An integrated device for laser cladding additive manufacturing of an ultra-long flight chain

Abstract

The application provides an integrated device for laser cladding additive manufacturing of an ultra-long scraper chain, relates to the field of additive manufacturing repair technology of curved surfaces and ring parts, and comprises a laser cladding mechanism, a chain guide mechanism, a support positioning mechanism and an adjusting mechanism. The support positioning mechanism comprises a positioning plate and a positioning structure. The chain guide mechanism comprises a servo motor, a driving wheel and a driven wheel. The laser cladding mechanism comprises a multi-joint industrial robot and a laser cladding head. The adjusting mechanism comprises a positioning magnet. The device is coordinated with the laser cladding additive manufacturing process, integrates a laser cladding system and a multi-joint industrial robot system. Under the condition of one-time clamping of the scraper chain, efficient laser cladding additive manufacturing of the worn part of the chain surface is realized, the repair efficiency of the worn chain is greatly improved, the positioning error caused by multiple clamping is reduced, the positioning accuracy and machining accuracy of the chain are improved, and the high-precision and efficient laser cladding additive manufacturing of the surface of the ultra-long scraper chain is facilitated.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing repair technology for curved and ring-shaped parts, and more particularly to an integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains. Background Technology

[0002] Scraper conveyors are core equipment for material transport in heavy industries such as coal mines and other mining sectors. Their chains, as critical transmission components, endure high loads, strong abrasion, corrosive media, and impact loads over extended periods. Especially in underground fully mechanized mining faces, the service environment of scraper conveyor chains is extremely harsh, resulting in a low average service life. Chain failure increases the failure rate of scraper conveyors, threatening production safety and causing significant economic losses. Therefore, improving the wear resistance, fatigue resistance, and corrosion resistance of the chains is crucial for ensuring continuous production and reducing operation and maintenance costs.

[0003] Repairing worn areas of scraper conveyor chains can effectively improve their mechanical properties, such as wear resistance, fatigue resistance, and corrosion resistance. Traditional repair techniques, such as arc welding, easily lead to workpiece deformation and hardened layer peeling, while replacing entire chains of hundreds of meters is costly and results in significant downtime losses. Although laser cladding technology can produce high-performance reinforced layers, existing equipment is ill-suited for the continuous processing requirements of ultra-long chains. On the one hand, the insufficient working stroke of conventional equipment forces segmented processing, which compromises structural integrity. On the other hand, the clamping of flexible chain links requires manual positioning of each link, resulting in low efficiency and poor accuracy. Furthermore, traditional laser cladding technology is prone to interruptions in the cladding trajectory, weakened interlayer bonding, and the need for manual intervention at corners, severely restricting coating consistency and fatigue resistance.

[0004] Based on the current research status, three major bottlenecks remain in the remanufacturing of scraper conveyor chains: First, existing equipment lacks the continuous processing capability for chains with dimensions of hundreds of meters, and segmented cladding leads to performance degradation in the remelting zone; second, existing equipment lacks an adaptive flexible clamping mechanism, making it difficult to stably fix multi-specification chain links and achieve dynamic following; third, existing equipment does not integrate an all-position cladding module, making it impossible to automatically plan the laser head posture and trajectory for flat links, vertical links, and corners. There is currently no integrated device in the industry that can simultaneously solve the problems of adaptability to ultra-long dimensions, efficient positioning, and fully automated cladding, greatly limiting the promotion of this technology in the field of mining equipment remanufacturing. Therefore, there is an urgent need to develop an integrated equipment that combines long-stroke drive, intelligent clamping, and collaborative control to achieve efficient and high-quality remanufacturing of ultra-long scraper conveyor chains. Summary of the Invention

[0005] The existing laser cladding technology suffers from poor processing capabilities and the inability to achieve dynamic following in the repair of worn scraper conveyor chains. Therefore, this invention provides an integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains. This invention aims to achieve high-precision and high-efficiency laser cladding remanufacturing of ultra-long scraper conveyor chains. It primarily utilizes the high-precision and controllable motion mechanism of multi-joint industrial robots and servo motors to precisely control parameters such as the laser cladding head posture and the rotation angle of the drive wheel, thereby completing laser cladding additive manufacturing that dynamically follows the complex curved surfaces and long distances of ultra-long scraper conveyor chains. The device also includes a chain guiding mechanism and a support and positioning mechanism, which solves the positioning and clamping problems of long chains during additive manufacturing, meeting the requirements for adaptability to ultra-long chain dimensions, efficient positioning, and fully automated cladding.

[0006] The technical means employed in this invention are as follows:

[0007] An integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains includes: a laser cladding mechanism, a chain guiding mechanism, a support and positioning mechanism, and an adjustment mechanism. The support and positioning mechanism includes a positioning plate and a positioning structure installed on one side of the positioning plate. The positioning plate is located at the lowest end of the integrated device and fixed to the ground. The chain guiding mechanism and the adjustment mechanism are both located above the positioning plate, and the laser cladding mechanism is located on one side of the integrated device.

[0008] The chain guiding mechanism includes a servo motor, a drive wheel, and a driven wheel. The servo motor is mounted on the other side of the positioning plate, and its output end is connected to the drive wheel. The driven wheel is connected above the positioning structure, and both sides of the scraper chain are meshed with the drive wheel and the driven wheel.

[0009] The laser cladding mechanism includes a multi-joint industrial robot and a laser cladding head. The multi-joint industrial robot is fixedly installed at a predetermined position within the working area. The laser cladding head is connected to the front end of the multi-joint industrial robot. The multi-joint industrial robot is used to realize the movement of the laser cladding head in spatial coordinates. The laser cladding head is used to perform cladding processing on the scraper conveyor chain.

[0010] The adjustment mechanism includes a positioning magnet, which is located on the top of the adjustment mechanism and is used to generate a controllable magnetic field in the working area to constrain the powder trajectory when the laser cladding head performs cladding processing on the scraper chain.

[0011] Furthermore, the positioning structure includes a slider, a support column, and a bearing. The slider is connected above the positioning plate, the support column is connected above the slider, and the driven wheel is connected to the top of the support column through the bearing.

[0012] Furthermore, the adjustment mechanism also includes a fixed magnet and a multi-degree-of-freedom adjustment mechanism. The fixed magnet is located at the bottom of the adjustment mechanism and is magnetically attracted to the positioning plate. The two sides of the multi-degree-of-freedom adjustment mechanism are respectively connected to the fixed magnet and the positioning magnet, and are used to adjust the direction and position of the positioning magnet.

[0013] Furthermore, the multi-joint industrial robot includes a multi-joint robotic arm and a drive system. The multi-joint robotic arm adopts a six-axis serial structure, with an integrated tool interface at the end connected to the laser cladding head. The tool interface is a flange structure. The drive system includes multiple high-precision AC servo motors to provide power to the multi-joint robotic arm and to realize various forms of movement of the laser cladding head through a control system. The multi-joint industrial robot control system drives the multi-joint robotic arm to work by reading the input program.

[0014] Furthermore, the driving wheel and the driven wheel are provided with limiting grooves that are the same shape as the scraper conveyor chain. The limiting grooves on the driving wheel and the driven wheel are paired and facing each other, adapting to the flat and vertical ring shapes of the chain during rotation. The driving wheel and the driven wheel are made of high-strength wear-resistant material.

[0015] Furthermore, a guide groove is provided on the positioning plate, and the slider is slidably connected to the guide groove to adjust the distance between the driving wheel and the driven wheel, thereby adjusting the tension of the scraper conveyor chain.

[0016] Furthermore, the positioning plate has threaded holes, and the servo motor, support column, and adjustment mechanism are all connected to the positioning plate by screws.

[0017] Furthermore, the positioning plate is located on the same horizontal plane as the bottom surface of the multi-joint industrial robot.

[0018] Furthermore, the servo motor and the drive wheel are interference-fitted.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] 1. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains provided by the present invention highly integrates chain conveying, precise positioning and laser cladding functions into a single equipment platform, which significantly simplifies the operation process and improves repair efficiency.

[0021] 2. The integrated device for laser cladding additive manufacturing of ultra-long scraper machine chains provided by the present invention combines the uniform and stable movement of the chain, the precise spatial positioning and dynamic tracking of the cladding head, and the precise synchronous application of energy and materials to ensure that the cladding layer has extremely high dimensional accuracy, uniformity and bonding strength on the complex moving chain surface (especially the flat ring / vertical ring transition area).

[0022] 3. The integrated device for laser cladding additive manufacturing of ultra-long scraper chain provided by the present invention combines the magnetic-assisted adjustment function of the adjustment mechanism with the multi-degree-of-freedom flexibility of the robot, effectively solving the problems of powder orientation deposition on complex curved surfaces of scraper chain links (such as grooves at hinges and sides of vertical rings) and the accessibility of the cladding head.

[0023] 4. The integrated device for laser cladding additive manufacturing of ultra-long scraper machine chains provided by the present invention, with its stable support base, wear-resistant chain guide components, and rigid positioning structure, ensures the overall rigidity and stability of the equipment under long-term, high-load cladding operations, reduces vibration interference, and improves process consistency and equipment lifespan.

[0024] Based on the above reasons, this invention can be widely applied in fields such as the processing of ultra-long scraper conveyor chains. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0027] Figure 2 This is a schematic diagram of the laser cladding mechanism of the present invention.

[0028] Figure 3 This is a schematic diagram of the chain guide mechanism of the present invention.

[0029] Figure 4 This is a schematic diagram of the supporting positioning mechanism of the present invention.

[0030] Figure 5 This is a schematic diagram of the adjustment mechanism of the present invention.

[0031] Figure 6 This is a schematic diagram of the structure of the multi-joint industrial robot of the present invention.

[0032] In the diagram: 1. Laser cladding mechanism; 2. Chain guiding mechanism; 3. Support and positioning mechanism; 4. Adjustment mechanism;

[0033] 11. Multi-joint industrial robot; 12. Laser cladding head; 111. Multi-joint robotic arm; 112. Drive system;

[0034] 21. Servo motor; 22. Drive wheel; 23. Driven wheel;

[0035] 31. Positioning plate; 32. Slider; 33. Support column; 34. Bearing;

[0036] 41. Fixed magnet; 42. Positioning magnet; 43. Multi-degree-of-freedom adjustment mechanism. Detailed Implementation

[0037] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0040] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0041] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0042] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0043] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0044] This invention provides an integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains. This device works in conjunction with the laser cladding additive manufacturing process, integrating a laser cladding system and a multi-joint industrial robot system. Under single-clamp conditions, it achieves highly efficient laser cladding additive manufacturing of worn areas on the scraper conveyor chain surface, significantly improving the repair efficiency of worn chains, reducing positioning errors caused by multiple clamping operations, and improving chain positioning and processing accuracy. This facilitates high-precision and high-efficiency laser cladding additive manufacturing of ultra-long scraper conveyor chains.

[0045] like Figure 1The diagram illustrates the overall structure of an integrated device embodiment for laser cladding additive manufacturing of ultra-long scraper conveyor chains proposed in this invention. The device is an integrated laser cladding equipment for scraper conveyor chain repair / reinforcement, mainly comprising: a laser cladding mechanism 1, a chain guiding mechanism 2, a support and positioning mechanism 3, and an adjustment mechanism 4. The support and positioning mechanism 3 serves as the support for the entire device, located at the lower end of the chain guiding mechanism 2 and fixedly mounted on the ground, ensuring the equipment is vibration-resistant and anti-tipping during operation, providing a reliable support platform for each mechanism. The chain guiding mechanism 2 is fixedly installed on top of the support and positioning mechanism 3, and its core function is... It can precisely guide and drive the scraper chain to be processed to move smoothly and at a constant speed along a predetermined path; the support and positioning mechanism 3 is set below the chain guide mechanism 2; the core function of the support and positioning mechanism 3 is to accurately position and stabilize the spatial position of the chain guide mechanism 2 relative to the moving chain; the laser cladding mechanism 1 is suspended directly above the chain guide mechanism 2 and the moving chain; as the core processing unit, its function is to receive the control system command and drive the laser cladding head to move along a precisely programmed trajectory in three-dimensional space, so as to synchronously apply the high-energy laser beam and metal powder to the surface of the moving scraper chain to achieve high-quality cladding layer deposition.

[0046] The laser cladding mechanism 1 includes a multi-joint industrial robot 11 and a laser cladding head 12. The multi-joint industrial robot 11, as the motion execution unit of the laser cladding mechanism 1, is fixedly positioned at a predetermined location within the working area, at the rightmost end of the laser cladding mechanism 1. This robot has six degrees of freedom, and its end effector flange is used for rigid mounting and precise positioning of the laser cladding head 12, which is located at the frontmost end of the laser cladding mechanism 1. By receiving instructions from the control system, the multi-joint industrial robot 11 can drive the laser cladding head 12 to move along any predetermined trajectory in a three-dimensional coordinate system with high precision and repeatability, realizing flexible programming and execution of the cladding path on the scraper conveyor chain surface. The laser cladding head 12, serving as the energy and material interaction terminal of the mechanism, is fixedly mounted on the end effector flange of the multi-joint industrial robot 11, and thus located at the working front end of the laser cladding mechanism 1. The laser cladding head 12 integrates a laser focusing optical path and a powder conveying channel. The nozzle of the laser cladding head 12 adopts a conical design and is made of high-temperature resistant and thermal shock resistant material to adapt to high-power laser irradiation and the high-temperature environment of the molten pool. The laser cladding head 12 is connected to an external laser generator via a high-power optical fiber to receive and focus a high-energy-density laser beam onto a predetermined area on the workpiece surface. The laser cladding head 12 is connected to an external powder feeder via a powder feeding pipeline. The powder feeder delivers metal powder of a preset composition (such as iron-based, nickel-based, or cobalt-based alloy powder) to the workpiece surface. Controllable flow rate and volume are conveyed through the powder conveying channel inside the laser cladding head 12 to its nozzle outlet, where it precisely intersects with the focused laser beam on the workpiece surface. A multi-joint industrial robot 11 is connected to the central control system via a control cable, receiving motion trajectory commands and precisely coordinating the spatial pose and speed of the laser cladding head 12. According to a preset program, the multi-joint industrial robot 11 precisely moves the laser cladding head 12 to the initial cladding position on the scraper conveyor chain link surface. The high-power laser beam output from the laser generator is transmitted via optical fiber and focused within the laser cladding head 12, forming a high-energy-density spot acting on the workpiece surface. The powder feeder delivers metal powder through the powder feeding pipeline and the laser cladding head 12, simultaneously... The laser beam precisely delivers the powder to the laser spot's action area using either a axial or off-axis method. Under the high energy of the laser beam, the metal powder melts instantly, forming a molten pool. As the multi-jointed industrial robot 11 drives the laser cladding head 12 in continuous movement, the powder is deposited layer by layer and rapidly solidified on the workpiece substrate surface, forming a metallurgically bonded cladding layer. The conical design significantly reduces the space occupied at the nozzle tip, making it particularly advantageous for cladding operations within or near the surface of complex, space-constrained scraper conveyor chain links, avoiding interference with the workpiece. High-temperature resistant materials ensure that the nozzle maintains structural integrity and dimensional stability under long-term exposure to radiant heat from the molten pool and potential impacts from splashing molten metal particles, extending its service life and reducing maintenance downtime.The high flexibility and multi-degree-of-freedom motion capability of the multi-joint industrial robot 11, combined with the precise positioning of the laser cladding head 12, enable the laser cladding mechanism 1 to perfectly adapt to the complex three-dimensional curved surface contours of workpieces such as scraper conveyor chains, achieving precise tracking of the cladding trajectory at all positions. The high repeatability of the multi-joint industrial robot 11 ensures high uniformity and consistency in the thickness, width, and overlap rate of the cladding layer, significantly improving cladding quality. Automated path programming and execution greatly improve the efficiency and automation of the cladding process, making it suitable for batch repair or manufacturing.

[0047] The chain guide mechanism 2 includes a servo motor 21, a drive wheel 22, and a driven wheel 23. The drive wheel 22 is located at the uppermost end of the chain guide mechanism 2 and is connected to the scraper conveyor chain and the servo motor 21. The servo motor 21 is located at the leftmost end of the chain guide mechanism 2 and is connected to the drive wheel 22 and the support positioning mechanism 3. The driven wheel 23 is located at the rightmost end of the chain guide mechanism 2 and is connected to the scraper conveyor chain and the support positioning mechanism 3.Specifically, the servo motor 21, as the power source of the chain guide mechanism 2, is fixedly installed at a predetermined position on the frame of the chain guide mechanism 2; the output shaft of the servo motor 21 is directly and rigidly connected to the central shaft hole of the drive wheel 22 through an interference fit, ensuring efficient and slip-free power transmission; the servo motor 21 body is fixedly connected to the external support positioning mechanism 3 to ensure overall stability; the drive wheel 22 is set at a predetermined position on the chain guide mechanism 2; its rim is precision machined with a limiting groove that matches the cross-sectional profile of the scraper conveyor chain link, which can effectively adapt to the flat and vertical ring shapes of the chain during rotation; the drive wheel 22 is directly subjected to the aforementioned interference fit. The servo motor 21 drives the drive wheel 22, which is made of high-strength wear-resistant material to withstand the load transmitted by the chain meshing and resist long-term wear. The driven wheel 23 is located at a predetermined position on the chain guide mechanism 2 and is spaced apart from the drive wheel 22 along the chain transmission direction. Its rim is also precision-machined with limiting grooves that are identical in structure to and relatively distributed with the limiting grooves of the drive wheel 22. The driven wheel 23 is also made of high-strength wear-resistant material. The driven wheel 23 is connected to the support positioning mechanism 3 via a bearing 34 assembly. Specifically, the inner ring of the bearing 34 is fixedly mounted on the support column 33 of the support positioning mechanism 3 by an interference fit, and the outer ring of the bearing 34 is aligned with the center of the driven wheel 23. The driven wheel 23 is fixedly connected to the support positioning mechanism 3, thus enabling free rotation of the driven wheel 23 relative to the support positioning mechanism 3. The limiting grooves on the driving wheel 22 and the driven wheel 23 are paired and facing each other, forming a continuous limiting space between them that matches the cross-sectional shape of the scraper conveyor chain links. When the servo motor 21 drives the driving wheel 22 to rotate, the chain links of the scraper conveyor chain are precisely constrained within this limiting space, ensuring a stable and reliable meshing between the chain and the driving wheel 22 and the driven wheel 23. The contour design of the limiting grooves can effectively accommodate and adapt to the height changes and shape differences of the scraper conveyor chain caused by structural characteristics during operation, significantly reducing the chain's stress at high speeds or under varying loads. The risk of jumping, slipping, or derailment during operation is reduced; the matched profile design helps to evenly distribute the chain tension on the contact surface of the limiting groove, reducing stress concentration and further extending the service life of the wheel and chain; both the drive wheel 22 and the driven wheel 23 are made of high-strength wear-resistant materials, which can withstand the large tension and impact load transmitted by the scraper conveyor chain, greatly reducing the wear rate between the wheel and the chain links, especially under harsh working conditions such as dust and high load, effectively extending the replacement cycle and maintenance interval of key components; the high hardness and stability of the material help to maintain the precise geometry of the limiting groove, ensuring the reliability and consistency of the guiding function during long-term operation.

[0048] The support positioning mechanism 3 includes a positioning plate 31, a slider 32, a support column 33, and a bearing 34. The positioning plate 31 serves as the base of the support positioning mechanism 3 and is fixedly installed at the bottom of the integrated device. Two parallel slides (guide grooves) are arranged on the upper surface of the positioning plate 31 to guide the linear sliding of the slider 32. One end of the positioning plate 31 is connected and fixed to the servo motor 21 (the positioning plate 31 has threaded holes, and the servo motor 21 is connected to the positioning plate 31 through the threaded holes and screws), and the other end is connected to the slider 32. The slider 32 is slidably installed above the positioning plate 31, specifically fitted into the two parallel slides, and slidably connected to the slides. It can adjust the distance between the driving wheel 22 and the driven wheel 23, thereby adjusting the tension of the scraper conveyor chain. The slider 32 is rigidly connected to the positioning plate 31 by four fastening screws. By moving the slider 32 along the slide rail, the center distance between the support column 33 (and the driven wheel 23 connected to its top) and the driving wheel 22 driven by the servo motor 21 can be precisely adjusted to accommodate chains of different specifications or to achieve chain tension. The support column 33 is vertically fixed above the slider 32. The bottom of the support column 33 is designed in the shape of a frustum to increase the contact area with the slider 32 and optimize the force transmission path, thereby significantly enhancing the vibration resistance and overall stability of the support positioning mechanism 3 during high-speed chain movement. The top of the support column 33 is connected to the shaft of the driven wheel 23 of the chain guide mechanism 2 through a bearing 34 assembly, providing support for the driven wheel 23 and transmitting the load.

[0049] The adjustment mechanism 4 includes a fixed magnet 41, a positioning magnet 42, and a multi-degree-of-freedom adjustment mechanism 43. The fixed magnet 41 is fixedly disposed at the bottom of the adjustment mechanism 4. The fixed magnet 41 uses its magnetic attraction to firmly attract and fix the entire adjustment mechanism 4 to the upper surface of the positioning plate 31. The multi-degree-of-freedom adjustment mechanism 43 is connected between the fixed magnet 41 and the positioning magnet 42 and is used to adjust the direction and position of the positioning magnet 42. The multi-degree-of-freedom adjustment mechanism 43 is configured to precisely adjust the position and orientation of the positioning magnet 42 connected to it in space. The positioning magnet 42 is disposed at the top of the adjustment mechanism 4 and is fixedly connected to the output end of the multi-degree-of-freedom adjustment mechanism 43. The positioning magnet 42 is configured to generate a controllable magnetic field in the working area. When the laser cladding head 12 performs cladding processing on the scraper chain, the conveyed metal powder is mainly affected by the powder feeding gas force and gravity. For scraper chains with complex curved surfaces, relying solely on gravity and airflow, it is difficult for the powder to achieve stable, uniform, and precise directional deposition, which can easily lead to powder scattering, deposition position deviation, or uneven cladding layer. To address issues such as uniformity, the adjustment mechanism 4 applies a controllable magnetic field to the working area via the positioning magnet 42, generating additional magnetic force on the metal powder (especially ferromagnetic or paramagnetic powder). This magnetic force, in conjunction with the powder's own gravity and airflow dynamics, effectively constrains the powder trajectory, overcomes interference from the powder delivery airflow, suppresses powder scattering, and significantly improves powder utilization. It guides the directional deposition of powder. By adjusting the multi-degree-of-freedom adjustment mechanism 43, the distribution and intensity gradient of the magnetic field generated by the positioning magnet 42 in space can be flexibly changed, thereby precisely guiding the powder flow to and adsorbing it to a predetermined position on the complex curved surface of the chain. The magnetic force helps the powder adhere more tightly to the chain surface, achieving stable and uniform pre-positioning even in curved areas where gravity is unfavorable. Under the controllable magnetic field generated by the positioning magnet 42, combined with the precise control of the magnetic field direction and position by the multi-degree-of-freedom adjustment mechanism 43, the problem of difficult directional powder deposition on complex curved surfaces of the scraper conveyor chain can be effectively solved, significantly improving the forming accuracy, uniformity, bonding strength, and overall cladding quality of the cladding layer on complex curved surfaces. The adjustment mechanism 4 controls the directional movement of the laser cladding powder by adjusting the direction and position of the positioning magnet 42, thereby achieving precise repair of the worn position of the scraper conveyor chain.

[0050] The multi-joint industrial robot 11 includes a multi-joint robotic arm 111 and a matching drive system 112. The multi-joint robotic arm 111 adopts a six-degree-of-freedom serial configuration, specifically comprising a first axis to a sixth axis connected sequentially along the direction from the base to the end effector. The first axis is located at the base of the multi-joint robotic arm 111 and is connected to the fixed base via a rotary joint. The second to fifth axes are connected end-to-end via rotary joints, forming the main structure of the multi-joint robotic arm 111. The sixth axis is located at the farthest end of the multi-joint robotic arm 111, and its end is integrated with a tool interface. The tool interface is preferably a standardized flange structure for reliably connecting to and driving the laser cladding head 12. The drive system 112... 12 includes multiple high-precision AC servo motors, which respectively drive the joint movements of the first to sixth axes. The drive system 112 works in coordination under the precise instructions of the control system to provide the laser cladding head 12 with high-precision and high-dynamic performance motion capabilities in multi-dimensional space, including but not limited to: precise linear translation along the X, Y, and Z axes; precise rotational motion around the X, Y, and Z axes; and complex spatial synthesis motion of the above motions. Furthermore, the multi-joint robotic arm 111 is designed with high rigidity and low vibration transmission characteristics to ensure the positioning accuracy and trajectory tracking accuracy of the end position when the laser cladding head 12 is integrated for additive manufacturing of scraper chain.

[0051] The control system of the multi-joint industrial robot 11 constitutes the core drive unit of the multi-joint robotic arm 111. It controls the motion trajectory and task of the end effector of the multi-joint robotic arm 111 by parsing and executing the input program. The input program is generated by the dedicated offline programming and simulation software Robot-Art (existing software). The control system runs in the KUKA.OfficeLite virtual simulation platform environment and adopts a layered architecture design, with the core control layer based on KUKA. Implemented using the RobotLanguage programming language, the system also provides flexible expansion and customization capabilities for upper-layer applications through open Java / .NET interfaces. At the motion control level, the control system integrates eight configurable working modes, from T1 to T8, to adapt to the safety and accuracy requirements of different application scenarios. Its trajectory planning engine is powerful and versatile, supporting various high-precision trajectory planning methods, including linear interpolation, circular interpolation, and spline curve fitting, ensuring smooth and accurate execution of complex spatial paths. Furthermore, the control system innovatively integrates an artificial intelligence module. This module, based on deep learning algorithms, dynamically analyzes historical operation data, environmental parameters, and robotic arm status information to perform real-time online optimization of motion paths, speed curves, and work cycles, significantly improving production efficiency and system responsiveness. In terms of system integration and communication, the control system has built-in support for OPCUA, PROFINET, EtherNet / IP, and Modbus. The system natively supports mainstream industrial communication protocols such as TCP / IP, building an open and standardized data interaction channel. It can seamlessly achieve data interaction and collaborative control with shop floor programmable logic controllers, manufacturing execution systems, and even enterprise resource planning systems, breaking down information silos and providing a solid foundation for flexible and intelligent manufacturing.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains, characterized in that, include: The laser cladding mechanism (1), chain guide mechanism (2), support and positioning mechanism (3) and adjustment mechanism (4) are provided. The support and positioning mechanism (3) includes a positioning plate (31) and a positioning structure installed on one side of the positioning plate (31). The positioning plate (31) is located at the bottom of the integrated device and fixed on the ground. The chain guide mechanism (2) and adjustment mechanism (4) are both located above the positioning plate (31). The laser cladding mechanism (1) is located on one side of the integrated device. The chain guide mechanism (2) includes a servo motor (21), a drive wheel (22), and a driven wheel (23). The servo motor (21) is installed on the other side of the positioning plate (31). The output end of the servo motor (21) is connected to the drive wheel (22). The driven wheel (23) is connected above the positioning structure. The two sides of the scraper chain are meshed with the drive wheel (22) and the driven wheel (23). The laser cladding mechanism (1) includes a multi-joint industrial robot (11) and a laser cladding head (12). The multi-joint industrial robot (11) is fixedly set at a predetermined position in the working area. The laser cladding head (12) is connected to the front end of the multi-joint industrial robot (11). The multi-joint industrial robot (11) is used to realize the movement of the laser cladding head (12) in spatial coordinates. The laser cladding head (12) is used to perform cladding processing on the scraper conveyor chain. The adjustment mechanism (4) includes a positioning magnet (42) which is located on the top of the adjustment mechanism (4) to generate a controllable magnetic field in the working area and generate an additional magnetic force on the metal powder. The magnetic force works in conjunction with the powder's own gravity and airflow to constrain the powder trajectory when the laser cladding head (12) performs cladding processing on the scraper chain. The adjustment mechanism (4) further includes a fixed magnet (41) and a multi-degree-of-freedom adjustment mechanism (43). The fixed magnet (41) is located at the bottom of the adjustment mechanism (4) and is magnetically attached to the positioning plate (31). The two sides of the multi-degree-of-freedom adjustment mechanism (43) are connected to the fixed magnet (41) and the positioning magnet (42) respectively, and are used to adjust the direction and position of the positioning magnet (42). The multi-degree-of-freedom adjustment mechanism (43) is configured to precisely adjust the position and attitude of the positioning magnet (42) connected to it in space. By adjusting the multi-degree-of-freedom adjustment mechanism (43), the distribution and intensity gradient of the magnetic field generated by the positioning magnet (42) in space can be flexibly changed, thereby accurately guiding the powder to flow to and adsorb to the predetermined position of the complex curved surface of the chain. The multi-joint industrial robot (11) includes a multi-joint robotic arm (111) and a drive system (112). The multi-joint robotic arm (111) adopts a six-axis serial structure, and the end-effector is connected to the laser cladding head (12). The drive system (112) includes multiple high-precision AC servo motors to provide power to the multi-joint robotic arm (111) and realize various forms of movement of the laser cladding head (12) through the control system. By utilizing the high-precision controllable motion mechanism of the multi-joint industrial robot (11) and the servo motors, the precise control of the posture of the laser cladding head (12) and the rotation angle parameters of the drive wheel (22) is realized, thereby completing the laser cladding additive manufacturing of complex curved surfaces and long-distance dynamic following of ultra-long scraper chain. The chain guide mechanism (2) is fixedly installed on the support and positioning mechanism (3). Its core function is to precisely guide and drive the scraper chain to be processed to move smoothly and at a constant speed along a predetermined path. The core function of the support and positioning mechanism (3) is to precisely position and stabilize the spatial position of the chain guide mechanism (2) relative to the moving chain. The laser cladding mechanism (1) is the core processing unit. Its function is to receive instructions from the control system and drive the laser cladding head (12) to move along a precisely programmed trajectory in three-dimensional space. The high-energy laser beam and metal powder are applied synchronously to the surface of the moving scraper chain to achieve high-quality cladding layer deposition.

2. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 1, characterized in that, The positioning structure includes a slider (32), a support column (33) and a bearing (34). The slider (32) is connected above the positioning plate (31), the support column (33) is connected above the slider (32), and the driven wheel (23) is connected to the top of the support column (33) through the bearing (34).

3. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 1, characterized in that, The tool interface is a flange structure; the control system of the multi-joint industrial robot (11) drives the multi-joint robotic arm (111) to work by reading the input program.

4. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 1, characterized in that, The drive wheel (22) and driven wheel (23) are provided with limiting grooves that are the same shape as the scraper conveyor chain. The limiting grooves on the drive wheel (22) and driven wheel (23) are paired and facing each other, adapting to the flat and vertical ring shapes of the chain during rotation. The drive wheel (22) and driven wheel (23) are made of high-strength wear-resistant material.

5. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 2, characterized in that, The positioning plate (31) has a guide groove, and the slider (32) is slidably connected to the guide groove to adjust the distance between the driving wheel (22) and the driven wheel (23), thereby adjusting the tension of the scraper conveyor chain.

6. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 2, characterized in that, The positioning plate (31) has threaded holes, and the servo motor (21) is connected to the positioning plate (31) by screws.

7. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 1, characterized in that, The positioning plate (31) and the bottom surface of the multi-joint industrial robot (11) are on the same horizontal plane.

8. The integrated device for laser cladding additive manufacturing of ultra-long scraper conveyor chains according to claim 1, characterized in that, The servo motor (21) and the drive wheel (22) are interference fit.

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