Fracturing valve body inner wall laser repairing system and method

Abstract

The invention belongs to the technical field of valve body inner wall repairing, and particularly relates to a fracturing valve body inner wall laser repairing system and method.The laser repairing system comprises a laser generator control cabinet, a powder feeder, a positioner, a valve body to be repaired, a machining head, a mechanical arm, a mechanical arm control cabinet, a voltage-stabilized source and a cooling-water machine; the positioner is used for installing and fixing a to-be-repaired valve body and can drive the to-be-repaired valve body to rotate, the mechanical arm can drive the machining head to enter the to-be-repaired valve body under the action of the mechanical arm control cabinet to complete the machining action, and the voltage-stabilized source is used for providing power output for the system. The cooling-water machine is used for providing cooling water for the laser generator control cabinet and the machining head. The problem of local repairing in the limited space in the valve body is solved, meanwhile, only one-time clamping and positioning are needed to be conducted on the valve body, time can be saved, the machining size precision can be guaranteed, and the problem that the size is out of tolerance in the machining process is avoided.

Description

Technical Field

[0001] This invention belongs to the field of valve body inner wall repair technology, specifically relating to a laser repair system and method for the inner wall of a fracturing valve body. Background Technology

[0002] The fracturing valves used in shale gas extraction operate under conditions of high pressure, corrosive media, and mud erosion. Therefore, localized wear and corrosion damage easily occurs at the contact points between the valve body and seat, leading to leakage during fracturing. Severe leakage can cause fracturing failure, necessitating timely replacement of damaged valve bodies. Furthermore, due to the high cost of valve bodies, simply scrapping them without repair would result in significant economic losses. Therefore, repairing the valve bodies can bring considerable economic benefits to the user.

[0003] Traditional valve body repair techniques mainly use electric arc welding. However, due to the large heat input of electric arc welding, thermal cracks are easily generated at the repair site during the repair process. Moreover, these thermal cracks are often hidden and are usually exposed during subsequent machining or even after machining is completed, leading to the failure of the entire repair process.

[0004] Compared with electric welding, laser cladding has advantages such as low heat input, minimal impact on the substrate, and dense cladding structure, making it a very reliable technical approach to avoid cracks during valve body repair.

[0005] Conventional laser cladding repair processes typically involve several steps: pre-processing (treating the surface to be repaired to meet the conditions for laser cladding, such as using turning, milling, or grinding to make irregular surfaces more regular, facilitating CNC / robotic programming for laser cladding repair), laser cladding, and post-processing (machining the laser-clad area to achieve the final dimensional accuracy and surface quality requirements). The processing and cladding processes are performed by different equipment, meaning the part needs to be clamped and positioned three times. However, for internal repairs of parts like valve bodies, clamping and positioning for each step not only reduces processing efficiency (part transfer and positioning takes time) but also increases the chance of machining errors. Therefore, achieving pre-processing + laser cladding + post-processing in a single clamping operation would significantly improve these issues. Summary of the Invention

[0006] The purpose of this invention is to solve the problem that the inner wall of a valve body needs to be clamped and positioned multiple times during the repair process in the prior art, and to provide a laser repair system and method for the inner wall of a fracturing valve body.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is: a laser repair system for the inner wall of a fracturing valve body, comprising: A laser generator control cabinet, which is used to provide the high-power laser beam required for laser cladding; A powder feeder is used to provide the alloy powder flow required for laser cladding; A positioner, which is used to install and fix the valve body to be repaired and can drive the valve body to be repaired to rotate. The robotic arm, under the control of the robotic arm control cabinet, can drive the processing head into the valve body to be repaired to complete the processing action; A regulated power supply, wherein the regulated power supply is used to provide power output to the system; A chiller is used to provide cooling water for the laser generator control cabinet and the processing head.

[0008] Preferably, the processing head is detachably connected to the robotic arm, and the processing head is a laser cladding head or a grinding head.

[0009] Preferably, one robotic arm is provided, and the laser cladding head and the grinding head are connected to the robotic arm in sequence according to the processing order.

[0010] Preferably, two robotic arms are provided, and the two robotic arms are used to connect the laser cladding head and the grinding head respectively.

[0011] Preferably, the valve body to be repaired is vertically clamped on the positioner, and the processing head enters the interior of the valve body to be repaired through the top through hole.

[0012] A laser repair method for the inner wall of a fracturing valve body, employing the aforementioned laser repair system, includes the following steps: S1. Fix the valve body to be repaired onto the positioner; S2. Program the robot motion control for the valve body to be repaired using the robot offline programming tool, and then transmit the motion control program to the robot control cabinet; S3. The robotic arm drives the grinding head into the valve body to be repaired to pre-process the area to be repaired. S4. After pre-processing is completed, the robot arm drives the grinding head to exit the valve body to be repaired, and then drives the laser cladding head into the valve body to be repaired to perform laser cladding repair processing on the area to be repaired. S5. After completing the laser cladding repair process, the robot arm drives the laser cladding head out of the valve body, and then drives the grinding head into the valve body to perform post-processing on the laser cladding repair area to achieve the required size and surface accuracy of the valve body. S6. After the processing is completed, the robot arm drives the grinding head to exit the valve body and remove the valve body from the positioner, thus completing the entire repair process.

[0013] Preferably, the motion control program in S1 includes a pre-grinding program, a laser cladding program, and a post-processing program.

[0014] After adopting the above technical solution, the laser repair system and method for the inner wall of a fracturing valve body provided by the present invention has the following beneficial effects: 1) This invention solves the problem of local repair in the confined space inside the valve body, and at the same time avoids the situation where traditional electric welding repair is prone to cracking, which leads to the scrapping of the entire part; 2) The laser repair system of the present invention integrates pre-grinding, laser cladding and post-processing, which can replace the processing of multiple independent devices, and at the same time can speed up the repair process and improve the repair efficiency; 3) The entire repair process of this invention only requires clamping and positioning the valve body once. There is no need to move and re-clamp the valve body at different processing steps, which can save time and ensure the dimensional accuracy of the processing, avoiding the problem of dimensional deviation during the processing. 4) This invention can complete the entire repair process with a single programming, which can further improve the repair effect and efficiency. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of a laser repair system for the inner wall of a fracturing valve body according to the present invention; Figure 2 This is a partial flowchart illustrating a laser repair method for the inner wall of a fracturing valve body according to the present invention. Figure 3 This is a schematic diagram illustrating the switching process of the processing head during the processing of the present invention.

[0016] The components include: 1. Laser generator control cabinet; 2. Powder feeder; 3. Positioner; 4. Valve body to be repaired; 5. Processing head; 6. Robotic arm; 7. Robotic arm control cabinet; 8. Voltage regulator; 9. Chiller. Detailed Implementation

[0017] The present invention will now be described more clearly and completely with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0018] 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 exemplary embodiments according to this application. 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.

[0019] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth 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.

[0020] 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.

[0021] For ease of description, spatial relative terms such as "above," "on top of," "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 beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" 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.

[0022] 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.

[0023] like Figure 1 As shown, the present invention provides a laser repair system for the inner wall of a fracturing valve body, comprising a laser generator control cabinet 1, a powder feeder 2, a positioner 3, a valve body to be repaired 4, a processing head 5, a robotic arm 6, a robotic arm control cabinet 7, a regulated power supply 8, and a chiller 9. The laser generator control cabinet 1 provides the high-power laser beam required for laser cladding; the powder feeder 2 provides the alloy powder flow required for laser cladding; the positioner 3 is used to install and fix the valve body to be repaired 4 and can drive the valve body to be repaired to rotate; the robotic arm 6, under the action of the robotic arm control cabinet 7, can drive the processing head 5 into the interior of the valve body to be repaired 4 to complete the processing action; the regulated power supply 8 provides power output to the system; and the chiller 9 provides cooling water to the laser generator control cabinet 1 and the processing head 5 to ensure that the laser generator control cabinet 1 and the processing head 5 are within a stable operating temperature range.

[0024] In this embodiment, the processing head 5 is detachably connected to the robotic arm 6, and the processing head 5 is a laser cladding head or a grinding head. Furthermore, one or two robotic arms 6 are provided. When one robotic arm 6 is provided, the laser cladding head and the grinding head can be connected to the robotic arm 6 in sequence according to the processing order. When two robotic arms 6 are provided, the two robotic arms 6 can be used to connect the laser cladding head and the grinding head respectively. That is, during the processing, there is no need to change the processing head 5 on the robotic arm 6, but you can directly change different robotic arms 6 to work.

[0025] It should be noted that in this embodiment, the valve body 4 to be repaired is vertically clamped on the positioner 3. The purpose is to facilitate the processing head 5 to enter the interior of the valve body 4 through the top through hole to repair the repair area. During the repair process, the positioner 3 simultaneously drives the valve body 4 to rotate.

[0026] like Figure 2-3 As shown, the present invention also provides a laser repair method for the inner wall of a fracturing valve body, which uses the above-mentioned laser repair system and includes the following steps: S1. Fix the valve body to be repaired onto the positioner; S2. The robot motion control program is programmed for the valve body to be repaired using the robot offline programming tool, and the motion control program is transmitted to the robot control cabinet. The motion control program includes a pre-grinding program, a laser cladding program, and a post-processing program. S3. The robotic arm drives the grinding head into the valve body to be repaired and runs the pre-grinding program to pre-process the area to be repaired. S4. After pre-processing is completed, the robot arm drives the grinding head to exit the valve body to be repaired, and then drives the laser cladding head into the valve body to be repaired, and runs the laser cladding program to perform laser cladding repair processing on the area to be repaired. S5. After completing the laser cladding repair process, the robot arm drives the laser cladding head out of the valve body, and then drives the grinding head into the valve body to run the post-processing program to perform post-processing on the laser cladding repair area to achieve the required size and surface accuracy of the valve body. S6. After the processing is completed, the robot arm drives the grinding head to exit the valve body and remove the valve body from the positioner, thus completing the entire repair process.

[0027] In summary, the laser repair system and method for the inner wall of a fracturing valve body provided by this invention solves the problem of local repair within the confined space inside the valve body. It also avoids the common problem of cracks easily caused by traditional electric welding repairs, which can lead to the scrapping of the entire part. This invention offers advantages such as good repair effect and high repair efficiency. Furthermore, the entire repair process of this invention only requires one clamping and positioning of the valve body, eliminating the need for handling and re-clamping at different processing steps. This saves time and ensures dimensional accuracy, preventing dimensional deviations during processing.

[0028] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A laser repair system for a fracturing valve body inner wall, characterized in that, It comprises: A laser generator control cabinet (1) for providing high-power laser beams required for laser cladding; A powder feeder (2) for providing alloy powder flow required for laser cladding; A positioner (3) for mounting and fixing the valve body (4) to be repaired and enabling the valve body (4) to be repaired to rotate; A manipulator (6) capable of driving the processing head (5) to enter the inside of the valve body (4) to be repaired to complete the processing action under the action of the manipulator control cabinet (7); A stabilized power supply (8) for providing power output for the system; A water chiller (9) for providing cooling water for the laser generator control cabinet (1) and the processing head (5).

2. The system for laser repair of a fracturing valve body inner wall according to claim 1, characterized in that: The processing head (5) is detachably connected to the manipulator (6), and the processing head (5) is a laser cladding head or a grinding head.

3. The laser repair system for a fracturing valve body inner wall of claim 2, wherein: The manipulator (6) is provided with one, and the laser cladding head and the grinding head are connected to the manipulator (6) in turn according to the processing sequence.

4. The laser repair system for a fracturing valve body inner wall of claim 2, wherein: The manipulator (6) is provided with two, and the two manipulators (6) are respectively used for connecting the laser cladding head and the grinding head.

5. The laser repair system for a fracturing valve body inner wall of claim 1, wherein: The valve body (4) to be repaired is vertically clamped on the positioner (3), and the processing head (5) enters the inside of the valve body (4) to be repaired through the through hole at the top of the valve body (4) to be repaired.

6. A method of laser repair of a fracturing valve body inner wall, characterized in that, The laser repair system according to any one of claims 1-5 comprises the following steps: S1, fixing the valve body to be repaired to the positioner; S2, programming the motion control of the manipulator for the valve body to be repaired through the manipulator offline programming tool, and transmitting the motion control program to the manipulator control cabinet; S3, the manipulator drives the grinding head to enter the inside of the valve body to be repaired to pre-process the repair area; S4, after the pre-processing is completed, the manipulator drives the grinding head to exit the valve body to be repaired, and then drives the laser cladding head to enter the inside of the valve body to be repaired to perform laser cladding repair processing on the repair area; S5, after the laser cladding repair processing is completed, the manipulator drives the laser cladding head to exit the valve body, and then drives the grinding head to enter the inside of the valve body to perform post-processing on the laser cladding repair area to achieve the required size and surface precision of the valve body; S6, after the post-processing is completed, the manipulator drives the grinding head to exit the valve body, and then takes down the valve body from the positioner, thereby completing the entire repair process.

7. The method of claim 6, wherein: The motion control program in S1 comprises a pre-grinding program, a laser cladding program and a post-processing program.

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