Marine propeller blade cladding welding robot
Through the marine propeller blade cladding welding robot, the three-axis sliding table and laser welding technology are used to solve the automation and precise control problems in the adjustable pitch propeller welding process, achieving efficient and accurate welding effects, and improving welding quality and life.
Patent Information
- Application Number
- CN202510910451.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-02
- Publication Date
- 2025-08-15
AI Technical Summary
In the prior art, the welding process of adjustable pitch propellers is difficult to achieve automation and precise control, resulting in low welding quality, high labor costs, long maintenance cycles, and easy welding defects, affecting service life and performance stability.
The marine propeller blade cladding welding robot is adopted, and the three-axis sliding table and laser welding technology is used, combining the thermal effect deformation principle and adaptive control algorithm to achieve automated and precise control of the welding process. The thermal effect deformation of the two parallel welding surfaces is cancelled out, reducing blade deformation, and ensuring welding accuracy through the PLC control system and position sensor.
It significantly improves welding accuracy and quality, reduces labor costs, shortens maintenance cycles, reduces welding defects, and improves the service life and performance stability of adjustable pitch propellers.
Smart Images
Figure CN120480397A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of welding robots, and specifically to a cladding welding robot for marine propeller blades. Background Art
[0002] A controllable pitch propeller (CPP) is a propulsion device that adjusts the blade angle through an internal mechanism in the hub. The core of the CPP is that the blade can rotate around an axis perpendicular to the propeller shaft, thereby changing the pitch angle (the angle of attack between the blade and the water flow) and achieving dynamic adjustment of the thrust size and direction.
[0003] The typical structure of an adjustable pitch propeller includes blades, a hub, a hydraulic system, an oil distributor and an electronic control unit. The adjustment process can be remotely controlled through the console. Adjustable pitch propellers are widely used in ships that require flexible control, such as tugboats, ferries, fishing boats, icebreakers, scientific research vessels, warships and other special ships. Its advantage lies in its adaptability to changing working conditions, such as port navigation, mooring and high-speed navigation.
[0004] As a core component for improving the maneuverability and propulsion efficiency of special ships, the adjustable pitch propeller has a complex and sophisticated manufacturing process. In addition, due to factors such as high technical barriers and special materials, the production cost is high, which makes its value in maintenance and replacement particularly significant.
[0005] Given its important position in the shipbuilding industry, the manufacturing quality of adjustable propellers directly affects the overall performance, operating efficiency and safety of the ship. Therefore, how to efficiently and accurately achieve the welding of adjustable propellers has become a key technical problem that needs to be solved urgently in the field of shipbuilding and repair. Therefore, it is necessary to provide a marine propeller blade cladding welding robot to solve the above problems. It should be noted that the above information disclosed in this Background section is only for understanding the background technology of the present application concept, and therefore, it may contain information that does not constitute prior art. Summary of the Invention
[0006] Based on the above-mentioned problems existing in the prior art, the problem to be solved by this application is: to provide a marine propeller blade cladding welding robot to achieve automation and precise control of the welding process of the adjustable pitch propeller, thereby effectively improving the welding quality and efficiency, reducing labor costs, shortening the maintenance cycle, and at the same time effectively reducing welding defects caused by human factors, and improving the service life and performance stability of the adjustable pitch propeller.
[0007] The technical solution adopted by the present application to solve its technical problems is: a marine propeller blade cladding welding robot, including two groups of cladding welding robots separated on both sides of the propeller blade, the cladding welding robot including: a base; a three-axis slide, the three-axis slide is arranged on the base, and the output end of the three-axis slide is provided with a second bracket; a laser welder, the laser welder has a laser welding gun head, and the laser welding gun head is installed on the second bracket; a wire feeder, the wire feeder is arranged on one side of the base, and the wire feeder is used to feed the welding wire to the position of the laser welding gun head; an operating table, the operating table is arranged on one side of the base, and a PLC control system is provided on the operating table.
[0008] Furthermore, the three-axis slide includes a first bracket fixedly mounted on the base, a first motor fixedly mounted on the first bracket, a second pulley fixedly mounted on the output end of the first motor, a first pulley mounted on a bearing on the first bracket, a belt transmitted between the first pulley and the second pulley; a rotating shaft fixedly mounted on the first pulley, and a stand fixedly mounted on the output end of the rotating shaft.
[0009] Furthermore, a second motor is fixedly installed on the top of the stand, a first screw is fixedly installed on the output end of the second motor, and the first screw bearing is installed on the stand; a vertical first slide is provided on the stand, a first slider is slidably provided on the first slide, and the first slider is transmission-connected to the first screw.
[0010] Furthermore, a cross frame is fixedly mounted on the first slider, a third motor is fixedly mounted on one end of the cross frame away from the propeller blades, a second screw is fixedly mounted on the output end of the second motor, and a bearing of the second screw is mounted on the cross frame.
[0011] Furthermore, a second slideway in a horizontal direction is provided on the horizontal frame, a second slider is slidably provided on the second slideway, and the second slider is transmission-connected to the second screw rod.
[0012] Furthermore, a mounting bracket is fixedly provided on the second sliding block, and the second bracket is fixedly mounted on the mounting bracket.
[0013] Furthermore, the laser welder has an optical fiber, which is connected to the laser welding gun head.
[0014] Furthermore, the wire feeder has a wire feeding frame placed on the ground, a wire feeding reel is rotatably provided on the wire feeding frame, and the welding wire is wound on the wire feeding reel.
[0015] Furthermore, a third bracket is provided on the second bracket, a wire feeding gun is installed on the third bracket, and a wire feeding tube is connected between the wire feeding gun and the wire feeding frame.
[0016] Furthermore, a position sensor is fixedly mounted on the second sliding block, and the position sensor is adapted to move synchronously with the welding head of the laser welding gun head to collect the position of the laser welding gun head in real time.
[0017] Beneficial effect: The present application provides a marine propeller blade cladding welding robot that utilizes the principle of thermal effect deformation generated by metal during the welding process. By simultaneously generating thermal effect deformation on two parallel welding surfaces to offset each other, the deformation of the blade is effectively controlled, thereby significantly improving welding accuracy and product quality.
[0018] In addition to the above-described purposes, features and advantages, the present application also has other purposes, features and advantages. The present application will be further described in detail below with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The drawings that constitute part of this application are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute an improper limitation on this application. In the drawings: Figure 1 This is an overall schematic diagram of a double-sided welding robot for cladding welding of marine propeller blades in this application; Figure 2 for Figure 1 A schematic diagram of the single-side welding structure of a marine propeller blade cladding welding robot; Figure 3 for Figure 2 Schematic diagram of the local structure at point A; Figure 4 for Figure 2 Schematic diagram of the local structure at B in the middle; Figure 5 for Figure 2 Schematic diagram of the local structure at point C in the middle; Figure 6 for Figure 2 Schematic diagram of the local structure at D in the middle; Figure 7 This is a real-life picture of a marine propeller blade cladding welding robot.
[0020] Among them, the reference numerals in the figures are: 1. Laser welder; 11. Optical fiber; 2. Wire feeder; 21. Wire feed rack; 22. Wire feed reel; 23. Welding wire; 24. Wire feed tube; 3. Base; 4. Operation table; 5. Three-axis slide; 51. First bracket; 52. First motor; 53. First pulley; 54. Vertical frame; 55. Second motor; 56. First slider; 57. Horizontal frame; 58. Third motor; 510. Second slider; 511. Mounting frame; 6. Paddle blades; 7. Position sensor; 8. Laser welding gun head; 81. Second bracket; 9. Wire feeding gun; 91. Third bracket. DETAILED DESCRIPTION
[0021] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.
[0022] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.
[0023] At present, as the core component of modern marine engineering special operation vessels, the importance of adjustable propellers is self-evident. This type of propeller can not only provide ships with high flexibility and maneuverability in various complex operating environments, but also ensure the stable operation of ships under harsh sea conditions, thereby effectively improving the safety and efficiency of marine operations. Especially in equipment such as the "Tiankun" heavy-duty cutter suction dredger, adjustable propellers play an irreplaceable role.
[0024] However, in actual use, adjustable propellers also face many challenges. Due to long-term underwater operations and complex and changeable working environments, the blades are often corroded and worn by various impurities, resulting in frequent maintenance needs. The traditional repair welding process not only has high technical requirements, but also has extremely high labor costs, usually accounting for about 80% of the repair costs. This not only increases maintenance costs, but also extends the maintenance cycle, seriously affecting the normal use and operating efficiency of the ship.
[0025] More seriously, traditional welding processes are prone to a series of problems during operation. For example, manual operation often makes it difficult to ensure welding accuracy and consistency, which can easily lead to blade distortion and deformation, making subsequent correction work extremely difficult. At the same time, welding quality is often difficult to guarantee, and defects such as weld cracking and porosity may occur, further reducing the service life and performance of the propeller. In order to solve the above problems, Figure 1-Figure 2 As shown, the present application provides a cladding welding robot for marine propeller blades, which is generally used in the production, repair and other operations of marine propeller blades. The cladding welding robot includes a platform for placing the propeller blade (hereinafter referred to as the blade 6). It should be noted that because the welding surface of the blade 6 is complex and the curvature is variable, a special fixture is generally provided to position and fix the blade 6 before welding, so that the blade 6 is approximately in the same position each time it is welded. In this way, in batch welding operations, there is no need to frequently modify the welding parameters and the uniformity of the welding can be ensured; like Figure 1 As shown, two groups of welding robots are arranged on the platform, and the two groups of welding robots are separated on both sides of the blade 6. In this application, the two groups of robots weld the positions of the blade 6 that need to be welded at the same time. In this way, the deformation principle of the thermal effect generated by the metal during the welding process can be utilized. By offsetting the thermal effect deformation generated by two parallel welding surfaces at the same time, the deformation of the blade 6 can be effectively controlled, thereby significantly improving the welding accuracy and product quality. For the sake of convenience, the following takes a group of welding robots as an example to explain in detail the structure and various functions of the welding robots. Specifically: like Figure 2-Figure 4 As shown, the welding robot includes a base 3 arranged on a platform, and a three-axis slide 5 is provided on the base 3. The three-axis slide 5 is composed of two groups of linear axes and one group of rotary axes. Specifically, the three-axis slide 5 includes a first bracket 51 fixedly mounted on the base 3, a first motor 52 is fixedly mounted on the first bracket 51, and a second pulley (not shown in the figure) is fixedly mounted on the output end of the first motor 52. At the same time, a first pulley 53 is mounted on a bearing on the first bracket 51, and a belt (not shown in the figure) is provided between the first pulley 53 and the second pulley, so that the first pulley 53 is suitable for rotating under the drive of the first motor 52; At the same time, a rotating shaft (not shown in the figure) is fixedly mounted on the first pulley 53, and a stand 54 is fixedly mounted on the output end of the rotating shaft, so that when the first pulley 53 rotates, the stand 54 can be driven to rotate synchronously through the rotating shaft; Combine Figure 2-Figure 3 It can be seen that the stand 54 is adapted to rotate in a vertical plane driven by the first motor 52. For the sake of convenience, the rotational movement direction of the stand 54 is defined as the A-axis, that is, the stand 54 is adapted to rotate along the A-axis driven by the first motor 52. Continue to refer Figure 2 and Figure 4 A second motor 55 is fixedly mounted on the top of the stand 54 , and a first screw (not shown in the figure) is fixedly mounted on the output end of the second motor 55 , and the bearing of the first screw is mounted on the stand 54 ; At the same time, a vertical first slideway (not shown in the figure) is provided on the stand 54, on which a first slider 56 is slidably provided. The first slider 56 is connected to the first screw rod in a transmission manner, so that starting the second motor 55 can drive the first screw rod to drive the first slider 56 to reciprocate in the vertical direction. In this application, the linear motion direction of the first slider 56 is defined as the Y axis, that is, the first slider 56 is adapted to reciprocate along the Y axis under the drive of the second motor 55 ; like Figure 2 、 Figure 4 and Figure 6 As shown, a cross frame 57 is fixedly mounted on the first slider 56, and a third motor 58 is fixedly mounted on the end of the cross frame 57 away from the blade 6. A second screw (not shown in the figure) is fixedly mounted on the output end of the second motor 55, and the second screw bearing is mounted on the cross frame 57; At the same time, a second horizontal slideway (not shown) is provided on the horizontal frame 57, on which a second slider 510 is slidably provided. The second slider 510 is connected to the second screw rod, so that starting the third motor 58 can drive the second screw rod, thereby driving the second slider 510 to reciprocate in the horizontal direction. In this application, the linear motion direction of the second slider 510 is defined as the X-axis, that is, the second slider 510 is adapted to reciprocate along the X-axis under the drive of the third motor 58 ; Continue to refer Figure 2 and Figure 6 A mounting bracket 511 is fixedly provided on the second slider 510, a second bracket 81 is fixedly mounted on the mounting bracket 511, and a laser welding gun head 8 is mounted on the second bracket 81. The laser welding gun head 8 is suitable for welding the blade 6; In summary, when the blade 6 needs to be welded, the initial position of the laser welding gun head 8 is adjusted by the three-axis slide 5. Here, because the blade 6 is fixed in the same position by the fixture on the platform each time, the laser welding gun head 8 can reach the preset position through the linear axis X, linear axis Y and A axis; Then, according to the preset program, the three-axis slide 5 is used to drive the laser welding gun head 8 to weld the blade 6 along the specified path.
[0026] In order to smoothly carry out the welding of blade 6, Figure 2 and Figure 5 As shown, a laser welder 1 is provided on one side of the base 3 , and the laser welder 1 has an optical fiber 11 , which is connected to a laser welding gun head 8 ; It is understood that the laser welder 1 utilizes a high-energy-density laser beam as a heat source, which is focused on the welding part through an optical system, causing the material to melt instantly and cool and solidify, thereby achieving a precise connection. The laser beam energy is concentrated, the heat-affected zone is small, and the welding deformation rate is 30% lower than that of traditional arc welding. It is particularly suitable for welding thin plates (0.1mm to 10mm) and precision parts. In addition, the welding speed can reach 5-10 times that of traditional methods, and the energy consumption is reduced by 40% to 60%. The subsequent grinding process is reduced, making it particularly suitable for the welding operation of the blade 6. In addition, in the present application, the laser beam is transmitted through the optical fiber 11, the minimum focused spot diameter can reach 0.3 mm, and the working distance is flexibly adjustable, which greatly improves the welding flexibility of the blade 6.
[0027] like Figure 2 and Figure 5-Figure 6 As shown, a wire feeder 2 is further provided on one side of the base 3. The wire feeder 2 comprises a wire feeding frame 21 placed on the ground, a wire feeding reel 22 is rotatably provided on the wire feeding frame 21, and a welding wire 23 is wound on the wire feeding reel 22; At the same time, a third bracket 91 is provided on the second bracket 81. A wire feeding gun 9 is mounted on the third bracket 91. A wire feeding tube 24 is connected between the wire feeding gun 9 and the wire feeding frame 21. Thus, the welding wire 23 is suitable for being unwound from the wire feeding reel 22 and reaching the position of the wire feeding gun 9 through the wire feeding tube 24. The wire feeding gun 9 corresponds to the laser welding gun head 8. Thus, the welding wire 23 can be evenly fed to the welding position by the wire feeding gun 9, and the laser welding gun head 8 welds the blade 6. It is understood that the wire feeder 2 is a key component of the welding automation system. It is responsible for delivering the welding wire 23 to the laser welding gun head 8 at a precise speed and stable tension to ensure the continuity and stability of the welding process. The wire feeder 2 also includes a wire feeding wheel and a motor provided on the wire feeding frame 21. The wire feeding action is driven by the motor to rotate the wire feeding wheel, and the welding wire 23 is fed out under the friction force of the wire feeding wheel. Automatic wire feeding can ensure continuous and stable feeding of the welding wire 23, reduce problems such as arc breaking and uneven welds during welding, thereby improving welding quality. In addition, by continuously feeding the welding wire 23, the welder's operating time for changing the welding wire 23 and adjusting the wire feeding speed is reduced, thereby improving production efficiency.
[0028] In order to ensure the accuracy of welding and collect welding positions in real time, such as Figure 2 and Figure 6 As shown, a position sensor 7 is fixedly mounted on the second slider 510 , and the position sensor 7 is adapted to move synchronously with the laser welding gun head 8 to acquire the position of the laser welding gun head 8 in real time, thereby obtaining the welding position.
[0029] In order to control the actions of the above components, Figure 1-Figure 2As shown, an operating table 4 is provided on one side of the base 3. The operating table 4 is provided with a PLC control system. The PLC control system has the following features: Integration of manual training and intelligent system: Through professional training, the core technology of Blade 6 is mastered and the optimal welding parameters and motion trajectory are recorded. At the same time, using this data, the intelligent welding system will be able to imitate manual operation and achieve more accurate and stable welding results through continuous learning and optimization.
[0030] High-precision positioning technology: In view of the particularity of blade 6 welding, the design adopts high-precision positioning technology to ensure the positioning accuracy during the welding process, thereby improving the welding quality and reducing errors.
[0031] Adaptive control algorithm: An intelligent control algorithm that automatically adjusts welding parameters based on real-time changes in welding parameters. The algorithm monitors key parameters such as welding current, voltage, and temperature in real time, and automatically adjusts welding parameters based on preset models and optimization strategies to ensure stability and consistency of the welding process.
[0032] Intelligent monitoring system: It has an intelligent monitoring system that integrates visual inspection, temperature monitoring and other functions. The system will monitor the welding quality in real time, detect and deal with potential problems in time, and ensure the safety and stability of the welding process.
[0033] Research on thermal deformation laws and control methods: By establishing models, testing and analyzing thermal deformation laws, and mastering methods to control thermal deformation, thermal deformation during welding can be reduced, and welding accuracy and product quality can be improved.
[0034] At the same time, physical welding tests will be carried out to verify the system performance, and optimization adjustments will be made based on the test results to ensure the reliability and stability of the system in actual applications.
[0035] In summary, the present application utilizes the principle of thermal deformation generated by metal during welding, and effectively controls the deformation of the blade 6 by offsetting the thermal deformation generated simultaneously by two parallel welding surfaces, thereby significantly improving welding accuracy and product quality. At the same time, by integrating manual training and intelligent technology, it not only has a high level of automation and intelligence, but also can achieve more accurate and stable welding effects through continuous learning and optimization; Furthermore, an intelligent monitoring system is constructed using adaptive control algorithms to achieve real-time monitoring and intelligent adjustment of the welding process, thereby improving the stability and consistency of the welding process and reducing errors and risks caused by human factors. By establishing a model to test the laws of thermal deformation and mastering the methods of controlling thermal deformation, we can effectively break through the difficulties of thermal deformation control technology, thereby reducing the amount of thermal deformation during welding and improving welding accuracy and product quality.
[0036] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Various modifications and variations are possible for those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.
Claims
1. A marine propeller blade cladding welding robot, characterized by: The cladding welding robot comprises two groups of cladding welding robots separated on both sides of the propeller blade, and the cladding welding robot comprises: Base (3); A three-axis slide (5), the three-axis slide (5) being arranged on the base (3), and a second bracket (81) being arranged at the output end of the three-axis slide (5); A laser welder (1), the laser welder (1) having a laser welding gun head (8), the laser welding gun head (8) being mounted on the second bracket (81); A wire feeder (2), the wire feeder (2) being arranged on one side of the base (3), the wire feeder (2) being used to feed the welding wire to the position of the laser welding gun head (8); An operating table (4) is provided on one side of the base (3), and a PLC control system is provided on the operating table (4).
2. The marine propeller blade cladding welding robot according to claim 1, characterized in that: The three-axis slide (5) includes a first bracket (51) fixedly mounted on the base (3), a first motor (52) fixedly mounted on the first bracket (51), a second pulley fixedly mounted on the output end of the first motor (52), a first pulley (53) mounted on a bearing on the first bracket (51), and a belt is provided between the first pulley (53) and the second pulley for transmission; A rotating shaft is fixedly mounted on the first pulley (53), and a stand (54) is fixedly mounted on the output end of the rotating shaft.
3. The marine propeller blade cladding welding robot according to claim 2, characterized in that: A second motor (55) is fixedly mounted on the top of the stand (54), a first screw rod is fixedly mounted on the output end of the second motor (55), and a bearing of the first screw rod is mounted on the stand (54); A vertical first slideway is provided on the stand (54), a first slider (56) is slidably provided on the first slideway, and the first slider (56) is transmission-connected to the first screw rod.
4. The marine propeller blade cladding welding robot according to claim 3, characterized in that: A cross frame (57) is fixedly mounted on the first slider (56), a third motor (58) is fixedly mounted on one end of the cross frame (57) distal to the propeller blade, and a second screw is fixedly mounted on the output end of the second motor (55), wherein a bearing of the second screw is mounted on the cross frame (57).
5. The marine propeller blade cladding welding robot according to claim 4, characterized in that: A second slideway in the horizontal direction is provided on the horizontal frame (57), a second slider (510) is slidably provided on the second slideway, and the second slider (510) is transmission-connected to the second screw rod.
6. The marine propeller blade cladding welding robot according to claim 5, characterized in that: A mounting frame (511) is fixedly provided on the second sliding block (510), and the second bracket (81) is fixedly mounted on the mounting frame (511).
7. The marine propeller blade cladding welding robot according to claim 6, characterized in that: The laser welder (1) has an optical fiber (11), and the optical fiber (11) is connected to the laser welding gun head (8).
8. The marine propeller blade cladding welding robot according to claim 7, characterized in that: The wire feeder (2) comprises a wire feeding frame (21) placed on the ground, a wire feeding reel (22) being rotatably arranged on the wire feeding frame (21), and welding wire being wound on the wire feeding reel (22).
9. The marine propeller blade cladding welding robot according to claim 8, characterized in that: A third bracket (91) is provided on the second bracket (81), a wire feeding gun (9) is mounted on the third bracket (91), and a wire feeding tube (24) is connected between the wire feeding gun (9) and the wire feeding frame (21).
10. The marine propeller blade cladding welding robot according to claim 9, characterized in that: A position sensor (7) is fixedly mounted on the second slider (510), and the position sensor (7) is adapted to move synchronously with the welding head of the laser welding gun head (8) to collect the position of the laser welding gun head (8) in real time.