Intelligent feedback magnetic stirring equipment for quantitative and uniform preparation of powder and cladding process method

Abstract

The invention provides intelligent feedback magnetic stirring equipment for quantitative and uniform preparation of powder and a cladding process method, and relates to the technical field of laser cladding equipment. The equipment comprises a low-speed stirring and heating device, an X-ray emitting device, a three-phase asynchronous stirring device, a three-way shunt, a high-speed camera shooting feedback system, a cladding platform device and a cladding device, wherein the low-speed stirring and heating device comprises a powder tank, a low-speed stirrer, a mixer, an auger blade and a heater; a first powder feeding detection passage and a second powder feeding detection passage are arranged in the X-ray emitting device; the three-phase asynchronous stirring device comprises a tank body, a driver, a stirring bin, a winding coil and a non-magnetic metal rod; the cladding device comprises a cladding head, and the cladding platform device comprises a cladding platform. The intelligent feedback magnetic stirring device for quantitative and uniform preparation of powder is introduced, and real-time monitoring and intelligent feedback are combined, so that the mixed powder is heated, crushed and uniformly stirred, and a cladding layer with a stable structure is obtained.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of laser cladding equipment, in particular, especially relates to a powder quantitative and uniform preparation intelligent feedback magnetic stirring equipment and a cladding process method. BACKGROUND

[0002] In the laser cladding technology, the powder feeder is the core device for realizing accurate powder supply, and its performance directly affects the composition uniformity, thickness consistency and forming quality of the cladding layer. At present, the widely used powder feeder mainly includes "air flow type" and "mechanical type", both of which have their own advantages, but still have certain limitations in actual application. Especially when the powder composition needs to be adjusted, such as introducing new alloy elements or reconfiguring the original element ratio, the problem of uneven stirring often occurs, which directly affects the subsequent process effect. Specifically, although the air flow type powder feeder can effectively isolate impurities with the help of inert gas, it is easy to mix unevenly when conveying multi-component composite powder, and even cause blockage due to powder caking; the mechanical type powder feeder pays attention to the strong viscosity adaptability and good proportioning of the powder, but due to the influence of inertia, the powder supply is easy to be excessive or insufficient in a short time, and the existing process still needs to be adjusted through multiple experiments to mix the powder ratio, such as the amount of S element added to achieve the appropriate ratio to improve the size and direction of the eddy current in the molten pool. Therefore, the present application completes the breaking of large lumps in the mixed powder by installing a heater and a small non-magnetic metal rod in the stirrer, the high-speed stirring makes the mixed powder fully stirred and uniform, and the feedback system detects the molten pool state to control the execution device and other cooperation modes to work together to complete the comprehensive consideration of the advantages and disadvantages of the above two and related directions in the industry.

[0003] Therefore, the present application proposes a new structure, which introduces a rotating magnetic field driven by three-phase alternating current in high-speed stirring to complete the sufficient stirring of the powder containing trace elements. However, when the stirring speed is too low, the mixed powder is not stirred evenly, resulting in obvious stratification in the molten pool, uneven organization of the cladding layer, and defects; when the stirring speed is too high, the centrifugal force is too large, causing the separation of different molecular content elements. At the same time, the feedback system is used to monitor the flow state in the molten pool to control the discharging speed of the surface active element (such as S element) powder tank in the low-speed stirring and heating device. In summary, the homogenization rate of the mixed powder and the content of the surface active element (such as S element) will affect the performance of the cladding layer. The homogenization rate of the mixed powder can be adjusted by the stirring speed, and the content of the surface active element (such as S element) can be adjusted by the calculation system. Different active element (such as S element) content and mixed powder homogenization rate have a greater impact on the performance of the cladding layer, and if multiple attempts are needed before cladding to select the best parameters, the process will increase the production cost and production cycle, and reduce the production efficiency.

[0004] In summary, in laser cladding, whether introducing new elements or adjusting the original element ratio, there is a core contradiction: low-speed stirring leads to uneven mixing, and high-speed stirring causes component separation due to centrifugal force. This contradiction makes the process parameters highly dependent on repeated trial and error, greatly restricting production efficiency and cost control. Therefore, the present application aims to provide a set of equipment and process methods that fundamentally solve this contradiction.

[0005] The patent document with publication number CN120249972A discloses an automatic feeding device for a laser cladding powder feeder. This invention can continuously feed powder without stopping and adds a anti-blocking component to clear the accumulated powder in the notch, avoiding blockage of the flow groove. However, it does not consider whether the powder is too large to be cleared in time, and secondly, it does not consider that the mixed powder is not stirred, leading to deterioration of the cladding layer performance due to uneven mixing of the powder.

[0006] The patent document with publication number CN120758875A discloses a laser cladding device for cylindrical surface repair. This invention can automatically adjust the flow and coverage of inert gas according to the diameter of the cylindrical workpiece, ensuring the effect of cladding repair. However, it does not consider adjusting the influence on the cladding layer by calculating the corresponding ratio of mixed powder, and adjusting the content of the corresponding trace elements in the mixed powder through the feedback system, leading to large fluctuations in the composition of the cladding layer and many defects after cladding. SUMMARY

[0007] According to the above technical problems, a powder quantitative and uniform preparation intelligent feedback magnetic stirring device and cladding process method are provided. The invention can effectively address the internal component organization disorder of the molten pool caused by uneven mixing of the mixed powder, significantly reduce the mechanical properties, and increase the risk of defects. Three coaxial powder feeding can improve the utilization rate of powder, reduce production cost, and increase the performance of the cladding layer. The feedback system can monitor the molten pool state, adjust the content of surface active elements, and control the cladding power.

[0008] The technical means adopted by the present application are as follows: A powder quantitative and uniform preparation intelligent feedback magnetic stirring device, comprising: a low-speed stirring and heating device, an X-ray emitting device, a three-phase asynchronous stirring device, a three-way diverter, a high-speed camera feedback system, a cladding platform device, and a cladding device. The low-speed stirring and heating device is fixed on the ground and includes multiple powder tanks, a low-speed stirrer, and a mixer. The multiple powder tanks are connected to the mixer, and the mixer is connected to the low-speed stirrer. The low-speed stirrer has auger blades inside, and the auger blades are equipped with heaters. The X-ray emitting device is located on one side of the low-speed stirring and heating device, and has a first powder feeding detection channel and a second powder feeding detection channel inside. The first powder feeding detection channel is connected with the three-phase asynchronous stirring device, and the second powder feeding detection channel is connected with the three-phase asynchronous stirring device and the three-way shunt. The cladding device is located on the other side of the low-speed stirring and heating device, and includes a cladding head connected with the three-way shunt. The cladding platform device includes a cladding platform, and a workpiece to be processed is fixed on the cladding platform. The high-speed camera feedback system is placed on one side of the cladding platform and is electrically connected with the low-speed stirring and heating device, the X-ray emitting device, the three-phase asynchronous stirring device and the cladding device.

[0009] Further, the low-speed stirring and heating device further includes a ball valve, a shell, a conveying pipe, a motor, a rotary valve and a fixing frame. The plurality of powder tanks are fastened and connected on the upper part of the shell outside by the fixing frame and bolts. The mixer is fixed on the upper part of the shell inside. The ball valve is arranged at the connection position of the powder tank and the mixer. The rotary valve is connected with the low-speed stirrer below the mixer. The low-speed stirrer is fixed at the center position of the bottom of the shell inside. The motor is located on one side of the shell inside and has an output end connected with the low-speed stirrer. The conveying pipe is connected with the first powder feeding detection channel.

[0010] Further, the low-speed stirrer further includes a reducer shell, a current conveyor, an output shaft, a wire and a baffle. The auger blade, the current conveyor and the baffle are arranged inside the reducer shell. The baffle is connected with the lower part of the auger blade. The bottom of the heater is provided with a brush. The current conveyor is located below the heater. The brush is in continuous contact with the electrified plate of the upper part of the current conveyor to perform power heating. The current conveyor is connected with the motor outside the low-speed stirrer through the wire. The bottom of the auger blade is connected with the output shaft through a bevel gear transmission. The output shaft is connected with the motor outside the low-speed stirrer through a shaft coupling.

[0011] Further, the X-ray emitting device generates X-rays to scan the powder in the first powder feeding detection channel and the second powder feeding detection channel. The outer surface of the X-ray emitting device is provided with an anti-radiation coating, and the inside is a constant temperature and humidity working environment.

[0012] Further, the bottom of the X-ray emitting device is mounted on a plurality of spring dampers. The bottom of the tank is fixed on the plurality of spring dampers. The spring dampers are fixed on the ground.

[0013] Further, the winding coil is connected to three-phase alternating current to generate a rotating magnetic field.

[0014] Further, the three-phase asynchronous stirring device further comprises a powder receiving input, a pressing cover and a powder feeding output, the pressing cover is flexibly connected to one end of the tank body, the powder receiving input is arranged on the pressing cover and connected to the first powder feeding detection channel, the powder feeding output is arranged on the side wall of the tank body and connected to the second powder feeding detection channel.

[0015] Further, the high-speed camera feedback system comprises an industrial camera, a tripod, a rotating bolt and a computing system, the industrial camera is fixed on the tripod through the rotating bolt, the tripod is placed on one side of the cladding platform, the computing system is located on one side of the tripod, the industrial camera is electrically connected to the computing system, and the computing system is electrically connected to the low-speed stirring and heating device and the three-phase asynchronous stirring device.

[0016] Further, the cladding device further comprises a mechanical arm, a machine case, powder feeding pipes and an end effector interface, the cladding head is fixed on the end effector interface, the end effector interface is connected to the end of the mechanical arm, the machine case is installed below the mechanical arm, the three-way distributor is located on one side of the machine case, the three-way distributor is connected to the machine case through three powder feeding pipes, the three powder feeding pipes are led out from the end effector interface as three powder feeding pipes, and the three powder feeding pipes are connected to the cladding head.

[0017] The application also provides a powder quantification and uniformity preparation intelligent feedback magnetic stirring device cladding process method, which comprises the following steps: Step 1, turn on all devices, including preheating the device with heat; inert gas is introduced to isolate air for protecting the powder and serving as a carrier to promote the uniform and stable conveying of the powder in the pipeline; Step 2, calculate the appropriate proportion, open the ball valve, and make the powders in multiple powder tanks enter the mixer according to the corresponding proportion to perform preliminary mixing; Step 3, when the mixed powder enters the low-speed stirrer in the low-speed stirring and heating device through the rotary valve, the auger blade operates at low speed to perform primary stirring on the mixed powder, and at the same time, the brush at the bottom of the heater fixed on the auger blade continuously rubs the electrified plate at the upper part of the current conveyor to make the heater start working and heating, so as to heat the powder and break the agglomerates in the mixed powder; the baffle is installed on the auger blade to prevent the mixed powder from falling into the current conveyor; Step 4, after the primary stirring, the mixed powder enters the X-ray emitting device through the conveying pipe, in the constant-temperature and constant-humidity working environment, the X-ray first detects whether the agglomerates in the mixed powder in the first powder feeding detection channel are broken in the first scanning, and then the mixed powder is fed to the three-phase asynchronous stirring device for high-speed stirring. Step 5, the mixed powder is put into a three-phase asynchronous stirring device for final stirring, a rotating magnetic field generated by a winding coil in the stirring device drives the metal substances in the mixed powder to rotate, so that the mixed powder is mixed more uniformly, and a plurality of small non-magnetic metal rods are fixedly installed in the stirring bin to fully break the small lumps of the mixed powder; then the mixed powder is sent to the second powder feeding detection channel of the X-ray emitting device for secondary detection, whether the element content in the mixed powder is uniformly stirred is detected for the second time, and then the mixed powder is sent to the three-way distributor for expansion to realize powder distribution; Step 6, after the three-way distributor connects the three powder feeding pipes to the case, the three powder feeding pipes in the case lead out the converted three-way powder feeding pipes through the end effector interface of the mechanical arm of the cladding device, and then the mixed powder is sent into the cladding head, so that the workpiece is fed with three coaxial powder beams, the powder feeding amount, the laser energy and the machining path are perfectly matched through the staged speed regulation, and the forming defects caused by lack of powder or excessive powder are avoided, so that the temperature and the composition in the molten pool are stabilized, and the mechanical properties of the cladding layer are improved. Step 7, the industrial camera of the high-speed camera feedback system collects the flow state image of the molten pool on the workpiece in real time, and sends the image to the computing system for comparison and analysis, if the flow image appears complex vortex, the discharging speed of the powder tank of the surface active element in the low-speed stirring and heating device is controlled, if obvious composition gradient appears in the molten pool, the signal is fed back to the low-speed stirring and heating device and the three-phase asynchronous stirring device for re-stirring, and the homogenization rate of the mixed powder is reasonably made through multiple tests. Step 8, finally, a high-performance cladding layer with uniform composition, flat and regular organization and few defects is formed on the surface of the workpiece.

[0018] Compared with the prior art, the present application has the following advantages: 1, the powder quantitative and uniform preparation intelligent feedback magnetic stirring equipment and cladding process method provided by the present application, the double stirring of the low-speed stirring and heating device and the three-phase asynchronous stirring device can uniformly stir the mixed powder, the low-speed stirring and heating device can effectively break the lumps in the mixed powder, avoid the blockage in the powder conveying process, ensure the stability of the powder conveying and the initial stirring, and the three-phase asynchronous stirring device can uniformly stir the mixed powder containing various trace elements through high-speed stirring. Therefore, the composition and organization in the cladding layer are uniform, the mechanical properties are stable, the wear resistance, corrosion resistance and strength are up to standard, there is no local failure, the working hours and material cost are saved, and the production efficiency is improved.

[0019] 2, the powder quantitative and uniform preparation intelligent feedback magnetic stirring equipment and cladding process method provided by the present application, the three-speed coaxial powder feeding of the end effector interface of the mechanical arm of the cladding device is matched with the laser energy and the machining path through the staged speed regulation method, so that the forming defects caused by lack of powder or excessive powder are avoided from the source, the temperature and the composition in the molten pool are stabilized, and the mechanical properties of the cladding layer are improved.

[0020] 3. The powder quantitative and uniform preparation intelligent feedback magnetic stirring equipment and cladding process method provided by the application, a high-speed camera feedback system compares the flow state of the molten pool with a calculation system, first transmits the feedback signal to a low-speed stirring and heating device, controls the discharging speed of the powder tank of the surface active element (such as S element) in the control device, adjusts the flow rate of the molten pool in the cladding layer, and then obtains a high-quality cladding layer; the calculation system compares the flow state of the molten pool, analyzes the component gradient change in the molten pool, feeds back the adjustment signal to the double stirring and heating device, adjusts the stirring speed, controls the homogenization rate of the mixed powder and the influence on the molten pool, and finally forms a perfect feedback system process. The feedback system can reduce powder waste, improve material utilization, reduce production cost, and improve production efficiency.

[0021] Based on the above reasons, the application can be widely popularized in the field of laser cladding. BRIEF DESCRIPTION OF DRAWINGS

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the drawings needed to be used in the embodiments or prior art description will be briefly introduced. Obviously, the drawings in the following description are some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0023] Figure 1 It is a schematic diagram of the overall structure of the application. Figure 2 It is a schematic diagram of the low-speed stirring and heating device of the application. Figure 3 It is a sectional view of the low-speed stirrer of the application. Figure 4 It is a schematic diagram of the auger blade of the application. Figure 5 It is a partial sectional view of the X-ray emitting device of the application. Figure 6 It is a schematic diagram of the three-phase asynchronous stirring device of the application. Figure 7 It is a sectional view of the three-phase asynchronous stirring device of the application. Figure 8 It is a schematic diagram of the high-speed camera feedback system of the application. Figure 9 It is a schematic diagram of the cladding platform device of the application. Figure 10 It is a schematic diagram of the cladding device of the application.

[0024] In the figure: 1, low-speed stirring heating device; 101, powder tank; 102, ball valve; 103, shell; 104, conveying pipe; 105, low-speed stirrer; 106, motor; 107, rotary valve; 108, mixer; 109, fixed frame; 105-1, reducer shell; 105-2, auger blade; 105-3, current conveyor; 105-4, output shaft; 105-5, line; 105-6, heater; 105-7, brush; 105-8, baffle; 2, X-ray emitting device; 201, first powder feeding detection channel; 202, second powder feeding detection channel; 3, three-phase asynchronous stirring device; 301, tank body; 302, spring damper; 303, powder input port; 304, compression cover; 305, transmission; 306, stirring bin; 307, powder output port; 308, non-magnetic metal rod; 4, three-way shunt; 5, computing system; 6, high-speed camera feedback system; 601, industrial camera; 602, tripod; 603, rotating bolt; 7, cladding platform device; 701, cladding platform; 702, workpiece to be processed; 8, water-cooled box; 9, cladding device; 901, mechanical arm; 902, case; 903, powder feeding pipe; 904, cladding head; 905, three-way powder feeding pipe; 906, end effector interface; 10, argon tank. DETAILED DESCRIPTION

[0025] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The technical solutions in the embodiments of the present application will be described in detail below with reference to the drawings and in combination with the embodiments.

[0026] To make the purposes, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below in combination with the drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. The description of the at least one exemplary embodiment is actually only illustrative, but not as any limitation on the present application and its application or use. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0027] It should be noted that the terms used herein are only for describing specific embodiments, and are not intended to limit the exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise, and it should also be understood that when the terms "comprise" and / or "include" are used in the specification, there is a presence of a feature, step, operation, device, component and / or combination thereof.

[0028] The foregoing is considered as illustrative only of the principles of the application. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the application to the exact construction and practice described. Accordingly, all such variations are intended to be included within the scope of the present application as defined in the following claims, along with full equivalents thereof.

[0029] In the description of the present application, it is to be understood that the orientation terms such as "front", "back", "up", "down", "left", "right", "transverse", "vertical", "horizontal", "top", "bottom", etc. indicate the orientation or positional relationship shown in the drawings, which are merely for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore cannot be construed as limiting the scope of protection of the present application. The orientation terms "inner", "outer" refer to the inner and outer relative to the contour of the components themselves.

[0030] For the convenience of description, spatial relative terms such as "over", "above", "upper surface", "upper", etc. can be used herein to describe the spatial positional relationship of one device or feature with respect to other devices or features as shown in the drawings. It should be understood that the spatial relative terms are intended to include different orientations in use or operation in addition to the orientation of the devices described in the drawings. For example, if the devices in the drawings are inverted, the device described as "above" or "over" other devices or structures will be positioned "below" or "under" the other devices or structures. Thus, the exemplary term "above" can include both "above" and "below" orientations. The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein are interpreted accordingly.

[0031] In addition, it should be noted that the use of the terms "first", "second", etc. to describe various components is merely intended to distinguish the corresponding components, and the above terms do not have special meanings unless otherwise stated, and therefore cannot be construed as limiting the scope of protection of the present application.

[0032] This invention addresses the problems that easily occur in existing laser cladding powder feeding processes, such as powder agglomeration, uneven powder mixing, and performance instability caused by uncertain flow velocity in the cladding layer. By introducing an intelligent feedback magnetic stirring device for quantitative and homogenized powder preparation, combined with real-time monitoring and intelligent feedback, the mixed powder is heated, broken up, and stirred evenly, thereby obtaining a structurally stable cladding layer.

[0033] like Figure 1 As shown, an intelligent feedback magnetic stirring device for quantitative and homogenized powder preparation includes a low-speed stirring and heating device 1, an X-ray emitting device 2, a three-phase asynchronous stirring device 3, a cladding device 9, a high-speed camera feedback system 6, and a cladding platform device 7. A powder tank 101 is fixed above the low-speed stirring and heating device 1, which is bolted to the ground. The X-ray emitting device 2 is fixed to one side of the low-speed stirring and heating device 1 via its inlet and outlet positioning, and its bottom is bolted to a spring damper 302. The three-phase asynchronous stirring device 3 is located to one side of the X-ray emitting device 2 and is bolted to the spring damper 302. All spring dampers 302 are placed on the ground. The cladding device 9 is located behind the low-speed stirring and heating device 1, and its cladding head 904 is fixed to the end effector interface 906. The workpiece 702 to be processed is bolted to the cladding platform 701 of the cladding platform device 7. After cladding with the workpiece 702 by the cladding head 904... A cladding layer is formed on the surface of the workpiece 702, and a molten pool is formed on the surface of the workpiece 702 when the cladding head 904 processes the workpiece 702. The high-speed camera feedback system 6 is electrically connected to the low-speed stirring and heating device 1, the X-ray emitting device 2, the three-phase asynchronous stirring device 3, and the cladding device 9. The high-speed camera feedback system 6 is placed on one side of the cladding platform 701, with a tripod 602 at the bottom and an industrial camera 601 at the top. It can detect the flow state in the molten pool in real time and feed the signal back to the low-speed stirring and heating device 1. By controlling the feeding speed of the surface active element (such as S element, including but not limited to S element) powder tank 101 in the device, the flow rate of the molten pool in the cladding layer is adjusted, thereby obtaining a high-quality cladding layer. The calculation system 5 is placed on one side of the tripod 602 and can perform comprehensive processing of signal feedback and stirring homogenization model. The argon tank 10 is placed in front of the low-speed stirring and heating device 1, and the water cooling box 8 is placed on the other side of the cladding platform 701. Argon tank 10 and water-cooled box 8 are auxiliary devices and existing devices can be used.

[0034] like Figures 2-4As shown, the low-speed stirring heating device 1 is composed of a shell 103, a powder tank 101, a fixing frame 109, a mixer 108, a conveying pipe 104, a low-speed stirrer 105, a motor 106 and the like; the fixing frame 109 fastens the powder tank 101 to the outside upper part of the shell 103 by bolts, the mixer 108 is fastened to the inside upper part of the shell 103 by bolts, a ball valve 102 is arranged at the connecting part of the powder tank 101 and the mixer 108, the low-speed stirrer 105 is fastened to the inside bottom center of the shell 103 by bolts; the lower part of the mixer 108 and the low-speed stirrer 105 are connected by a rotary valve 107; the motor 106 is located at one side in the shell 103, the output end of the motor 106 is connected with the low-speed stirrer 105 to provide power for the low-speed stirrer 105; the conveying pipe 104 is connected to the side wall of the low-speed stirrer 105 and is connected with a first powder feeding detection passage 201 of the X-ray emitting device 2. The low-speed stirrer 105 is composed of an auger blade 105-2, a current conveyor 105-3, a baffle 105-8, an output shaft 105-4 and the like, the auger blade 105-2, the current conveyor 105-3 and the baffle 105-8 are all arranged inside a reducer housing 105-1; a heater 105-6 is arranged on the auger blade 105-2 inside the low-speed stirrer 105 to heat and break the mixed powder, the baffle 105-8 is fixedly arranged on the auger blade 105-2 at a distance position to prevent the powder from leaking; the auger blade 105-2 is driven by bevel gears; the bottom of the heater 105-6 is provided with a brush 105-7, the current conveyor 105-3 is located below the heater 105-6, and the brush 105-7 is in continuous contact with the upper electrified plate of the current conveyor 105-3 to conduct electricity and heat; the current conveyor 105-3 and the output shaft 105-4 are connected with the motor 106, wherein the current conveyor 105-3 is connected to the motor 106 outside the low-speed stirrer 105 through a line 105-5, the auger blade 105-2 is driven by the bevel gears of the output shaft 105-4, and the output shaft 105-4 is connected with the motor 106 outside the low-speed stirrer 105 through a coupling.

[0035] As shown in the drawings, Figure 5 The X-ray emitting device 2 is fixedly installed beside the low-speed stirring heating device 1, the outer surface of the device is coated with a radiation-proof coating, and the inside is a constant-temperature and constant-humidity working environment; the inside contains two passages, a first powder feeding detection passage 201 leading to a three-phase asynchronous stirring device 3 to detect whether the mixed powder is broken, and a second powder feeding detection passage 202 leading from the three-phase asynchronous stirring device 3 to a three-way distributor 4 to detect whether the mixed powder is stirred uniformly; the X-ray emitting device 2 can generate X-rays to scan the powder in the first powder feeding detection passage 201 and the second powder feeding detection passage 202; the bottom of the X-ray emitting device 2 is fixedly connected with a spring damper 302 by bolts to avoid strong mechanical vibration and impact.

[0036] As shown in Figures 6-7 Three-phase asynchronous stirring device 3 is composed of spring damper 302, tank 301, compression cover 304, transmission 305, stirring bin 306 and other components; tank 301 and compression cover 304 are connected in flexible fit, compression cover 304 is provided with powder receiving input port 303, powder receiving input port 303 is connected with first powder feeding detection passage 201, side wall of tank 301 is provided with powder feeding output port 307, powder feeding output port 307 is connected with second powder feeding detection passage 202, bottom of tank 301 is fastened and installed with spring damper 302 through bolts, spring damper 302 is fastened and installed on the ground through bolts, spring damper 302 can effectively buffer the impact of the device, transmission 305 is fixedly installed inside tank 301 through axial positioning fit, stirring bin 306 is fixedly installed inside transmission 305 through axial positioning fit, winding coil is installed on transmission 305, three-phase alternating current is connected from outside tank 301, so that winding coil generates rotating magnetic field, so that mixed powder is high-speed stirred, there is small non-magnetic metal rod 308 inside stirring bin 306, which can fully break the smaller agglomerates in the mixed powder.

[0037] As shown in Figures 8-10As shown, the cladding device 9 mainly consists of a cladding head 904, an end effector interface 906, a mechanical arm 901, a machine case 902, a three-way shunt 4 and other components; the cladding head 904 is rigidly locked on the end effector interface 906 connecting rod through bolts, the end effector interface 906 is precisely connected with the mechanical arm 901 through the adapter flange, the machine case 902 is installed below the mechanical arm 901 through bolt fastening, and the three-way shunt 4 is installed on one side of the machine case 902; three powder feeding pipes 903 are expanded through the three-way shunt 4, the powder feeding pipe 903 is fed into the end effector interface 906 after being connected to the machine case 902, and the three-way powder feeding pipe 905 is led out from the end effector interface 906, and the end effector interface 906 can connect the three-way powder feeding pipe 905 (three pipes) to the cladding head 904 to complete the coaxial powder feeding of three beams; the high-speed camera feedback system 6 consists of an industrial camera 601, a tripod 602 and a computing system 5; the industrial camera 601 is fixed on the tripod 602 through a rotating bolt 603, the tripod 602 is placed on one side of the cladding platform 701, and the computing system 5 is located on one side of the tripod 602; the industrial camera 601 is electrically connected with the computing system 5, the industrial camera 601 can detect the molten pool flow state image in real time during the laser cladding process, and feed the image to the computing system 5 for comparison, if the flow image appears complex vortex flow in multiple directions or vortex flow with different number, size, direction and position, the signal is fed back to the low-speed stirring and heating device 1 to adjust the discharging speed of the surfactant element (such as S element) powder tank; if the flow image appears obvious gradient stratification and local flow disorder, the signal is fed back to the double stirring device (low-speed stirring and heating device 1 and three-phase asynchronous stirring device 3) to adjust the stirring speed. When adjusting, the whole process does not need to replace the workpiece, the present application (except the high-speed camera feedback system) is mainly applied to the parameter adjustment process before cladding, including the adjustment of the low-speed stirring and heating device 1 (stirring speed, heating temperature) and the three-phase asynchronous stirring device 3 (stirring speed). The powder waste generated in this process can be used in the cladding process parameter adjustment process (the parameter adjustment process mainly observes the macro cladding layer width, thickness, metallurgical bonding strength and other factors, which mainly depend on the laser power, laser radius, powder feeding rate, laser scanning speed, etc., and has nothing to do with whether the powder is stirred evenly, so the waste can be used for parameter adjustment).Adopt two-factor control experiment, wherein the stirring speed is 20rpm, 30rpm, 40rpm each three groups, S discharge speed 0.03wt%, 0.05wt%, 0.07wt% corresponding each three groups, a total of 9 groups of data, through the least square method to establish model fitting obtained stirring speed is 33rpm, S discharge speed is 0.05wt% when, the generated cladding layer is the most smooth and flat. At this time, in the three-phase asynchronous stirring device 3, through the bisection method gradually segment stirring speed, finally through the second powder detection passage 202 and the comprehensive feedback of the cladding layer, determine the stirring speed of the three-phase asynchronous stirring device 3 is about 1500rpm.

[0038] As Figures 1-10As shown, the working principle of the powder quantitative and uniform preparation intelligent feedback magnetic stirring equipment of the present application is as follows: each powder tank 101 falls into the inside mixer 108 of the shell 103 through the ball valve 102 to form mixed powder. The mixed powder flows into the low-speed stirrer 105 through the rotary valve 107 for primary stirring. The auger blade 105-2 in the low-speed stirrer 105 can heat, break and primary stir the mixed powder. Finally, the mixed powder is detected by the first powder feeding detection passage 201 of the X-ray emitting device 2 through the conveying pipe 104 to detect whether the mixed powder is broken into large pieces and primary stirred (when not stirred, the mixed powder may contain agglomeration phenomenon, the size range is greater than 500 μm, after primary stirring, the mixed powder still contains large agglomerates, the size is 150-500 μm, and after complete stirring, the size of the mixed powder is 20-150 μm). Then the mixed powder is sent to the three-phase asynchronous stirring device 3 through the powder input port 303 for high-speed stirring to make the mixed powder uniform and completely broken (if the mixed powder is not broken, when flowing through the second powder feeding detection passage 202, the X-ray energy spectrum analysis shows that each element (such as S) is uniformly distributed without local enrichment, which indicates that it is completely broken). The mixed powder passes through the powder output port 307 and is detected by the second powder feeding detection passage 202 of the X-ray emitting device 2 to detect whether the mixed powder is stirred uniformly, and the adjustment signal is fed back to the computing system 5 for calculation to determine and confirm whether to adjust the stirring speed of the three-phase asynchronous stirring device 3. When the mixed powder is not stirred uniformly, the speed of the three-phase asynchronous stirring device 3 is adjusted to be faster, and the speed is maintained after the mixed powder is stirred uniformly. If the mixed powder is stirred uniformly, the gray value corresponding to the powder area in the image will present a very uniform distribution. If the mixed powder is not stirred uniformly, it will show a consistent gray value (brighter or darker) in a certain area. The completely stirred mixed powder passes through the X-ray emitting device 2 to the three-way distributor 4, which sends the powder through the three powder feeding pipes 903 into the case 902 below the mechanical arm 901 of the cladding device 9. The powder feeding pipe 903 leads out the three-way powder feeding pipe 905 through the end effector interface 906 at the end of the mechanical arm 901, and is connected to the cladding head 904 to complete the three-beam coaxial powder feeding of the workpiece to be processed 702. The industrial camera 601 on the upper part of the tripod support 602 feeds back the monitoring signal to the computing system 5 for comparison by monitoring the flow state of the molten pool in the cladding layer, so as to determine whether the surface active element (such as S element) in the mixed powder is too much or too little. If the fluid in the molten pool flows from the edge of the molten pool to the center of the molten pool, and there are different number, size, direction and position of eddy currents, then the surface active element is too much, and the feeding speed of the surface active element (such as S element) powder tank in the low-speed stirring and heating device 1 is reduced. If the fluid flow in the molten pool is complex and there are multiple direction eddy currents, then the surface active element is too little, and the feeding speed of the surface active element (such as S element) powder tank in the low-speed stirring and heating device 1 is increased.The high-speed camera feedback system 6 is debugged for multiple times, so that the cladding layer with good morphology, uniform organization and high performance is obtained, and the program meets the production requirements.

[0039] The application further provides a powder quantification and uniformization preparation intelligent feedback magnetic stirring device cladding process method, which comprises the following steps: (1) all devices are turned on, and the devices containing heat are preheated; inert gas (such as argon in an argon tank 10) is introduced to isolate air for protecting the powder and serving as a carrier to promote the uniform and stable conveying of the powder in the pipeline; it should be noted that inert gas is introduced into all devices through which the mixed powder flows, that is, the inert gas is introduced into the powder tank, flows to the low-speed stirring and heating device 1, the X-ray generating device 2, the three-phase asynchronous stirring device 3, the three-way shunt 4, the cladding device 5 and the cladding head 904, and serves as a protective gas and a conveying carrier; (2) the appropriate proportion is calculated, the ball valve 102 is opened, and the powders in the multiple powder tanks 101 enter the mixer 108 according to the corresponding proportion to be preliminarily mixed; (3) when the mixed powder enters the low-speed stirrer 105 (10-50 rpm) in the low-speed stirring and heating device 1 through the rotary valve 107, the auger blade 105-2 is operated at low speed to preliminarily stir the mixed powder, and meanwhile, the heater 105-6 fixed on the auger blade 105-2 starts to continuously rub the charged plate on the upper part of the current conveyor 105-3 with the brush 105-7 at the bottom of the heater 105-6, so that the heater 105-6 starts to work and generate heat (50-200 DEG C, which is adjusted according to the type of elements), which can heat the powder, is conducive to stirring, and can also break the agglomerates in the mixed powder; the baffle 105-8 installed on the auger blade 105-2 can effectively prevent the mixed powder from falling into the current conveyor 105-3; (4) after the mixed powder is preliminarily stirred, the mixed powder enters the X-ray emitting device 2 through the conveying pipe 104, in the constant-temperature and constant-humidity working environment, the X-ray generated by the X-ray emitting device 2 first detects whether the agglomerates of the mixed powder in the first powder feeding detection channel 201 are broken in the first scanning, and then the mixed powder is conveyed to the three-phase asynchronous stirring device 3 for high-speed stirring; after the X-ray scanning, the scanning result is transmitted to the existing display device, and then whether the agglomerates formed by the pure S powder or the S-rich powder are broken is judged by whether the dark clumps are contained in the image; if the phenomenon that the agglomerates are not broken exists after the scanning detection, the feedback signal is transmitted to the computing system (such as a computer), so that the stirring speed of the three-phase asynchronous stirring device 3 is adjusted step by step, so that the powder is broken and uniformly stirred; (5) the mixed powder enters a three-phase asynchronous stirring device 3 (500-3000 rpm) for final stirring, a rotating magnetic field generated by a winding coil inside the three-phase asynchronous stirring device 3 drives the metal substances in the mixed powder to rotate, so that the mixed powder is mixed more uniformly, a plurality of small non-magnetic metal rods 308 are fixedly installed in the stirring bin 306, so that small clumps of the mixed powder can be fully broken; then the mixed powder is sent to the second powder feeding detection channel 202 of the X-ray emitting device 2 again for secondary detection, whether the element content in the mixed powder is stirred uniformly (if it is detected that the mixed powder is not stirred uniformly in the second powder feeding detection channel 202, a signal is fed back to the three-phase asynchronous stirring device 3 by the computing system to increase the stirring speed), and then the mixed powder is sent to the three-way distributor 4 for expansion to realize powder distribution; (6) the three-way distributor 4 connects the three powder feeding pipes 903 to the case 902, and then the three powder feeding pipes 903 in the case 902 lead out the converted three-way powder feeding pipe 905 through the end effector interface 906 to send the mixed powder into the cladding head 904, so as to perform three-beam coaxial powder feeding on the workpiece 702 to be processed, through "staged speed regulation", the powder feeding amount is perfectly matched with the laser energy and the processing path, so as to avoid forming defects caused by "lack of powder" and "excessive powder"; (7) after the cladding head 904 performs laser cladding on the workpiece 702 to be processed, a molten pool is formed on the workpiece 702 to be processed, the frame rate of the industrial camera 601 of the high-speed camera feedback system 6 is greater than or equal to 200 fps, so that the flow state image of the molten pool can be collected in real time, and the image is sent to the computing system 5 for comparative analysis, if the flow image appears complex vortex, the discharging speed of the powder tank 101 containing the surface active element (such as S element) in the low-speed stirring and heating device 1 is controlled (only one powder tank 101 contains S powder, and the rest are ordinary commonly used powder); if there is an obvious composition gradient in the molten pool, a signal is fed back to the double stirring device (the low-speed stirring and heating device 1 and the three-phase asynchronous stirring device 3) for re-stirring, and the homogenization rate of the mixed powder is reasonably adjusted through multiple tests; (8) finally, a high-performance cladding layer with uniform composition, flat and regular organization and few defects is formed on the substrate surface.

[0040] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, but not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: the technical solutions recorded in the foregoing embodiments can still be modified, or some or all of the technical features can be replaced equivalently; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A powder quantitative, uniform preparation intelligent feedback magnetic stirring device, characterized in that, The application relates to a low-speed stirring and heating device (1), an X-ray emitting device (2), a three-phase asynchronous stirring device (3), a three-way shunt (4), a high-speed camera feedback system (6), a cladding platform device (7) and a cladding device (9), wherein the low-speed stirring and heating device (1) is fixed on the ground and comprises a plurality of powder tanks (101), a low-speed stirrer (105) and a mixer (108); the plurality of powder tanks (101) are connected with the mixer (108); the mixer (108) is connected with the low-speed stirrer (105); the low-speed stirrer (105) is internally provided with auger blades (105-2), and the auger blades (105-2) are provided with heaters (105-6). The X-ray emitting device (2) is located on one side of the low-speed stirring and heating device (1) and internally has a first powder feeding detection channel (201) and a second powder feeding detection channel (202); the first powder feeding detection channel (201) is connected with the three-phase asynchronous stirring device (3); the second powder feeding detection channel (202) is connected with the three-phase asynchronous stirring device (3) and the three-way shunt (4); the three-phase asynchronous stirring device (3) is located on one side of the X-ray emitting device (2) and comprises a tank body (301), a transmission device (305) coaxially arranged in the tank body (301) and a stirring bin (306) coaxially arranged in the transmission device (305); the transmission device (305) is provided with a winding coil; the stirring bin (306) is internally provided with small non-magnetic metal rods (308). The cladding device (9) is located on the other side of the low-speed stirring and heating device (1) and comprises a cladding head (904) connected with the three-way shunt (4); the cladding platform device (7) comprises a cladding platform (701), a workpiece (702) is fixed on the cladding platform (701), the high-speed camera feedback system (6) is placed on one side of the cladding platform (701) and is electrically connected with the low-speed stirring and heating device (1), the X-ray emitting device (2), the three-phase asynchronous stirring device (3) and the cladding device (9). The low-speed stirring and heating device (1) further comprises a ball valve (102), a shell (103), a conveying pipe (104), a motor (106), a rotary valve (107) and a fixing frame (109); the plurality of powder tanks (101) are fastened and connected on the upper portion outside the shell (103) through the fixing frame (109) and bolts; the mixer (108) is fixed on the upper portion inside the shell (103); the connection position of the powder tank (101) and the mixer (108) is provided with the ball valve (102); the lower portion of the mixer (108) is connected with the low-speed stirrer (105) through the rotary valve (107); the low-speed stirrer (105) is fixed on the inner bottom center position of the shell (103); the motor (106) is located on one side in the shell (103) and is connected with the low-speed stirrer (105) through an output end; the conveying pipe (104) is connected with the low-speed stirrer (105) and is connected with the first powder feeding detection channel (201).

2. The powder dosing, homogenizing, and preparing intelligent feedback magnetic stirring device according to claim 1, characterized in that, ​ 3. The powder dosing, homogenizing, and preparing intelligent feedback magnetic stirring device according to claim 2, characterized in that, The low-speed stirrer (105) further comprises a reducer housing (105-1), a current conveyor (105-3), an output shaft (105-4), a wire (105-5) and a baffle (105-8), the auger blade (105-2), the current conveyor (105-3) and the baffle (105-8) are all arranged inside the reducer housing (105-1), the baffle (105-8) is connected to the lower part of the auger blade (105-2), the bottom of the heater (105-6) is provided with a brush (105-7), the current conveyor (105-3) is located below the heater (105-6), the brush (105-7) is in continuous contact with the electrified plate on the upper part of the current conveyor (105-3) for power heating, the current conveyor (105-3) is connected with the motor (106) outside the low-speed stirrer (105) through the wire (105-5), the bottom of the auger blade (105-2) is connected with the output shaft (105-4) through a bevel gear transmission, and the output shaft (105-4) is connected with the motor (106) outside the low-speed stirrer (105) through a shaft coupling.

4. The powder dosing, homogenizing, and preparing intelligent feedback magnetic stirring device according to claim 1, characterized in that, The X-ray emitting device (2) generates X-rays to scan the powder in the first powder feeding detection channel (201) and the second powder feeding detection channel (202); the outer surface of the X-ray emitting device (2) has a radiation-proof coating, and the inside is a constant-temperature and constant-humidity working environment.

5. The powder dosing, homogenizing, and preparation intelligent feedback magnetic stirring device according to claim 1, characterized in that, The bottom of the X-ray emitting device (2) is mounted on a plurality of spring dampers (302), and the bottom of the tank body (301) is fixed on the plurality of spring dampers (302), and the spring dampers (302) are all fixed on the ground.

6. The powder dosing, homogenizing, and preparation intelligent feedback magnetic stirring device according to claim 1, characterized in that, The winding coil is connected to three-phase alternating current to generate a rotating magnetic field.

7. The powder dosing, homogenizing, and preparing intelligent feedback magnetic stirring device according to claim 1, characterized in that, The three-phase asynchronous stirring device (3) further comprises a powder receiving input port (303), a pressing cover (304) and a powder feeding output port (307), the pressing cover (304) is flexibly connected to one end of the tank body (301), the powder receiving input port (303) is arranged on the pressing cover (304) and connected with the first powder feeding detection channel (201); the powder feeding output port (307) is arranged on the side wall of the tank body (301) and connected with the second powder feeding detection channel (202).

8. The powder dosing, homogenizing, and preparing intelligent feedback magnetic stirring device according to claim 1, characterized in that, The high-speed camera feedback system (6) comprises an industrial camera (601), a tripod (602), a rotating bolt (603) and a computing system (5), the industrial camera (601) is fixed on the tripod (602) through the rotating bolt (603), the tripod (602) is placed on one side of the cladding platform (701), the computing system (5) is located on one side of the tripod (602), the industrial camera (601) is electrically connected with the computing system (5), and the computing system (5) is electrically connected with the low-speed stirring and heating device (1) and the three-phase asynchronous stirring device (3).

9. The powder dosing, homogenizing, and preparing intelligent feedback magnetic stirring device according to claim 1, characterized in that, The cladding device (9) further comprises a mechanical arm (901), a machine box (902), a powder feeding pipe (903) and an end effector interface (906), the cladding head (904) is fixed on the end effector interface (906), the end effector interface (906) is connected with the end of the mechanical arm (901), the machine box (902) is installed below the mechanical arm (901), the three-way shunt (4) is located on one side of the machine box (902), the three-way shunt (4) is connected with the machine box (902) through three powder feeding pipes (903), the three powder feeding pipes (903) lead out three-way powder feeding pipes (905) through the end effector interface (906), and the three-way powder feeding pipes (905) are connected with the cladding head (904).

10. A powder quantification, homogenization preparation intelligent feedback magnetic stirring device cladding process method according to any one of claims 1-9, characterized in that, The method comprises the following steps: Step 1, turn on all devices, including preheating the device with heat; inert gas is introduced to isolate air for the protection of the powder and as a carrier to promote the uniform and stable delivery of the powder in the pipeline; Step 2, calculate the appropriate proportion, open the ball valve (102), and make the powders in multiple powder tanks (101) enter the mixer (108) according to the corresponding proportion for preliminary mixing; Step 3, when the mixed powder enters the low-speed stirrer (105) in the low-speed stirring and heating device (1) through the rotary valve (107), the auger blade (105-2) operates at low speed to preliminarily stir the mixed powder, and at the same time, the brush (105-7) at the bottom of the heater (105-6) fixed on the auger blade (105-2) continuously rubs the electrified plate at the upper part of the current conveyor (105-3) to make the heater (105-6) start to work and generate heat, which not only heats the powder but also breaks the agglomerates in the mixed powder; the baffle (105-8) installed on the auger blade (105-2) prevents the mixed powder from falling into the current conveyor (105-3); Step 4, after the preliminary stirring of the mixed powder, the mixed powder enters the X-ray emitting device (2) through the conveying pipe (104), and in the constant-temperature and constant-humidity working environment, the X-ray first detects whether the agglomerates in the mixed powder in the first powder feeding detection channel (201) are broken in the first scanning, and then the mixed powder is sent to the three-phase asynchronous stirring device (3) for high-speed stirring; Step 5, the mixed powder enters the three-phase asynchronous stirring device (3) for final stirring, the rotating magnetic field generated by the winding coil drives the metal substances in the mixed powder to rotate, so that the mixed powder is more uniformly mixed, and a plurality of small non-magnetic metal rods (308) are fixedly installed in the stirring bin (306), so that the small agglomerates of the mixed powder are fully broken; then the mixed powder is sent to the second powder feeding detection channel (202) of the X-ray emitting device (2) for secondary detection, whether the element content in the mixed powder is uniformly stirred is detected for the second time, and then the mixed powder is sent to the three-way shunt (4) for expansion to realize the shunting of the powder; Step 6, after the three-way shunt (4) connects the three powder feeding pipes (903) to the cabinet (902), the three powder feeding pipes (903) in the cabinet (902) lead out the converted three-way powder feeding pipe (905) through the end effector interface (906) to send the mixed powder into the cladding head (904), then three coaxial powder feeding beams are formed on the workpiece (702), through phased speed adjustment, the powder feeding volume is perfectly matched with the laser energy and the processing path, and the forming defects caused by lack of powder or excessive powder are avoided; Step 7, the industrial camera (601) of the high-speed camera feedback system (6) collects the flow state image of the molten pool on the workpiece (702) in real time, and sends the image to the computing system (5) for comparative analysis, if the flow image appears complex vortex, the unloading speed of the surface active element powder tank (101) in the low-speed stirring and heating device (1) is controlled; if there is obvious composition gradient in the molten pool, the signal is fed back to the low-speed stirring and heating device (1) and the three-phase asynchronous stirring device (3) for re-stirring, and through multiple tests, the homogenization rate of the mixed powder is reasonable; Step 8, finally, a high-performance cladding layer with uniform composition, smooth and regular surface, and few defects is formed on the surface of the workpiece (702).

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