Blade repairing method and blade repairing system

Abstract

The invention provides a blade repairing method and a blade repairing system, and belongs to the technical field of additive manufacturing, and the blade repairing method comprises the steps that the maximum cross section is selected from the cross sections of each to-be-repaired blade in a plurality of to-be-repaired blades; determining an acquisition height according to the maximum cross section; according to the collection height, collecting all the to-be-repaired blades as a whole to obtain overall point cloud data of all the to-be-repaired blades; and repairing the to-be-repaired blade according to the overall point cloud data and a preset repairing height. The blades can be repaired in batches, and the repairing precision is high.

Description

Technical Field

[0001] The present disclosure relates to the field of additive manufacturing technology, and in particular to a blade repair method and a blade repair system. Background Art

[0002] In the aerospace field, blades are key parts of aerospace engines and steam turbines. Their surface accuracy directly affects the performance indicators of the engine. Due to their high cost, laser cladding technology is widely used to repair blades.

[0003] The traditional repair method uses manual marking of repair points and teaching to repair. Repair personnel need to manually identify the area to be repaired and mark the repair points on the blade surface. This process relies on the operator's visual judgment and experience, so there is a large degree of subjectivity, resulting in inaccurate marking. The teaching method is used for repair, that is, the operator guides the repair equipment to operate through a pre-set path or action. This method usually requires the operator to program the repair equipment one by one, which is cumbersome and time-consuming.

[0004] Therefore, the traditional repair method has low repair accuracy and efficiency. Summary of the invention

[0005] The present disclosure provides a blade repair method and a blade repair system, which are capable of repairing blades in batches with high repair accuracy.

[0006] The technical solution of the present disclosure is achieved as follows: In a first aspect, the present disclosure provides a blade repair method, which includes: selecting the maximum cross-section from the cross-sections of each blade to be repaired among multiple blades to be repaired; determining a collection height based on the maximum cross-section; based on the collection height, collecting all blades to be repaired as a whole to obtain overall point cloud data of all blades to be repaired; and repairing the blade to be repaired based on the overall point cloud data and a preset repair height.

[0007] In a second aspect, the present disclosure provides a blade repair system, which includes: a controller, a laser profile scanner, a data processing module, and a laser cladding head, wherein the laser profile scanner, the data processing module, and the laser cladding head are respectively connected to the controller to exchange data through the controller; the data processing module is configured to select a maximum cross-section from the cross-sections of each blade to be repaired among multiple blades to be repaired based on the control of the controller; and, determine a collection height according to the maximum cross-section, and transmit the collection height to the controller; the laser profile scanner is configured to collect all blades to be repaired as a whole based on the control of the controller according to the collection height, obtain overall point cloud data of all blades to be repaired, and transmit the overall point cloud data to the controller; the laser cladding head is configured to repair the blade to be repaired based on the control of the controller according to the overall point cloud data and a preset repair height.

[0008] In a third aspect, the present disclosure provides a computer-readable storage medium storing a program or instruction, which implements the steps of the blade repair method as described in the first aspect when executed by a processor.

[0009] In a fourth aspect, the present disclosure provides a computer program product, wherein the computer program product includes a computer program or instructions. When the computer program product runs on a processor, the processor executes the computer program or instructions to implement the steps of the blade repair method as described in the first aspect.

[0010] In a fifth aspect, the present disclosure provides a chip, comprising a processor and a communication interface, wherein the communication interface is coupled to the processor, and the processor is used to run a program or instruction to implement the blade repair method as described in the first aspect.

[0011] The present disclosure provides a blade repair method. For multiple blades to be repaired that need to be repaired in batches, the acquisition height of the laser profile scanner is accurately determined according to the maximum cross-section of all the blades to be repaired, thereby ensuring that the collected point cloud data will not be missing, avoiding the need for subsequent data splicing and interpolation, etc., and improving the processing efficiency of the point cloud data. In addition, due to the high accuracy of the collected point cloud data, the accuracy of the subsequent repair of the blade to be repaired based on the point cloud data is guaranteed. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 A schematic diagram of a process of a blade repair method provided by the present disclosure; Figure 2 A schematic diagram of a blade to be repaired provided by the present disclosure; Figure 3 A schematic diagram of the acquisition height and scanning range of the laser profile scanner provided by the present disclosure; Figure 4 A schematic diagram of the minimum circumscribed rectangle of the cross section of the blade to be repaired provided by the present disclosure; Figure 5 A schematic diagram of a data collection path provided for the present disclosure; Figure 6 A schematic diagram of a serpentine data collection path provided by the present disclosure; Figure 7 A schematic diagram of dividing point cloud data according to the coordinate interval of the blade clamping groove provided by the present disclosure; Figure 8 A schematic diagram of using a conical calibration piece to determine the conversion relationship between a mechanical coordinate system and a laser profiler coordinate system provided by the present disclosure; Fig. 9 A schematic diagram of the structure of a blade repair system provided by the present invention; Fig.10 A schematic diagram of the relative position relationship between the laser profile scanner and the laser cladding head provided in the present disclosure; Fig.11 A schematic diagram of an isolation piece provided between a laser profile scanner and a laser cladding head provided in the present invention. DETAILED DESCRIPTION

[0013] The following will be combined with the drawings in the present disclosure to clearly describe the technical solutions in the embodiments of the present disclosure. Obviously, the described embodiments are part of the embodiments of the present disclosure, rather than all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments in the present disclosure are within the scope of protection of the present disclosure.

[0014] In the field of aerospace, blades are key parts of aerospace engines and steam turbines, and their surface accuracy directly affects the performance indicators of the engine. However, blades rotate under high temperature and high pressure for a long time, and the blade tips are easily worn. Such wear will affect the aerodynamic performance of the blades, reduce engine efficiency, and seriously affect flight safety. Due to their high cost, regular inspection and repair of engine blades are essential.

[0015] Laser cladding technology is an advanced surface modification technology that adds cladding material to the surface of the substrate and uses a high-energy-density laser beam to melt it together with a thin layer on the surface of the substrate to form a cladding layer. Laser cladding technology is widely used to repair blades due to its advantages such as local heating and low heat input.

[0016] However, the blades are made by traditional casting technology, and each blade is not completely the same. When repairing, it is necessary to manually trace points one by one to plan the path and the origin, which is inefficient. In addition, in related technologies, single blades are usually repaired, and there is no batch repair of multiple blades.

[0017] In addition, when collecting blade data using a laser profile scanner, the point cloud data obtained is redundant or missing due to factors such as the blade size, the working range of the laser profile scanner, and the scanning path. The point cloud data needs to be subsequently aligned and spliced, which reduces the point cloud processing speed and the accuracy cannot meet the needs of blade repair.

[0018] Therefore, the present disclosure aims to provide a blade repair method that can improve repair efficiency and repair accuracy.

[0019] like Figure 1 As shown, the blade repair method provided by the present disclosure is exemplarily described. The method may include the following steps S101 to S104.

[0020] In step S101, a maximum cross-section is selected from the cross-sections of each blade to be repaired among a plurality of blades to be repaired.

[0021] In step S102, the acquisition height is determined according to the maximum cross section.

[0022] The cross section of the blade to be repaired refers to the cross-sectional view obtained after the blade is cut vertically along its length direction (center line). Figure 2 , which is a schematic diagram of a blade 201 to be repaired, a section perpendicular to the axis 202 is the cross section, and a surface obtained by cutting along the cross section line 200 is the cross section.

[0023] Since the blades to be repaired are along the length direction, in some examples, the sizes of the cross-sections obtained by cutting at different positions are different. Since the laser profile scanner can scan different ranges along the direction perpendicular to the moving direction at different heights, in order to collect the complete point cloud data of all the blades to be repaired, the largest cross-section is selected from the cross-sections of all the blades to be repaired in the same batch, and the height of the laser profile scanner when the complete and largest cross-section can be collected is the final collection height.

[0024] like Figure 3 , which is a schematic diagram of the acquisition height and scanning range of the laser profile scanner 10. The relative position of the laser profile scanner 10 and the laser cladding head 30 remains unchanged during the initial scanning and subsequent repair process. Figure 3 2 shows a cross section 203 of each of the 36 blades to be repaired included in the support base 40. The laser profile scanner 10 moves along the Y-axis direction, and the longitudinal (along the X-axis) scanning range 11 at least covers the width of a cross section 203 in the X-axis direction, that is, the laser profile scanner 10 does not need to move along the X-axis, but moves along the path shown by the dotted line to collect the complete point cloud data of the 6 blades to be repaired covered by the dotted line.

[0025] In step S103, all blades to be repaired are collected as a whole according to the collection height to obtain the overall point cloud data of all blades to be repaired.

[0026] Point cloud data refers to a data set of spatial points scanned by the laser profile scanner 10. Each point cloud contains information about three-dimensional coordinates and laser reflection intensity. As the laser profile scanner 10 moves, each blade to be repaired is scanned in sequence, and all blades to be repaired are scanned to obtain the overall point cloud data.

[0027] In some embodiments, to ensure the accuracy of the point cloud data, when the test scanning frequency is greater than 100 Hz and the scanning speed is less than 150 mm / min, the collected point cloud data can meet the repair accuracy. However, this is not a limitation of the present disclosure. The higher the scanning frequency and the lower the scanning speed, the higher the accuracy of the obtained point cloud data. In practical applications, the appropriate scanning frequency and scanning speed are selected according to the accuracy requirements.

[0028] In step S104, the blade to be repaired is repaired according to the overall point cloud data and a preset repair height.

[0029] For each blade to be repaired, the laser cladding head 30 is first used to incrementally repair it to a preset repair height, that is, all blades to be repaired are incrementally repaired to a preset repair height, and then subsequent cutting processes, polishing, etc. are performed to obtain the required finished blades.

[0030] In the present disclosure, for multiple blades to be repaired that need to be repaired in batches, the acquisition height of the laser profile scanner 10 is accurately determined according to the maximum cross-section of all the blades to be repaired, thereby ensuring that the collected point cloud data will not be missing, avoiding the need for subsequent data splicing and interpolation, etc., and improving the processing efficiency of the point cloud data. In addition, due to the high accuracy of the collected point cloud data, the accuracy of the subsequent repair of the blades to be repaired based on the point cloud data is guaranteed.

[0031] In some embodiments, the above-mentioned step S101 selects the largest cross-section from the cross-sections of each blade to be repaired among multiple blades to be repaired, specifically including dividing each blade to be repaired according to a preset number to obtain a corresponding preset number of cross-sections; and selecting the largest cross-section from the cross-sections obtained from all the blades to be repaired according to the width of the minimum circumscribed rectangle.

[0032] Usually, the cross section at the bottom of the blade is the largest. Therefore, for each blade to be repaired, its cross section at the bottom is obtained, and the cross section with the largest width among the minimum circumscribed rectangles of all the cross sections at the bottom of all the blades to be repaired is determined as the largest cross section. However, for some special blades, the cross section at the bottom is not the largest cross section among the blades. Therefore, a preset number can be set according to the shape of the blades to be repaired in the same batch, and each blade to be repaired obtains a preset number of cross sections. From the minimum circumscribed rectangles of the preset number of cross sections corresponding to each blade to be repaired among all the blades to be repaired, the maximum cross section corresponding to the minimum circumscribed rectangle with the largest width is selected. Figure 4 As shown, the solid-line frame 12 in the figure is the minimum circumscribed rectangle of the cross section 203, and the dashed-line arrow indicates the width of the minimum circumscribed rectangle.

[0033] In this way, it is possible to ensure that the point cloud data obtained from a single scan covers the entire blade in width, and to avoid collecting redundant data.

[0034] In some embodiments, the above step S102 determines the acquisition height according to the maximum cross section, including: determining the acquisition height according to the width of the minimum circumscribed rectangle of the maximum cross section and the width of the blade clamping groove.

[0035] In the process of collecting point cloud data of the blade to be repaired, the blade to be repaired is fixed on the blade clamping groove, and the width of the blade clamping groove is greater than or equal to the width of the minimum circumscribed rectangle of any cross section of the blade to be repaired. Therefore, the lower limit of the collection height can be determined according to the width of the minimum circumscribed rectangle of the largest cross section, and the upper limit of the collection height can be determined according to the width of the blade clamping groove. The collection height is flexibly selected within this range to quickly adjust the laser profile scanner 10 to the correct position while ensuring that the point cloud data covers all the blades to be repaired and has little redundancy.

[0036] In some embodiments, the blade repair method also includes: planning the shortest data acquisition path according to the distribution positions of multiple blades to be repaired in the processing area; the above-mentioned acquiring data of all blades to be repaired as a whole according to the acquisition height to obtain the overall point cloud data of all blades to be repaired, including: acquiring data of all blades to be repaired as a whole according to the acquisition height and the shortest data acquisition path to obtain the overall point cloud data of all blades to be repaired.

[0037] Reasonable planning of the data acquisition path can avoid redundant point cloud data while improving data acquisition efficiency. Specifically, the distribution positions of multiple blades to be repaired in the processing area are connected in a certain order, and any two positions are connected in pairs, and the connection with the shortest distance is determined as the shortest data acquisition path, so that the laser profile scanner 10 can move the shortest distance and scan all the blades to be repaired.

[0038] like Figure 5 As shown, point 1, point 2, point 3 and point 4 respectively represent the distribution positions of the blade to be repaired in the processing area, the distance between point 1 and point 3, point 2 and point 4 is m, and the distance between point 1 and point 2, point 3 and point 4 is n. The first data acquisition path is point 1, point 2, point 3, point 4, the moving distance of the laser profile scanner 10 is the distance n between point 1 and point 2, the distance from point 2 back to point 1, and then to point 3 is n+m, the distance from point 3 to point 4 is n, and the total distance is 3n+m; the second data acquisition path is point 1, point 2, point 4, point 3, the moving distance of the laser profile scanner 10 is the distance n between point 1 and point 2, the distance from point 2 to point 4 is m, and the distance from point 4 to point 3 is n, and the total distance is 2n+m; and so on, traverse all data acquisition paths to find the shortest data acquisition path.

[0039] In addition, since the blade to be repaired is fixed on the blade clamping groove for data collection and repair, the distribution position of the blade clamping groove on the support base 40 is fixed, so the data collection path can be preset to avoid determining the data collection path every time. Figure 6 As shown, 36 blade clamping grooves 41 are distributed on the support seat 40 in 6 rows and 6 columns. When collecting point cloud data on the blade tooling (including the support seat 40 and the blade clamping grooves 41), the point cloud data is collected according to the serpentine data collection path shown by the black solid line with arrows in the figure, and the data collection path is used as the preset data collection path for repairing blades on the blade tooling.

[0040] In the disclosed embodiment, by rationally planning the data collection path, the data collection efficiency can be improved and the laser profile scanner 10 can be prevented from collecting redundant point cloud data during movement.

[0041] In some embodiments, the above-mentioned step S104 repairs the blade to be repaired according to the overall point cloud data and the preset repair height, including: determining the point cloud data corresponding to each blade to be repaired from the overall point cloud data according to the coordinate interval of each blade clamp groove; and repairing the blade to be repaired according to the point cloud data corresponding to each blade to be repaired and the preset repair height.

[0042] Each blade groove has a corresponding coordinate range, that is, the width range and length range of the blade groove. According to the X-coordinate and Y-coordinate of the point cloud data, the overall point cloud data and the point cloud data falling into the coordinate range of the same blade groove are determined as the point cloud data of the same blade to be repaired.

[0043] like Figure 7 As shown, the center of the positioning member 42 (which may be cylindrical) is taken as the origin, and the distance between the blade clamping groove 41 closest to the positioning member 42 and the origin in the Y-axis direction is d L , the distance from the origin in the X-axis direction is d w, the distance between the two blade clamping grooves in the Y-axis direction is d 2 , the spacing in the X-axis direction is d 1 , the width of the blade clamping groove 41 in the X-axis direction is W, and the length in the Y-axis direction is L. Then the coordinate interval corresponding to the blade clamping groove 41 in the figure where the blade 201 to be repaired is fixed in the X-axis direction is: [d w +5W+5d 1 , d w +6W+5d 1 ], in the Y-axis direction: [d L , d L + L], traverse the entire point cloud data, and determine the X coordinate and Y coordinate within the above interval as the point cloud data of a blade to be repaired; similarly, repeat the above steps to complete the division of the entire point cloud data.

[0044] In some embodiments, the above-mentioned repairing the blades to be repaired according to the point cloud data corresponding to each blade to be repaired and the preset repair height includes: determining the outline of each blade to be repaired according to the point cloud data corresponding to each blade to be repaired; determining the repair path of each blade to be repaired according to the outline of each blade to be repaired and the preset repair height; and repairing the blades to be repaired according to the repair path of each blade to be repaired.

[0045] For the point cloud data corresponding to each blade to be repaired, data preprocessing is first performed to remove noise points in the point cloud data and improve data quality; the initial contour of each blade to be repaired is obtained through contour extraction algorithms (such as edge detection algorithms, least squares fitting, etc.), and the initial contour of each blade to be repaired is smoothed to eliminate small fluctuations caused by measurement errors or noise, and finally the contour of each blade to be repaired is obtained.

[0046] A repair path is generated according to the contour of each blade to be repaired and in combination with printing parameters, including a preset repair height, and also includes the power and delay of the laser cladding head 30. The laser cladding head 30 repairs each blade to be repaired according to the repair path. In this way, batch automated blade repair can be achieved.

[0047] In the related art, the blade point cloud is cut by feature points or point cloud curvature changes. When the number of blades to be repaired is very large, the corresponding point cloud processing data volume will also be larger, and the point cloud processing efficiency will also be reduced. In the embodiment of the present disclosure, the overall point cloud data is divided into point cloud data corresponding to a single blade to be repaired according to the coordinate interval of the blade clamping groove. The division process of the overall point cloud data is simple, and it can also greatly improve the subsequent recognition efficiency of the blade to be repaired based on the point cloud data.

[0048] In some embodiments, the above-mentioned repairing the blade to be repaired according to the point cloud data corresponding to each blade to be repaired and the preset repair height includes: determining the data points belonging to the maximum height range corresponding to each blade to be repaired from the point cloud data corresponding to each blade to be repaired; determining the starting point of the repair height of the corresponding blade to be repaired according to the data points belonging to the maximum height range corresponding to each blade to be repaired; and repairing the blade to be repaired from the corresponding repair height starting point according to the point cloud data corresponding to each blade to be repaired and the preset repair height.

[0049] Since different blades to be repaired have different damages, the starting point of the repair height of each blade to be repaired is also different. For the point cloud data corresponding to each blade to be repaired, the point cloud data is divided into different intervals according to the preset Z value range. Each preset Z value range corresponds to the thickness of a layer of material clad during the repair process. The Z values ​​included in each Z value range are different, and are divided according to the size of the Z value. For example, there are 100 preset Z value ranges, any Z value in the first Z value range is less than any value in the second Z value range, any Z value in the second Z value range is less than any value in the third Z value range, and so on, any Z value in the 100th Z value range is less than any value in the ninety-ninth Z value range. For each blade to be repaired, it is divided into N (N is a positive integer) groups according to the preset Z value range, and the range with the largest Z value in the N preset ranges is determined as the maximum height range. The Z value of any data point whose Z value falls into the maximum range is determined as the starting point of the repair height, or the average value of the Z values ​​of the data points falling into the maximum range is determined, and the data points with the same average value are determined as the starting point of the repair height. After determining the starting point of the repair height, repair is performed along the center line from left to right or from right to left according to the preset rules.

[0050] Exemplarily, the four preset Z value ranges are: the first range is a Z value greater than 0 and less than or equal to 1, the second range is a Z value greater than 1 and less than or equal to 2, the third range is a Z value greater than 2 and less than or equal to 3, and the fourth range is a Z value greater than 3 and less than or equal to 4. The Z values ​​of 1000 point cloud data of a blade to be repaired are divided according to the four preset Z value ranges, 300 of which fall into the first range, 350 of which fall into the second range, 350 of which fall into the third range, and none of which fall into the fourth range. Then, the maximum height range corresponding to the blade to be repaired is determined to be the third range, and any data point falling into the third range is determined as the starting point of the repair height, or the average value of the Z values ​​of the data points falling into the third range is determined as the starting point of the repair height.

[0051] In this way, for each blade to be repaired, the laser cladding head 30 can automatically adjust to the starting point of the repair height of each blade to be repaired, thereby achieving automatic focusing.

[0052] In some embodiments, the blade repair method further includes: determining that the blade to be repaired is an unqualified blade when the ratio of the data point with the maximum height of each blade to be repaired to the corresponding original height of each blade to be repaired is less than a ratio threshold.

[0053] When the ratio of the height of the data point with the highest height in the point cloud data corresponding to a blade to be repaired, that is, the maximum Z coordinate value, to the original height of the blade to be repaired is less than the ratio threshold (such as 0.9), it means that there is an error in the collected point cloud data, or the pre-processing (such as cleaning, geometric reconstruction, etc.) of the blade to be repaired is not in place before repair, or the blade to be repaired is severely worn and cannot be repaired. This type of blade to be repaired is determined as an unqualified blade, and the repair of this type of blade will be automatically skipped during the repair process. For blades to be repaired with errors in point cloud data and inadequate pre-processing before repair, the scrapping of blades caused by erroneous repair can be avoided. For blades that cannot be repaired, waste of resources (such as materials, time consumed by each process, etc.) can be avoided.

[0054] In some embodiments, the blade repair method further includes: determining the conversion relationship between the laser profile scanner coordinate system and the mechanical coordinate system according to the coordinates in the mechanical coordinate system and the coordinates in the laser profile scanner coordinate system at each position at multiple different positions in the processing area; the above step S103 collects all the blades to be repaired as a whole according to the acquisition height to obtain the overall point cloud data of all the blades to be repaired, including: collecting all the blades to be repaired as a whole according to the acquisition height to obtain the initial overall point cloud data of all the blades to be repaired in the laser scanner coordinate system; according to the coordinate conversion relationship, converting the initial overall point cloud data into the overall point cloud data in the mechanical coordinate system. To ensure that the point cloud data obtained by the laser profile scanner 10 can guide the laser cladding head 30 to repair the blade.

[0055] Specifically, the laser profile scanner 10 is fixed on the laser cladding head 30, and the motion module drives the laser cladding head 30 and the laser profile scanner 10 to move in space; the laser cladding head 30 is moved to the center position of the positioning member 42, and the red light is turned on (the red light is used for positioning, and the laser is used for cladding), and the coaxial camera of the laser cladding head 30 is observed to determine that the red light is aligned with the center position of the positioning member 42, and this point is set as the origin of the processing area (support base 40) in the mechanical coordinate system.

[0056] like Figure 8 As shown in the figure, the cone calibration piece 43 is located at position 1 in the processing area. Turn on the red light and move the laser cladding head 30. Observe the coaxial camera to determine that the laser cladding head 30 is aligned with the vertex P of the cone calibration piece 43 at position 1, and record the vertex coordinate P in the mechanical coordinate system. 1w (x 1w ,y 1w , z1w ); Move the laser profile scanner 10 so that the line laser passes through the vertex P of the cone calibration piece 43 at position 1, and determine the coordinate point with the largest Z value as the vertex coordinate P in the laser profiler coordinate system. 1c (x 1c ,y 1c , z 1c ), repeat the above steps twice to obtain the vertex coordinate P in the mechanical coordinate system when the cone calibration piece 43 is located at any position 2 in the processing area different from position 1 2w (x 2w ,y 2w , z 2w ), and the vertex coordinates P in the laser profiler coordinate system 2c (x 2c ,y 2c , z 2c ), the vertex coordinate P in the mechanical coordinate system when the cone calibration piece 43 is located at any position 3 in the processing area different from positions 1 and 2 3w (x 3w ,y 3w , z 3w ), and the vertex coordinates P in the laser profiler coordinate system 3c (x 3c ,y 3c , z 3c ).

[0057] Knowing the coordinates of the above three non-collinear points in the mechanical coordinate system and the coordinates of the laser profiler, the coordinate transformation relationship between the mechanical coordinate system and the laser profiler coordinate system can be determined as:

[0058] in, is the scale parameter, R is the rotation matrix, is the translation vector, c represents the coordinates of the laser profiler coordinate system, and w represents the coordinates of the mechanical coordinate system. 1c and P 2c The distance between 1w and P 2w The ratio of the distance is the proportional parameter :

[0059] P 1c , P 2c , P 1w , P 2w Substitute into equation (1) and subtract to eliminate

[0060] (2) Let (2) be expressed as (3) Use the antisymmetric matrix S to construct the rotation matrix R: R= (4) Among them, the antisymmetric matrix (5), a, b, c are parameters to be determined.

[0061] Substituting (4) into (3) we obtain: (6) Substituting (5) into (6) we obtain:

[0062] =

[0063]

[0064]

[0065] = (7) Similarly, according to P 1c , P 3c , P 1w , P 3w and P 2c , P 3c , P 2w , P 3w We can get: = (8) = (9) By combining equations (7), (8), and (9), we can obtain the values ​​of a, b, and c. Substituting a, b, and c into equation (5) yields the antisymmetric matrix S. Substituting S into equation (4) yields the rotation matrix R. Substituting R and the coordinates of the mechanical coordinate system and the coordinates of the laser profiler coordinate system of any point into equation (1) yields the translation vector , thus obtaining the coordinate transformation relationship between the mechanical coordinate system and the laser profiler coordinate system.

[0066] Since only the coordinates x and y of the cone calibration piece 43 at positions 1, 2 and 3 are changed, the coordinate z is the same, that is, the above z 1w 、z 2w 、z 3w The same, the above z 1c 、z 2c 、z 3cThe same, therefore, only the laser profile scanner 10 and the laser cladding head 30 need to be adjusted at position 1, and no adjustment is required in the Z-axis direction at positions 2 and 3. In this way, the coordinates of the three positions that need to determine the coordinate transformation relationship are obtained more quickly, and the same coordinate z also makes it simpler to obtain the coordinate transformation relationship.

[0067] In addition, since the laser cladding head 30 and the laser profile scanner 10 are fixed together, the distance between the laser beam emitted by the laser cladding head 30 and the line laser emitted by the laser profile scanner 10 in the Y-axis direction is also fixed and recorded as Y L , determine the vertex coordinates P in the mechanical coordinate system 1w (x 1w ,y 1w , z 1w ), the motion module drives the laser cladding head 30 and the laser profile scanner 10 to move Y along the Y axis direction L At this time, the laser profile scanner 10 is aligned with the vertex P of the cone calibration piece 43, and P 1c (x 1c ,y 1c , z 1c ), the rest of the positions are the same. Conversely, once the vertex coordinates in the laser profiler coordinate system are determined, the vertex coordinates in the corresponding mechanical coordinate system can also be quickly obtained. Therefore, the laser cladding head 30 and the laser profile scanner 10 are fixed together, and the coordinates of the position points on which the coordinate conversion relationship depends are more efficient, and the fixed relative distance can also reduce the error of the coordinates at each position point, thereby making the obtained coordinate conversion relationship more accurate.

[0068] Based on the same concept as the above blade repair method, Fig. 9 FIG. 1 is a schematic diagram of the composition structure of a blade repair system shown in the present disclosure, such as Fig. 9 As shown, it includes: a controller 50, a laser profile scanner 10, a data processing module 20, and a laser cladding head 30. The laser profile scanner 10, the data processing module 20, and the laser cladding head 30 are respectively connected to the controller 50 to perform data exchange through the controller 50.

[0069] The data processing module 20 is configured to select the maximum cross-section from the cross-sections of each blade to be repaired among the multiple blades to be repaired based on the control of the controller 50; and determine the acquisition height according to the maximum cross-section, and transmit the acquisition height to the controller 50; the laser profile scanner 10 is configured to acquire the entirety of all the blades to be repaired based on the control of the controller 50 according to the acquisition height, obtain the overall point cloud data of all the blades to be repaired, and transmit the overall point cloud data to the controller 50; the laser cladding head 30 is configured to repair the blade to be repaired based on the control of the controller 50 according to the overall point cloud data and the preset repair height.

[0070] The laser profile scanner 10 and the laser cladding head 30 are fixedly connected. Fig.10 FIG. 1 is a schematic diagram of the relative position relationship between the laser profile scanner 10 and the laser cladding head 30. The laser cladding head 30 includes a coaxial camera 301 for determining the cladding position. The enlarged field of view of the coaxial camera 301 includes a field scale line 3011. The field center 3012 corresponds to the center line (shown by a dotted line in the figure) of the laser cladding head 30. The field center 3012 is aligned with the center of the positioning member 42, which is the origin of the above-mentioned mechanical coordinate system.

[0071] The laser profile scanner 10 is fixed to the laser cladding head 30. After obtaining the point cloud data through the laser profile scanner 10, subsequent processing can be continued directly until the blade to be repaired is repaired through the laser cladding head 30. The repair process is carried out continuously. There is no need to scan to obtain the point cloud data and then evacuate the laser profile scanner 10, and then move the laser cladding head 30 to the working point. The integrated laser cladding head 30 and laser profile scanner 10 can work continuously, realizing full automation from data collection to repair process, thereby improving the efficiency of blade repair.

[0072] In some embodiments, reference Figure 6 The blade repair system also includes: a blade tooling, the blade tooling includes a support 40 and a blade clamping groove 41; a plurality of blade clamping grooves 41 are arranged on the support seat 40; the blade clamping groove 41 is configured to fix the blade to be repaired; the data processing module 20 is specifically configured to determine the collection height according to the width of the minimum circumscribed rectangle of the maximum cross-section and the width of the blade clamping groove.

[0073] In some embodiments, reference Fig.11 An isolation member 60 is provided between the laser profile scanner 10 and the laser cladding head 30; the isolation member 60 is configured to isolate the laser of the laser cladding head 30 to prevent the laser profile scanner 10 from being burned by the reflected laser during the process of the laser cladding head 30 repairing the blade to be repaired.

[0074] In some embodiments, the blade repair system further includes: a powder delivery module connected to the controller 50; the powder delivery module is configured to deliver the processing material to the processing area according to the powder delivery setting during the repair of the blade to be repaired based on the control of the controller 50. The powder delivery setting can be obtained by the data processing module 20 according to the parsed processing parameter configuration file and transmitted to the controller 50 before the blade repair, and the powder delivery setting includes the powder delivery amount, the powder disk speed, etc.

[0075] In some embodiments, the blade repair system further includes: a motion module connected to the laser cladding head 30, the laser profile scanner 10, and the controller 50 respectively; the motion module is configured to drive the laser profile scanner 10 and the laser cladding head 30 to move based on the control of the controller 50. The motion module drives the laser profile scanner 10 and the laser cladding head 30 to move along the three directions of the X axis, the Y axis, and the Z axis. The motion module includes: a lead screw, a guide rail, a servo motor, etc. The servo motor drives the lead screw to move on the Z axis and drives the guide rail to move along the X and Y axes according to the received control signal.

[0076] In some embodiments, the blade repair system further includes: a shaped sealed cabin; the shaped sealed cabin is configured to provide an inert gas processing environment with a cabin pressure within a preset pressure range and an oxygen content less than a preset threshold value during the process of repairing the blade to be repaired, such as an oxygen content less than or equal to 100 ppm and a cabin pressure of 3 mbar to 7 mbar.

[0077] In the disclosed embodiment, each module of the blade repair system can implement the blade repair method provided by the above method embodiment and can achieve the same technical effect. To avoid repetition, it will not be described here.

[0078] The present disclosure also provides a computer-readable storage medium storing at least one instruction, wherein the at least one instruction is used to be executed by a processor to implement the blade repair method described in the above embodiments.

[0079] The present disclosure also provides a computer program product, which includes computer instructions stored in a computer-readable storage medium; a processor of an electronic device reads the computer instructions from the computer-readable storage medium, and the processor executes the computer instructions, so that the electronic device executes to implement the blade repair method described in the above-mentioned embodiments.

[0080] The disclosed embodiment further provides a chip, which includes a processor and a communication interface, wherein the communication interface is coupled to the processor, and the processor is used to run programs or instructions to implement the various processes of the above-mentioned blade repair method embodiment, and can achieve the same technical effect. To avoid repetition, it will not be repeated here.

[0081] It should be understood that the chip mentioned in the embodiments of the present disclosure may also be referred to as a system-level chip, a system chip, a chip system, or a system-on-chip chip, etc.

[0082] In the several embodiments provided in the present disclosure, it should be understood that the disclosed systems, devices, servers and methods can be implemented in other ways. For example, the device embodiments described above are only schematic. For example, the division of the units is only a logical function division. There may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0083] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0084] In addition, each functional unit in each embodiment of the present disclosure may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0085] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present disclosure is essentially or the part that contributes to the prior art or all or part of the technical solution can be embodied in the form of a software product. The computer software product is stored in a storage medium, including a number of instructions to enable a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method described in each embodiment of the present disclosure. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM), random access memory (RAM), disk or optical disk, etc., various media that can store program codes.

[0086] Those skilled in the art should be aware that in one or more of the above examples, the functions described in the present disclosure can be implemented using hardware, software, firmware, or any combination thereof. When implemented using software, these functions can be stored in a computer-readable medium or transmitted as one or more instructions or codes on a computer-readable medium. Computer-readable media include computer storage media and communication media, wherein communication media include any media that facilitates the transmission of computer programs from one place to another. Storage media can be any available media that can be accessed by a general or special-purpose computer.

[0087] It should be noted that the technical solutions described in the present disclosure can be combined arbitrarily without conflict.

[0088] The above description is only a specific implementation mode of the present disclosure, but the protection scope of the present disclosure is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present disclosure, which should be covered within the protection scope of the present invention.

Claims

1. A blade repair method, characterized in that: The blade repair method comprises: Selecting the largest cross-section from the cross-sections of each blade to be repaired among the plurality of blades to be repaired; Determining a collection height according to the maximum cross section; According to the acquisition height, all blades to be repaired are acquired as a whole to obtain the overall point cloud data of all blades to be repaired; The blade to be repaired is repaired according to the overall point cloud data and a preset repair height.

2. The blade repair method according to claim 1, characterized in that: The step of selecting the maximum cross-section from the cross-sections of each blade to be repaired among the plurality of blades to be repaired comprises: Divide each blade to be repaired into a preset number of cross sections to obtain a corresponding preset number of cross sections; From the cross sections obtained from all the blades to be repaired, the largest cross section is selected according to the width of the minimum circumscribed rectangle.

3. The blade repair method according to claim 2, characterized in that: Determining the acquisition height according to the maximum cross section includes: The collection height is determined based on the width of the minimum circumscribed rectangle of the maximum cross section and the width of the blade clip groove.

4. The blade repair method according to claim 1, characterized in that: The blade repair method further comprises: Planning the shortest data collection path according to the distribution positions of the plurality of blades to be repaired in the processing area; According to the acquisition height, all blades to be repaired are collected as a whole to obtain the overall point cloud data of all blades to be repaired, including: According to the acquisition height and the shortest data acquisition path, all blades to be repaired are acquired as a whole to obtain the overall point cloud data of all blades to be repaired.

5. The blade repair method according to claim 1, characterized in that: The step of repairing the blade to be repaired according to the overall point cloud data and the preset repair height includes: According to the coordinate interval of each blade clamping groove, the point cloud data corresponding to each blade to be repaired is determined from the overall point cloud data; The blades to be repaired are repaired according to the point cloud data corresponding to each blade to be repaired and a preset repair height.

6. The blade repair method according to claim 5, characterized in that: The step of repairing the blade to be repaired according to the point cloud data corresponding to each blade to be repaired and the preset repair height comprises: Determine the contour of each blade to be repaired according to the point cloud data corresponding to each blade to be repaired; Determining a repair path for each blade to be repaired according to the profile of each blade to be repaired and a preset repair height; The blades to be repaired are repaired according to the repair path of each blade to be repaired.

7. The blade repair method according to claim 5 or 6, characterized in that: The step of repairing the blade to be repaired according to the point cloud data corresponding to each blade to be repaired and the preset repair height comprises: Determine, from the point cloud data corresponding to each blade to be repaired, data points belonging to the maximum height range corresponding to each blade to be repaired; Determine the starting point of the repair height of the corresponding blade to be repaired according to the data points belonging to the maximum height range corresponding to each blade to be repaired; According to the point cloud data corresponding to each blade to be repaired and the preset repair height, the blade to be repaired is repaired from a starting point at the corresponding repair height.

8. The blade repair method according to claim 5 or 6, characterized in that: The blade repair method further comprises: When the ratio of the data point with the maximum height of each blade to be repaired to the corresponding original height of each blade to be repaired is less than a ratio threshold, the blade to be repaired is determined to be an unqualified blade.

9. The blade repair method according to claim 1, characterized in that: The blade repair method further comprises: Determine the conversion relationship between the laser profile scanner coordinate system and the mechanical coordinate system according to the coordinates of each position in the mechanical coordinate system and the coordinates of the laser profile scanner coordinate system at multiple different positions in the processing area; According to the acquisition height, all blades to be repaired are collected as a whole to obtain the overall point cloud data of all blades to be repaired, including: According to the acquisition height, all blades to be repaired are acquired as a whole to obtain initial overall point cloud data of all blades to be repaired in the laser scanner coordinate system; According to the coordinate transformation relationship, the initial overall point cloud data is transformed into the overall point cloud data in a mechanical coordinate system.

10. A blade repair system, characterized in that: The blade repair system comprises: a controller, a laser profile scanner, a data processing module, and a laser cladding head, wherein the laser profile scanner, the data processing module, and the laser cladding head are respectively connected to the controller to perform data exchange through the controller; The data processing module is configured to select the largest cross-section from the cross-sections of each blade to be repaired among the plurality of blades to be repaired based on the control of the controller; and, determining a collection height according to the maximum cross-section, and transmitting the collection height to the controller; The laser profile scanner is configured to collect the entirety of all the blades to be repaired according to the collection height based on the control of the controller, obtain the entirety of the point cloud data of all the blades to be repaired, and transmit the entirety of the point cloud data to the controller; The laser cladding head is configured to repair the blade to be repaired based on the control of the controller and according to the overall point cloud data and a preset repair height.

11. The blade repair system according to claim 10, characterized in that: The blade repair system further includes: a blade tooling, the blade tooling including a support seat and a blade clamping groove; The support seat is provided with a plurality of blade clamping grooves; The blade clamping groove is configured to fix the blade to be repaired; The data processing module is specifically configured to determine the acquisition height according to the width of the minimum circumscribed rectangle of the maximum cross section and the width of the blade clip groove.

12. The blade repair system according to claim 10, characterized in that: An isolation piece is provided between the laser profile scanner and the laser cladding head; The isolation member is configured to isolate the laser of the laser cladding head.

13. The blade repair system according to claim 10, characterized in that: The blade repair system further includes: a powder delivery module connected to the controller; The powder feeding module is configured to transport the processing material to the processing area according to the powder feeding setting based on the control of the controller during the process of repairing the blade to be repaired.

14. The blade repair system according to claim 10, characterized in that: The blade repair system further includes: a motion module connected to the laser cladding head, the laser profile scanner, and the controller respectively; The motion module is configured to drive the laser profile scanner and the laser cladding head to move based on the control of the controller.

15. The blade repair system according to claim 10, characterized in that: The blade repair system further comprises: a formed sealing cabin; The shaped sealed cabin is configured to provide an inert gas processing environment with a cabin pressure within a preset pressure range and an oxygen content less than a preset threshold value during the process of repairing the blade to be repaired.

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