Rotor shaft repairing device for civil aviation maintenance and laser cladding repairing method

Abstract

The invention relates to the technical field of rotor shaft repairing, and discloses a rotor shaft repairing device for civil aviation maintenance and a laser cladding repairing method. The rotor shaft repairing device for civil aviation maintenance comprises a clamping mechanism, the clamping mechanism comprises a moving assembly and a supporting assembly, and the moving assembly is arranged on a rack and can move in the length direction of the rack; the supporting assembly is arranged on the moving assembly and used for supporting the rotor shaft. In the moving process of the moving assembly, the supporting assembly abuts against the surface of the rotor shaft all the time. The laser cladding repair method comprises the following steps: step 300, judging whether the distance between the repaired part of the rotor shaft and the end part of the diameter shaft section meets a first preset distance or not; and if yes, the clamping mechanism is moved to the to-be-repaired shaft section, and if not, the clamping mechanism is moved to the adjacent shaft section, and a second preset distance is kept. According to the technical scheme, the technical problem that geometric interference or function failure exists in the shaft shoulder position of a rotor shaft repairing device in the prior art is solved.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of rotor shaft repair, in particular to a rotor shaft repair device for civil aviation maintenance and a laser cladding repair method. BACKGROUND

[0002] Rotor shafts are important transmission components in mechanical systems and are widely used in various industrial production and manufacturing links. However, the application scenarios of rotor shafts are relatively harsh, and the rotor shafts often work under heavy load, high temperature and high speed. During long-term service, the rotor shafts may be damaged due to friction and wear, medium corrosion, alternating load and the like, and failure problems such as wear, pitting, cracks and size out-of-tolerance may occur on the surface of the rotor shafts, which may reduce the precision of the rotor shafts, shorten the service life of the rotor shafts, even cause equipment downtime failure, and cause huge economic losses.

[0003] When the traditional repair device repairs different shaft sections of a long rotor shaft, the support components of the repair device may face the dilemma of geometric interference or functional failure at the shaft shoulder due to the elongated rotor shaft and the multiple shaft shoulders, thereby affecting the repair effect. SUMMARY

[0004] The application discloses a rotor shaft repair device for civil aviation maintenance and a laser cladding repair method to solve the technical problem of geometric interference or functional failure at the shaft shoulder in the rotor shaft repair device in the related art.

[0005] To solve the above problems, the application adopts the following technical solutions: In a first aspect, the application discloses a rotor shaft repair device for civil aviation maintenance, which comprises a clamping mechanism, the clamping mechanism comprising a moving assembly and a support assembly, the moving assembly being arranged on a rack and being movable along the length direction of the rack, and the support assembly being arranged on the moving assembly and being used for supporting a rotor shaft. During the movement of the moving assembly, the support assembly is always in abutment with the surface of the rotor shaft.

[0006] In some solutions, the support assembly comprises a plurality of support pieces, each support piece comprising a telescopic part and an abutment part, the telescopic part being arranged on the moving assembly. The abutment part is used for abutting against the surface of the rotor shaft, is connected with the telescopic part through an elastic piece and is movable along the axial direction of the telescopic part.

[0007] In some solutions, the abutment part comprises a first connecting block and a first roller, the first connecting block being connected with the telescopic part through an elastic piece and being movable along the axial direction of the telescopic part, and the first roller being rotatably arranged on the telescopic part and being used for abutting against the surface of the rotor shaft.

[0008] In some designs, the stop portion includes a second connecting block, two rotating arms, and two second rollers. The second connecting block is connected to the telescopic portion via an elastic element and can move axially along the telescopic portion. One end of each of the two rotating arms is rotatably connected to the second connecting block, and the other end is rotatably connected to the second rollers. The second rollers are used to stop against the surface of the rotor shaft.

[0009] In some solutions, the clamping mechanism also includes a measuring element, which is disposed corresponding to the first connecting block and / or the second connecting block, for measuring the displacement of the first connecting block and / or the second connecting block; And / or, the first roller is spherical; And / or, the second roller is spherical; And / or, the rotating arm is rotatably connected to the second connecting block via a torsion spring; And / or, the moving component has a limiting protrusion corresponding to the rotating arm, the limiting protrusion being used to abut against the rotating arm to limit the rotation of the rotating arm.

[0010] In some solutions, the measuring element includes a displacement sensor and a scale, with the scale disposed on a first connecting block and / or a second connecting block; The displacement sensor is installed on the moving component, and its detection end is set with a scale.

[0011] In some designs, the moving assembly includes a moving frame and two clamping blocks, with a through hole formed between the end faces of the two clamping blocks for the rotor shaft to pass through. The two clamping blocks are rotatably connected on one side and locked on the other side by fasteners; the movable frame is located at the bottom of the clamping blocks and connected to the frame, and can move along the length of the frame.

[0012] In some designs, the mobile frame includes a frame body and sliding wheels, with the frame body connected to the clamping block and the sliding wheels located at the bottom of the frame body; The frame has rails along its length, and the sliding wheels are embedded in the rails.

[0013] Secondly, a laser cladding repair method, using the civil aviation maintenance rotor shaft repair device described in the first aspect, includes the following steps: Step 100: Inspect the defective areas of the rotor shaft and determine the location of the defective areas; Step 200: Remove the cracks and surrounding fatigue layer in the defective area, and clean it; Step 300: Determine whether the distance between the repair part of the rotor shaft and the end of the shaft segment of the specified diameter meets the first preset distance; if yes, move the clamping mechanism to the shaft segment to be repaired; if no, move the clamping mechanism to the adjacent shaft segment while maintaining the second preset distance. Step 400: Repair the area to be repaired using a laser head and a powder feeder; Step 500, repeat steps 300 and 400 until the repair is complete.

[0014] In some schemes, the value of the second preset distance is greater than the value of the first preset distance.

[0015] The technical solution adopted in this invention can achieve the following beneficial effects: The rotor shaft repair device of this application provides active and controllable displacement along the rotor shaft axial direction through a moving component, driving the support component to move synchronously. During this process, the support component maintains contact and support force on the rotor shaft surface at all times. This allows the support point to dynamically follow the repair operation position, and when it is necessary to cross the shaft shoulder, axial position adjustment can be performed without completely detaching from the shaft surface, thereby achieving uninterrupted continuous support. While maintaining the continuity of the reference, it avoids geometric interference with the shaft shoulder, providing a stable, movable, and adaptive mechanical reference for the entire repair process. Attached Figure Description

[0016] 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 only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 These are isometric views of a rotor shaft repair device for civil aviation maintenance disclosed in some embodiments of this application; Figure 2 yes Figure 1 Enlarged view of point A in the middle; Figure 3 This is a top view of a rotor shaft repair device for civil aviation maintenance disclosed in some embodiments of this application; Figure 4 yes Figure 3 A sectional view of plane aa in the middle; Figure 5 yes Figure 4 Enlarged view of point B in the middle; Figure 6 This is an isometric view of the clamping mechanism disclosed in some embodiments of this application; Figure 7 This is a cross-sectional view of the clamping mechanism disclosed in some embodiments of this application; Figure 8 This is the isometric view of the support member disclosed in some embodiments of this application. Figure 1 ; Figure 9 This is a cross-sectional view of the support member disclosed in some embodiments of this application. Figure 1 ; Figure 10This is the isometric view of the support member disclosed in some embodiments of this application. Figure 2 ; Figure 11 This is a cross-sectional view of the support member disclosed in some embodiments of this application. Figure 2 .

[0018] In the picture: 100-Clamping mechanism, 110-Moving component, 111-Clamping block, 1111-Limiting protrusion, 1112-Fastener, 112-Moving frame, 1121-Frame body, 1122-Sliding wheel, 120-Support member, 121-Telescopic part, 122-Stop part, 1221-First connecting block, 1222-First roller, 1223-Second connecting block, 1224-Rotating arm, 1225-Second roller, 123-Elastic member, 130-Measuring member, 131-Displacement sensor, 132-Scale; 200 - rack, 210 - rail; 300-Chuck; 400-laser head; 500-rotor shaft. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0020] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0021] Traditional repair devices with fixed support components (such as rigid V-blocks or ejector pins) present a fundamental adaptation challenge when repairing slender rotor shafts with multiple shoulders. Their inherent structural rigidity and fixed position lead to a significant adaptation problem: as the repair work progresses from one shaft segment to an adjacent segment, the fixed contour of the support component (such as a V-groove) directly collides with the vertical end face or variable-diameter slope of the shoulder, creating geometric interference and forcing a complete interruption of the repair process. Operators must manually remove the support, retract it to avoid the shoulder, and then, after the repair head crosses the shoulder, reposition the support on the new shaft segment, significantly reducing repair efficiency. Furthermore, this break in precision caused by support interruption directly disrupts the overall coaxiality, cylindricity, and geometric continuity of the shoulder transition zone of the rotor shaft. This can easily lead to vibration and stress concentration in the repaired rotor shaft during high-speed rotation, severely affecting its dynamic balance performance.

[0022] The following is in conjunction with the appendix Figures 1 to 11 This application provides a detailed description of a rotor shaft repair device and laser cladding repair method for civil aviation maintenance through specific embodiments and application scenarios.

[0023] Some embodiments of this application disclose a rotor shaft repair device for civil aviation maintenance, including a clamping mechanism 100, a frame 200, a chuck 300, and a laser head 400.

[0024] like Figure 1 As shown, the clamping mechanism 100 includes a moving component 110 and a supporting component. The moving component 110 is disposed on the frame 200 and can move along the length of the frame 200. The supporting component is disposed on the moving component 110 and is used to support the rotor shaft 500. By enabling the moving component 110 to move along the length of the frame 200, the support point can be repositioned in real time and flexibly to the most suitable support area of ​​the current shaft segment according to the progress of the repair operation during the repair of the rotor shaft 500, providing the most basic and critical degree of freedom of motion for achieving uninterrupted repair operations.

[0025] like Figure 1 and Figure 3As shown, during the movement of the moving component 110, the support component always abuts against the surface of the rotor shaft 500. During the axial movement of the support component driven by the moving component 110, the support component maintains contact and support with the surface of the rotor shaft 500, achieving continuous maintenance of the support state and support reference. Compared with traditional repair device modes, the support component in this embodiment avoids the momentary unrestrained state of the rotor shaft 500 caused by the complete removal of support, thereby effectively suppressing axial drift and vibration. Through dynamic continuous contact, not only is the physical continuity of the operation process guaranteed, but more importantly, when crossing key processes such as shaft shoulders, a smooth transition axial positioning reference is provided for the rotor shaft 500, minimizing the repeated positioning errors introduced by support reinstallation, and fundamentally maintaining the coaxiality inheritance and geometric continuity between the repaired shaft segment and the repaired shaft segment.

[0026] In this embodiment, as Figure 1 , Figure 3 and Figure 4 As shown, the chuck 300 is mounted on the frame 200 and is used to clamp the rotor shaft 500.

[0027] In this embodiment, as Figure 1 , Figure 3 and Figure 4 As shown, the laser head 400 is mounted on the frame 200 and is positioned corresponding to the rotor shaft 500. The laser head 400 can move along the length of the frame 200 to change the repair position of the laser head 400.

[0028] like Figure 5 , Figure 6 ,and Figure 7 As shown, the support assembly includes multiple support members 120. Each support member 120 includes a telescopic portion 121 and a stop portion 122. The telescopic portion 121 is disposed on the moving assembly 110. The stop portion 122 is used to abut against the surface of the rotor shaft 500, is connected to the telescopic portion 121 via an elastic member 123, and can move axially along the telescopic portion 121. During the repair of the rotor shaft 500, the telescopic portion 121 extends to compress the elastic member 123, reducing the extension allowance of the stop portion 122, thereby allowing the stop portion 122 to continuously and stably abut against the rotor shaft 500 with a set preload. Furthermore, due to the presence of the elastic element 123, the stop part 122 can adaptively fine-tune its position to compensate for the thermal deformation of the rotor shaft 500 during the repair process. When the shaft diameter changes slightly due to heat, the elastic element 123 buffers the impact on the support force by compression or release, thereby maintaining a relatively constant and controllable support contact. This avoids the working conditions of excessively tight (causing additional stress) or excessively loose (causing instability) support due to thermal expansion, ensuring the alignment accuracy and process stability of the repair section under hot conditions.

[0029] When the clamping mechanism 100 needs to be moved, the telescopic part 121 shortens to release the elastic element 123, increasing the telescopic allowance of the elastic element 123, which in turn reduces the preload applied to the rotor shaft 500 by the stop part 122. This allows the stop part 122 to slide over the vertical end face of the shaft shoulder with lower contact pressure and smoother following when passing through the shoulder of the rotor shaft 500. The active reduction of the preload significantly reduces the sliding friction resistance and lateral interference force that may occur between the stop part 122 and the shaft shoulder contour, thereby avoiding hard scraping or jamming and ensuring a smooth and stable axial movement. At the same time, the increased telescopic allowance provides sufficient deformation space for the elastic element 123, enabling it to better absorb geometrical changes and vibrations along the path, achieving a damage-free and low-disturbance crossing of the support point, providing a key motion guarantee for continuous repair operations.

[0030] In this embodiment, the telescopic part 121 can be a hydraulic cylinder or an electric cylinder.

[0031] Firstly, such as Figure 7 , Figure 8 and Figure 9 As shown, the stop portion 122 includes a first connecting block 1221 and a first roller 1222. The first connecting block 1221 is connected to the telescopic portion 121 via an elastic member 123 and can move axially along the telescopic portion 121. The first roller 1222 is rotatably disposed on the telescopic portion 121 and is used to stop against the surface of the rotor shaft 500. The first connecting block 1221 converts the axial displacement of the telescopic portion 121 and the extension and retraction of the elastic member 123 into constant pressure contact between the first roller 1222 and the rotor shaft 500. At the same time, the first roller 1222 converts the sliding friction between the support member and the surface of the rotor shaft 500 into rolling friction. When the support point moves axially or the rotor shaft 500 rotates, the first roller 1222 can roll smoothly, greatly reducing frictional resistance and heat accumulation, and avoiding scratching the repaired surface. Combined with the self-adaptive capability of the elastic element 123, the first roller 1222 can smoothly roll over geometric features such as shaft shoulders and rounded corners, minimizing lateral interference while maintaining continuous contact. This significantly improves the smoothness of movement, positioning stability, and adaptability to the microstructure of the rotor shaft 500 of the support assembly, providing a more accurate and stable dynamic reference for the repair process.

[0032] Secondly, such as Figure 7 , Figure 10 and Figure 11As shown, the stop portion 122 includes a second connecting block 1223, two rotating arms 1224, and two second rollers 1225. The second connecting block 1223 is connected to the telescopic portion 121 via an elastic member 123 and can move axially along the telescopic portion 121. One end of each of the two rotating arms 1224 is rotatably connected to the second connecting block 1223, and the other end is rotatably connected to the second rollers 1225. The second rollers 1225 are used to abut against the surface of the rotor shaft 500. The axial movement of the second connecting block 1223 is converted into a symmetrical engagement or release motion of the two second rollers 1225 against the surface of the rotor shaft 500 through the lever action of the two rotating arms 1224, while the elastic member 123 provides a constant radial preload. The two rollers form a dynamic V-shaped support surface, significantly improving the radial rigidity and stability of the support and effectively suppressing radial movement and vibration of the rotor shaft 500. Simultaneously, the hinged structure of the rotating arm 1224 allows the two rollers to float independently during axial movement, automatically adapting to minute changes in shaft diameter and transition geometry of the shaft shoulder, ensuring uniform contact between the two rollers and smooth rolling over obstacles. This further enhances the support system's adaptability to complex shaft shapes, providing centering accuracy and dynamic balance for the rotor shaft 500 during continuous repairs.

[0033] In this embodiment, the support member 120 is preferably two, namely the support member 120 described in the first aspect and the second aspect. A first roller 1222 and two second rollers 1225 together provide three-point support for the rotor shaft 500. While ensuring the degree of freedom of motion (to accommodate crossing the shaft shoulder and thermal deformation), the spatial attitude of the rotor shaft 500 is constrained with fewer contact points. This reduces the occurrence of drift caused by under-constraint or internal stress caused by over-constraint. Therefore, during continuous repair, this provides the most critical and efficient static and dynamic benchmarks for ensuring the geometric concentricity, straightness, and final dynamic balance performance of the rotor shaft 500.

[0034] As is preferred in this embodiment, such as Figure 9 As shown, the first roller 1222 is spherical. The spherical first roller 1222 achieves omnidirectional low-resistance rolling, eliminating lateral sliding friction caused by directional deviation during axial movement, and enabling the first roller 1222 to more smoothly and adaptively cross the shaft shoulder.

[0035] As is preferred in this embodiment, such as Figure 11 As shown, the second roller 1225 is spherical. The spherical second roller 1225 achieves omnidirectional low-resistance rolling, eliminating lateral sliding friction caused by directional deviation during axial movement, and enabling the second roller 1225 to more smoothly and adaptively cross the shaft shoulder.

[0036] In this preferred embodiment, the rotating arm 1224 is rotatably connected to the second connecting block 1223 via a torsion spring. The torsion spring provides a continuous elastic restoring torque to the rotating arm 1224, enabling the two second rollers 1225 to adaptively and tightly engage with the surface of the rotor shaft 500, and maintain stable and continuous radial contact pressure when crossing geometrical abrupt changes such as shaft shoulders, thereby significantly improving the dynamic fit and stability of the support.

[0037] As is preferred in this embodiment, such as Figure 7 As shown, the moving component 110 is provided with a limiting protrusion 1111 corresponding to the rotating arm 1224. The limiting protrusion 1111 is used to abut against the rotating arm 1224 to limit the rotation of the rotating arm 1224. The limiting protrusion 1111 sets a reliable mechanical stop for the rotating arm 1224, preventing it from opening or closing excessively due to inertia or external force, ensuring the determinism and repeatability of the support geometry, thereby maintaining the rigidity, stability and safety boundary of the support system when dynamically crossing the shoulder.

[0038] like Figure 6 , Figure 8 and Figure 9 As shown, the clamping mechanism 100 also includes a measuring element 130, which is configured corresponding to the first connecting block 1221 and / or the second connecting block 1223, and is used to measure the displacement of the first connecting block 1221 and / or the second connecting block 1223. By setting the measuring element 130 on the first connecting block 1221 and / or the second connecting block 1223 to monitor its displacement in real time, the thermal expansion of the shaft diameter, which is difficult to measure directly, is converted into a value of the change in compression of the elastic element 123 that can be read directly and in real time. By continuously monitoring the trend and rate of change of this displacement data, the system can quantitatively evaluate the local temperature rise and expansion effect caused by the repair heat input. This provides a basis for dynamic compensation of the process system: for example, when the displacement data shows that thermal expansion causes the support preload to increase continuously, the repair parameters can be finely adjusted simultaneously (such as reducing the heat source power or adjusting the feed speed) or the telescopic part 121 can be actively controlled to retract slightly, thereby neutralizing the additional stress brought by thermal deformation to the support system and the shaft itself in real time during the repair process, avoiding the internal stress and subsequent deformation caused by the rigid constraint of thermal expansion, and fundamentally ensuring that the repair area can still maintain accurate geometric dimensions and ideal residual stress state after cooling.

[0039] In some embodiments, the measuring element 130 is configured to correspond to the first connecting block 1221.

[0040] In some embodiments, the measuring element 130 is configured corresponding to the second connecting block 1223. In some embodiments, the measuring element 130 is provided corresponding to the first connecting block 1221 and the second connecting block 1223.

[0041] like Figure 9As shown, the measuring component 130 includes a displacement sensor 131 and a scale 132. The scale 132 is disposed on the first connecting block 1221 and / or the second connecting block 1223. The displacement sensor 131 is disposed on the moving component 110, with its detection end corresponding to the scale 132. The scale 132 serves as a measurement reference and moves together with the first connecting block 1221 or the second connecting block 1223. Its displacement directly reflects the compression / release amount of the elastic element 123. The displacement sensor 131 detects the position change of the scale 132 in real time through a light contact method, thereby accurately acquiring the axial displacement data of the connecting block and realizing direct, stable, and high-precision in-situ measurement.

[0042] like Figure 6 and Figure 7 As shown, the moving assembly 110 includes a moving frame 112 and two clamping blocks 111. A through hole is formed between the end faces of the two clamping blocks 111 for the rotor shaft 500 to pass through. The two clamping blocks 111 form a through hole with a defined centering reference, providing a rigid and precisely guided mounting and bearing base for the entire repair device, ensuring the overall structural stability and linearity of the support assembly during axial movement.

[0043] like Figure 6 As shown, the two clamping blocks 111 are rotatably connected on one side and locked on the other side by fasteners 1112. The movable frame 112 is located at the bottom of the clamping blocks 111 and connected to the frame 200, and can move along the length of the frame 200. The rotatable connection on one side forms an opening and closing hub, and the fasteners 1112 on the other side lock it in place. This facilitates the quick insertion and removal of the rotor shaft 500 and provides a stable closed-loop load-bearing frame for the entire support system after locking. Combined with the bottom movable frame 112, this ensures that the rigid frame can move accurately and stably along the axial direction as a whole.

[0044] In this embodiment, the fastener 1112 is a bolt.

[0045] like Figure 2 , Figure 6 and Figure 7As shown, the movable frame 112 includes a frame body 1121 and sliding wheels 1122. The frame body 1121 is connected to the clamping block 111, and the sliding wheels 1122 are located at the bottom of the frame body 1121. The frame 200 has a track 210 along its length, and the sliding wheels 1122 are embedded in the track 210. Through the precise engagement of the sliding wheels 1122 and the track 210, the relative motion between the movable frame 112 and the frame 200 is constrained to a linear motion along a single axis. This ensures that the support assembly has excellent linearity, guiding stability, and load-bearing rigidity when it makes long-stroke, repeatable positioning movements along the slender rotor shaft 500. This provides a stable, low-friction, and wobbly moving reference for continuous repair operations across the shaft shoulder, fundamentally guaranteeing the spatial trajectory accuracy of the support reference during the entire shaft repair process.

[0046] Some embodiments of this application also disclose a laser cladding repair method, which uses a civil aviation maintenance rotor shaft 500 repair device, and includes the following steps: Step 100: Inspect the defective area of ​​the rotor shaft 500 and determine the location of the defective area; Step 200: Remove the cracks and surrounding fatigue layer in the defective area, and clean it; Step 300: Determine whether the distance between the repair part of the rotor shaft 500 and the end of the shaft segment of the diameter meets the first preset distance; if yes, move the clamping mechanism 100 to the shaft segment to be repaired; if no, move the clamping mechanism 100 to the adjacent shaft segment and maintain the second preset distance. Step 400: Repair the area to be repaired using a laser head 400 and a powder feeder; Step 500, repeat steps 300 and 400 until the repair is complete.

[0047] In step 400, the axial relative position of the clamping mechanism 100 and the laser head 400 is dynamically adjusted to achieve the optimal dynamic configuration of the support points: when the repair area allows, the clamping mechanism 100 provides close support to the coaxial section, directly providing a strong anti-deformation torque to suppress thermal deformation; when the repair area is close to the shaft shoulder, the rollers automatically switch to the adjacent shaft section and provide support at a larger interval, ensuring effective support while also taking into account the heat avoidance and heat dissipation requirements of the rollers. This support method allows the laser cladding process to always be carried out under stable conditions of continuous reference, controllable support force, and active management of thermal deformation. It not only leverages the advantages of laser cladding itself in terms of precise heat input and high metallurgical bonding quality, but also ensures that the repair layer has excellent dimensional accuracy, uniform structure, and geometric continuity with the substrate through uninterrupted continuous operation and real-time support position optimization. Ultimately, the repaired rotor shaft 500 fully meets the stringent reliability standards of civil aviation in terms of fatigue strength, coaxiality, and dynamic balance performance.

[0048] The second preset distance is greater than the first preset distance. By setting the second preset distance > the first preset distance, the smaller first preset distance aims to achieve the optimal anti-deformation effect. When conditions permit, the support point is placed as close as possible to the heat source to provide the most direct and effective reverse constraint torque to suppress thermally induced deformation. However, when the repair area is close to the shoulder, making it impossible to meet the minimum distance A, a larger second preset distance is used, placing the support point on an adjacent shaft segment. The larger spacing prioritizes ensuring that the support roller itself is outside the heat-affected zone, avoiding overheating damage and guaranteeing the long-term reliability and stability of the support assembly. It also provides a safe operating space for the shoulder's geometric profile.

[0049] Specifically, during the repair of rotor shaft 500, a zoned, layer-by-layer cladding strategy was adopted. For areas with significant wear, multiple overlapping cladding layers were used, with the overlap rate controlled at around 40%-60%. Appropriate cladding materials were selected based on the material of the component substrate.

[0050] Tilt the laser head 400° at a certain angle to avoid diffuse reflection of the laser from the base metal. The lens receiving the laser will melt the metal vapor during the cladding process, forming contaminants. Tilt the laser head about 10° along the axial direction, with a laser power of 180-230W, a scanning speed of 2-3.5mm / s, a powder feed rate of 3-5g / min, a workpiece rotation speed of 5-8r / min, and a laser head axial movement speed of 0.05-0.07mm / s. The preheating temperature is 200-450℃, and the inert gas (argon) flow rate is 12-18L / min. As the number of layers increases, the cooling time should be appropriately extended, and the laser power for cladding should be reduced layer by layer to minimize part deformation.

[0051] The powder feeder and laser head 400 coaxially feed powder in a ring, and the laser beam is focused on the surface to be repaired to form a molten pool. Ni-183 powder is used for cladding. The Ni-183 powder is a nickel-based alloy powder with the following chemical composition (mass fraction): Cr: 17-19%, Fe: ≤4%, Si: 0.8-1.5%, B: 2.5-3.5%, C: ≤0.1%, Ni: balance. The powder particle size is 50-150μm. It has good metallurgical compatibility with most structural steel substrates, ensuring good bonding between the cladding layer and the substrate.

[0052] After the cladding is completed, the rotor shaft is machined and worn by turning 500, and the diameter of the part is restored to its original size.

[0053] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0054] Furthermore, it should be noted that the scope of the methods and apparatus in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. In addition, features described with reference to certain examples may be combined in other examples.

[0055] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A rotor shaft repair device for civil aviation maintenance, characterized in that, The clamping mechanism comprises a moving assembly and a supporting assembly, the moving assembly is arranged on a rack and is movable along the length direction of the rack, and the supporting assembly is arranged on the moving assembly and is used for supporting a rotor shaft. During the movement of the moving assembly, the supporting assembly is always in abutment with the surface of the rotor shaft.

2. A rotor shaft repair device for civil aviation maintenance according to claim 1, characterized in that, The supporting assembly comprises a plurality of supporting members, each of the supporting members comprises a telescopic part and an abutment part, the telescopic part is arranged on the moving assembly, and the abutment part is used for abutting with the surface of the rotor shaft, is connected with the telescopic part through an elastic member and is movable along the axial direction of the telescopic part. The abutment part comprises a first connecting block and a first roller, the first connecting block is connected with the telescopic part through the elastic member and is movable along the axial direction of the telescopic part, and the first roller is rotationally arranged on the telescopic part and is used for abutting with the surface of the rotor shaft.

3. A rotor shaft repair device for civil aviation maintenance according to claim 2, characterized in that The abutment part comprises a second connecting block, two rotating arms and two second rollers, the second connecting block is connected with the telescopic part through the elastic member and is movable along the axial direction of the telescopic part, one end of each of the two rotating arms is rotationally connected with the second connecting block, the other end of each of the two rotating arms is rotationally connected with the second roller, and the second roller is used for abutting with the surface of the rotor shaft.

4. A rotor shaft repair device for civil aviation maintenance according to claim 3, characterized in that The clamping mechanism further comprises a measuring member, the measuring member is arranged corresponding to the first connecting block and / or the second connecting block and is used for measuring the displacement of the first connecting block and / or the second connecting block.

5. A rotor shaft repair device for civil aviation maintenance according to claim 4, characterized in that The first roller is spherical. The second roller is spherical. The rotating arm is rotationally connected with the second connecting block through a torsional spring. The moving assembly is provided with a limiting protrusion corresponding to the rotating arm, the limiting protrusion is used for abutting with the rotating arm to limit the rotation of the rotating arm. The measuring member comprises a displacement sensor and a scale, and the scale is arranged on the first connecting block and / or the second connecting block.

6. A rotor shaft repair device for civil aviation maintenance according to claim 5, characterized in that The displacement sensor is arranged on the moving assembly, and a detection end of the displacement sensor is arranged corresponding to the scale. The moving assembly comprises a moving frame and two clamping blocks, and a through hole for the rotor shaft to pass through is formed between the end faces of the two clamping blocks.

7. A rotor shaft repair device for civil aviation maintenance according to claim 1, characterized in that, One side of each of the two clamping blocks is rotationally connected, and the other side is locked through a fastener, the moving frame is arranged at the bottom of the clamping blocks and is connected with the rack and is movable along the length direction of the rack. The moving frame comprises a frame body and a sliding wheel, the frame body is connected with the clamping blocks, and the sliding wheel is arranged at the bottom of the frame body.

8. A rotor shaft repair device for civil aviation maintenance according to claim 7, characterized in that The rack is provided with a track along the length direction, and the sliding wheel is embedded in the track. The method comprises the following steps:

9. A laser cladding repair method using the rotor shaft repair device for civil aviation maintenance according to any one of claims 1-8, characterized in that, Step 100: detecting a defect area of the rotor shaft and determining the position of the defect area; Step 200: removing the cracks and surrounding fatigue layer of the defect area and cleaning; Step 300: judging whether the distance between the repaired part of the rotor shaft and the end of the diameter shaft section satisfies a first preset distance, if yes, moving the clamping mechanism to the shaft section to be repaired, and if no, moving the clamping mechanism to the adjacent shaft section and keeping a second preset distance. ​ Step 400, repairing the region to be repaired by using the laser head and the powder feeder; Step 500, repeating the step 300 and the step 400 until the repairing is completed.

10. The method of claim 9, wherein the laser cladding is performed by a laser beam having a power of 1 to 5 kW. The value of the second preset distance is greater than the value of the first preset distance.

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