Large wind power casting sand core surface coating quality intelligent detection system and method

Abstract

The invention discloses a large wind power casting sand core surface coating quality intelligent detection system and method, and belongs to the technical field of detection equipment, the system comprises a rotating platform and a scanning system, a casting sand core can be arranged on the rotating platform, a coating is arranged on the surface of the casting sand core, and the scanning system can scan the coating on the surface of the casting sand core. The rotating platform can rotate; and the scanning system comprises a robot, a control assembly, a detection assembly and a repairing assembly, the control assembly can control the robot, the detection assembly can scan the casting sand core arranged on the rotating platform, and the repairing assembly can repair a coating on the surface of the casting sand core. According to the invention, the scanning system can scan and repair the surface coating of the casting sand core. And intelligent and rapid detection and supplementary brushing operation are realized. Omnibearing automatic detection and supplementary brushing operation on a sand core surface coating of a large casting are realized, the quality of an inner cavity of the casting is ensured, and the labor intensity of workers is reduced.

Description

Technical Field

[0001] The invention relates to an intelligent detection system and method for the quality of surface coating of a sand core of a large-scale wind power casting, belonging to the technical field of detection equipment. Background Art

[0002] Large wind power castings are one of the core components of wind turbines, mainly including hubs, bases, main shafts, bearing seats, supports, etc. They have complex shapes and structures, and have very strict requirements on the material properties of wind power castings, such as fatigue strength, reliability, durability and other mechanical properties. They need to meet the high reliability standard requirements of 20-30 years without replacement. For example, the main shaft of a wind turbine is a key component connecting the wind rotor and the motor. When the wind blades are driven to rotate by the wind, the rotational power is transmitted to the generator through the main shaft. The main shaft bears the gravity and torque of the wind rotor. Its quality directly determines the stability and reliability of the wind turbine system. The main shaft of large-scale high-power offshore wind turbines with a capacity of 9 to 22MW is made of QT500-14, with a bottom diameter of 2.5-4.5 meters, an upper diameter of 1.5-2.5 meters, a height of 2.8-5.6 meters, and a casting weight of 25-86 tons. The working environment is harsh, and high requirements are placed on the quality of the main shaft castings, the reliability and safety of the castings. No casting defects are allowed, and the castings must be tested by UT and MT.

[0003] At present, the manufacture of large wind turbine main shafts mainly adopts resin sand molding and core making. Among them, the quality requirements of resin sand shaft hole sand core are high. When pouring, it is surrounded by a large amount of molten iron, which has a great impact on the quality of the inner cavity of the casting. If it is not handled properly, the inner cavity of the casting will produce defects such as sand sticking, sand, air holes, sand holes, and slag inclusions. The current shaft hole sand core size: bottom diameter 2.0-4.0 meters, upper diameter 1.5-2.0 meters, height 2.8 -5.6m, sand core weight 15-25 tons.

[0004] Since the spindle hole sand core is tall and has a large surface area, the current manual brushing of the spindle hole sand core has a high strength and needs to be brushed two to three times. After ignition and drying, the surface of the sand core is manually polished smooth with fine sandpaper, and then the surface quality of the sand core is manually checked and additional brushing and polishing is performed. The accuracy and uniformity of the manual brushing and polishing of the sand core surface coating in this production method are inconsistent, the production efficiency is low, and there are deviations in the manual inspection of the sand core surface coating quality. Therefore, it is necessary to develop and design an intelligent detection system and method for the surface coating quality of large-scale wind power casting sand cores to improve the quality of sand cores and production efficiency and meet the environmental protection needs of large-scale wind power casting production. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide an intelligent detection system and method for the quality of surface coating of sand cores of large-scale wind power castings, which solves the problem of cumbersome process and poor precision in inspecting the surface coating of sand cores.

[0006] The technical problem to be solved by the present invention is achieved by adopting the following technical solutions: an intelligent detection system for the surface coating quality of sand cores of large wind power castings, comprising: A rotating platform and a scanning system, wherein a casting sand core can be arranged on the rotating platform, and a coating is arranged on the surface of the casting sand core, and the scanning system can scan the coating on the surface of the casting sand core. The rotating platform is capable of rotating; The scanning system includes a robot, a control component, a detection component, and a repair component. The detection component and the repair component are arranged on the robot. The control component is connected to the detection component. The control component can control the robot to rotate around the surface of the casting sand core. The detection component can scan and detect whether there are defects in the casting sand core. The repair component repairs the coating on the surface of the casting sand core according to the defects.

[0007] Preferably, the rotating platform comprises a basic base, a supporting base and a fixed base, the supporting base is arranged on the top of the basic base, the fixed base is arranged on the top of the supporting base, and the fixed base can fix the casting sand core.

[0008] Preferably, the basic base is fixed, and the supporting base can rotate relative to the basic base; and the fixed base can rotate relative to the basic base.

[0009] Preferably, when the supporting base rotates, the fixed base is fixed; when the fixed base rotates, the supporting base is fixed.

[0010] Preferably, the robot comprises a robotic arm capable of moving around the casting sand core.

[0011] Preferably, the detection component includes a laser scanner and an infrared thermal imager. The laser scanner can heat the surface coating of the casting sand core to form a heat wave; the infrared thermal imager can detect the temperature distribution on the surface of the material and detect the temperature difference generated during the transmission of the heat wave inside the coating.

[0012] Preferably, the thickness of the coating can be detected by the detection component. The formula for calculating coating thickness is: in is the thickness of zircon powder coating, is the thermal conductivity of zircon powder, is the specific heat capacity of zircon powder, is the density of zircon powder, t is the heating time of the laser scanner, It is the temperature rise value of the casting sand core.

[0013] Preferably, the repair component comprises a paint supply part and a nozzle, the nozzle is arranged on the top of the robot, and the nozzle is connected to the paint supply part through a pump.

[0014] Preferably, the robot moves on the surface of the casting sand core, and the detection component arranged on the top of the robot scans the casting sand core; the control component controls the repair component to brush the defective parts of the surface coating of the casting sand core according to the scanning result of the detection component.

[0015] A method for intelligently detecting the surface coating quality of a large wind power casting sand core preferably comprises the following steps: Step 1: fix the casting sand core to the top of the rotating platform, and the control component controls the rotating platform to rotate; Step 2: The control component controls the robot to rotate around the surface of the casting sand core; Step 3: The control component controls the detection component to scan the coating on the surface of the casting sand core; Step 4: The control component controls the repair component to repair the coating defects on the surface of the casting sand core according to the scanning result of the detection component.

[0016] Preferably, in step 2, the fixed base drives the detection assembly to rotate or the supporting base drives the casting sand core to rotate.

[0017] The beneficial effects of the present invention are: (1) Through the present invention, a casting sand core is arranged on a rotating platform, and a scanning system is fixed on the side of the rotating platform. The rotating system can control the rotation of the casting sand core or the scanning system. When relative rotation occurs between the casting sand core and the scanning system, the scanning system can scan and repair the surface coating of the casting sand core. Intelligent and rapid detection and supplementary brushing operations are realized. The present invention is easy to operate, and realizes all-round automatic detection and supplementary brushing operations of the surface coating of the sand core of large castings. The sand core has good surface quality and high smoothness, which ensures the quality of the inner cavity of the casting, greatly improves production efficiency, reduces the labor intensity of workers, saves energy and reduces carbon emissions, and is green and environmentally friendly.

[0018] (2) Through the present invention, a robot, a scanning component, a repair component, and a control component are provided in the scanning system, wherein the scanning component includes a laser scanner and an infrared thermal imager. The laser scanner can heat the surface of the casting sand core, and the infrared thermal imager can record the surface temperature and temperature change of the casting sand core, and transmit it to the control component for calculation. The control component can determine the coating quality of the casting sand core surface according to the detection signal of the scanning component.

[0019] (3) Through the present invention, the scanning component and the repair component are both arranged on the top of the robot. The repair component can repair the coating quality defects on the surface of the casting sand core according to the calculation of the control component, and can realize the surface coating detection and repair of the casting sand core. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a structural schematic diagram of the present invention.

[0021] In the figure: 11-basic base, 12-supporting base, 13-fixed base, 21-robot, 22-detection component, 23-repair component, 3-casting sand core. DETAILED DESCRIPTION

[0022] In order to make the technical means, creative features, objectives and effects of the present invention easier to understand, the present invention is further described below in conjunction with specific embodiments.

[0023] Example 1 like Figure 1 As shown, A large-scale wind power casting sand core surface coating quality intelligent detection system comprises a rotating platform and a scanning system. A casting sand core 3 can be set on the rotating platform, and a coating is set on the surface of the casting sand core 3. The scanning system can detect the coating covering the surface of the casting sand core 3.

[0024] During the casting process, the surface coating quality of the casting sand core 3 has certain requirements, among which the coating thickness is relatively important and needs to meet the thickness of the surface coating quality of the casting sand core 3 .

[0025] The rotating platform can rotate. In this embodiment, the rotating platform includes a base 11, a support base 12, and a fixed base 13. The top of the base 11 is provided with a support base 12, and the top of the support base 12 is provided with a fixed base 13. The support base 12 is provided with a support plate protruding outward at the edge, and a scanning system is provided on the support plate. A hole for accommodating the casting sand core 3 is provided at the center of the fixed base 13 above the support base 12, and the casting sand core 3 can be fixed in the middle of the support base 12.

[0026] In this embodiment, the rotating platform can rotate, specifically: the basic base 11 is fixed on the bottom surface, and a rotating motor is arranged inside the supporting base 12, and the rotating motor can control the rotation of the supporting base 12. When the supporting base 12 rotates, the fixed base 13 can rotate without following the supporting base 12, and the scanning system can rotate with the supporting base 12 and surround the surface of the casting sand core 3; the supporting base 12 can be fixed on the basic base 11, and the fixed base 13 arranged on the top of the supporting base 12 can rotate. When the fixed base 13 rotates, it can drive the casting sand core 3 to rotate. At this time, the supporting base 12 is fixed, and the bottom of the scanning system arranged on the supporting base is fixed, and the scanning system can scan the rotating casting sand core 3.

[0027] The scanning system arranged on the supporting base 12 includes a robot 21, a detection component 22, a repair component 23, and a control component. The detection component 22 and the repair component 23 are both arranged on the top of the robot 21. The control component includes a PLC controller, which connects and controls the robot 21 to rotate around the surface of the casting sand core and the operation of the detection component 22 and the repair component 23.

[0028] The robot 21 includes a robotic arm, the bottom of which is fixed to the extension plate of the support base 12. A total of four axes are arranged inside the robotic arm. The robotic arm can move around the casting sand core 3 arranged on the fixed base 13. The distance and position between the detection component 22 and the repair component 23 arranged on the top of the robotic arm and the casting sand core 3 can be adjusted through the bearings inside the robotic arm. The detection component 22 can scan the casting sand core 3 arranged on the rotating platform, and the repair component 23 can repair the coating on the surface of the sand core of the casting sand core 3.

[0029] The detection component 22 includes a laser scanner and an infrared thermal imager, wherein the laser scanner can heat the surface coating of the casting sand core, forming a heat wave during heating, and the heat wave diffuses in the coating on the surface of the casting sand core 3, and the infrared thermal imager can detect the coating temperature distribution on the surface of the casting sand core 3 and the temperature difference generated during the transmission of the heat wave inside the coating. The laser scanner and the infrared thermal imager are both set on the top of the robot 21, and the robot 21 can adjust the distance between the detection component 22 and the surface coating of the casting sand core 3 to ensure that there is no other interference in the working conditions of the detection component 22.

[0030] The repair component 23 includes a paint supply part and a nozzle. The paint supply part is provided with a coating paint for brushing on the surface of the casting sand core. The paint is connected to the nozzle through a pipeline. A pump is provided inside the paint supply part, which can transfer the paint inside the paint supply part to the nozzle, and the coating on the surface of the casting sand core 3 is brushed through the nozzle.

[0031] The control component can control the robot 21, and control the relative rotation between the casting sand core 3 and the scanning system by moving the supporting base 12 or the fixed base 13. In this embodiment, the mobile supporting base 12 is used to keep the fixed base 13 stationary for detection.

[0032] An intelligent detection method for the surface coating quality of a large wind power casting sand core of this embodiment is as follows: Step 1: Fix the casting sand core 3 on the top of the rotating platform. A hole for accommodating the casting sand core 3 is provided at the center of the fixed base 13 of the rotating platform. The casting sand core 3 is provided at the center of the fixed base 13 .

[0033] Step 2: The control component controls the robot 21 to rotate on the surface of the casting sand core 3.

[0034] Step 3: During the rotation process, the detection component 22 is controlled to scan the surface coating of the casting sand core 3 to identify the quality of the coating.

[0035] Step 4: The coating quality signal detected by the detection component 22 is transmitted to the control device. After the control device confirms the area on the surface of the casting sand core 3 that needs to be re-brushed, it controls the control robot to move to the area that needs to be repaired, and at the same time, the repair component 23 re-brushes the area that needs to be repaired.

[0036] As another embodiment, during the detection process, the support base 12 is fixed on the basic base 11 and does not move, and the fixed base 13 arranged on the top drives the casting sand core 3 to rotate. During the rotation of the casting sand core 3, the robot 21 can adjust the height and distance between the scanning system and the casting sand core 3. It is ensured that the detection component 22 in the scanning system can detect the quality of the surface coating of the casting sand core 3, and the repair component 23 moves to the coating defect of the casting sand core 3 to repair the coating.

[0037] In this embodiment, the detection component 22 can move around along the surface of the casting sand core 3 driven by the robot 21, and the moving path of the detection component 22 is expanded to form the X-axis direction and the Y-axis direction. The initial scanning path starts from the minimum point of the X-axis and the minimum point of the Y-axis, and moves upward after scanning along the X-axis. The casting covers the entire surface of the casting sand core 3 to confirm the coating quality of the casting sand core 3.

[0038] Provide a method to calculate coating thickness: The detection component 22 includes a laser scanner and an infrared thermal imager. The coating on the surface of the casting sand core 3 is made of zircon powder. The main component of the casting sand core 3 is silicon dioxide. The thermophysical parameters are: Thermal conductivity ≈1.7 Specific heat ≈480 density ≈4600 The proportion of the binder constituting the coating is small and the thermal conductivity is poor. In this embodiment, a thermal conductivity of 0.2 Specific heat capacity 1500 , density is 1200 .

[0039] The infrared imager can detect the coating temperature in a certain area on the surface of the casting sand core 3. Before starting the detection, the initial surface temperature of the casting sand core 3 is recorded as When the laser scanner is working, it can heat the coating on the surface of the casting sand core 3. At this time, the surface temperature of the coating rises. The infrared imager records the surface temperature of a certain area of ​​the casting sand core 3 as .

[0040] The temperature gradient is where q is the heat flux per unit area, is the total thermal resistance of heat transfer, in is the thickness of zircon powder coating, is the thermal conductivity of zircon powder.

[0041] When the laser scanner is heated, the heating time As small as possible, to ensure that heat is only transmitted to the surface coating of the casting sand core 3. The infrared imager detects the temperature change of the surface coating of the casting sand core 3, and forms a curve of temperature T changing with time t.

[0042] According to the temperature change curve detected by the infrared imager, the formula for estimating the coating thickness is: The temperature curve of the casting sand core 3 surface over time is obtained by thermal imaging. That is The coating on the surface of each casting sand core 3 has different thicknesses depending on the casting being cast. When the detection component 22 detects that the surface coating thickness of some casting sand cores 3 does not meet the requirements, the repair component 23 set on the robot 21 repairs the surface defects of the casting sand core 3. The surface coating requirements of the casting sand core 3 are as follows: the surface coating should be uniform and smooth, there should be no paint accumulation and sagging, ensure the coating thickness is consistent, the coating surface should be relatively smooth, the edges and corners should be clean, there should be no obvious brush marks and missing coating, the coating thickness should be within 1-2mm, the sand core surface should be flat, the edges and corners should be clear, the size and shape should be correct, it should have high strength, high temperature crack resistance and high resistance to high temperature metal liquid penetration; the sand core chill surface should use special high temperature refractory chill coating to ensure that the coating layer is flat and smooth.

[0043] During the inspection process, the laser scanner and infrared thermal imager of the inspection component 22 are responsible for the accurate measurement of the thickness of the sand core and the monitoring of the temperature distribution, respectively. The laser scanner emits a laser beam to heat the temperature of the coating on the surface of the sand core, and then detects it through the infrared thermal imager. If the thickness is lower than the set standard thickness, it is judged as an unqualified area. In addition, the surface temperature distribution can be monitored by the infrared thermal imager, and uneven temperature changes may also indicate potential defects or abnormal thickness.

[0044] The criteria for judging the surface quality of casting sand cores are: 1. Surface roughness: The surface flatness of the sand core is ≤0.2mm and the surface finish of the sand core is ≤Ra12.5μm, so as to avoid excessive roughness that affects the appearance and performance of the casting. If the data exceeds this standard, rework and repair are required. The use of 3D scanning technology can provide high-resolution 3D surface morphology, so as to more comprehensively evaluate the surface finish of the sand core.

[0045] 2. Surface defects: Obvious brush marks, coating omissions, paint accumulation and sagging on the surface of the sand core, and peeling and bumps after the coating is dried will be marked as unqualified circles.

[0046] 4. Coating thickness: The coating thickness on the sand core surface is 1-2mm, and the coating thickness on the cold iron is 0.5-1mm.

[0047] When manufacturing different castings, the requirements for the surface thickness of the casting sand core are different.

[0048] The detection component 22 can obtain the thickness of the surface coating of the casting sand core 3 through the detection data. The coating thickness of each area on the surface of the casting sand core 3 is different. The coating thickness of some areas does not meet the casting requirements. It is necessary to paint the coating of the areas that do not meet the requirements, repair and repaint the surface coating of the casting sand core 3, so as to avoid the quality of the finished casting being reduced due to insufficient coating thickness of the casting sand core 3.

[0049] Defect judgment criteria: When the detection component detects that the thickness value of a certain area is lower than the preset threshold, or the temperature distribution is obviously abnormal, the area will be marked as a repair area that does not meet the standard. The information of such areas, including position coordinates, thickness difference and other related parameters, will be transmitted to the control component for subsequent repair. In this embodiment, the preset threshold is 95% of the normal value.

[0050] After receiving the thickness data sent back by the detection component 22, the control component generates a three-dimensional map containing all non-compliant areas, marking all areas that do not meet the thickness requirements. The coating areas that do not meet the requirements are divided. The repair component 23 starts repairing from the repair area located at the minimum point of the X-axis and the minimum point of the Y-axis. After repairing all the areas that need to be repaired in the X-axis, it detects whether there is an unrepaired area in the current X-axis; when there is no repaired area in the current X-axis, the area detected by the Y-axis extends upward until the repair area on the surface of the casting sand core 3 is completely repaired. During the repair process, the movement path of the robot 21 will automatically avoid the repaired area to ensure the uniformity and accuracy of the repair.

[0051] In this embodiment, the repair component 23 includes a paint supply unit and a nozzle. The paint supply unit is arranged at the bottom of the robot 21, and a pump is installed inside the paint supply unit, which is responsible for delivering the paint to the nozzle. The paint is delivered to the nozzle located at the top of the robot by a pipeline. The nozzle covers the non-conforming area on the surface of the sand core with an appropriate amount of paint through precise control, so as to achieve the surface coating thickness of the casting sand core 3.

[0052] Inspection and confirmation after repair is completed.

[0053] After all the repaired areas have been repaired, the control assembly will instruct the detection assembly 22 to conduct a comprehensive re-inspection of the entire casting sand core 3 to ensure that all areas meet the thickness standard. If all the repaired areas pass the inspection, the repair process is complete.

[0054] The basic principles, main features and advantages of the present invention are shown and described above. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. An intelligent detection system for the surface coating quality of sand cores of large wind power castings, including A rotating platform and a scanning system, wherein a casting sand core can be arranged on the rotating platform, and a coating is arranged on the surface of the casting sand core, and the scanning system can scan the coating on the surface of the casting sand core. Features: The rotating platform is capable of rotating; The scanning system includes a robot, a control component, a detection component, and a repair component. The detection component and the repair component are arranged on the robot. The control component is connected to the detection component. The control component can control the robot to rotate around the surface of the casting sand core. The detection component can scan and detect whether there are defects in the casting sand core. The repair component repairs the coating on the surface of the casting sand core according to the defects.

2. According to claim 1, a large-scale wind power casting sand core surface coating quality intelligent detection system is characterized by: The rotating platform comprises a basic base, a supporting base and a fixed base. The supporting base is arranged on the top of the basic base, and the fixed base is arranged on the top of the supporting base. The fixed base can fix the casting sand core.

3. According to claim 2, a large-scale wind power casting sand core surface coating quality intelligent detection system is characterized by: The basic base is fixed, and the supporting base can rotate relative to the basic base; the fixed base can rotate relative to the basic base.

4. According to claim 3, a large-scale wind power casting sand core surface coating quality intelligent detection system is characterized by: When the supporting base rotates, the fixed base is fixed; when the fixed base rotates, the supporting base is fixed.

5. According to claim 1, a large-scale wind power casting sand core surface coating quality intelligent detection system is characterized by: The robot includes a robotic arm that can be moved around a casting sand core.

6. The intelligent detection system for surface coating quality of large-scale wind power casting sand core according to claim 1 is characterized by: The detection component includes a laser scanner and an infrared thermal imager. The laser scanner can heat the surface coating of the casting sand core to form a heat wave; the infrared thermal imager can detect the temperature distribution on the surface of the material and detect the temperature difference generated during the transmission of the heat wave inside the coating.

7. The intelligent detection system for surface coating quality of sand core of large-scale wind power casting according to claim 6 is characterized by: The thickness of the coating can be detected by the detection component. The formula for calculating coating thickness is: in is the thickness of zircon powder coating, is the thermal conductivity of zircon powder, is the specific heat capacity of zircon powder, is the density of zircon powder, t is the heating time of the laser scanner, It is the temperature rise value of the casting sand core.

8. The intelligent detection system for surface coating quality of large-scale wind power casting sand core according to claim 1 is characterized by: The repair component includes a paint supply part and a nozzle. The nozzle is arranged on the top of the robot, and the nozzle is connected to the paint supply part through a pump.

9. An intelligent detection system for surface coating quality of sand cores of large-scale wind power castings according to any one of claims 5 to 8, characterized in that: The robot moves on the surface of the casting sand core, and the detection component arranged on the top of the robot scans the casting sand core; the control component controls the repair component to brush the defective parts of the casting sand core surface coating according to the scanning result of the detection component.

10. A method for intelligently detecting the surface coating quality of sand cores of large-scale wind power castings, wherein the method is implemented by using a system for intelligently detecting the surface coating quality of sand cores of large-scale wind power castings according to any one of claims 1 to 9, and is characterized in that: The following steps are involved: Step 1: fix the casting sand core to the top of the rotating platform, and the control component controls the rotating platform to rotate; Step 2: The control component controls the robot to rotate around the surface of the casting sand core; Step 3: The control component controls the detection component to scan the coating on the surface of the casting sand core; Step 4: The control component controls the repair component to repair the coating defects on the surface of the casting sand core according to the scanning result of the detection component.

11. The intelligent detection method for surface coating quality of sand core of large-scale wind power casting according to claim 10, characterized in that: In step 2, the fixed base drives the detection assembly to rotate or the supporting base drives the casting sand core to rotate.

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