Generation method of robot moving program during blade spraying and spraying method and system

Abstract

The invention discloses a method for generating a moving program of a robot during blade spraying and a spraying method and system, and relates to the field of blade spraying, and the method mainly comprises the steps that after profile base points of a blade are obtained, the spraying angle is adjusted to meet the spraying requirement, and then the complete moving program of a spraying robot is generated according to longitudinal connection of the profile base points; during spraying, a moving program of the spraying robot is obtained by using the method, and the moving program controls the spraying path and angle of the spraying robot, so that the coating is uniformly sprayed, the quality stability of batch preparation of the coating is ensured, and a guarantee is provided for the service life of turbine blades and safe operation of a unit.

Description

Technical Field

[0001] The invention relates to the field of blade spraying, in particular to a method for generating a robot movement program during blade spraying and a spraying method and system. Background Art

[0002] Heavy-duty gas turbines are the heavy equipment of a great country. They are important strategic high-end technical equipment to ensure national defense security, energy security and industrial competitiveness. They are widely used in power generation, ship power and other fields, and are known as the "crown" of the power machinery manufacturing industry. High-temperature turbine blades are even more known as the "crown jewel". They serve under coupled harsh working conditions such as high temperature, high load and high corrosion, far exceeding the current use limit of high-temperature alloy substrates. A layer of thermal insulation / anti-oxidation coating (TBC / MCrAlY) must be sprayed on the surface of the substrate to extend the service life of turbine blades and improve unit efficiency.

[0003] In order to ensure the power generation efficiency of heavy-duty gas turbines, turbine static blades are often designed with a small throat width and a connected structure. Due to the mutual occlusion and interference between the blades and the small throat width between the blades, achieving uniform coating preparation faces great challenges. However, uniform preparation is not only a guarantee of coating quality and a prerequisite for mass production, but also a guarantee for the service life of turbine static blades and safe operation of the unit. Therefore, a spraying solution is needed for turbine static blades with small throat width and connected structures. Summary of the invention

[0004] The purpose of the present invention is to address the above-mentioned problems and provide a method for generating a robot movement program during blade spraying, as well as a spraying method and system, so that the coating is sprayed evenly, thereby ensuring the quality stability of batch preparation of the coating, and also providing protection for the life of the turbine blades and the safe operation of the unit.

[0005] The technical solution adopted by the present invention is as follows: a method for generating a robot movement program when spraying a blade, wherein the blade is a gas turbine ventilator stationary blade having small throat width and conjoined characteristics, and the gas turbine ventilator stationary blade comprises a first blade and a second blade; the generating method comprises the following steps:

[0006] S1: Based on the characteristics of the blades, at least three profile curves are generated on the first blade and the second blade respectively, wherein there are profile curves at the blade tip and the blade root;

[0007] S2: Generate profile base points according to the profile curves, and the profile base points meet the following requirements: the number of profile base points on different profile curves is equal, and the distance between adjacent profile base points is less than the size required for flame flow overlap;

[0008] S3: In step S2, if the profile base points on different profile curves have inevitable interference, proceed to step S31 to step S33;

[0009] S31: Adjust the spraying angles of all profile base points to 90°;

[0010] S32: For the interfering profile base points, adjust the spraying angles until the spraying requirements are met;

[0011] S33: Conduct linkage calculations for all profile base points and adjust the axis angles of the spraying robot to be consistent;

[0012] S4: Move the profile curve at the blade tip upward along the profile by a certain distance and move the profile curve at the blade root downward along the profile by a certain distance to generate the target points for idle running;

[0013] S5: Use the movement instructions and functions of the spraying robot to longitudinally connect the profile base points on the blade body and the target points for idle running to generate a complete movement program for the spraying robot.

[0014] Furthermore, the number of profile curves is three.

[0015] Furthermore, on the stationary blades of the gas turbine, the patch method is used for verification and optimization of the movement program of the spraying robot, and the optimized parameters are the spraying angle and the movement speed.

[0016] A spraying method for blades, for spraying the stationary blades of the gas turbine, comprising the following steps:

[0017] A1: Clean and fixture the stationary blades of the gas turbine;

[0018] A2: Sandblast the spraying area of the stationary blades of the gas turbine with white corundum;

[0019] A3: Clean the sandblasted surface of the stationary blades of the gas turbine, check whether the sandblasted area is complete, and if not, use step A2 for supplementary spraying;

[0020] A4: Fix the stationary blades of the gas turbine on the turntable, and on the premise that the turntable angle is 0°, adjust the actual installation of the stationary blades of the gas turbine to be consistent with the installation of the stationary blades of the gas turbine in the spraying software;

[0021] A5: Use the method for generating the movement program of the robot during spraying of the blades according to any one of claims 1 - 3 to generate the movement program of the spraying robot, and call the spraying program to spray the stationary blades of the gas turbine until the spraying of the stationary blades of the gas turbine is completed.

[0022] Furthermore, in step A1, the cleaning process is to clean the grease and contaminants on the surface of the stationary blades of the gas turbine with organic solvents.

[0023] Furthermore, in step A2, the sandblasting pressure is 0.4 - 0.6 MPa, the sandblasting distance is 100 - 150 mm, and the sandblasting angle is 45° - 75°.

[0024] Furthermore, in step A3, the sandblasted surface is cleaned with clean, dry compressed air.

[0025] Furthermore, after spraying in step A5 is completed, the powder, dirt, and coating in the non-spraying area are cleaned with sandpaper or a file.

[0026] A blade spraying system is applied to the blade spraying method, and is characterized by comprising a tooling structure, a turntable and a spraying robot, wherein the turntable is mounted on a support column, and the tooling structure is mounted on the support column.

[0027] Furthermore, the tooling structure includes a blade crown shielding box and a blade root shielding box connected by a fastening structure, the blade crown shielding box is composed of a top plate and a first side plate surrounding the top plate, and the blade root shielding box is composed of a bottom plate and a second side plate surrounding the bottom plate, and the fastening structure is a double-headed screw, and both ends of the double-headed screw pass through the top plate and the bottom plate respectively and are connected to the nut

[0028] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0029] 1. The method disclosed in the present invention is aimed at the gas turbine turbine blades with small throat width and conjoined characteristics. By acquiring the profile base points and correcting the interference base points, the spray robot can achieve full coverage and uniformity on the gas turbine turbine blades.

[0030] 2. In the system disclosed in the present invention, due to the existence of the tooling structure, the blade crown shielding box and the blade root shielding box can completely fit the blade crown (blade top) and blade root of the turbine turbine static blade respectively during use, so that the blade crown and blade root are not affected by sandblasting and spraying. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0032] Figure 1 This is a schematic diagram of the structure of a gas turbine turbine blade;

[0033] Figure 2 This is a schematic diagram of the position distribution of the profile base points numbered 01-36;

[0034] Figure 3 It is a schematic diagram of the position distribution of the profile base points numbered 27-36 on the second blade;

[0035] Figure 4 This is a schematic diagram of the position distribution of the profile base points numbered 37-58 on the first blade;

[0036] Figure 5 Schematic diagram of thickness distribution after the first spraying;

[0037] Figure 6 Schematic diagram of thickness distribution after the second spraying;

[0038] Figure 7 It is a schematic diagram of the tooling structure;

[0039] Figure 8 It is a structural schematic diagram of the spraying system;

[0040] Markings in the figure: 1- turbine blade; 11- first blade; 12- second blade; 13- profile curve; 2- fastening structure; 3- blade crown shielding box; 4- blade root shielding box; 5- turntable; 6- spraying robot. DETAILED DESCRIPTION

[0041] In the description of this specification, it should be noted that if the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the drawings, or is the orientation or position relationship in which the product of this specification is usually placed when used. It is only for the convenience of describing this specification and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this specification.

[0042] In addition, if the terms "horizontal" or "vertical" appear in the description of this specification, it does not mean that the components are required to be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" only 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.

[0043] In the description of this specification, it should also be noted that, unless otherwise clearly stipulated and limited, the terms "set", "installed", "connected" and "connected" should be understood in a broad sense. For example, the connection can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be a connection between the internal parts of two elements.

[0044] Example 1

[0045] A method for generating a robot movement program during blade spraying, wherein the blade is a gas turbine ventilator stationary blade 1 having small throat width and conjoined characteristics, and the gas turbine ventilator stationary blade 1 comprises a first blade 11 and a second blade 12; the generating method comprises the following steps:

[0046] S1: Combine the characteristics of the blades and generate three profile curves 13 on the first blade 11 and the second blade 12 respectively, with profile curves 13 at both the blade tip and the blade root positions. Of course, the number of profile curves 13 can be more. The more the number, the more the movement program of the spraying robot 6 fits the profiles of the first blade 11 and the second blade 12, and the spraying is more accurate and uniform.

[0047] S2: Generate profile base points according to the profile curves 13. The profile base points meet the following requirements: the number of profile base points on different profile curves 13 is equal, and the distance between adjacent profile base points is less than the size required for flame stream lap. The control of the distance between profile base points is mainly restricted by the size of the flame beam, and its purpose is to make the coating lap more uniform.

[0048] S3: In step S2, if inevitable interference occurs among the profile base points on different profile curves 13, perform steps S31 - S33;

[0049] S31: Adjust the spraying angle of all profile base points to 90°. The spraying angle of 90° is the best spraying angle for all profile base points. However, for the interfering profile base points, the spray gun cannot achieve a spraying angle of 90°, so the spraying parameters of the interfering profile base points need to be appropriately adjusted.

[0050] S32: For the interfering profile base points, adjust the spraying angle until the spraying requirements are met. Usually, the adjustment method is to reduce the spraying angle and lower the speed.

[0051] S33: Perform linkage calculation on all profile base points and adjust the axis angles of the spraying robot 6 to be consistent. The purpose is that after the correction in steps S31 and S32, for each profile base point, the axis angles configured by the spraying robot 6 have obvious differences, which easily leads to spraying interruption. Through this step, this problem can be effectively solved.

[0052] S4: Move the profile curve 13 at the blade tip 80 mm upward along the profile, and move the profile curve 13 at the blade bottom 80 mm downward along the profile to generate target points for idle running, which actually defines the starting point and the ending point of each path.

[0053] S5: Use the movement instructions and functions of the spraying robot 6 to longitudinally connect the profile base points on the blade body and the target points for idle running to generate a complete movement program for the spraying robot 6. Running this program can make the spraying robot 6 move longitudinally to form a series of movement trajectories. On the one hand, this movement rule enables full coverage of the spraying on the stationary blades 1 of the gas turbine, and on the other hand, it makes the spraying parameters of each profile base point basically consistent.

[0054] Furthermore, the movement program of the spraying robot 6 was verified and optimized by using the patch method on the stationary blades 1 of the gas turbine. The optimized parameters were the spraying angle and the movement speed. The verification results showed that the thickness uniformity of the coating could meet the design requirements.

[0055] Example 2

[0056] A spraying method for blades, using the blade spraying system described below, sprays the stationary blades 1 of the gas turbine described in Example 1, including the following steps:

[0057] A1: Clean and fixture the stationary blades 1 of the gas turbine; during the cleaning process, a rag or brush is dipped in an organic solvent to clean the grease and contaminants on the surface of the stationary blades 1 of the gas turbine, and after drying, it is fixture. The fixture structure used during fixture can use the fixture structure described below.

[0058] A2: Sandblast the spraying area of the stationary blades 1 of the gas turbine with white corundum; the sandblasting pressure is 0.4 - 0.6 MPa, the sandblasting distance is 100 - 150 mm, and the sandblasting angle is 45° - 75°; the purpose of sandblasting is to enhance the attachment points for subsequent spraying and improve the stability of spraying.

[0059] A3: Clean the sandblasted surface of the stationary blades 1 of the gas turbine, and check whether the sandblasted area is complete. If it is not complete, re - spray using step A2; when cleaning the sandblasted surface, clean it with clean and dry compressed air, and confirm that there are no attachments such as grease, dirt, scale, paint, etc. on the surface.

[0060] A4: Fix the stationary blades 1 of the gas turbine on the turntable 5, and on the premise that the angle of the turntable 5 is 0°, adjust the actual installation of the stationary blades 1 of the gas turbine to be consistent with the installation of the stationary blades 1 in the spraying software, so that the operation of the software can be reflected in real - time and correctly in the actual spraying of the stationary blades 1 of the gas turbine.

[0061] A5: Use the method for generating the movement program of the spraying robot 6 during blade spraying described in Example 1 to generate the movement program of the spraying robot 6, and call the spraying program to spray the stationary blades 1 of the gas turbine until the spraying of the stationary blades 1 of the gas turbine is completed.

[0062] Furthermore, after the spraying in step A5 is completed, clean the powder, dirt, and coating in the non - spraying area with sandpaper or a file.

[0063] Through the above steps, the stationary blades 1 of the gas turbine are sprayed twice, as Figure 1As shown, three profile curves 13 are respectively generated on the first blade 11 and the second blade 12, namely the tip curve, the middle curve and the root curve. There is a 10-mm spacing between the tip curve and the blade tip. The distance from the tip curve to the middle curve is 50 mm, and the distance from the middle curve to the root curve is 50 mm. Profile base points are generated according to the three profile curves 13. The number of base points on each profile curve 13 is 58 profile base points, which are numbered 01 - 58 respectively. For the interfering profile base points, after adjusting the spraying angle as Figures 2-4 shown ( Figures 2-4 in which "1" and "2" respectively represent the first blade 11 and the second blade 12), the profile base point numbers 27 - 36 are on the outer arc of the intake side of the blade (including the first blade 11 and the second blade 12), the profile base point numbers 01 - 26 are on the inner arc of the blade (including the first blade 11 and the second blade 12), and the profile base point numbers 37 - 58 are on the outer arc of the exhaust side of the blade (including the first blade 11 and the second blade 12). Spraying is carried out twice. For the first spraying, MCrAlY is used for spraying. The spraying result is as Figure 5 shown. It can be seen that only the thickness at the positions of the profile base points 27 - 36 on the blade profile of the first blade 11 is 0.07 - 0.09 mm, which is close to half of the profile base points at other positions. For the blade, this position is the interfering position. Being able to reach half of the thickness has exceeded the thickness required by the technology, that is, the thickness uniformity is significantly improved. For the second spraying, 8YSZ is used for spraying. The spraying result is as Figure 6 shown. Similarly, only the thickness at the positions of the profile base points 27 - 36 on the blade profile of the first blade 11 is 0.13 - 0.16 mm, which also reaches or is close to half of the profile base points at other positions, that is, the thickness uniformity is significantly improved.

[0064] Embodiment 3

[0065] As Figures 7-8 shown, a spraying system for a blade, which is applied to the blade spraying method described in Embodiment 3, includes a tooling structure, a turntable 5 and a spraying robot 6. A support column is installed on the turntable 5, and the tooling structure is installed on the support column. The turntable 5 is actually the outer axis of the spraying robot 6. The gas turbine stationary blade 1 is installed on the tooling structure, so that the gas turbine stationary blade 1, the turntable 5 and the spraying robot 6 form an organic whole to form a spraying system for spraying the gas turbine stationary blade 1.

[0066] Furthermore, the tooling structure includes a shroud box 3 and a root shroud box 4 connected by a fastening structure 2. The shroud box 3 is composed of a top plate and a first side plate surrounding the top plate, and the outer shape of the first side plate is designed according to the shroud profile; the root shroud box 4 is composed of a bottom plate and a second side plate surrounding the bottom plate, and the outer shape of the second side plate is designed according to the root profile; the fastening structure 2 is a double-headed screw, and both ends of the double-headed screw pass through the top plate and the bottom plate respectively and are connected to nuts. By tightening the nuts, it is avoided that the stationary blades 1 of the gas turbine become loose or fall off during the sandblasting and spraying processes.

[0067] In this embodiment, due to the existence of the tooling structure, the shroud box 3 and the root shroud box 4 can be fully attached to the shroud (tip) and root of the stationary blades 1 of the gas turbine respectively during use, so that the shroud and root are not affected by sandblasting and spraying.

[0068] The present invention is not limited to the foregoing specific embodiments. The present invention extends to any new feature or any new combination disclosed in this specification, as well as any new method or process step or any new combination disclosed.

Claims

1. A method for generating a robot movement program during blade spraying, characterized in that: The blade is a combustion turbine stationary blade (1) with both a small throat width and a joined structure. The combustion turbine stationary blade (1) includes a first blade (11) and a second blade (12). The generation method includes the following steps: S1: Considering the characteristics of the blade, at least three profile curves (13) are generated on the first blade (11) and the second blade (12) respectively, with profile curves (13) existing at both the blade tip and the blade root positions. S2: Profile base points are generated according to the profile curves (13), and these profile base points meet the following requirements: the number of profile base points on different profile curves (13) is equal, and the distance between adjacent profile base points is less than the size required for flame flow overlap. S3: In step S2, if inevitable interference occurs among the profile base points on different profile curves (13), steps S31 - S33 are carried out. S31: Adjust the spraying angles of all profile base points to 90°. S32: For the interfering profile base points, adjust the spraying angles until the spraying requirements are met. S33: Conduct a linkage calculation for all profile base points to adjust the axis angles of the spraying robot (6) to be consistent. S4: Move the profile curve (13) at the blade tip upward along the profile by a certain distance, and move the profile curve (13) at the blade bottom downward along the profile by a certain distance to generate the target points for idle travel. S5: Use the movement instructions and functions of the spraying robot (6) to longitudinally connect the profile base points on the blade body and the target points for idle travel to generate a complete movement program for the spraying robot (6).

2. The generation method according to claim 1, wherein: The number of profile curves (13) is three.

3. The generation method according to claim 1, characterized in that: On the combustion turbine stationary blade (1), the patch method is used to verify and optimize the movement program of the spraying robot (6), and the optimized parameters are the spraying angle and the movement speed.

4. A spraying method for a blade, which sprays the combustion turbine stationary blade (1) described in any one of claims 1 - 3, including the following steps: A1: Clean and fixture the combustion turbine stationary blade (1). A2: Sandblast the spraying area of the combustion turbine stationary blade (1) with white corundum. A3: Clean the sandblasted surface of the combustion turbine stationary blade (1), check whether the sandblasted area is complete. If not, use step A2 for supplementary spraying. A4: Fix the combustion turbine stationary blade (1) on the turntable (5), and on the premise that the angle of the turntable (5) is 0°, adjust the actual installation of the combustion turbine stationary blade (1) to be consistent with the installation of the combustion turbine stationary blade (1) in the spraying software. A5: Use the method for generating the movement program of the robot during spraying of the blade described in any one of claims 1 - 3 to generate the movement program of the spraying robot (6), and call the spraying program to spray the combustion turbine stationary blade (1) until the spraying of the combustion turbine stationary blade (1) is completed.

5. The spraying method according to claim 4, characterized in that: In step A1, during the cleaning process, the surface of the combustion turbine stationary blade (1) is cleaned of grease and contaminants with organic solvents.

6. The spraying method according to claim 4, wherein: In step A2, the sandblasting pressure is 0.4 - 0.6 MPa, the sandblasting distance is 100 - 150 mm, and the sandblasting angle is 45° - 75°.

7. The spraying method according to claim 4, characterized in that: In step A3, when cleaning the sandblasted surface, clean it with clean and dry compressed air.

8. The spraying method according to claim 4, characterized in that: After the spraying in step A5 is completed, clean the powder, dirt, and coating in the non-sprayed area with sandpaper or a file.

9. A spraying system for a blade, which is applied to the spraying method of the blade according to any one of claims 4-8, and is characterized in that: It includes a tooling structure, a turntable (5), and a spraying robot (6). Pillars are installed on the turntable (5), and the tooling structure is installed on the pillars.

10. The spraying system according to claim 9, wherein: The tooling structure includes a shroud box for the blade tip (3) and a shroud box for the blade root (4) connected by a fastening structure (2). The shroud box for the blade tip (3) consists of a top plate and a first side plate surrounding the top plate. The shroud box for the blade root (4) consists of a bottom plate and a second side plate surrounding the bottom plate. The fastening structure (2) is a double-headed screw, and both ends of the double-headed screw pass through the top plate and the bottom plate and are connected to nuts respectively.

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