A submerged arc additive printing device and method for large metal components

Abstract

This invention discloses a submerged arc additive manufacturing (SAW) device and method for large metal components. The welding torch is mounted on the Z-axis motion system of a multi-axis motion mechanism. One end of the flux feeding pipe is located on one side of the welding torch, and the other end is connected to the output end of the feeding mechanism. The inlet of the flux recovery pipe is located on the other side of the welding torch and is fixed on the first R-axis motion system. The other end of the flux recovery pipe is connected to one end of a collecting device, and the other end of the collecting device is connected to the input end of a flux and slag screening device. The output end of the flux and slag screening device is connected to the input end of the feeding mechanism. The slag cleaning device is located on the same side of the welding torch as the flux recovery pipe and is fixed on the second R-axis motion system. A CCD camera monitoring system is mounted on the third R-axis motion system. This invention combines conformal automatic flux application and slag cleaning functions to achieve automated printing, flux recovery, and slag removal, reducing flux waste, saving labor costs, and improving production efficiency.

Description

Technical Field

[0001] This 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 Technology

[0002] Due to its unparalleled efficiency and cost advantages compared to other additive manufacturing technologies, submerged arc additive manufacturing is particularly suitable for the low-cost, high-efficiency, and rapid near-net-shape forming of large-sized, complex metal components. In existing arc additive manufacturing technologies, the mainstream heat source for additive manufacturing equipment is the cold metal transfer (CMT) arc welding heat source, with a printing efficiency of approximately 3 kg / h for steel materials. However, single-gun submerged arc additive manufacturing technology can successfully increase the printing efficiency of steel materials to 8 kg / h.

[0003] In the 1970s, German scholars proposed using submerged arc welding for surfacing. However, due to the need for pre-weld flux application and post-weld slag removal, coupled with the weight of the submerged arc welding torch and limitations on automation, there were no reports of its engineering applications. In recent years, with technological advancements, technologies related to submerged arc welding and additive manufacturing have begun to emerge. Foshan Yuren Intelligent Technology Co., Ltd., based on the concept of laser powder bed fusion technology, provides a fully automated metal additive submerged arc printing equipment and method, and specifically describes the flux application auxiliary device for submerged arc additive manufacturing (application numbers: 202010260537.7, 202020479735.8). In this scheme, the flux application, welding torch, flux recovery, and slag removal devices are all installed on the motion mechanism. The workflow is based on the laser powder bed fusion (SLM) process, and the main process flow is: flux application - motion mechanism reset - submerged arc printing - motion mechanism reset - flux removal - motion mechanism reset - slag removal - motion mechanism reset cyclic operation. The original single-pass submerged arc welding process of laying welding, surfacing, recovering flux and cleaning slag was broken down into 8 steps. Although submerged arc additive manufacturing can be achieved, the excessive number of motion steps reduces printing efficiency, flux filling cannot be automated, and the slag after welding cannot be automatically cleaned. At the same time, the additional flux consumption also increases costs. Summary of the Invention

[0004] The purpose of this invention is to solve the problems in the prior art and provide a submerged arc additive printing equipment and method for large metal components, which solves the problems of non-automatic flux filling, non-automatic slag cleaning after welding, and low production efficiency in existing submerged arc welding.

[0005] To achieve the above objectives, the present invention employs the following technical solution:

[0006] A submerged arc additive printing device for large metal components includes a multi-axis motion mechanism, a flux recovery pipeline, a slag cleaning device, a welding torch, a flux feeding pipeline, a feeding mechanism, a flux and slag screening device, a material collection device, and a CCD camera monitoring system.

[0007] One end of the flux recovery pipe is fixed to the first R-axis motion system in the multi-axis motion mechanism. The other end of the flux recovery pipe 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 and slag screening device. The output end of the flux and 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 pipe. The other end of the flux feeding pipe is located on one side of the welding torch. The other side of the welding torch is the flux recovery pipe. The welding torch is installed on the Z-axis motion system in the multi-axis motion mechanism. The slag cleaning device is fixed to the second R-axis motion system in the multi-axis motion mechanism. The slag cleaning device is located on one side of the flux recovery pipe. 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 mounted 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 torch.

[0010] Furthermore, the welding torch is fixedly connected to the flux feeding pipe.

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

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

[0013] Furthermore, the scraper disc has several first grooves, and the feeding body has a second groove, which is connected to the flux feeding pipe.

[0014] Furthermore, the flux and slag screening device includes an inlet, a screen, and an outlet;

[0015] The feed inlet is connected to the material collection device via a pipe, the discharge outlet is connected to the feeding mechanism via a pipe, and the screen is detachably installed in the flux and slag screening device.

[0016] Furthermore, a fan is installed inside the material collection device, and a ventilation duct is fixedly connected to one side of the material collection device by a clamp sealing strip. A filter box is installed on the ventilation duct, and the filter box is fixedly connected to the ventilation duct by a clamp sealing strip.

[0017] Furthermore, the material collection device and the flux recovery pipeline are fixedly connected by clamp sealing strips.

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

[0019] During the welding torch printing process, the multi-axis motion mechanism controls the flux recovery pipe on the first R-axis motion system, the 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 along the same trajectory as the welding torch. The CCD camera monitoring system collects images of the welding area, the slag cleaning device breaks up and cleans the slag adhering to the weld bead, and the collecting device generates suction through the operation of the fan and sucks the unmelted flux into the collecting device through the flux recovery pipe. The remaining material falls into the flux and slag screening device for screening. The screened flux falls into the feeding mechanism for reuse under gravity. Driven by the feeding mechanism, the flux is evenly discharged from the flux feeding pipe and falls in front of the welding torch. The welding torch uses the falling flux to perform welding.

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

[0021] This invention provides a submerged arc additive manufacturing (SAW) printing device for large metal components. By installing a slag cleaning device behind the welding torch, the device automatically cleans the residual material after welding, achieving automated slag removal. A collection device draws the residual material into the collection device via a flux recovery pipe. After being screened by a flux and slag separation device, a flux feeding pipe installed in front of the welding torch delivers the flux from the residual material by gravity to the front of the welding torch for welding utilization, thus automating flux feeding. This invention combines conformal automatic flux application and slag removal functions to achieve automated printing and automated flux recovery, reducing flux waste, saving labor costs, and improving production efficiency. It can achieve real-time automatic adjustment of welding parameters, and multiple functional modules can operate collaboratively according to the planned welding trajectory.

[0022] Furthermore, a filter box is installed on the ventilation duct. The ventilation duct is filtered before being exhausted outdoors, which can protect the environment from pollution by toxic particulate matter.

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

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

[0025] Furthermore, the 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 torch's trajectory is planned by software, the distance between each R-axis motion module and the welding torch's central axis is a fixed value. The rotation angle of each R-axis motion module can be calculated by software, ensuring that the motion trajectory of each R-axis motion module and the welding torch is the same, thus achieving multi-module follow-up control. The flux recovery pipeline and slag cleaning device are installed on different R-axis, and through the above control, the flux and slag can be moved along the welding trajectory during recovery and cleaning.

[0026] Furthermore, by detecting real-time changes in the welding machine current and feeding them 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 magnitude of the current during the welding process, it is converted into a signal to control the Z-axis motion. The welding torch height can be adjusted in real time through the Z-axis motion system, thereby controlling the welding arc length and ensuring welding quality. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

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

[0029] Figure 2 This is a schematic diagram of the flux and slag screening device of the present invention, which is applied to a submerged arc additive printing equipment for large metal components.

[0030] Figure 3 This is a schematic diagram of the feeding mechanism structure of the present invention applied to a submerged arc additive printing equipment for large metal components.

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

[0032] The components are: 1-Multi-axis motion mechanism, 2-Fluoride recovery pipe, 3-Second R-axis motion system, 4-Slag cleaning device, 5-Welding torch, 6-First R-axis motion system, 7-Fluoride feeding pipe, 8-Feeding mechanism, 9-Fluoride and slag screening device, 10-Filter box, 11-Exhaust pipe, 12-Collection device, 13-Inlet, 14-Screen, 15-Outlet, 16-Inlet cover, 17-Scraper disc, 18-Coupling, 19-Feeding body, 20-Third R-axis motion system, 21-Z-axis motion system, 22-CCD camera monitoring system. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0034] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0035] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

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

[0037] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and 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 should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0039] The present invention will now be described in further detail with reference to the accompanying drawings:

[0040] See Figure 1 This invention provides a submerged arc additive manufacturing equipment for large metal components, including a multi-axis motion mechanism 1, a flux recovery pipe 2, a slag cleaning device 4, a welding torch 5, a flux feeding pipe 7, a feeding mechanism 8, a flux and slag screening device 9, a filter box 10, a ventilation duct 11, a material collection device 12, and a CCD camera monitoring system 22. The Z-axis motion system 21 of the multi-axis motion mechanism 1 is equipped 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 achieve multi-axis motion control (X, Y, Z, R, etc.) to realize layer-by-layer welding. One end of the flux recovery pipe 2 is fixed to the first R-axis motion system 6, which can rotate around the central axis of the welding torch, and is located at the rear end of the welding torch 5. The other end is connected to the material collection device 12, which contains a fan. The fan is sealed by a sealing strip and clamps to ensure its airtightness and concentrate its suction. The slag cleaning device 4 is fixed on the second R-axis motion system 3, which can rotate around the central axis of the welding torch, and is located behind the flux recovery pipe 2. The welding torch 5 is mounted 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 torch 5, and the other end of the flux feeding pipe 7 is fixedly connected to the feeding mechanism 8 by a clamp. The feeding drive motor is connected to the feeding mechanism 8 through a coupling 18. The output end of the flux and slag screening device 9 is connected to the input end of the feeding mechanism 8, and the input end of the flux and slag screening device 9 is connected to the collection device 12. The ventilation duct 11 is fixed to the collection device 12 by a clamp sealing strip to ensure its airtightness. The filter box 10 is fixed to the ventilation duct 11 by a clamp sealing strip to ensure its airtightness. After filtration, the air is exhausted outdoors. The CCD camera monitoring system 22 is mounted on the third R-axis motion system 20, which can rotate around the central axis of the welding torch.

[0041] like Figure 2As shown, the flux and slag separation device 9 includes an inlet 13, a screen 14, and an outlet 15. The inlet 13 is connected to the collecting device 12 via a pipe, and the outlet 15 is connected to the feeding mechanism 8 via a pipe. The flux and slag separation device 9 feeds into the screen 14 through the inlet 13. Some slag, due to its large size, will be intercepted on the screen 14, while the normal flux that meets the particle size of the screen 14 will pass through, thus achieving the purpose of separating flux and slag. The screen 14 is detachable and installed in the flux and slag separation device 9, and needs to be cleaned regularly.

[0042] like Figure 3 As shown, the feeding mechanism 8 includes an inlet cap 16, a scraper disc 17, a coupling 18, and a feeding body 19. The inlet cap 16 is connected to the feeding body 19 by screws and a sealing strip. The scraper disc 17 is disposed in the feeding body 19 and is connected to the feeding drive motor 7 via the coupling 18. The feeding drive motor 7 drives the scraper disc 17 to rotate. The scraper disc 17 has multiple disc-shaped first grooves. The flux leaking from the flux and slag screening device 9 falls into the first grooves on the scraper disc 17. The feeding body 19 has second grooves that connect to the flux feeding pipe 6. When the first grooves on the scraper disc 17 overlap with the second grooves on the feeding body 19, the flux in the first grooves leaks into the flux feeding pipe 7. Different rotation speeds of the feeding drive motor can control the amount of flux delivered, thus ensuring that the flux falling into the welding gun below is uniform.

[0043] like Figure 4 As shown, the welding head follow-up system includes a welding torch 5, a CCD camera monitoring system 22, a Z-axis motion system 21 and multiple R-axis motion systems in the multi-axis motion mechanism 1, a flux recovery pipe 2, a slag cleaning device 4, and a flux feeding pipe 7. The welding torch 5 is connected to the Z-axis motion system 21, which controls the up and down movement of the welding torch 5. By detecting the real-time changes in the welding machine current, feedback is sent to the Z-axis motion system. Since the welding current is positively correlated with the arc length, the current magnitude during the welding process is converted into a signal to control the Z-axis movement, thereby controlling the Z-axis height in real time and adjusting the arc length to maintain stability, thus ensuring welding quality. The CCD camera monitoring system 22, the flux recovery pipe 2, and the slag cleaning device 4 are connected to multiple R-axis motion systems, each R-axis being a pre-designed fixed distance from the welding torch center axis. After the trajectory of the welding torch 5 is planned by the programming software, the follow-up attitude of other R-axis modules can be calculated by the software. This mainly involves the rotation angle of the R-axis around the central axis of the welding torch. By controlling the rotation angle of each R-axis, multiple modules can follow the same motion trajectory, thus realizing the follow-up control of multiple R-axis motion systems and the trajectory of the welding torch 5.

[0044] The present invention provides a method for submerged arc additive printing of large metal components:

[0045] During the welding process of the welding torch 5, 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 move along the same trajectory as the welding torch 5, but at certain intervals. The time sequence of each R-axis motion trajectory 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 image of the welding area. The slag cleaning device 4 installed behind the welding torch breaks up and cleans the slag adhering to the weld bead after welding. The fan in the collection device 12 generates suction, which draws unmelted flux residue into the collection device 12 through the flux recovery pipe 2. The flux residue falls into the flux and slag screening device 9 for screening due to gravity. Large particles of flux and slag are trapped above the screen. After each stage of work is completed, the flux and slag are periodically collected and cleaned to prevent screen blockage. The sieved flux falls into the feeding mechanism 8 under gravity. Driven by the feeding mechanism 8, the flux is evenly discharged from the flux feeding pipe 7 and falls in front of the welding torch 5, realizing automated 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 magnitude during the welding process, a signal is converted into a control signal for the Z-axis motion, which controls the Z-axis height in real time and adjusts the arc length to keep it stable, thereby ensuring welding quality.

[0046] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A large metal component submerged arc additive printing apparatus, characterized by, The device comprises a multi-axis motion mechanism (1), a flux recovery pipeline (2), a slag cleaning device (4), a welding torch (5), a flux feeding pipeline (7), a feeding mechanism (8), a flux and slag screening device (9), a material collecting device (12) and a CCD camera monitoring system (22); One end of the flux recovery pipeline (2) is fixed on the first R-axis motion system (6) in the multi-axis motion mechanism (1), the other end of the flux recovery pipeline (2) is connected to one end of the material collecting device (12), the other end of the material collecting device (12) is connected to the input end of the flux and slag screening device (9), the output end of the flux and slag screening device (9) is connected to the input end of the feeding mechanism (8), the output end of the feeding mechanism (8) is connected to one end of the flux feeding pipeline (7), the other end of the flux feeding pipeline (7) is located at one side of the welding torch (5), the other side of the welding torch (5) is the flux recovery pipeline (2), the welding torch (5) is installed on the Z-axis motion system (21) in the multi-axis motion mechanism (1), the slag cleaning device (4) is fixed on the second R-axis motion system (3) in the multi-axis motion mechanism (1), the slag cleaning device (4) is located at one side of the flux recovery pipeline (2), the CCD camera monitoring system (22) is installed on the third R-axis motion system (20) in the multi-axis motion mechanism (1); 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); 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 torch (5); The feeding mechanism (8) comprises a feeding port cover (16), a scraper (17), a shaft coupling (18) and a feeding body (19); The feeding port cover (16) and the feeding body (19) are connected through screws and sealing strips, the scraper (17) is arranged in the feeding body (19), and the scraper (17) is connected with a feeding driving motor through the shaft coupling (18); A plurality of first grooves are formed in the scraper (17), a second groove is formed in the feeding body (19), and the second groove is communicated with the flux feeding pipeline (7); A fan is arranged in the material collecting device (12), one side of the material collecting device (12) is fixedly connected with a ventilation pipeline (11) through a clamp sealing strip, a filter box (10) is arranged on the ventilation pipeline (11), and the filter box (10) is fixedly connected with the ventilation pipeline (11) through a clamp sealing strip; The slag cleaning device (4), the flux recovery pipeline (2) and the CCD camera monitoring system (22) are installed on the R-axis motion system of the multi-axis motion mechanism, and when the running track of the welding gun (5) is planned through software, the distance between each R-axis motion module and the center axis of the welding gun (5) is a fixed value, the rotation angle of each R-axis motion module is calculated through software, the movement track of each R-axis motion module and the welding gun (5) is the same set of movement track, so that the multi-module follow-up control is realized.

2. A large metal component submerged arc additive printing apparatus according to claim 1, characterized in that, The welding gun (5) is connected and fixed with the flux feeding pipeline (7).

3. A large metal component submerged arc additive printing apparatus according to claim 1, characterized in that, The screening flux slag device (9) comprises a feeding port (13), a screen (14) and a discharge port (15). The feeding port (13) is connected with the material collecting device (12) through a pipeline, the discharge port (15) is connected with the feeding mechanism (8) through a pipeline, and the screen (14) is detachably arranged in the screening flux slag device (9).

4. A large metal component submerged arc additive printing apparatus according to claim 1, characterized in that, The material collecting device (12) is fixedly connected with the flux recovery pipeline (2) through a clamp sealing strip.

5. A method for submerged arc additive printing of large metal components with the apparatus according to any one of claims 1 to 4, characterized in that Comprise: During the printing process of the welding gun (5), the multi-axis motion mechanism (1) controls the flux recovery pipeline (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 with the welding gun (5) on the same track, the CCD camera monitoring system (22) collects the image of the welding area, the slag cleaning device (4) breaks and cleans the slag attached to the welding bead, the material collecting device (12) generates suction through the operation of the fan and absorbs the un-melted flux into the material collecting device (12) through the flux recovery pipeline (2), the remaining material falls into the screening flux slag device (9) for screening, the screened flux falls into the feeding mechanism (8) for reuse under the driving of the feeding mechanism (8), the flux is uniformly discharged from the flux feeding pipeline (7) and falls in front of the welding gun (5), and the welding gun (5) uses the fallen flux for welding.

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