A method for repairing wear-resistant steel and a method for preparing repair materials.

Abstract

This application provides a method for repairing wear-resistant steel and a method for preparing repair materials. The method includes: determining the depth to be repaired of the concave surface and the width to be repaired of each weld layer; determining repair parameters based on a preset repair parameter correspondence, the depth to be repaired, and the width to be repaired of each weld layer; and controlling the feeding system and welding system based on the repair parameters to repair the concave surface. No manual intervention is required. Based on the repair parameter correspondence determined through creative labor, the repair parameters used for repair can be determined automatically, enabling the feeding system and welding system to repair the concave surface based on the repair parameters. This significantly reduces the workload of welding operators, improves repair efficiency, and ensures the stability of the repair effect.

Description

Technical Field

[0001] This application relates to the field of wear-resistant parts repair technology, and in particular to a method for repairing wear-resistant steel and a method for preparing repair materials. Background Technology

[0002] Wear-resistant steel is widely used in machinery such as coal mining machines and agricultural machinery due to its high wear resistance. However, after a certain period of use, wear-resistant steel will inevitably experience localized wear due to impact wear, friction wear, and other reasons. This wear results in a large consumption of energy and raw materials, causing significant economic losses and steel consumption. Figure 1 As shown, the wear-resistant steel exhibits a wear surface with a width of 'a' and a length of 'b'. Figure 2 As shown, the wear surface of the wear-resistant steel is concave, with a depth of h. If the wear-resistant steel is not replaced in time, it may be worn through, severely affecting equipment operation. However, replacing the wear-resistant steel is often very expensive; therefore, localized welding repair is generally the preferred option.

[0003] However, existing partial welding repairs are done manually, which is not only inefficient, but also affects the repair results due to the welding experience of the operators. Summary of the Invention

[0004] This application provides a method for repairing wear-resistant steel, as well as a method, apparatus, equipment, storage medium, and product for preparing repair materials, which can solve the technical problems of low repair efficiency and unstable repair effect caused by manual repair.

[0005] In a first aspect, this application provides a method for repairing wear-resistant steel, the method comprising:

[0006] Remove the fatigue layer of the wear-resistant steel to be repaired to obtain the concave surface to be repaired;

[0007] Determine the repair depth of the concave surface to be repaired and the repair width of each weld layer;

[0008] Based on the preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer, repair parameters are determined. The repair parameters include the number of weld beads in each weld layer, the required thickness of the repair material to be delivered for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the width to be repaired, a second correspondence between the delivery thickness and the thickness of the weld overlay, and a third correspondence between the welding current and the thickness of the weld overlay.

[0009] Based on the repair parameters, the feeding system and welding system are controlled to repair the concave surface to be repaired.

[0010] In some possible implementations, the included angle between the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired is 120° to 150°.

[0011] In some possible implementations, determining the repair depth of the concave surface and the repair width of each weld layer specifically includes:

[0012] The laser detection system is controlled to scan the concave surface to be repaired, thereby obtaining the depth to be repaired and the width of the surface to be repaired.

[0013] Based on the depth to be repaired and the preset weld overlay thickness range, determine the target thickness of each weld overlay.

[0014] Based on the surface layer width to be repaired, the target thickness, and the included angle, the width to be repaired for each weld overlay layer other than the surface weld overlay layer is determined.

[0015] In some possible implementations, the repair width of each weld overlay layer, excluding the surface weld overlay layer, is determined based on the surface weld overlay width to be repaired, the target thickness, and the included angle. Specifically, this includes:

[0016] The width increment is determined based on the target thickness and the included angle, and the width increment is the width difference between two adjacent weld overlay layers;

[0017] For each weld overlay except the surface weld overlay, the target increment of the weld overlay is determined based on the width increment and the difference in the number of layers between the weld overlay and the surface weld overlay.

[0018] Based on the surface layer width to be repaired and the target increment of each weld layer other than the surface weld overlay, the width to be repaired for each weld layer other than the surface weld overlay is determined.

[0019] In some possible implementations, the width increment = target thickness * tan(angle - 90 degrees);

[0020] For each weld overlay except the surface weld overlay, the width to be repaired for that weld overlay is equal to the width to be repaired for the surface weld overlay minus the target increment.

[0021] In some possible implementations, the repair parameters are determined based on a preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer. Specifically, this includes:

[0022] For each weld bead stack, the weld width is determined based on the width to be repaired and the preset weld width range.

[0023] Based on the width to be repaired of the weld overlay, the weld width of the weld overlay, and the first correspondence, the number of weld passes of the weld overlay is determined. When the width to be repaired of the weld overlay is less than a first preset value, the preset weld width range is a preset first range. When the width to be repaired of the weld overlay is not less than the first preset value, the preset weld width range is a preset second range. The maximum value of the preset first range is not greater than the minimum value of the preset second range. The first correspondence is that the width to be repaired of the weld overlay is positively correlated with the number of weld passes of the weld overlay.

[0024] For each weld overlay, the required thickness of the repair material is determined based on the target thickness of the weld overlay, the preset delivery coefficient, and the second correspondence. The second correspondence is that the delivery thickness is positively correlated with the target thickness, and the target thickness is determined based on the depth to be repaired.

[0025] For each weld bead in the weld bead layer, the welding current of the weld bead in the weld bead layer is determined according to the preset current coefficient, the target thickness of the weld bead layer and the third correspondence relationship, wherein the third correspondence relationship is that the welding current is positively correlated with the target thickness.

[0026] In some possible implementations, the number of weld passes = width to be repaired / weld width.

[0027] In some possible implementations, the welding method used by the welding system includes tungsten inert gas (TIG) welding.

[0028] In some possible implementations, repairing the concave surface to be repaired specifically includes:

[0029] For each weld layer on the concave surface to be repaired, perform the following operations until each weld layer is repaired:

[0030] Repair the weld overlay based on the number of weld beads, the required thickness of the repair material, and the welding current of the weld.

[0031] The method further includes:

[0032] Inspect the weld overlay to check for weld repair quality issues;

[0033] If so, the weld overlay should be ground and cleaned, and then repaired by welding.

[0034] Secondly, this application provides a method for preparing a repair material for wear-resistant steel, wherein the repair material is applied to the above-mentioned repair method for wear-resistant steel, and the method includes:

[0035] The composition of the alloy powder is determined based on the composition and hardness of the wear-resistant steel to be repaired.

[0036] Prepare alloy powder according to the alloy powder composition;

[0037] The alloy powder is fused with an adhesive to obtain a fluid repair material.

[0038] Thirdly, this application provides a repair system for wear-resistant steel, the system comprising: a control system, a feeding system, and a welding system, wherein:

[0039] The control system is used to determine the repair depth of the concave surface to be repaired and the repair width of each weld layer. Based on the preset repair parameter correspondence, the repair depth, and the repair width of each weld layer, repair parameters are determined and sent to the feeding system and welding system to repair the concave surface. The repair parameters include the number of weld beads in each weld layer, the conveying thickness of the repair material required for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the repair width, a second correspondence between the conveying thickness and the thickness of the weld layer, and a third correspondence between the welding current and the thickness of the weld layer. The concave surface to be repaired is obtained by removing the fatigue layer of the wear-resistant steel to be repaired.

[0040] The feeding system and the welding system are used to receive repair parameters sent by the control system, and repair the concave surface to be repaired based on the repair parameters.

[0041] Fourthly, this application provides a repair device for wear-resistant steel, the device comprising:

[0042] The pre-processing module is used to remove the fatigue layer of the wear-resistant steel to be repaired, so as to obtain the concave surface to be repaired;

[0043] The basic parameter determination module is used to determine the repair depth of the concave surface to be repaired and the repair width of each weld layer;

[0044] The repair parameter determination module is used to determine repair parameters based on a preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer. The repair parameters include the number of weld beads in each weld layer, the thickness of the repair material to be delivered for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the width to be repaired, a second correspondence between the delivery thickness and the thickness of the weld overlay, and a third correspondence between the welding current and the thickness of the weld overlay.

[0045] The repair module is used to control the feeding system and welding system to repair the concave surface to be repaired based on the repair parameters.

[0046] Fifthly, this application provides an apparatus for preparing a repair material for wear-resistant steel, wherein the repair material is applied to the aforementioned repair method for wear-resistant steel, and the apparatus includes:

[0047] The composition determination module is used to determine the composition of the alloy powder based on the composition and hardness of the wear-resistant steel to be repaired.

[0048] A configuration module is used to prepare alloy powder according to the composition of the alloy powder;

[0049] A fusion module is used to fuse the alloy powder with an adhesive to obtain a fluid repair material.

[0050] Sixthly, this application provides a repair device for wear-resistant steel, the device comprising: a processor, and a memory storing computer program instructions; the processor reads and executes the computer program instructions to implement the repair method for wear-resistant steel as described above.

[0051] In a seventh aspect, this application provides a computer-readable storage medium storing computer program instructions, which, when executed by a processor, implement the wear-resistant steel repair method described above.

[0052] Eighthly, this application provides a computer program product in which instructions, when executed by the processor of an electronic device, cause the electronic device to perform the wear-resistant steel repair method described above.

[0053] The repair method, preparation method, apparatus, equipment, storage medium, and products for wear-resistant steel provided in this application embodiment require no manual intervention. By automatically removing the fatigue layer of the wear-resistant steel, the repair effect and service life of the wear-resistant steel are improved. This prevents the fatigue cracks in the fatigue layer from being transmitted to other undamaged areas, thus reducing the service life of the repaired wear-resistant steel. Because the correspondence between various repair parameters used in the repair process is pre-set, subsequent use does not require a significant amount of time to determine the repair parameters. Based on the pre-set correspondence, the repair parameters used for repair are determined automatically, reducing the time required for parameter determination. This facilitates the feeding system and welding system in repairing the concave surface based on the repair parameters, greatly reducing the workload of welding operators, improving repair efficiency, and ensuring the stability of the repair effect. Attached Figure Description

[0054] This application can be better understood from the following description of specific embodiments in conjunction with the accompanying drawings, wherein:

[0055] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings, wherein the same or similar reference numerals denote the same or similar features.

[0056] Figure 1 A schematic diagram of the wear surface of a wear-resistant steel provided in an embodiment of this application;

[0057] Figure 2 This is a schematic diagram of a concave wear surface provided in an embodiment of this application;

[0058] Figure 3 This is a schematic flowchart of the repair method for wear-resistant steel provided in the embodiments of this application;

[0059] Figure 4 This application provides a schematic diagram of a concave surface to be repaired.

[0060] Figure 5 This is a schematic diagram of another concave surface to be repaired, provided in an embodiment of this application.

[0061] Figure 6 A schematic diagram of width increment provided for an embodiment of this application;

[0062] Figure 7 A schematic diagram of a concave surface to be repaired with three layers of weld overlay provided in this application embodiment;

[0063] Figure 8 This application provides an example of a repaired effect diagram;

[0064] Figure 9 A schematic flowchart illustrating a method for preparing a wear-resistant steel repair material according to an embodiment of this application;

[0065] Figure 10 A schematic diagram of a wear-resistant steel with a short operating time provided for an embodiment of this application;

[0066] Figure 11 This is a schematic diagram of a polished concave surface provided in an embodiment of this application;

[0067] Figure 12 A schematic diagram of a wear-resistant steel with a long operating time provided for an embodiment of this application;

[0068] Figure 13 This is a schematic diagram of another polished concave surface provided in an embodiment of this application;

[0069] Figure 14 A schematic diagram of a wear-resistant steel with a long operating time provided for an embodiment of this application;

[0070] Figure 15This is a schematic diagram of another polished concave surface provided in an embodiment of this application;

[0071] Figure 16 This is a schematic diagram of the structure of a wear-resistant steel repair device provided in one embodiment of this application;

[0072] Figure 17 This is a schematic diagram of the hardware structure of the wear-resistant steel repair device provided in the embodiments of this application. Detailed Implementation

[0073] The features and exemplary embodiments of various aspects of this application will be described in detail below. To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain this application and not to limit it. For those skilled in the art, this application can be implemented without some of these specific details. The following description of the embodiments is merely to provide a better understanding of this application by illustrating examples.

[0074] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes said element.

[0075] Although wear-resistant steel has high wear resistance, it can still be worn down due to harsh working environments, resulting in defects such as… Figure 1 and Figure 2 The worn surface is shown. To reduce repair costs, localized welding repair is generally chosen. However, existing localized welding repair methods are manual, resulting in low repair efficiency, and the welding experience of the operators affects the repair effect.

[0076] To address the problems of existing technologies, this application provides a method for repairing wear-resistant steel, as well as a method, apparatus, equipment, storage medium, and product for preparing repair materials. In preparing the repair materials, an adhesive is used to prepare an alloy powder for repairing wear-resistant steel into a paste-like alloy. The original concave surface is then ground and cleaned to remove the fatigue layer, resulting in the concave surface to be repaired. The depth, length, and width of the concave surface are measured. Repair parameters are then determined through a preset repair parameter correspondence. Finally, a feeding system, a welding system, and a manual or laser inspection system are alternately used to perform feeding, welding, and inspection operations to complete the repair. The method for repairing wear-resistant steel provided in this application is described below.

[0077] Figure 3 A schematic flowchart of the repair method for wear-resistant steel provided in an embodiment of this application is shown. Figure 1 As shown, the method is applied to a control system and may include the following steps: S101 to S104.

[0078] S101: Remove the fatigue layer of the wear-resistant steel to be repaired to obtain the concave surface to be repaired.

[0079] In this embodiment, the fatigue layer is distributed on the surface of the original concave surface of the wear-resistant steel to be repaired. Removing the fatigue layer from the original concave surface of the wear-resistant steel before repair can significantly improve the bonding strength between the old and new materials and reduce the risk of delamination or peeling. Furthermore, the fatigue layer typically contains fine cracks; removing the fatigue layer can prevent these cracks from further propagating to other intact areas during use, thus avoiding impacting the safety and stability of the entire repaired area and even the entire wear-resistant steel.

[0080] Specifically, the control system can use a grinding machine or manually to grind the original concave surface of the wear-resistant steel to be repaired for a preset time to remove the fatigue layer. Generally, the removal of any fatigue cracks is sufficient. The presence of fatigue cracks can be determined using penetrant testing. For example, a colorant can be sprayed onto the wear-resistant steel; monitoring the concave surface for color development indicates the presence of cracks. If a colorant is present, it indicates the existence of fatigue cracks, and grinding should continue. If not, grinding can be stopped.

[0081] Of course, the grinding depth and width can also be set based on experience. Generally speaking, both the grinding depth and width are positively correlated with the time the wear-resistant steel has been used. If the wear-resistant steel has been used for a short time and the wear is relatively minor, and the fatigue layer on the original concave surface is thin, then the grinding depth is shallow and the grinding width is narrow. Conversely, if the usage time is longer, the grinding depth is deeper and the grinding width is wider.

[0082] During grinding, based on experience, a pre-defined area and depth can be ground at the center of the bottom of the original concave surface. This pre-defined area can be any area within a range of 7850–31400 mm². If this area is a circle, the diameter of the circle will range from 50–100 mm. The pre-defined depth can also be any depth within a range of 1–15 mm. Therefore, for workpieces with severe wear, the fatigue layer is generally thicker, with a pre-defined depth range of 8–15 mm; for workpieces with less wear, the fatigue layer is generally thinner, with a pre-defined depth range of 1–8 mm. Then, non-destructive testing methods such as dye penetrant testing and magnetic particle testing are used to detect internal defects such as fatigue cracks. If defects are found, grinding continues until the defects pass the testing. After grinding, the concave surface to be repaired can be cleaned to remove grinding debris.

[0083] Figure 4 This application provides a schematic diagram of a concave surface to be repaired, as shown in the embodiment. Figure 4 As shown.

[0084] The dashed line in the concave surface represents the original depth contour of the concave surface, and the solid line below the dashed line represents the contour of the concave surface to be repaired. The original depth h of the original concave surface is the distance from the unworn surface (wear-resistant steel surface) to the depth contour of the original concave surface. The depth to be repaired H (depth after grinding) is the distance from the unworn surface to the contour of the concave surface to be repaired. The width between the left and right ends of the depth contour of the original concave surface is the original width a, and the width to be repaired a' (the width to be repaired on the surface after grinding) is the width between the left and right ends of the contour of the concave surface to be repaired.

[0085] Before polishing, the original width of the original concave surface is a, and the original depth is h. After polishing, the surface width to be repaired of the concave surface is a', and the repair depth is H.

[0086] By grinding and cleaning the original concave surface to remove the fatigue layer, the bonding performance between the weld overlay repair layer and the substrate is ensured, ultimately guaranteeing the quality of the weld overlay repair.

[0087] S102: Determine the repair depth of the concave surface to be repaired and the repair width of each weld layer.

[0088] Specifically, the repair depth of the concave surface to be repaired and the repair width of each weld layer can be determined by either manual measurement, control system-controlled laser detection system scanning the concave surface to be repaired, or control system-controlled X-ray computed tomography (CT) technology scanning the concave surface to be repaired.

[0089] It should be noted that, based on the depth of the concave surface to be repaired, the concave surface can be divided into several weld overlay layers. Repairing each weld overlay layer helps improve the quality of the repaired wear-resistant steel. However, since the bottom of the concave surface is curved, the required repair width will differ for weld overlay layers at different depths. Therefore, when determining the required repair width, what is actually being determined is the required repair width for each individual weld overlay layer.

[0090] S103: Determine the repair parameters based on the preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer.

[0091] The repair parameters are those related to repairing the concave surface to be repaired. The aforementioned repair depth and repair width of each weld layer are the basic repair parameters. The repair parameters include the number of weld beads N in each weld layer, the required material delivery thickness h2 for each weld layer, and the welding current I of the weld seam in each weld layer. The preset repair parameter correspondences include a first correspondence between the number of weld beads and the repair width, a second correspondence between the delivery thickness and the weld overlay thickness h1, and a third correspondence between the welding current and the weld overlay thickness.

[0092] It is understandable that the number of weld passes is related to both the weld width and the width to be repaired. When the weld width is constant, the number of weld passes is positively correlated with the width to be repaired.

[0093] The conveyed thickness refers to the thickness of the weld overlay after it has been filled with repair material. Generally, because the density of the repair material is lower than that of the original material constituting the wear-resistant steel, the conveyed thickness is usually higher than the original thickness of the weld overlay before repair, so that the actual thickness of the repaired weld overlay matches the original thickness. Welding current refers to the current used during welding, and the welding current is positively correlated with the thickness of the weld overlay.

[0094] When determining repair parameters, the system can identify those that meet the requirements based on preset first, second, and third correspondences. Since these correspondences are preset, there is no need for manual on-site repair planning; the control system can automatically determine each repair parameter according to the preset correspondences, thus improving repair efficiency.

[0095] S104: Based on the repair parameters, control the feeding system and welding system to repair the concave surface to be repaired.

[0096] The control system sends the repair parameters to the feeding system and the welding system, so that the feeding system and the welding system can repair the concave surface to be repaired based on the repair parameters.

[0097] Specifically, the feeding system determines the required volume of repair material based on the thickness of the required repair material for the weld overlay, obtains the required volume of repair material, and transmits it to the welding system. The welding system places the repair material in the concave surface to be repaired and performs a smoothing operation to make the repaired weld overlay a smooth surface. Then, it repairs the concave surface according to the number of weld passes and welding current specified in the repair parameters.

[0098] The welding system may employ methods such as tungsten inert gas (TIG) welding, which uses an argon arc as the heat source to melt the repair material. Since the shielding gas in TIG welding is argon, an inert gas with no oxidizing properties, it significantly reduces the loss of alloying elements and produces minimal welding fumes, thus greatly improving the working environment for the repair work. When manual welding is used, this method reduces the amount of welding fumes that could harm the health of the welding operators due to the presence of manganese, chromium, and other alloying elements in the wear-resistant steel repair material, protecting their health.

[0099] Of course, other local welding repair methods such as shielded metal arc welding, flux-cored wire gas shielded welding, flame spraying, and laser cladding can also be used.

[0100] The wear-resistant steel repair method provided in this application eliminates the need for manual intervention during repair. By automatically removing the fatigue layer, the repair effect and service life of the wear-resistant steel are improved. This method prevents fatigue cracks from being transmitted to other undamaged areas due to the presence of the fatigue layer, thus reducing the service life of the repaired wear-resistant steel. Since the correspondence between various repair parameters is pre-set, subsequent use eliminates the need for extensive time to determine these parameters. Based on the pre-set correspondence, the repair parameters are determined automatically, reducing the time required for parameter determination. This facilitates the feeding and welding systems in repairing the concave surface based on the repair parameters, significantly reducing the workload of welding operators, improving repair efficiency, and ensuring the stability of the repair effect.

[0101] Regarding step S101, when the control system is controlling the grinding machine or continuing grinding, in order to ensure the bonding effect and repair quality of the edge of the worn area (original concave surface) during the weld repair process, the edge of the original concave surface can be ground to a certain bevel to ensure that the angle formed by the contact between the unworn surface and the original concave surface is an obtuse angle. This obtuse angle can be any angle between 120° and 150°. That is, the angle formed by the contact between the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired is 120° to 150°. Figure 4As shown, α and β are the included angles formed by the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired. During grinding, the included angles on the left and right sides can be the same or different, depending on the specific needs. This application embodiment does not impose any restrictions on this. That is, α and β can be equal or unequal. It should be noted that the wear-resistant steel to be repaired has multiple unworn surfaces, but the included angle is the included angle formed by the unworn surface that is in contact with the concave surface to be repaired. In this application embodiment, the unworn surface specifically refers to the unworn surface that is in contact with the concave surface to be repaired.

[0102] By grinding the angle formed by the original concave surface and the unworn surface of the wear-resistant steel to be repaired into an obtuse angle of 120°–150°, the contact area between the old and new materials is increased. This helps improve the mechanical bonding force during welding and also facilitates better filling and fusion of the welding material into the original material, ensuring a good metallurgical bond between the old and new materials and avoiding incomplete fusion defects. The obtuse angle design also disperses stress, reducing the risk of cracking. This is because sharp edges are prone to stress concentration, which can lead to crack initiation and propagation. The obtuse bevel provides a better entry angle for welding tools used in subsequent welding systems, making welding operations more convenient and efficient, especially important for complex shapes or hard-to-access locations.

[0103] For step S102, the control system can control the laser detection system to scan the concave surface to be repaired to obtain the repair depth and surface repair width of the concave surface; based on the repair depth and the preset weld overlay thickness range, the target thickness of each weld overlay is determined; based on the surface repair width, the target thickness and the included angle, the repair width of each weld overlay except the surface weld overlay is determined.

[0104] It is understandable that the width to be repaired includes the width to be repaired for each weld overlay. For the surface weld overlay, that is, the weld overlay whose top surface is flush with the wear-resistant steel surface, its width to be repaired can be called the surface weld overlay width.

[0105] The control system can also determine the repair depth and surface repair width of the concave surface to be repaired using X-ray computed tomography (CT) and image recognition technology. This application does not limit how the repair depth and surface repair width of the concave surface to be repaired are determined. For example, an image of the concave surface to be repaired can be acquired using an image acquisition device, and the concave surface contour line in the image can be identified using image recognition technology. Based on the distance between the left and right sides of the concave surface contour line, the height between the unworn surface and the bottom of the concave surface, and the intrinsic and extrinsic parameters of the image acquisition device, the repair depth and surface repair width of the concave surface to be repaired can be determined.

[0106] For weld overlays other than the surface weld overlay, when determining the width to be repaired, the control system can first determine the target thickness of each weld overlay so that the scanning equipment can determine the correspondence between the depth and the weld overlay. Based on the correspondence, the width to be repaired for each weld overlay can be determined.

[0107] Specifically, the control system can select a target weld overlay thickness within a preset range, and then divide the depth to be repaired based on this target thickness to obtain the target thickness for each weld overlay. Alternatively, different target weld overlay thicknesses can be selected for different weld overlays, and the sum of the target thicknesses of all weld overlays equals the depth to be repaired, ensuring that the top surface of the repaired part is flush with or approximately flush with the unworn surface when welding is completed. The preset weld overlay thickness range can be 3–4 mm, or can be set as needed.

[0108] When dividing the layers, we try to ensure that the target thickness of each weld layer is consistent, and the number of weld layers M obtained based on the target weld layer thickness is an integer.

[0109] For example, if tungsten inert gas (TIG) welding is used for surfacing repair, the target thickness h1 of the surfacing layer is 3-4 mm. If h1 is too small, the surfacing repair efficiency is low; if h1 is too large, the surfacing repair quality is difficult to guarantee. For instance, if H is 7, then h1 is 3.5, resulting in M ​​of 2. If H is 8, then h1 is 4, resulting in M ​​of 2. When H is 9, then h1 is 3, resulting in M ​​of [missing value]. When H is 10, then h1 is 3.33, resulting in M ​​of approximately 3. When H is 11, then h1 is 3.67, resulting in M ​​of approximately 3. When H is 12, then h1 is 4, resulting in M ​​of 3. When H is 13, then h1 is 3.25, resulting in M ​​of 4.

[0110] When the thickness of each weld layer is kept consistent, subsequent determination of other repair parameters only needs to be done once, reducing the amount of calculation and improving the efficiency of determining repair parameters.

[0111] For example, if the target thickness of each weld layer is the same, only the conveying thickness needs to be determined once. Based on the conveying thickness, the volume of repair material can be determined, thus obtaining the same volume of repair material for each weld layer. However, for weld layers with different target thicknesses, the corresponding conveying thickness needs to be determined for the target thickness of each weld layer.

[0112] However, regardless of whether the target thickness of each weld layer is consistent, its repair efficiency is higher than that of existing manual repair methods.

[0113] In addition, in order to achieve high welding repair efficiency and ensure low welding material consumption, the target thickness should be as large as possible, which can reduce the number of feeding operations of the feeding system and the number of welding operations of the welding system.

[0114] After determining the target thickness of each weld overlay, the control system can send the target thickness of each weld overlay to the laser detection system. The laser detection system can then arbitrarily select a width within the range corresponding to each weld overlay as the width to be repaired for that weld overlay.

[0115] Of course, it is also possible to scan only the width of the surface layer to be repaired, and determine the width of other weld overlays to be repaired based on the positional relationship between the surface weld overlay and other weld overlays. This is because, through creative work, it was discovered that, when the included angle formed by the concave surface to be repaired after grinding and the unworn surface of the wear-resistant steel to be repaired remains unchanged, the difference between the widths to be repaired of any two adjacent weld overlays is a constant value, and this difference is related to the included angle.

[0116] Specifically, the control system can determine the width increment based on the target thickness and the included angle. The width increment is the width difference between two adjacent weld overlay layers. For each weld overlay layer other than the surface weld overlay layer, the target increment of the weld overlay layer is determined based on the width increment and the difference in the number of layers between the weld overlay layer and the surface weld overlay layer. Based on the width to be repaired of the surface layer and the target increment of each weld overlay layer other than the surface weld overlay layer, the width to be repaired of each weld overlay layer other than the surface weld overlay layer is determined.

[0117] Figure 5 This is another schematic diagram of the concave surface to be repaired provided in the embodiments of this application, such as... Figure 5 As shown.

[0118] Both c and d are width increments. For ease of description, c can be considered the first width increment and d the second width increment. Different included angles correspond to different width increments. The width of the surface to be repaired can be obtained not only by scanning the concave surface using a laser detection system, but also by calculation. Based on... Figure 5 As shown, the surface width to be repaired = original width + 2 * (depth to be repaired - original depth) + first width increment + second width increment, that is, a' = a + 2 * (Hh) + c + d.

[0119] Figure 6 A schematic diagram of width increment provided for an embodiment of this application, such as Figure 6 As shown.

[0120] Suppose that the included angle formed by the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired is β, and β is divided into a right angle and an acute angle, with the opposite side of the acute angle being the width increment of the weld overlay and the adjacent side being the target thickness h1 of the weld overlay, then the width increment of the weld overlay = target thickness * tan(included angle - 90 degrees).

[0121] Since the included angle formed by the contact between the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired includes a first included angle formed by the contact between the left side of the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired, and a second included angle formed by the contact between the right side of the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired, there is a width increment for each included angle. That is, a weld overlay layer has two width increments, namely a first width increment corresponding to the first included angle and a second width increment corresponding to the second included angle. When the first included angle and the second included angle are the same, the two width increments are the same; when the first included angle and the second included angle are different, the two width increments are different.

[0122] Based on the aforementioned relationship between the width increment and the included angle determined through creative labor, an alternative method for determining the width to be repaired for each weld layer is provided, besides using systems such as lasers. This significantly reduces the computational load on the control system for determining repair parameters, improves the accuracy and efficiency of determining the width to be repaired, reduces calculation errors, and facilitates automated processing.

[0123] Furthermore, the control system can also determine the difference in the number of layers between each weld overlay and the surface weld overlay. For example, if there are three weld overlays, labeled as layer one, layer two, and layer three from the top to the bottom, then for the third weld overlay, the numerical difference between this weld overlay and the surface weld overlay (layer one) is 2.

[0124] This difference can be the coefficient of the width increment when determining the target increment. Therefore, when determining the target increment, the target increment = z * target thickness * tan(first included angle - 90 degrees) + z * target thickness * tan(second included angle - 90 degrees), where z is the numerical difference between the weld overlay layer and the surface weld overlay layer.

[0125] Therefore, for each weld overlay except the surface weld overlay, the width to be repaired of the weld overlay is equal to the width to be repaired of the surface weld overlay minus the target increment.

[0126] The repair width of each weld layer is determined based on the surface repair width and the target increment of each weld layer. During laser scanning, only the surface repair width needs to be obtained, and the remaining weld layers can be determined by calculation. This reduces the time required to determine the repair width of each weld layer and improves repair efficiency.

[0127] Continue Figure 5 For example, the width difference between the two upper layers on the left side of the concave surface to be repaired is c = h1 * tan(β - 90°). Similarly, the width difference between the two upper layers on the right side of the concave surface to be repaired is d = h1 * tan(α - 90°). Therefore, the width of the middle layer is the width a' of the top layer of the concave surface to be repaired minus the differences c and d on the left and right sides, i.e., a' - h1 * tan(β - 90°) - h1 * tan(α - 90°).

[0128] Similarly, the width of the surface layer to be repaired at the bottom layer is a'-2*h1*tan(β-90°)-2*h1*tan(α-90°).

[0129] The above shows the width of each layer using a 3-layer example. For concave surfaces with greater wear depth that require more weld overlay layers for repair, the width of each layer can be deduced accordingly.

[0130] Regarding step S103, the number of weld beads is typically related to the weld width and the width to be repaired. Since the width to be repaired and the weld width can be different for each weld stack, the control system needs to determine the number of weld beads for each weld stack. Because the width to be repaired is already determined, a larger weld width e results in a smaller number of weld beads N. When determining the number of weld beads, since the width to be repaired has already been determined in the aforementioned steps, in step S103, the control system only needs to determine the weld width. The weld width can be determined within different preset weld width ranges based on the relationship between the width to be repaired and a preset value.

[0131] Specifically, for each weld bead of a weld overlay, the control system determines the weld width of the weld overlay based on the width to be repaired and the preset weld width range; and determines the number of weld beads of the weld overlay based on the width to be repaired, the weld width of the weld overlay, and the first correspondence. When the width to be repaired of the weld overlay is less than the first preset value, the preset weld width range is the preset first range; when the width to be repaired of the weld overlay is not less than the first preset value, the preset weld width range is the preset second range. The maximum value of the preset first range is not greater than the minimum value of the preset second range.

[0132] The first preset value can be 500. If the width of the weld overlay to be repaired is less than 500 mm, the preset weld width range is 10-18 mm, and the weld width of the weld overlay can be 10 ≤ e < 18. When the width of the weld overlay to be repaired is not less than 500 mm, in order to improve the repair efficiency, the preset weld width range is 18-30 mm, and the weld width of the weld overlay can be 18 ≤ e < 30.

[0133] Given a fixed weld width e, the number N of weld beads in each weld stack is determined by the width of the weld stack to be repaired. Therefore, after determining the weld width e based on the width of the weld stack to be repaired, the number of weld beads in each weld stack can be determined. Specifically, the number of weld beads = width to be repaired / weld width. If the resulting number of weld beads is not an integer, it is rounded up to the nearest integer.

[0134] Taking a concave surface to be repaired that includes three layers of weld overlay as an example, Figure 7 A schematic diagram of a concave surface to be repaired with three layers of weld overlay provided in this application embodiment, as shown below. Figure 7 As shown, the target width of each stack of solder layers is the same.

[0135] Based on the aforementioned process for determining the number of weld beads, the number of weld beads for each layer is as follows:

[0136] The number of weld beads in the top layer, N1 = a' / e;

[0137] The number of weld beads in the intermediate layer, N2 = [a' - h1 * tan(β - 90°) - h1 * tan(α - 90°)] / e;

[0138] The number of weld beads in the bottom layer, N3, is calculated as follows: N3 = [a' - 2 * h1 * tan(β - 90°) - 2 * h1 * tan(α - 90°)] / e.

[0139] Since the preset weld width range is determined in advance based on experience or manual determination and meets the requirements, the width to be repaired is judged based on the first preset value to determine the range of possible weld width values. This improves the determination efficiency while ensuring that the weld width meets the requirements.

[0140] When determining the required conveying thickness of the repair material for each weld layer, the control system can determine the required conveying thickness of the repair material for each weld layer based on the target thickness of the weld layer, the preset conveying coefficient, and the second correspondence. The second correspondence is that the conveying thickness is positively correlated with the target thickness, and the target thickness is determined based on the depth to be repaired.

[0141] Specifically, controlling the feeding thickness of each layer of repair material is crucial to ensuring the required thickness of each weld layer is achieved in subsequent welding processes. Due to the density of the repair material, the thickness will decrease after welding; therefore, the feeding thickness should be slightly greater than the target thickness of the weld layer. Since the feeding thickness h2 is positively correlated with the target thickness h1, and the feeding thickness is slightly greater than the target thickness of the weld layer, the feeding thickness = k0 * target thickness, where k0 is a thickness coefficient, which can be 1.2 to 1.5, and the unit of the feeding thickness h2 is mm.

[0142] For each weld bead in the weld bead layer, the welding current is determined based on the preset current coefficient, the target thickness of the weld bead layer, and the third correspondence. The welding current is positively correlated with the target thickness.

[0143] Welding current is a type of welding parameter, and the welding parameters for each weld pass are related to the thickness h1 of the weld overlay. The larger the target thickness h1 of the weld overlay, the larger the required welding parameters are to ensure sufficient arc energy to penetrate each layer of the paste alloy and guarantee good weld quality. Since the main welding parameter affecting the penetration depth in argon arc welding is the welding current I, the welding current is selected as the welding parameter. The relationship between the target thickness h1 of the weld overlay and the welding current I can be expressed as I = k1 * h1, where k1 is the current coefficient, which can be 65–75, and the unit of the welding current I is amperes.

[0144] When performing step S104, each stack of weld layers can be repaired. In order to improve the repair effect, after each stack of weld layers is repaired, the stack of weld layers can be inspected to check for any repair quality problems.

[0145] Specifically, for each weld layer on the concave surface to be repaired, the following operations are performed until each weld layer is repaired: repair the weld layer according to the number of weld beads, the required thickness of the repair material, and the welding current of the weld; check whether there are any weld repair quality problems in the weld layer; if so, grind and clean the weld layer and perform repair welding.

[0146] Specifically, the control system can send the required repair material thickness for each weld layer to the feeding system, and the number of weld beads and welding current for each weld layer to the welding system. This allows the feeding system to determine the volume of repair material needed for each weld layer based on the required thickness, acquire that volume of repair material, and deliver it to the welding system. The welding system places the repair material in the concave surface to be repaired and smooths it to create a smooth surface. Then, it repairs the concave surface according to the number of weld beads and welding current specified in the repair parameters. Afterward, the control system can also control a laser inspection system or perform manual inspection to determine if there are any quality issues with the weld repair. If problems are found, the affected area is ground and cleaned, and then appropriately repaired by welding. This process continues layer by layer feeding and welding until the repaired worn area is complete.

[0147] After each weld layer is repaired, a repair quality inspection is conducted to promptly identify and rectify repair defects, thereby improving repair quality, ensuring repair effectiveness, increasing the service life of the repaired parts, and reducing rework costs.

[0148] Figure 8 An example of a repaired effect diagram provided in this application embodiment, such as... Figure 8 As shown.

[0149] During the repair process, three weld overlay layers were determined based on the depth to be repaired, and each weld overlay layer was repaired. After the concave surface was repaired by weld overlay, the repaired part was obtained.

[0150] This application also provides a method for preparing wear-resistant steel repair materials. Figure 9 This is a schematic flowchart illustrating a method for preparing a repair material for wear-resistant steel according to an embodiment of this application. The repair material is applied to the above-mentioned method for repairing wear-resistant steel, which includes steps S201 to S203:

[0151] S201: Determine the composition of the alloy powder based on the composition and hardness of the wear-resistant steel to be repaired.

[0152] To ensure good wear resistance, alloy powder is generally high in chromium, and the higher the wear resistance of the wear-resistant steel, the higher the chromium content of the alloy powder.

[0153] Generally, the alloy powder composition, expressed as a percentage by mass, is as follows when the wear resistance requirement of the wear-resistant steel is low: C 0.25%–0.8%, Cr 5%–15%, Mn 1.2%–2.5%, Si 0.5%–1.0%, Mo 0.8%–2.0%, with the balance being Fe. When the wear resistance requirement of the wear-resistant steel is high, the alloy powder composition is as follows: C 4.0%–5.2%, Cr 15%–25%, Mn 1.2%–2.5%, Si 0.6%–1.0%, Mo 1.5%–3%, with the balance being Fe. The wear resistance of the wear-resistant steel can be measured by the Rockwell hardness of the wear-resistant layer. When the wear resistance requirement is low, the Rockwell hardness of the wear-resistant layer is less than 58; when the wear resistance requirement is high, the Rockwell hardness of the wear-resistant layer is not less than 58.

[0154] S202: Prepare alloy powder according to the composition of this alloy powder.

[0155] Based on the proportion of each alloy in the alloy powder composition, obtain the corresponding proportion of alloy powder, and thoroughly mix the powders of each alloy to obtain a homogeneous alloy powder.

[0156] S203: The alloy powder is fused with an adhesive to obtain a repair material with flowability.

[0157] Specifically, carboxymethyl cellulose and deionized water are mixed at a mass ratio of 1:20 to 1:15 and stirred evenly to form a paste-like solution. Alternatively, polyvinyl alcohol and deionized water are mixed at a mass ratio of 1:10 to 1:13, heated to 80 to 90°C, and stirred evenly to form a paste-like solution. The paste-like solution from either of the above formulations is then mixed evenly with a homogenized alloy powder at a mass ratio of 1:8 to 1:5 to form a paste-like alloy with good flowability. Good flowability ensures that the paste-like alloy achieves self-leveling through its own fluidity, thereby improving the efficiency of weld overlay repair. After obtaining the repair material, it can be sealed and stored for use when repairing wear-resistant steel.

[0158] The repair materials prepared based on the above-mentioned wear-resistant steel repair materials can ensure the service life of the repaired wear-resistant steel and achieve good repair results when used to repair wear-resistant steel.

[0159] To better understand and illustrate the practical value of the solutions provided in the embodiments of this application, the optional implementation methods of this application will be described below in conjunction with specific scenario embodiments.

[0160] Example 1

[0161] Figure 10 A schematic diagram of a wear-resistant steel with a short operating time is provided for an embodiment of this application, as shown below. Figure 10 As shown, the original length of the original concave surface is 10000mm, the original width is 400mm, and the original depth is 2.5mm.

[0162] 1. Preparation of repair materials

[0163] Based on the composition and hardness of the wear-resistant steel, prepare a matching alloy powder for weld overlay repair, mix thoroughly, and set aside. Obtain carboxymethyl cellulose and deionized water, mix them at a mass ratio of 1:17, and stir until homogeneous to form a paste-like solution. Mix the paste-like solution with the homogeneous alloy powder at a mass ratio of 1:6.5 to form a fluid, paste-like alloy.

[0164] 2. Remove fatigue layer

[0165] The worn area was ground and cleaned to remove the fatigue layer. Due to the short operating time, grinding a 1mm thick fatigue layer was sufficient to pass the flaw detection. The left and right edges of the original concave surface depth contour line were ground to form a 140° obtuse angle to create the concave surface to be repaired.

[0166] 3. Detect the basic parameters for repairing the concave surface.

[0167] Figure 11 This is a schematic diagram of a polished concave surface provided in an embodiment of this application, as shown below. Figure 11 As shown.

[0168] The basic repair parameters obtained by manually inspecting the concave surface to be repaired are as follows: the width a' to be repaired on the surface is 410.34 mm, the original length b is 10000 mm, and the depth H to be repaired is 3.5 mm.

[0169] 4. Determine the repair parameters

[0170] The repair parameters are determined manually as follows:

[0171] The welding method selected is tungsten inert gas welding, which uses tungsten inert gas as the heat source to melt the paste alloy for welding repair.

[0172] During the welding process, since the depth H to be repaired is relatively small, one layer of welding is sufficient to complete the repair, i.e., the number of welding layers M = 1, and the target thickness h1 of each welding layer is 3.5 mm. Since the width of the concave surface to be repaired is relatively small, the weld width e is taken as 16 mm. Therefore, the number of welds N = a' / e = 410.34 / 16 = 25.65, which is rounded up to 27. That is, 27 welds are required to complete the repair.

[0173] Since the target thickness of each weld layer is h1 = 3.5 mm, which is relatively small, the thickness coefficient k0 is taken as 1.2. The thickness of the paste alloy during feeding is h2 = k0 * h1 = 1.2 * 3.5 = 4.2 mm. The current coefficient k1 is taken as 70. Then the welding current of argon arc welding is I = k1 * h1 = 70 * 3.5 = 245 A.

[0174] 5. Repair

[0175] The control system sends the repair parameters to the feeding and welding systems. The feeding system delivers the paste alloy according to the required thickness specified in the repair parameters and smooths it manually. The welding system performs the overlay welding according to the welding current, weld width, and number of weld passes specified in the repair parameters. After each layer is welded, manual inspection checks for any welding repair issues. If necessary, additional welding is performed to complete the repair.

[0176] Example 2

[0177] Figure 12 A schematic diagram of a wear-resistant steel with a long operating time is provided for an embodiment of this application, as shown below. Figure 12 As shown, the original length of the original concave surface is 10000mm, the original width is 600mm, and the original depth is 5mm.

[0178] 1. Preparation of repair materials

[0179] Based on the composition and hardness of the wear-resistant steel, prepare a matching alloy powder for weld overlay repair, mix it thoroughly, and set it aside. Obtain carboxymethyl cellulose and deionized water, mix them at a mass ratio of 1:20 to 1:15, and stir evenly. Prepare a paste-like solution, and mix the paste-like solution with the mixed alloy powder at a mass ratio of 1:8 to 1:5 to prepare a paste-like alloy with good flowability.

[0180] 2. Remove fatigue layer

[0181] The worn area was ground and cleaned to remove the fatigue layer. Due to the short operating time, the 3mm thick fatigue layer passed the flaw detection test after grinding. The left and right edges of the original concave surface depth contour line were ground to form a 135° obtuse angle to create the concave surface to be repaired.

[0182] 3. Detect the basic parameters for repairing the concave surface.

[0183] Figure 13 This is a schematic diagram of another polished concave surface provided in an embodiment of this application, as shown below. Figure 13 As shown.

[0184] The basic repair parameters obtained by scanning the concave surface to be repaired using a laser detection system are as follows: the width a' to be repaired on the surface is 622mm, the original length b is 10000mm, and the depth H to be repaired is 8mm.

[0185] 4. Determine the repair parameters

[0186] The control system determines the repair parameters as follows:

[0187] The welding method selected is tungsten inert gas welding, which uses tungsten inert gas as the heat source to melt the paste alloy for welding repair.

[0188] During the welding process, due to the large depth H to be repaired, two layers are required to complete the repair, i.e., the number of welding layers M = 2, and the target thickness h1 of each welding layer is 4mm. The width to be repaired of the bottom layer of the concave surface is 622 - 2 * h1 * tan(135° - 90°) = 614mm.

[0189] Since the width of the concave surface to be repaired is relatively large, the weld width e1 of the bottom layer is taken as 20mm. Therefore, the number of welds for the bottom layer is N1 = 614 / 20 = 30.7, which is rounded up to 31, meaning that 31 welds are needed for the bottom layer. The weld width e2 of the top layer is taken as 21mm. The number of welds for the top layer is N2 = 622 / 21 = 29.62, which is rounded up to 30, meaning that 30 welds are needed for the top layer.

[0190] Since the target thickness of each weld layer is h1 = 4 mm, which is slightly larger, the thickness coefficient k0 is taken as 1.4. The thickness of the paste alloy during feeding is h2 = k0 * h1 = 1.4 * 4 = 5.6 mm. The current coefficient k1 is taken as 75. Then the welding current of argon arc welding is I = k1 * h1 = 75 * 4 = 300 A.

[0191] 5. Repair

[0192] The control system sends the repair parameters to the feeding system and welding system. The feeding system delivers the paste alloy according to the required thickness in the repair parameters and smooths it appropriately using the welding system. The welding system performs the first layer of overlay welding repair according to the welding current, weld width, and number of weld passes specified in the repair parameters. After welding one layer, a laser inspection system checks for any welding quality issues and performs additional welding as needed. Then, another layer is welded according to the same repair parameters, and the system checks for any repair quality issues and performs additional welding as needed to complete the repair.

[0193] Example 3

[0194] Figure 14 A schematic diagram of a wear-resistant steel with a long operating time is provided for an embodiment of this application, as shown below. Figure 14 As shown, the original length of the original concave surface is 10000mm, the original width is 1000mm, and the original depth is 8mm.

[0195] 1. Preparation of repair materials

[0196] Based on the composition and hardness of the wear-resistant steel, prepare a matching alloy powder for weld overlay repair, mix thoroughly, and set aside. Obtain carboxymethyl cellulose and deionized water, mix them at a mass ratio of 1:16, and stir until homogeneous to form a paste-like solution. Mix the paste-like solution with the homogeneous alloy powder at a mass ratio of 1:6 to form a fluid, paste-like alloy.

[0197] 2. Remove fatigue layer

[0198] The worn area was ground and cleaned to remove the fatigue layer. Due to the short operating time, the 4mm thick fatigue layer passed the flaw detection test after grinding. The left and right edges of the original concave surface depth contour line were ground to form a 125° obtuse angle to create the concave surface to be repaired.

[0199] 3. Detect the basic parameters for repairing the concave surface.

[0200] Figure 15 This is a schematic diagram of another polished concave surface provided in an embodiment of this application, as shown below. Figure 15 As shown.

[0201] The concave surface to be repaired was examined using X-ray computed tomography (CT) technology. The basic parameters for repair were as follows: the width to be repaired on the surface, a', was 1024.8 mm; the original length, b, was 10000 mm; and the depth to be repaired, H, was 12 mm.

[0202] 4. Determine the repair parameters

[0203] The repair process determined by the control system is as follows:

[0204] The welding method selected is tungsten inert gas welding, which uses tungsten inert gas as the heat source to melt the paste alloy for welding repair.

[0205] During the welding process, due to the large depth H to be repaired, three layers are required to complete the repair, i.e., the number of welding layers M=3, and the target thickness h1 of each welding layer is 4mm. The width to be repaired for the middle layer of the concave surface is 1024.8-2*h1*tan(125°-90°)=1019.2mm, and the width to be repaired for the bottom layer is 1024.8-4*h1*tan(125°-90°)=1013.6mm.

[0206] Since the width of the concave surface to be repaired is relatively large, the weld width e1 of the bottom layer is taken as 21mm, so the number of welds for the bottom layer is 1013.6 / 21 = 48.27, rounded down to 49, meaning the bottom layer needs to be welded 49 times. The weld width e2 of the middle layer is taken as 23mm, so the number of welds for the middle layer is 1019.2 / 23 = 44.31, rounded down to 45, meaning the middle layer needs to be welded 45 times. The weld width e3 of the top layer is taken as 24mm, so the number of welds for the top layer is 1024.8 / 24 = 42.7, rounded down to 43, meaning the top layer needs to be welded 43 times.

[0207] Since the target thickness of each weld layer is h1 = 4 mm, which is slightly larger, the thickness coefficient k0 is taken as 1.4. The thickness of the paste alloy during feeding is h2 = k0 * h1 = 1.4 * 4 = 5.6 mm. The current coefficient k1 is taken as 75. Then the welding current of argon arc welding is I = k1 * h1 = 75 * 4 = 300 A.

[0208] 5. Repair

[0209] The control system sends the repair parameters to the feeding and welding systems. The feeding system delivers the paste alloy according to the specified thickness in the repair parameters and smooths it manually as needed. The welding system performs the first layer of overlay welding repair according to the welding current, weld width, and number of weld passes specified in the repair parameters. After welding one layer, manual inspection is performed to check for repair quality issues, and additional welding is done as needed. Then, another layer is welded according to the above repair parameters, and the repair is completed by checking for repair quality issues and adding additional welding as needed.

[0210] Based on the repair method for wear-resistant steel provided in the above embodiments, this application also provides a specific implementation of a repair device for wear-resistant steel. Please refer to the following embodiments.

[0211] First see Figure 16 The wear-resistant steel repair device 1600 provided in this application embodiment includes the following modules:

[0212] The preprocessing module 1601 is used to remove the fatigue layer of the wear-resistant steel to be repaired, so as to obtain the concave surface to be repaired;

[0213] The basic parameter determination module 1602 is used to determine the repair depth of the concave surface to be repaired and the repair width of each weld layer;

[0214] The repair parameter determination module 1603 is used to determine repair parameters based on a preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer. The repair parameters include the number of weld beads in each weld layer, the thickness of the repair material to be delivered for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the width to be repaired, a second correspondence between the delivery thickness and the thickness of the weld overlay, and a third correspondence between the welding current and the thickness of the weld overlay.

[0215] The repair module 1604 is used to control the feeding system and welding system to repair the concave surface to be repaired based on the repair parameters.

[0216] As one implementation of this application, the included angle formed by the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired is 120° to 150°.

[0217] As one implementation of this application, the basic parameter determination module 1602 further includes:

[0218] The first parameter determination unit is used to control the laser detection system to scan the concave surface to be repaired, and to obtain the repair depth and surface repair width of the concave surface to be repaired.

[0219] The target thickness determination unit is used to determine the target thickness of each weld overlay based on the depth to be repaired and the preset weld overlay thickness range.

[0220] The second parameter determination unit is used to determine the width to be repaired of each weld overlay layer other than the surface weld overlay layer based on the width to be repaired of the surface layer, the target thickness, and the included angle.

[0221] As one implementation of this application, the second parameter determining unit further includes:

[0222] A width increment determination unit is used to determine the width increment based on the target thickness and the included angle, wherein the width increment is the width difference between two adjacent weld overlay layers;

[0223] The target increment determination unit is used to determine the target increment of each weld overlay layer, except for the surface weld overlay layer, based on the width increment and the difference in the number of layers between the weld overlay layer and the surface weld overlay layer.

[0224] The non-surface layer repair width determination unit is used to determine the repair width of each weld layer other than the surface layer based on the repair width of the surface layer and the target increment of each weld layer other than the surface layer weld overlay.

[0225] As one implementation of this application, the width increment = target thickness * tan(angle - 90 degrees); for each weld overlay except the surface weld overlay, the width to be repaired of the weld overlay = the width to be repaired of the surface weld overlay - target increment.

[0226] As one implementation of this application, the repair parameter determination module 1603 further includes:

[0227] The weld width determination unit is used to determine the weld width of each weld overlay based on the width to be repaired and the preset weld width range, taking into account the number of weld passes for each weld overlay.

[0228] The weld bead number determination unit is used to determine the number of weld beads of the weld overlay layer based on the width to be repaired of the weld overlay layer, the weld width of the weld overlay layer, and the first correspondence relationship. When the width to be repaired of the weld overlay layer is less than a first preset value, the preset weld width range is a preset first range. When the width to be repaired of the weld overlay layer is not less than the first preset value, the preset weld width range is a preset second range. The maximum value of the preset first range is not greater than the minimum value of the preset second range. The first correspondence relationship is that the width to be repaired of the weld overlay layer is positively correlated with the number of weld beads of the weld overlay layer.

[0229] The conveying thickness determination unit is used to determine the conveying thickness of the repair material required for each weld overlay layer based on the target thickness of the weld overlay layer, a preset conveying coefficient, and the second correspondence relationship. The second correspondence relationship is that the conveying thickness is positively correlated with the target thickness, and the target thickness is determined based on the depth to be repaired.

[0230] The welding current determination unit is used to determine the welding current of the weld in each weld overlay layer based on a preset current coefficient, the target thickness of the weld overlay layer, and the third correspondence relationship, wherein the third correspondence relationship is that the welding current is positively correlated with the target thickness.

[0231] As one implementation of this application, the number of weld passes = width to be repaired / weld width.

[0232] As one implementation of this application, the welding method used in the welding system includes tungsten inert gas (TIG) welding.

[0233] As one implementation of this application, the repair module 1604 also includes:

[0234] A single-layer repair unit is used to perform the following operations for each weld layer of the concave surface to be repaired, until each weld layer is repaired:

[0235] Repair the weld overlay based on the number of weld beads, the required thickness of the repair material, and the welding current of the weld.

[0236] The detection unit is used to detect whether there are any quality problems with the weld overlay; if so, the weld overlay is ground and cleaned, and then repaired by welding.

[0237] Each module in the wear-resistant steel repair device provided in this application embodiment can realize each step in the above-mentioned wear-resistant steel repair method and achieve the corresponding effect. For the sake of brevity, it will not be described in detail here.

[0238] This application embodiment also provides a repair system for wear-resistant steel, the system comprising: a control system, a feeding system, and a welding system, wherein:

[0239] The control system is used to determine the repair depth of the concave surface to be repaired and the repair width of each weld layer. Based on the preset repair parameter correspondence, the repair depth, and the repair width of each weld layer, repair parameters are determined and sent to the feeding system and welding system to repair the concave surface. The repair parameters include the number of weld beads in each weld layer, the conveying thickness of the repair material required for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the repair width, a second correspondence between the conveying thickness and the thickness of the weld layer, and a third correspondence between the welding current and the thickness of the weld layer. The concave surface to be repaired is obtained by removing the fatigue layer of the wear-resistant steel to be repaired.

[0240] The feeding system and the welding system are used to receive repair parameters sent by the control system, and repair the concave surface to be repaired based on the repair parameters.

[0241] Figure 17 A schematic diagram of the structure of the wear-resistant steel repair device provided in the embodiment of this application is shown.

[0242] The repair equipment for wear-resistant steel may include a processor 1701 and a memory 1702 storing computer program instructions.

[0243] Specifically, the processor 1701 may include a central processing unit (CPU), an application-specific integrated circuit (ASIC), or one or more integrated circuits that can be configured to implement the embodiments of this application.

[0244] Memory 1702 may include mass storage for data or instructions. For example, and not limitingly, memory 1702 may include a hard disk drive (HDD), floppy disk drive, flash memory, optical disk, magneto-optical disk, magnetic tape, or Universal Serial Bus (USB) drive, or a combination of two or more of these. Where appropriate, memory 1702 may include removable or non-removable (or fixed) media. Where appropriate, memory 1702 may be internal or external to the integrated gateway disaster recovery device. In a particular embodiment, memory 1702 is non-volatile solid-state memory.

[0245] The memory may include read-only memory (ROM), random access memory (RAM), disk storage media devices, optical storage media devices, flash memory devices, and electrical, optical, or other physical / tangible memory storage devices. Therefore, typically, memory includes one or more tangible (non-transitory) computer-readable storage media (e.g., memory devices) encoded with software including computer-executable instructions, and when the software is executed (e.g., by one or more processors), it is operable to perform the operations described with reference to the method of repairing wear-resistant steel according to any embodiment of this disclosure.

[0246] The processor 1701 reads and executes computer program instructions stored in the memory 1702 to implement any of the wear-resistant steel repair methods in the above embodiments.

[0247] In one example, the repair equipment for wear-resistant steel may also include a communication interface 1702 and a bus 1710. Wherein, as Figure 17 As shown, the processor 1701, memory 1702, and communication interface 1702 are connected through bus 1710 and complete communication with each other.

[0248] The communication interface 1702 is mainly used to realize communication between various modules, devices, units and / or equipment in the embodiments of this application.

[0249] Bus 1710 includes hardware, software, or both, that couples components of an online data traffic metering device together. For example, and not limitingly, the bus may include an Accelerated Graphics Port (AGP) or other graphics bus, an Enhanced Industry Standard Architecture (EISA) bus, a Front Side Bus (FSB), HyperTransport (HT) interconnect, an Industry Standard Architecture (ISA) bus, an Infinite Bandwidth Interconnect, a Low Pin Count (LPC) bus, a memory bus, a Microchannel Architecture (MCA) bus, a Peripheral Component Interconnect (PCI) bus, a PCI-Express (PCI-X) bus, a Serial Advanced Technology Attachment (SATA) bus, a Video Electronics Standards Association Local (VLB) bus, or other suitable buses, or combinations of two or more of these. Where appropriate, bus 1710 may include one or more buses. Although specific buses are described and illustrated in embodiments of this application, any suitable bus or interconnect is contemplated herein.

[0250] Furthermore, in conjunction with the methods for repairing wear-resistant steel described in the above embodiments, this application embodiment can provide a computer storage medium for implementation. This computer storage medium stores computer program instructions. When these computer program instructions are executed by a processor, they implement any of the methods for repairing wear-resistant steel described in the above embodiments.

[0251] This application also provides a computer program product, including a computer program, which, when executed, implements any of the methods for repairing wear-resistant steel described in the above embodiments.

[0252] It should be clarified that this application is not limited to the specific configurations and processes described above and shown in the figures. For the sake of brevity, detailed descriptions of known methods are omitted here. In the above embodiments, several specific steps are described and shown as examples. However, the method process of this application is not limited to the specific steps described and shown. Those skilled in the art can make various changes, modifications, and additions, or change the order of steps, after understanding the spirit of this application.

[0253] The functional blocks shown in the above-described structural diagram can be implemented as hardware, software, firmware, or a combination thereof. When implemented in hardware, they can be, for example, electronic circuits, application-specific integrated circuits (ASICs), appropriate firmware, plug-ins, function cards, etc. When implemented in software, the elements of this application are programs or code segments used to perform the required tasks. Programs or code segments can be stored on a machine-readable medium or transmitted over a transmission medium or communication link via data signals carried on a carrier wave. "Machine-readable medium" can include any medium capable of storing or transmitting information. Examples of machine-readable media include electronic circuits, semiconductor memory devices, ROM, flash memory, erasable ROM (EROM), floppy disks, CD-ROMs, optical disks, hard disks, fiber optic media, radio frequency (RF) links, etc. Code segments can be downloaded via computer networks such as the Internet, intranets, etc.

[0254] It should also be noted that the exemplary embodiments mentioned in this application describe methods or systems based on a series of steps or apparatus. However, this application is not limited to the order of the above steps; that is, the steps can be performed in the order mentioned in the embodiments, or in a different order, or several steps can be performed simultaneously.

[0255] The aspects of this disclosure have been described above with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this disclosure. It should be understood that each block in the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing apparatus to produce a machine such that these instructions, executable via the processor of the computer or other programmable data processing apparatus, enable the implementation of the functions / actions specified in one or more blocks of the flowchart illustrations and / or block diagrams. Such a processor can be, but is not limited to, a general-purpose processor, a special-purpose processor, a special application processor, or a field-programmable logic circuit. It is also understood that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can also be implemented by special-purpose hardware performing the specified functions or actions, or can be implemented by a combination of special-purpose hardware and computer instructions.

[0256] The above description is merely a specific implementation of this application. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, modules, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the protection scope of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the protection scope of this application.

Claims

1. A method for repairing wear-resistant steel, characterized in that, The method includes: Remove the fatigue layer of the wear-resistant steel to be repaired to obtain a concave surface to be repaired. The angle between the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired is 120°~150°. Determine the repair depth of the concave surface to be repaired and the repair width of each weld layer; Based on the preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer, repair parameters are determined. The repair parameters include the number of weld beads in each weld layer, the required thickness of the repair material to be delivered for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the width to be repaired, a second correspondence between the delivery thickness and the thickness of the weld overlay, and a third correspondence between the welding current and the thickness of the weld overlay. Based on the repair parameters, the feeding system and welding system are controlled to repair the concave surface to be repaired; Determining the repair depth of the concave surface and the repair width of each weld layer specifically includes: The laser detection system is controlled to scan the concave surface to be repaired, thereby obtaining the depth to be repaired and the width of the surface to be repaired. Based on the depth to be repaired and the preset weld overlay thickness range, determine the target thickness of each weld overlay. Based on the surface layer width to be repaired, the target thickness, and the included angle, the width to be repaired for each weld overlay layer, excluding the surface weld overlay layer, is determined.

2. The method for repairing wear-resistant steel according to claim 1, characterized in that, Based on the surface layer width to be repaired, the target thickness, and the included angle, the width to be repaired for each weld overlay layer, excluding the surface weld overlay layer, is determined, specifically including: The width increment is determined based on the target thickness and the included angle, and the width increment is the width difference between two adjacent weld overlay layers; For each weld overlay except the surface weld overlay, the target increment of the weld overlay is determined based on the width increment and the difference in the number of layers between the weld overlay and the surface weld overlay. Based on the surface layer width to be repaired and the target increment of each weld layer other than the surface weld overlay, the width to be repaired for each weld layer other than the surface weld overlay is determined.

3. The method for repairing wear-resistant steel according to claim 2, characterized in that, The width increment = target thickness * tan(angle - 90 degrees); For each weld overlay except the surface weld overlay, the width to be repaired for that weld overlay is equal to the width to be repaired for the surface weld overlay minus the target increment.

4. The method for repairing wear-resistant steel according to claim 1, characterized in that, Based on the preset repair parameter correspondence, the depth to be repaired, and the width to be repaired for each weld layer, the repair parameters are determined, specifically including: For each weld bead stack, the weld width is determined based on the width to be repaired and the preset weld width range. Based on the width to be repaired of the weld overlay, the weld width of the weld overlay, and the first correspondence, the number of weld passes of the weld overlay is determined. When the width to be repaired of the weld overlay is less than a first preset value, the preset weld width range is a preset first range. When the width to be repaired of the weld overlay is not less than the first preset value, the preset weld width range is a preset second range. The maximum value of the preset first range is not greater than the minimum value of the preset second range. The first correspondence is that the width to be repaired of the weld overlay is positively correlated with the number of weld passes of the weld overlay. For each weld overlay, the required thickness of the repair material is determined based on the target thickness of the weld overlay, the preset delivery coefficient, and the second correspondence. The second correspondence is that the delivery thickness is positively correlated with the target thickness, and the target thickness is determined based on the depth to be repaired. For each weld bead in the weld bead layer, the welding current of the weld bead in the weld bead layer is determined according to the preset current coefficient, the target thickness of the weld bead layer and the third correspondence relationship, wherein the third correspondence relationship is that the welding current is positively correlated with the target thickness.

5. The method for repairing wear-resistant steel according to claim 4, characterized in that, Number of weld passes = width to be repaired / weld width.

6. The method for repairing wear-resistant steel according to claim 1, characterized in that, The welding method used in the welding system includes tungsten inert gas (TIG) welding.

7. The method for repairing wear-resistant steel according to claim 1, characterized in that, Repairing the concave surface to be repaired specifically includes: For each weld layer on the concave surface to be repaired, perform the following operations until each weld layer is repaired: Repair the weld overlay based on the number of weld beads, the required thickness of the repair material, and the welding current of the weld. The method further includes: Inspect the weld overlay to check for weld repair quality issues; If so, the weld overlay should be ground and cleaned, and then repaired by welding.

8. A method for preparing a wear-resistant steel repair material, characterized in that, The repair material is applied to the repair method of wear-resistant steel according to any one of claims 1 to 7, the method comprising: The composition of the alloy powder is determined based on the composition and hardness of the wear-resistant steel to be repaired. Prepare alloy powder according to the alloy powder composition; The alloy powder is fused with an adhesive to obtain a fluid repair material.

9. A repair system for wear-resistant steel, characterized in that, The system includes: a control system, a feeding system, and a welding system, wherein: The control system is used to determine the repair depth of the concave surface to be repaired and the repair width of each weld layer. Based on the preset repair parameter correspondence, the repair depth, and the repair width of each weld layer, the repair parameters are determined and sent to the feeding system and welding system to repair the concave surface. The repair parameters include the number of weld beads in each weld layer, the conveying thickness of the repair material required for each weld layer, and the welding current of the weld in each weld layer. The preset repair parameter correspondence includes a first correspondence between the number of weld beads and the repair width, a second correspondence between the conveying thickness and the thickness of the weld layer, and a third correspondence between the welding current and the thickness of the weld layer. The concave surface to be repaired is obtained by removing the fatigue layer of the wear-resistant steel to be repaired, and the included angle formed by the concave surface to be repaired and the unworn surface of the wear-resistant steel to be repaired is 120°~150°. The feeding system and the welding system are used to receive repair parameters sent by the control system, and repair the concave surface to be repaired based on the repair parameters; The control system is also used to control the laser detection system to scan the concave surface to be repaired, to obtain the repair depth and surface repair width of the concave surface; to determine the target thickness of each weld layer according to the repair depth and the preset weld overlay thickness range; and to determine the repair width of each weld layer other than the surface weld overlay based on the surface repair width, the target thickness and the included angle.

10. A repair device for wear-resistant steel, characterized in that, The device includes: a processor and a memory storing computer program instructions; the processor reads and executes the computer program instructions to implement the repair method for wear-resistant steel as described in any one of claims 1 to 7.

11. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer program instructions, which, when executed by a processor, implement the method for repairing wear-resistant steel as described in any one of claims 1 to 7.

12. A computer program product, characterized in that, When the instructions in the computer program product are executed by the processor of the electronic device, the electronic device performs the repair method for wear-resistant steel as described in any one of claims 1 to 7.

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