises:

[0019] During the welding gun printing process, the multi-axis motion mechanism controls the flux recovery pipeline on the first R-axis motion system, the welding slag cleaning device on the second R-axis motion system and the CCD camera monitoring system on the third R-axis motion system to move in the same trajectory as the welding gun. The CCD camera monitoring system collects images of the welding area. The welding slag cleaning device crushes and cleans the welding slag attached to the weld. The gathering device generates suction through the operation of the fan and sucks the unmelted flux into the gathering device through the flux recovery pipeline. The residual material falls into the flux screening slag device for screening. The screened flux falls into the feeding mechanism with gravity for reuse. Driven by the feeding mechanism, the flux is evenly discharged from the flux feeding pipeline and falls in front of the welding gun. The welding gun uses the fallen flux for welding.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention provides a submerged arc additive printing device for large metal components. By installing a welding slag cleaning device behind the welding gun, the welding slag cleaning device is used to clean the residual material after welding, thereby realizing automatic cleaning of welding slag. The collecting device sucks the residual material after welding into the collecting device through a flux recovery pipeline, and then screens it through a flux separation and welding slag device. The flux feeding pipeline is installed in front of the welding gun, and the flux in the residual material is sent by gravity to fall in front of the welding gun for welding, thereby realizing the automation of flux feeding. The present invention combines the functions of automatic flux laying and welding slag cleaning to realize automatic printing, automatic flux recovery, reduce flux waste, save labor costs, and improve production efficiency. It can realize real-time automatic adjustment of welding parameters, and multiple functional modules can operate in coordination with each other according to the planned trajectory of surfacing.

[0022] Furthermore, a filter box is provided on the ventilation duct, and the ventilation duct exhausts air to the outdoors after filtering through the filter box, thereby protecting the environment from being polluted by toxic particles.

[0023] Furthermore, the built-in screen of the flux and slag screening device can separate the welding slag and large particles from the reusable flux, so that the flux always meets the welding use standards and ensures its good welding quality.

[0024] Furthermore, the feeding device is driven by a feeding drive motor to ensure feeding uniformity, and the feeding speed is controlled by the rotation speed of the motor.

[0025] Furthermore, the welding slag cleaning system, flux recovery pipeline and CCD camera monitoring system are installed on the R-axis motion system of the multi-axis motion mechanism. After the welding gun running track is planned by software, the distance between each set of R-axis motion modules and the central axis of the welding gun is a fixed value, and the rotation angle of each R-axis motion module can be calculated by software to achieve the same set of motion trajectories of each R-axis motion module and the welding gun, thereby realizing multi-module follow-up control. The flux recovery pipeline and welding slag cleaning device are installed on different R axes respectively. Through the above control, the flux and welding slag can be recovered and cleaned along the welding trajectory.

[0026] Furthermore, by detecting the real-time current changes of the welding machine and feeding back to the Z-axis control system of the multi-axis motion mechanism, the welding current is positively correlated with the arc length. By detecting the current size of the welding process and converting it into a signal for controlling the Z-axis motion, the welding gun height can be adjusted in real time through the Z-axis motion system, thereby controlling the welding arc length and ensuring the welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0028] Figure 1 It is a schematic diagram of the submerged arc additive printing equipment for large metal components of the present invention.

[0029] Figure 2 It is a schematic structural diagram of a device for screening flux and welding slag applied to a submerged arc additive printing device for large metal components according to the present invention.

[0030] Figure 3 The figure is a schematic structural diagram of the feeding mechanism of the submerged arc additive printing device for large metal components of the present invention.

[0031] Figure 4 This is a schematic diagram of the head follow-up system of the submerged arc additive printing equipment for large metal components of the present invention.

[0032] Among them: 1-multi-axis motion mechanism, 2-flux recovery pipeline, 3-second R-axis motion system, 4-welding slag cleaning device, 5-welding gun, 6-first R-axis motion system, 7-flux feeding pipeline, 8-feeding mechanism, 9-flux slag screening device, 10-filter box, 11-exhaust duct, 12-collecting device, 13-feeding port, 14-screen, 15-discharging port, 16-feeding port cover, 17-scraper plate, 18-coupling, 19-feeding body, 20-third R-axis motion system, 21-Z-axis motion system, 22-CCD camera monitoring system. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0034] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0036] In the description of the embodiments of the present invention, it should be noted that if the terms "upper", "lower", "horizontal", "inner", etc. indicate an orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use, it is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0037] In addition, if the term "horizontal" appears, it does not mean that the component must be absolutely horizontal, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", which does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0038] In the description of the embodiments of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0039] The present invention is further described in detail below in conjunction with the accompanying drawings:

[0040] See also Figure 1 The present invention provides a large-scale metal component submerged arc additive printing device, including a multi-axis motion mechanism 1, a flux recovery pipeline 2, a welding slag cleaning device 4, a welding gun 5, a flux feeding pipeline 7, a feeding mechanism 8, a flux slag screening device 9, a filter box 10, a ventilation duct 11, a collection device 12, and a CCD camera monitoring system 22. The Z-axis motion system 21 in the multi-axis motion mechanism 1 is installed with a first R-axis motion system 6, a second R-axis motion system 3 and a third R-axis motion system 20. The multi-axis motion mechanism 1 can realize multi-axis motion control such as X, Y, Z, and R, and realize the lifting layer by layer cladding. One end of the flux recovery pipeline 2 is fixed on the first R-axis motion system 6 that can rotate around the central axis of the welding gun, and is located at the rear end of the welding gun 5. The other end is connected to the collection device 12. A fan is arranged in the collection device 12. By configuring a sealing strip and a clamp to lock it, its sealing is ensured, so that the suction of the fan is more concentrated. The welding slag cleaning device 4 is fixed on the second R-axis motion system 3 that can rotate around the central axis of the welding gun, and is located behind the flux recovery pipeline 2. The welding gun 5 is installed on the Z-axis motion system 21 of the multi-axis motion mechanism 1, one end of the flux feeding pipe 7 is fixed in front of the welding gun 5, and the other end of the flux feeding pipe 7 is fixedly connected to the feeding mechanism 8 through a clamp. The feeding drive motor is connected to the feeding mechanism 8 through a coupling 18, the output end of the screening flux welding slag device 9 is connected to the input end of the feeding mechanism 8, and the input end of the screening flux welding slag device 9 is connected to the collection device 12. The ventilation duct 11 and the collection device 12 are fixed by a clamp sealing strip to ensure their sealing. The filter box 10 is fixed to the ventilation duct 11 by a clamp sealing strip to ensure its sealing, and the air is exhausted to the outside after filtering. The CCD camera monitoring system 22 is installed on the third R-axis motion system 20 that can rotate around the central axis of the welding gun.

[0041] like Figure 2As shown, the device 9 for screening flux and welding slag includes a feed port 13, a screen 14 and a discharge port 15. The feed port 13 is connected to the collecting device 12 through a pipeline, and the discharge port 15 is connected to the feeding mechanism 8 through a pipeline. The device 9 for screening flux and welding slag feeds from the feed port 13 and falls onto the screen 14. Some welding slag will be intercepted on the screen 14 due to its large volume, while normal flux that meets the particle size of the screen 14 will leak down, so as to achieve the purpose of separating welding slag and welding. The screen 14 is detachably installed in the device 9 for separating flux and welding slag, and needs to be cleaned regularly.

[0042] like Figure 3 As shown, the feeding mechanism 8 includes a feed inlet cover 16, a scraper plate 17, a coupling 18 and a feed body 19. The feed inlet cover 16 is connected to the feed body 19 by screws and sealing strips, the scraper plate 17 is arranged in the feed body 19, the scraper plate 17 is connected to the feed drive motor 7 by the coupling 18, the feed drive motor 7 drives the scraper plate 17 to rotate, the scraper plate 17 is provided with a plurality of disc-shaped first grooves, the flux leaked from the screening flux welding slag device 9 falls into the first groove on the scraper plate 17, the feed body 19 is provided with a second groove, and the second groove is connected to the flux feeding pipeline 6. When the first groove on the scraper plate 17 overlaps with the second groove provided on the feed body 19, the flux in the first groove will leak into the pipeline flux feeding pipeline 7, and the different rotation speeds of the feed drive motor can control the amount of flux conveyed, so that the flux falling before the welding gun below is uniform.

[0043] like Figure 4 As shown, the head follow-up system includes a welding gun 5, a CCD camera monitoring system 22, a Z-axis motion system 21 in a multi-axis motion mechanism 1 and multiple R-axis motion systems, a flux recovery pipeline 2, a welding slag cleaning device 4 and a flux feeding pipeline 7. The welding gun 5 is connected to the Z-axis motion system 21, and the up and down movement of the welding gun 5 can be controlled. By detecting the real-time current change of the welding machine and feeding it back to the Z-axis motion system, since the welding current is positively correlated with the arc length, the current size of the welding process is detected and converted into a signal to control the Z-axis motion, and the Z-axis height is controlled in real time, and the arc length is adjusted to keep it stable, thereby ensuring the welding quality. The CCD camera monitoring system 22, the flux recovery pipeline 2, and the welding slag cleaning device 4 are connected to multiple R-axis motion systems, and each R axis is at a pre-designed fixed distance from the center axis of the welding gun. After planning the running trajectory of the welding gun 5 through the programming software, the follow-up posture of other R-axis modules can be calculated through the software, mainly the rotation angle of the R-axis around the central axis of the welding gun, and by controlling the rotation angle of each R-axis, multiple modules can follow the same set of motion trajectories, realizing the follow-up control of multiple R-axis motion systems and the trajectory of the welding gun 5.

[0044] Submerged arc additive printing method for large metal components of the present invention:

[0045] During the printing process of the welding gun 5, the flux recovery pipe 2 on the first R-axis motion system 6, the welding slag cleaning device 4 on the second R-axis motion system 3 and the CCD camera monitoring system 22 on the third R-axis motion system 20 move in the same trajectory as the welding gun 5 but at a certain time interval. The time sequence of the motion trajectory of each R-axis is related to the arm length of each R-axis from the center of the Z-axis. The CCD camera monitoring system 22 monitors the welding area image, and the welding slag cleaning device 4 installed behind the welding gun crushes and cleans the welding slag attached to the weld after welding. The fan in the collection device 12 generates suction through the flux recovery pipe 2 to suck the unmelted flux residue into the collection device 12. The flux residue falls into the screening flux and welding slag device 9 due to gravity for screening, and the mixed large particles of flux and welding slag are trapped above the screen. After the stage work is completed, it is regularly recovered and cleaned to avoid clogging the screen. The screened flux falls into the feeding mechanism 8 by gravity. Driven by the feeding mechanism 8, the flux is uniformly discharged from the flux feeding pipe 7 and falls in front of the welding gun 5, realizing the automation of flux feeding. During the welding process, the real-time current change of the welding machine is detected and fed back to the Z-axis motion system 21. The welding current is positively correlated with the arc length. By detecting the current size of the welding process, it is converted into a signal for controlling the Z-axis motion, and the Z-axis height is controlled in real time to adjust the arc length to keep it stable, thereby ensuring the welding quality.

[0046] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A submerged arc additive printing device for large metal components, characterized in that: It comprises a multi-axis motion mechanism (1), a flux recovery pipeline (2), a welding slag cleaning device (4), a welding gun (5), a flux feeding pipeline (7), a feeding mechanism (8), a flux slag screening device (9), a material collecting device (12) and a CCD camera monitoring system (22); One end of the flux recovery pipe (2) is fixed to the first R-axis motion system (6) in the multi-axis motion mechanism (1), the other end of the flux recovery pipe (2) is connected to one end of a collecting device (12), the other end of the collecting device (12) is connected to the input end of a device (9) for screening flux and slag, the output end of the device (9) for screening flux and slag is connected to the input end of a feeding mechanism (8), the output end of the feeding mechanism (8) is connected to one end of a flux feeding pipe (7), the other end of the flux feeding pipe (7) is connected to the input end of a feeding mechanism (8), the output end of the feeding mechanism (8) is connected to one end of a flux feeding pipe (7), the other end of the flux feeding pipe (7) is connected to the input end of a feeding mechanism (8), and the output end of the feeding mechanism (8) is connected to one end of a flux feeding pipe (7). One end is located on one side of the welding gun (5), the other side of the welding gun (5) is a flux recovery pipe (2), the welding gun (5) is installed on the Z-axis motion system (21) in the multi-axis motion mechanism (1), the welding slag cleaning device (4) is fixed on the second R-axis motion system (3) in the multi-axis motion mechanism (1), the welding slag cleaning device (4) is located on one side of the flux recovery pipe (2), and the CCD camera monitoring system (22) is installed on the third R-axis motion system (20) in the multi-axis motion mechanism (1).

2. A large-scale metal component submerged arc additive printing device according to claim 1, characterized in that: The first R-axis motion system (6), the second R-axis motion system (3) and the third R-axis motion system (20) are all installed on the Z-axis motion system (21) in the multi-axis motion mechanism (1).

3. The large-scale metal component submerged arc additive printing equipment according to claim 1, characterized in that: The motion trajectories of the first R-axis motion system (6), the second R-axis motion system (3) and the third R-axis motion system (20) are all the same as the motion trajectory of the welding gun (5).

4. The large-scale metal component submerged arc additive printing device according to claim 1, characterized in that: The welding gun (5) is fixedly connected to the flux feeding pipeline (7).

5. The large-scale metal component submerged arc additive printing device according to claim 1, characterized in that: The feeding mechanism (8) comprises a feed inlet cover (16), a scraper plate (17), a coupling (18) and a feeding body (19); The feed inlet cover (16) is connected to the feeding body (19) via screws and sealing strips, the scraper plate (17) is arranged in the feeding body (19), and the scraper plate (17) is connected to the feeding drive motor via a coupling (18).

6. The large-scale metal component submerged arc additive printing device according to claim 4, characterized in that: The scraper plate (17) is provided with a plurality of first grooves, and the feeder body (19) is provided with a second groove, wherein the second groove is connected to the flux feeder pipe (7).

7. The large-scale metal component submerged arc additive printing device according to claim 1, characterized in that: The device (9) for screening flux and welding slag comprises a feed port (13), a screen (14) and a discharge port (15); The feed port (13) is connected to the material collecting device (12) via a pipeline, the discharge port (15) is connected to the feeding mechanism (8) via a pipeline, and the screen (14) is detachably arranged in the welding flux and welding slag screening device (9).

8. The large-scale metal component submerged arc additive printing device according to claim 1, characterized in that: A fan is arranged in the material collecting device (12), one side of the material collecting device (12) is fixedly connected to the ventilation duct (11) via a clamp sealing strip, a filter box (10) is arranged on the ventilation duct (11), and the filter box (10) and the ventilation duct (11) are fixedly connected via a clamp sealing strip.

9. The large-scale metal component submerged arc additive printing device according to claim 1, characterized in that: The material collecting device (12) is fixedly connected to the flux recovery pipeline (2) via a clamp sealing strip.

10. A submerged arc additive printing method for large metal components using the device according to any one of claims 1 to 9, characterized in that: include: During the printing process of the welding gun (5), the multi-axis motion mechanism (1) controls the flux recovery pipe (2) on the first R-axis motion system (6), the slag cleaning device (4) on the second R-axis motion system (3) and the CCD camera monitoring system (22) on the third R-axis motion system (20) to move in the same trajectory as the welding gun (5). The CCD camera monitoring system (22) collects images of the welding area. The slag cleaning device (4) crushes and cleans the slag attached to the weld. The collecting device (12) generates suction through the operation of the fan and sucks the unmelted flux into the collecting device (12) through the flux recovery pipe (2). The remaining material falls into the flux slag screening device (9) for screening. The screened flux falls into the feeding mechanism (8) with gravity for reuse. Driven by the feeding mechanism (8), the flux is evenly discharged from the flux feeding pipe (7) and falls in front of the welding gun (5). The welding gun (5) uses the fallen flux to perform welding.

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