Method for repairing deformed steel joint through laser additive based on man-machine interaction

Abstract

The invention discloses a man-machine interaction-based deformed steel joint laser additive repairing method, which combines a man-machine interaction technology and a laser additive repairing technology, and overcomes the problems of insufficient repairing precision, low repairing efficiency and the like of a traditional repairing method in a complex environment. The whole process covers three core links of damage identification and data acquisition, man-machine interaction and repair parameter optimization and program setting and laser cladding, and efficient, accurate and intelligent repair operation is achieved. The invention relates to the technical field of steel structure repairing.

Description

Technical Field

[0001] The present application relates to the technical field of steel structure repair, and in particular to a method for repairing special-shaped steel nodes by laser additive manufacturing based on human-computer interaction. Background Art

[0002] With the increasing complexity of modern engineering structures and the harshness of their operating environments, the repair of special-shaped steel nodes under complex working conditions has gradually become a long-standing problem faced by the engineering field. As key connecting components in engineering structures such as bridges and buildings, special-shaped steel nodes are subjected to complex working conditions such as high loads, corrosion, fatigue, and impact for a long time. They are prone to damage such as cracks, wear, and deformation, which seriously threaten the safety and service life of the structure. Especially in complex environments such as extreme loads, confined spaces, and high-altitude operations, the difficulty of repairing special-shaped steel nodes is further increased. Traditional repair methods mostly rely on manual operation or mechanical equipment. However, under these complex working conditions, traditional methods often have problems such as low precision, cumbersome processes, or low efficiency, making it difficult to meet actual engineering needs.

[0003] Laser cladding (LC), an advanced manufacturing technology, offers a new solution for repairing irregular steel joints. Its principle is to use a high-energy laser beam to melt and deposit metal powder layer by layer, creating a repair layer at the damaged site with properties comparable to the base material. LC technology offers advantages such as high precision, high efficiency, and high material utilization, and has shown great potential in the field of steel structure repair. However, LC technology still faces several limitations in the repair of irregular steel joints under complex working conditions. First, irregular steel joints are structurally complex, and damaged areas are irregularly shaped and unevenly distributed. This is particularly true under extreme loads, confined spaces, and high-altitude working environments, making the scanning path for repairing irregular steel joints even more complex. Relying solely on robotic precision control cannot meet these requirements, potentially resulting in insufficient repair accuracy or unsatisfactory results. Second, the repair environment under complex working conditions is highly variable, such as temperature fluctuations and vibration interference. These factors place higher demands on the stability of the repair process. Pre-set automated programs struggle to dynamically adapt to these changes, potentially causing repair parameters to deviate from the optimal range, impacting repair quality. Finally, the ability to monitor the structural status of the LC repair process is insufficient in real time. Real-time monitoring and feedback mechanisms for key parameters such as melt pool temperature and morphology are not yet fully developed, making it difficult to fully control the repair quality. This can lead to repair defects or anomalies not being discovered and corrected in a timely manner. These limitations, to a certain extent, restrict the widespread application of LC technology for repairing special-shaped steel joints under complex working conditions, and further optimization and breakthroughs are needed through technological innovation. Summary of the Invention

[0004] This application aims to solve at least one of the technical problems existing in the prior art. To this end, this application proposes a laser additive repair method for special-shaped steel nodes based on human-machine interaction, which can perform efficient and accurate special-shaped steel node repair under complex working conditions, overcoming the shortcomings of the prior art.

[0005] According to an embodiment of the present application, a laser additive repair method for special-shaped steel nodes based on human-computer interaction includes the following steps:

[0006] Use a surround-view camera to perform a 360° pre-scan of the special-shaped steel node to quickly capture panoramic information of the damaged area;

[0007] Scanning the special-shaped steel node at top, side and oblique angles using a laser scanner;

[0008] Transmitting the scan data to a remote operation platform, fusing the scan data from different devices, and quantifying the damage depth of the special-shaped steel node;

[0009] Perform unified registration, noise reduction, and fine-tuning on the fused data to generate a visual 3D model;

[0010] Arrange sensors around the special-shaped steel nodes to build a real-time monitoring system;

[0011] Starting the laser cladding system to melt the special-shaped steel node, while the real-time monitoring system monitors the molten pool temperature and stress distribution of the special-shaped steel node, and transmits the monitoring results to the remote operation platform;

[0012] Based on the monitoring results, the staff adjusted the laser power and scanning path to ensure that there were no obvious cracks in the repair area and that the cladding layer was uniform.

[0013] The human-machine interaction-based laser additive repair method for special-shaped steel joints according to the embodiments of this application has at least the following beneficial effects: By combining human-machine interaction with laser additive repair technology, this invention overcomes the problems of traditional repair methods, such as insufficient precision and low efficiency in complex environments. The overall process encompasses three core steps: damage identification and data collection; human-machine interaction and repair parameter optimization; and program setting and laser cladding, achieving efficient, accurate, and intelligent repair operations.

[0014] According to some embodiments of the present application, when scanning the special-shaped steel node, for the back side of the special-shaped steel node that is completely blocked, symmetrical mirror mapping is performed based on the scanning model of the laser scanner to obtain a model of the back side that is completely blocked.

[0015] According to some embodiments of the present application, the remote operation platform performs program setting and algorithm analysis on the monitoring results to evaluate the dynamic response during the repair process.

[0016] According to some embodiments of the present application, the powder feeding rate of the laser cladding system is set to 16 to 18 g / min, the scanning speed is 1.2 mm / min, and the power of the laser transmitter is 2200 W.

[0017] According to some embodiments of the present application, the laser cladding system includes a five-axis robot, a powder feeder and a laser emitter. The powder feeder and the laser emitter are both installed at the end of the five-axis robot. The five-axis robot adjusts its posture through five-axis linkage to ensure that the powder delivered by the powder feeder adheres to the damaged area of ​​the special-shaped steel node, and the laser emitted by the laser emitter melts and consolidates the powder.

[0018] According to some embodiments of the present application, the powder feeder and the laser emitter are coaxially arranged.

[0019] According to some embodiments of the present application, the thickness of each cladding layer of the laser cladding system is 0.9 to 1.1 mm.

[0020] According to some embodiments of the present application, the molten pool temperature of the laser cladding system is 1500 to 2000°C.

[0021] According to some embodiments of the present application, each time the laser cladding system completes the forming of a cladding layer, the laser cladding system cools down and controls the interlayer temperature to be lower than 200°C.

[0022] According to some embodiments of the present application, the real-time monitoring system includes a fiber Bragg grating sensor, which captures changes in the temperature field of the molten pool at a rate of 1000 frames per second.

[0023] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become obvious from the description below, or will be learned through practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings are used to provide a further understanding of the technical solutions disclosed in this application and constitute a part of the specification. Together with the embodiments disclosed in this application, they are used to explain the technical solutions disclosed in this application and do not constitute a limitation on the technical solutions disclosed in this application.

[0025] Figure 1 This is a flow chart of a method for repairing special-shaped steel nodes with laser additive manufacturing based on human-computer interaction according to an embodiment of the present application;

[0026] Figure 2 This is a three-dimensional diagram of the special-shaped steel node in the example;

[0027] Figure 3 This is a top view of the special-shaped steel node in the example. DETAILED DESCRIPTION

[0028] The following describes in detail embodiments of the present application. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present application and are not to be construed as limiting the present application.

[0029] In the description of this application, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on this application.

[0030] In the description of this application, "several" means more than one, "plurality" means more than two, "greater than," "less than," and "exceed" are understood to exclude the number itself, while "above," "below," and "within" are understood to include the number itself. The use of "first" and "second" in the description is solely for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0031] In the description of this application, unless otherwise clearly defined, terms such as setting, installing, and connecting should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in this application based on the specific content of the technical solution.

[0032] In the description of this application, reference to the terms "one embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of this application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any appropriate manner in any one or more embodiments or examples.

[0033] With the increasing complexity of modern engineering structures and the harshness of their operating environments, the repair of special-shaped steel nodes under complex working conditions has gradually become a long-standing problem faced by the engineering field. As key connecting components in engineering structures such as bridges and buildings, special-shaped steel nodes are subjected to complex working conditions such as high loads, corrosion, fatigue, and impact for a long time. They are prone to damage such as cracks, wear, and deformation, which seriously threaten the safety and service life of the structure. Especially in complex environments such as extreme loads, confined spaces, and high-altitude operations, the difficulty of repairing special-shaped steel nodes is further increased. Traditional repair methods mostly rely on manual operation or mechanical equipment. However, under these complex working conditions, traditional methods often have problems such as low precision, cumbersome processes, or low efficiency, making it difficult to meet actual engineering needs.

[0034] Laser cladding (LC), an advanced manufacturing technology, offers a new solution for repairing irregular steel joints. Its principle is to use a high-energy laser beam to melt and deposit metal powder layer by layer, creating a repair layer at the damaged site with properties comparable to the base material. LC technology offers advantages such as high precision, high efficiency, and high material utilization, and has shown great potential in the field of steel structure repair. However, LC technology still faces several limitations in the repair of irregular steel joints under complex working conditions. First, irregular steel joints are structurally complex, and damaged areas are irregularly shaped and unevenly distributed. This is particularly true under extreme loads, confined spaces, and high-altitude working environments, making the scanning path for repairing irregular steel joints even more complex. Relying solely on robotic precision control cannot meet these requirements, potentially resulting in insufficient repair accuracy or unsatisfactory results. Second, the repair environment under complex working conditions is highly variable, such as temperature fluctuations and vibration interference. These factors place higher demands on the stability of the repair process. Pre-set automated programs struggle to dynamically adapt to these changes, potentially causing repair parameters to deviate from the optimal range, impacting repair quality. Finally, the ability to monitor the structural status of the LC repair process is insufficient in real time. Real-time monitoring and feedback mechanisms for key parameters such as melt pool temperature and morphology are not yet fully developed, making it difficult to fully control the repair quality. This can lead to repair defects or anomalies not being discovered and corrected in a timely manner. These limitations, to a certain extent, restrict the widespread application of LC technology for repairing special-shaped steel joints under complex working conditions, and further optimization and breakthroughs are needed through technological innovation.

[0035] On the other hand, human-computer interaction (HCI) technology, serving as a bridge between humans and computers, offers new insights into addressing the limitations of LC technology in the repair of special-shaped steel joints under complex working conditions. By applying HCI technology to the LC repair process, repair efficiency and quality can be effectively improved. First, 3D scanning and modeling techniques can rapidly acquire 3D topographic data of the damaged area. This, combined with a human-computer interface, allows for intuitive repair path planning, simplifying the complexity of repair path planning. Second, machine learning algorithms can establish a mapping between repair parameters and repair quality. This, combined with a human-computer interface, allows for real-time parameter adjustment and optimization, addressing the difficulty of optimizing repair parameters. Furthermore, intelligent wireless sensors, high-speed cameras, and other devices can monitor key parameters during the repair process in real time. This, combined with a human-computer interface, allows for visual display and early warning, enabling online monitoring and control of repair quality. Finally, by developing a user-friendly human-computer interface, the operation of LC repair equipment can be simplified, reducing operational complexity and improving repair efficiency.

[0036] Therefore, this application proposes a laser additive repair method for special-shaped steel joints based on human-machine interaction. This method combines human-machine interaction with laser additive repair technology, overcoming the limitations of traditional repair methods in complex environments, including insufficient precision and inefficiency. The overall process encompasses three core steps: damage identification and data collection; human-machine interaction and repair parameter optimization; and program setting and laser cladding. This enables efficient, precise, and intelligent repair operations.

[0037] In this application, special-shaped steel nodes refer to steel node structures with complex and multiple welding points. Figure 2 and Figure 3 , take this steel node as an example. It is a special-shaped steel node composed of two upper and lower regular hexagonal plates and six outward-extending corbels, which is used for deep-sea drilling platforms. The node is located at the connection between the main support structure of the platform and the peripheral equipment. Its core function is to evenly distribute dynamic loads (such as wave impact, equipment vibration) and support the main structure and peripheral equipment. The six corbels are distributed radially and symmetrically, and the load is transferred through a rectangular cross-section to ensure the overall stability of the platform. The node is located in a high-altitude working area (about 60 meters from sea level), and is exposed to high salt spray, high humidity and extreme temperature fluctuations all year round, which leads to increased structural corrosion and fatigue damage. The repair work needs to be completed in a small space and must avoid affecting the normal operation of the platform.

[0038] The center of the node to be repaired is a solid hexahedron, 2.5 meters tall. Flanked by 0.8-meter-long hexagonal plates made of Q355 low-alloy, high-strength structural steel, are hexagonal plates above and below. Corbels are located 0.5 meters above and below the hexagonal plates and extend 2 meters outward. These closed rectangular tubes, measuring 0.8 meters wide by 1.5 meters high, are made of the same material as the hexagonal plates.

[0039] The inventive concept of the present application is described using the special-shaped steel node in the above example, but it should be noted that the present application is not limited to this specific steel node structure, and the present application does not make any specific limitation on the steel node structure.

[0040] Reference Figure 1 The laser additive repair method for special-shaped steel nodes based on human-computer interaction in the embodiment of the present application includes the following steps:

[0041] S100. Use a surround-view camera to perform a 360° pre-scan of the special-shaped steel node to quickly capture panoramic information of the damaged area;

[0042] S200. Use a laser scanner to scan the special-shaped steel node from top, side, and oblique angles. The laser scanner has an accuracy of ±0.02mm.

[0043] S300 transmits scan data to a remote operation platform and fuses scan data from different devices. It can then combine AI algorithms to quantify the damage depth of special-shaped steel nodes and assess bearing capacity loss.

[0044] S400. The fused data is uniformly registered, denoised, and fine-tuned to generate a visual 3D model. The operator reviews and re-scans any missing locations. The system plans the cladding path based on the geometric features of the marked damaged area.

[0045] S500. Install sensors around the special-shaped steel nodes and build a real-time monitoring system;

[0046] S600. Start the laser cladding system to melt the special-shaped steel nodes. At the same time, the real-time monitoring system monitors the molten pool temperature and stress distribution of the special-shaped steel nodes and transmits the monitoring results to the remote operation platform.

[0047] S700. The staff adjusted the laser power and scanning path based on the monitoring results and recorded the optimized parameters to ensure that there were no obvious cracks in the repair area and that the cladding layer was uniform.

[0048] Specifically, when scanning a special-shaped steel node, it may be impossible to scan the completely obscured back side of the node, resulting in the loss of some model features. Therefore, a symmetrical mirror mapping can be performed based on the laser scanner's scanned model. Using the scannable front side, the completely obscured back side model can be mirrored to obtain a complete model.

[0049] Furthermore, after receiving the monitoring results from the real-time monitoring system, the remote operation platform performs program setting and algorithm analysis on the monitoring results to evaluate the dynamic response during the repair process.

[0050] Furthermore, the laser cladding system includes a five-axis robot, a powder feeder and a laser emitter. The powder feeder and the laser emitter are both installed at the end of the five-axis robot. The five-axis robot adjusts its posture through five-axis linkage to ensure that the powder delivered by the powder feeder adheres to the damaged area of ​​the special-shaped steel node, and the laser emitted by the laser emitter melts and consolidates the powder.

[0051] Furthermore, the powder feeding rate of the laser cladding system was set to 16 to 18 g / min, the scanning speed was 1.2 mm / min, and the power of the laser transmitter was 2200 W.

[0052] Furthermore, the powder feeder and the laser emitter are coaxially arranged, so that the powder feeding direction is consistent with the laser direction of the laser emitter.

[0053] Furthermore, the thickness of each cladding layer of the laser cladding system is 0.9 to 1.1 mm, and the molten pool temperature of the laser cladding system is 1500 to 2000°C.

[0054] Furthermore, each time the laser cladding system completes the forming of a cladding layer, the laser cladding system cools down and controls the interlayer temperature to be lower than 200°C to avoid deformation caused by accumulation of thermal stress.

[0055] Furthermore, the real-time monitoring system includes a fiber grating sensor, which captures changes in the molten pool temperature field at a rate of 1000 frames per second and has a higher refresh rate, thereby accurately monitoring changes in the molten pool temperature field.

[0056] The embodiments of the present application have been described in detail above with reference to the accompanying drawings. However, the present application is not limited to the above embodiments. Various modifications can be made within the scope of knowledge possessed by ordinary technicians in the relevant technical field without departing from the purpose of the present application. In addition, the embodiments of the present application and the features of the embodiments can be combined with each other unless there is a conflict.

Claims

1. A laser additive repair method for special-shaped steel nodes based on human-computer interaction, characterized in that: include: Use a surround-view camera to perform a 360° pre-scan of the special-shaped steel node to quickly capture panoramic information of the damaged area; Scanning the special-shaped steel node at top, side and oblique angles using a laser scanner; Transmitting the scan data to a remote operation platform, fusing the scan data from different devices, and quantifying the damage depth of the special-shaped steel node; Perform unified registration, noise reduction, and fine-tuning on the fused data to generate a visual 3D model; Arrange sensors around the special-shaped steel nodes to build a real-time monitoring system; Starting the laser cladding system to melt the special-shaped steel node, while the real-time monitoring system monitors the molten pool temperature and stress distribution of the special-shaped steel node, and transmits the monitoring results to the remote operation platform; Based on the monitoring results, the staff adjusted the laser power and scanning path to ensure that there were no obvious cracks in the repair area and that the cladding layer was uniform.

2. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1 is characterized in that: When scanning the special-shaped steel node, for the back side of the special-shaped steel node that is completely blocked, symmetrical mirror mapping is performed based on the scanning model of the laser scanner to obtain a model of the back side that is completely blocked.

3. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1 is characterized in that: The remote operation platform performs program setting and algorithm analysis on the monitoring results to evaluate the dynamic response during the repair process.

4. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1 is characterized in that: The laser cladding system includes a five-axis robot, a powder feeder and a laser emitter. The powder feeder and the laser emitter are both installed at the end of the five-axis robot. The five-axis robot adjusts its posture through five-axis linkage to ensure that the powder delivered by the powder feeder adheres to the damaged area of ​​the special-shaped steel node, and the laser emitted by the laser emitter melts and consolidates the powder.

5. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 4 is characterized in that: The powder feeder and the laser emitter are coaxially arranged.

6. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 4 is characterized in that: The powder feeding rate of the laser cladding system was set to 16 to 18 g / min, the scanning speed was 1.2 mm / min, and the power of the laser transmitter was 2200 W.

7. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1 is characterized in that: The thickness of each cladding layer of the laser cladding system is 0.9 to 1.1 mm.

8. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1 is characterized in that: The molten pool temperature of the laser cladding system is 1500 to 2000°C.

9. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1, characterized in that: Each time the laser cladding system completes the forming work of a cladding layer, the laser cladding system cools down and controls the interlayer temperature to be lower than 200°C.

10. The laser additive repair method for special-shaped steel nodes based on human-computer interaction according to claim 1, characterized in that: The real-time monitoring system includes a fiber grating sensor, which captures changes in the temperature field of the molten pool at a rate of 1000 frames per second.

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