Cold spraying system and method for in-situ repair of aviation component

Abstract

The invention discloses a cold spraying system and method for in-situ repairing of an aviation component. The cold spraying system for in-situ repairing of the aviation component comprises a spraying workbench, a fixing structure, a plurality of positioning structures, a detection unit, a repairing unit and a post-processing unit. At least three working areas are sequentially formed on the spraying workbench in the workpiece conveying direction. The fixing structure is used for bearing the aviation parts and is movably arranged in all the working areas in the conveying direction. The plurality of positioning structures are correspondingly arranged in the working areas respectively; the detection unit is arranged in a working area, close to the feeding end, of the spraying workbench; the repairing unit is arranged in a working area behind the detection unit and comprises a spraying module and a monitoring module; and the post-processing unit is arranged in the working area, close to the discharging end, of the spraying workbench. Detection, repairing and post-processing functions are integrated on the assembly line type working platform, and full-process in-situ automatic operation from damage recognition to final forming is achieved.

Description

Technical Field

[0001] This invention relates to the field of aircraft component repair technology, and specifically to a cold spraying system and method for in-situ repair of aircraft components. Background Technology

[0002] Efficient and high-quality repair of aerospace components is crucial for ensuring aircraft availability and operational safety. Traditional repair methods, such as welding or thermal spraying, often face challenges such as large heat-affected zones, altered material properties, and easy deformation of the workpiece. Cold spraying technology, as a solid-state deposition process, achieves metallurgical bonding through high-speed particle impaction. It offers significant advantages such as extremely low heat input to the substrate and a wide range of depositable materials, providing a revolutionary technological path for the repair of critical aerospace components.

[0003] The existing patent publication number CN112760632A provides a method and system for rapid repair of high-strength metals and alloys using cold spraying in a space environment. To address the special constraints of extreme environments such as space stations, this technology designs a simplified cold spraying device powered solely by a high-pressure gas source. Its core contribution lies in achieving lightweight and adaptable equipment by eliminating auxiliary heating, and focusing on achieving high-strength repair in an on-orbit environment.

[0004] However, the aforementioned existing solutions and similar ground-based cold spraying technologies are mostly focused on offline repair scenarios, lacking a systematic solution that integrates in-situ operations, intelligent damage identification, online monitoring and feedback control, and automated finishing. When applied to modern aviation maintenance scenarios with extremely high requirements for efficiency, accuracy, and consistency, the entire repair process requires multiple discrete stages that rely on manual coordination and interpretation. The repair work heavily depends on the operator's experience for process coordination and parameter adjustment, making it difficult to achieve standardization, automation, and quality traceability in the repair process. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned technical deficiencies and propose a cold spraying system and method for in-situ repair of aerospace components, thereby solving the technical problems of process discreteness, high dependence on manual labor, and poor quality traceability in the offline repair scenario of aerospace components using existing cold spraying repair technology.

[0006] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a cold spraying system for in-situ repair of aerospace components, comprising a spraying worktable, a fixing structure, several positioning structures, a detection unit, a repair unit, and a post-processing unit; the spraying worktable sequentially forms at least three working areas along the workpiece conveying direction; the fixing structure is used to carry the aerospace component and is movably arranged in each working area along the conveying direction; several positioning structures are respectively correspondingly arranged in each of the working areas for positioning and fixing the fixing structure entering the corresponding working area; the detection unit is arranged in the working area of ​​the spraying worktable near the feeding end for performing damage scanning on the component; the repair unit is arranged in the working area behind the detection unit, and includes a spraying module and a monitoring module, wherein the spraying module is used to perform cold spraying repair on the area to be repaired, and the monitoring module is used to monitor the deposition process online; the post-processing unit is arranged in the working area of ​​the spraying worktable near the discharge end for performing finishing processing on the repaired area.

[0007] In some embodiments, the positioning structure includes at least two sets of positioning components and a driving component; the at least two sets of positioning components are respectively disposed on both sides of the working area, each positioning component includes two opposing positioning elements, one end of the positioning element is rotatably connected to the spraying worktable, and the other end forms a positioning end, the positioning element has a positioning state in which the positioning end rotates into the working area and a clearance state in which it rotates out of the working area; when the positioning element is in the positioning state, the positioning end contacts and engages with the edge of the fixed structure to limit and fix the fixed structure in the horizontal plane; the driving end of the driving component is connected to each of the positioning elements and is used to synchronously drive the positioning elements to switch between the positioning state and the clearance state.

[0008] In some embodiments, the driving component includes a driving member and two sets of transmission assemblies; the driving member is mounted on the spraying workbench, and the two sets of transmission assemblies are respectively disposed on both sides of the driving member and connected to the driving end of the driving member. Each set of transmission assemblies is connected to two positioning members of a positioning member, and is used to drive the positioning members to rotate synchronously inward to the positioning state or outward to the avoidance state under the drive of the driving member.

[0009] In some embodiments, the driving component includes a rotary motor, a rotary disk, and two transmission rods. The rotary disk is rotatably mounted on the spraying worktable. The output shaft of the rotary motor is drivenly connected to the rotary disk. One end of each of the two transmission rods is rotatably connected to an eccentric position on the rotary disk. The transmission assembly includes a sliding seat and two connecting rods. The sliding seat is slidably disposed along the lateral side of the spraying worktable. One end of each of the two connecting rods is rotatably connected to the sliding seat, and the other end is correspondingly connected to two positioning members of a set of positioning components. The end of each transmission rod away from the rotary disk is rotatably connected to the sliding seat. When the rotary motor drives the rotary disk to rotate, the two transmission rods respectively drive the corresponding sliding seats on the side to slide in opposite directions along the lateral side of the spraying worktable, so as to drive the positioning members to switch between a positioning state and an avoidance state through the connecting rods.

[0010] In some embodiments, the fixing structure includes a fixing platform, two sets of oppositely arranged clamping members, and a clamping drive connecting the two sets of clamping members. The two sets of clamping members are slidably disposed on the upper surface of the fixing platform. The output end of the clamping drive is connected to the two sets of clamping members respectively, and is used to drive the two sets of clamping members to move closer to each other along the lateral direction of the fixing platform to clamp the workpiece or to move away from each other to release the workpiece.

[0011] In some embodiments, the cold spraying system for in-situ repair of aerospace components further includes a conveying mechanism mounted on a spraying workbench or integrated into the fixed structure, for driving the fixed structure to move stepwise between adjacent work areas along the conveying direction.

[0012] In some embodiments, the detection unit includes a three-dimensional scanning module and a laser cleaning module. The three-dimensional scanning module is used to perform three-dimensional morphological scanning on the surface of the aerospace component, acquire morphological data of the damaged area, and generate a three-dimensional damage model. The laser cleaning module is used to perform laser cleaning treatment on the surface of the component to be repaired based on the damaged area determined by the three-dimensional damage model.

[0013] In some embodiments, the monitoring module includes an infrared thermal imager and a laser ultrasonic thickness gauge; the infrared thermal imager is used to monitor the temperature distribution of the repair area in real time during the cold spraying process; the laser ultrasonic thickness gauge is used to non-contactly measure the thickness of the cold sprayed deposit layer in real time.

[0014] In some embodiments, the cold spraying system for in-situ repair of aerospace components further includes a moving device and several robotic arms. The moving device is mounted above the spraying workbench, and the number of robotic arms corresponds to the work area. One end of each robotic arm is connected to the moving device, and the other end is respectively equipped with the corresponding functional module of the detection unit, repair unit, or post-processing unit. The moving device is used to drive each robotic arm to perform multi-degree-of-freedom position adjustment along the length, width, and / or height directions of the spraying workbench.

[0015] Secondly, the present invention also provides a cold spraying method for in-situ repair of aerospace components, using a cold spraying system for in-situ repair of aerospace components as described in any one of the above claims, the method comprising: The aircraft component to be repaired is clamped onto the fixed structure and fed into the corresponding working area of ​​the testing unit along the conveying direction; The detection unit performs a three-dimensional scan of the component surface, identifies the damaged area and generates a repair model, and then performs laser cleaning on the damaged area. The fixed structure is moved to the corresponding working area of ​​the repair unit, and the spraying module performs cold spraying deposition according to the repair model. At the same time, the deposition process is monitored in real time by the monitoring module, and the spraying module dynamically adjusts the spraying parameters according to the online monitoring results fed back by the monitoring module. The fixed structure is moved to the corresponding working area of ​​the post-processing unit, and the post-processing unit is used to perform fine processing on the repaired area.

[0016] Compared with existing technologies, the cold spraying system and method for in-situ repair of aerospace components provided by this invention constructs a fully automated production line platform by setting up at least three working areas arranged sequentially along the conveying direction, along with corresponding detection, repair, and post-processing units. This allows the aerospace components to be repaired to sequentially undergo automatic damage identification, controllable cold spraying deposition, and finishing treatment, achieving a complete repair closed loop from damage assessment to functional restoration. By setting up a movable fixed structure, the fixed structure can stably support the aerospace components and move them sequentially through multiple working areas, allowing the components to enter the detection, repair, and post-processing stations in sequence, achieving continuous and automatic connection of processes. With the help of the positioning structure, the fixed structure can be precisely locked and calibrated as the components move to each working area, ensuring that the workpiece maintains the same reference attitude and spatial position as initially set throughout the key processes such as detection, spraying, and processing, thus providing a fundamental guarantee for high-precision operation throughout the entire process. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the cold spraying system and method for in-situ repair of aerospace components provided in this embodiment of the invention; Figure 2This is a cross-sectional structural diagram of the spraying workbench, fixing structure, and positioning structure installation of the cold spraying system and method for in-situ repair of aerospace components provided in this embodiment of the invention. Figure 3 This is a schematic diagram of the positioning component of the cold spraying system and method for in-situ repair of aerospace components provided in this embodiment of the invention when it is in the positioning state. Figure 4 This is a schematic diagram of the positioning component of the cold spraying system and method for in-situ repair of aerospace components provided in this embodiment of the invention when the positioning component is in an avoidance state. Figure 5 This is a top view of the positioning structure of the cold spraying system and method for in-situ repair of aerospace components provided in this embodiment of the invention. Figure 6 This is a cross-sectional schematic diagram of the fixing structure of the cold spraying system and method for in-situ repair of aerospace components provided in an embodiment of the present invention; Figure 7 yes Figure 1 Enlarged structural diagram at point A in the middle.

[0018] Explanation of reference numerals in the attached figures: 1. Spray painting workbench; 2. Fixed structure; 21. Fixed platform; 211. Movable groove; 212. Slide groove; 22. Clamping plate; 23. Sliding block; 24. Double-acting lead screw; 25. Handle; 3. Positioning structure; 31. Positioning component; 311. Positioning rod; 32. Driving component; 321. Driving element; 3211. Rotary disk; 3212. Transmission rod; 322. Transmission assembly; 3221. Sliding seat; 3222. Connecting rod; 3223. Mounting base; 4. Detection unit; 5. Repair unit; 6. Post-processing unit; 7. Conveying structure; 71. Roller; 8. Moving device; 81. First guide rail; 82. Second guide rail; 83. Moving seat; 84. Electric roller; 9. Robotic arm. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0020] To address the technical challenges of discrete processes, high reliance on manual labor, and poor quality traceability in offline repair of aerospace components using cold spraying repair technology, this invention provides a cold spraying system and method for in-situ repair of aerospace components. By integrating detection, repair, and post-processing functions into a streamlined work platform, it achieves fully automated in-situ operation from damage identification to final shaping. This not only significantly improves the accuracy and consistency of a single repair operation but also provides reliable data support for the standardization and continuous optimization of aerospace maintenance processes, thereby making the application of cold spraying technology in in-situ repair of aerospace components more systematic, intelligent, and engineered.

[0021] In a first aspect, the present invention provides a cold spraying system for in-situ repair of aerospace components, comprising a spraying worktable 1, a fixing structure 2, several positioning structures 3, a detection unit 4, a repair unit 5, and a post-processing unit 6; the spraying worktable 1 forms at least three working areas sequentially along the workpiece conveying direction; the fixing structure 2 is used to carry the aerospace component and is movably arranged in each working area along the conveying direction; several positioning structures 3 are respectively arranged in each working area to position and fix the fixing structure 2 entering the corresponding working area; the detection unit 4 is arranged in the working area of ​​the spraying worktable 1 near the feeding end and is used to scan the component for damage; the repair unit 5 is arranged in the working area behind the detection unit 4, and includes a spraying module and a monitoring module, the spraying module is used to perform cold spraying repair operation on the area to be repaired, and the monitoring module is used to monitor the deposition process online; the post-processing unit 6 is arranged in the working area of ​​the spraying worktable 1 near the discharge end and is used to perform finishing processing on the repaired area.

[0022] In this solution, the spraying workbench 1 forms at least three working areas along the workpiece conveying direction. The fixed structure 2 can support the movement of the aerospace component within each working area along the conveying direction. The positioning structure 3 precisely positions the fixed structure 2 within each working area, ensuring the positional stability of the aerospace component during inspection, repair, and post-processing. The inspection unit 4 uses advanced damage scanning technology to quickly identify damaged areas on the component's surface and internal structure, generating a detailed damage model to provide the repair unit 5 with precise repair paths and parameter data. The repair unit 5 employs cold spraying technology, spraying high-speed particles onto the area to be repaired to achieve solid-state material deposition. The monitoring module collects key data such as the thickness and temperature of the deposited layer in real time during the spraying process and feeds this information back to the control system for timely adjustment of spraying parameters, ensuring the quality and performance of the deposited layer. The post-processing unit 6 performs fine processing on the repaired area according to the size and precision requirements of the repaired component, such as grinding and polishing, to achieve the same flatness and smoothness as the original component, further ensuring that the repaired component meets the stringent standards of aerospace operations. The entire system is highly integrated, with each unit working collaboratively. Through the orderly movement of the fixed structure 2 in each work area and the precise positioning of the positioning structure 3, seamless connection of each process is achieved, effectively improving the efficiency, accuracy and reliability of in-situ repair of aerospace components.

[0023] To construct a highly automated repair production line with seamless process connections, in some possible embodiments, the spraying workbench 1 is designed as a high-rigidity platform structure, divided along its length into three stations: an inspection station, a repair station, and a post-processing station. This system employs a design where a fixed structure 2 works in conjunction with a conveying mechanism and a positioning structure 3. The conveying mechanism is mounted on the spraying workbench 1 or integrated into the fixed structure 2, driving the fixed structure 2 to move stepwise between adjacent work areas along the conveying direction.

[0024] Specifically, in this embodiment, the conveying mechanism adopts a roller conveying structure, including several parallel conveying rollers 71. The two ends of each roller 71 are rotatably mounted on the side frames of the spraying workbench 1 via bearing seats, and the outer circumferential surface of each roller 71 contacts the bottom of the fixed structure 2. The rotation of the rollers 71 drives the fixed structure 2 to move along the conveying direction. To ensure the stability of the fixed structure 2 during movement, the center distance between adjacent rollers 71 is no greater than one-third of the length of the bottom support surface of the fixed structure 2. Simultaneously, a servo motor and a reduction gearbox are provided at the drive end of the conveying rollers 71, enabling precise adjustment of the conveying speed through a PLC control system.

[0025] Please see Figures 1 to 5To achieve precise positioning and locking of the fixed structure 2 at each workstation and to reliably avoid obstacles to allow passage when not in operation, in some possible embodiments, the positioning structure 3 includes at least two sets of positioning components 31 and a driving component 32. At least two sets of positioning components 31 are respectively disposed on both sides of the work area. Each positioning component 31 includes two opposing positioning elements. One end of the positioning element is rotatably connected to the spraying worktable 1, and the other end forms a positioning end. The positioning element has a positioning state where the positioning end rotates into the work area and an avoidance state where it rotates out of the work area. The driving component 32 includes a driving element 321 and two sets of transmission assemblies 322. The driving element 321 is mounted on the spraying worktable 1. The two sets of transmission assemblies 322 are respectively disposed on both sides of the driving element 321 and connected to the driving end of the driving element 321. Each set of transmission assemblies 322 connects to two positioning elements of a set of positioning components 31, and is used to drive the positioning component 31 to rotate synchronously inward to the positioning state or outward to the avoidance state under the drive of the driving element 321. When the positioning component is in the positioning state, the positioning end contacts and engages with the edge of the fixed structure 2. Multiple sets of positioning components apply clamping force from the outer periphery of the fixed structure 2 to the center, thereby achieving mechanical rigid positioning of the fixed structure 2. When the positioning component switches to the avoidance state, its positioning end rotates completely to the outside of the working area to avoid interference with the moving fixed structure 2 and ensure that the fixed structure 2 can smoothly pass through the transition section between each working area.

[0026] In one possible embodiment, the driving component 321 includes a rotary motor, a rotary disk 3211, and two transmission rods 3212. The transmission assembly 322 includes a sliding seat 3221 and two connecting rods 3222. The positioning component includes four positioning rods 311, which are respectively located at the four edges of the working area and symmetrically arranged on both sides of the travel path of the fixed structure 2. The rotary disk 3211 is rotatably mounted on the spraying workbench 1. The output shaft of the rotary motor is connected to the rotary disk 3211. One end of each of the two transmission rods 3212 is rotatably connected to an eccentric position on the rotary disk 3211, and the end of the transmission rod 3212 away from the rotary disk 3211 is rotatably connected to the sliding seat 3221. On the spraying workbench 1, corresponding to both sides of the rotary disk 3211, two mounting seats 3223 are provided. Each mounting seat 3223 has a horizontally arranged guide rod, and the sliding seat 3221 is slidably sleeved on the guide rod. The upper part can slide laterally along the spraying worktable 1; one end of each of the two connecting rods 3222 is rotatably connected to the sliding seat 3221, and the other end passes through the gap between the corresponding two rollers 71 and is rotatably connected to the positioning rod 311; when the rotary motor drives the rotating disk 3211 to rotate, the two transmission rods 3212 drive the sliding seats 3221 on both sides to make lateral reciprocating motion along the guide rod as the rotating disk 3211 rotates eccentrically, and then push the positioning rod 311 to rotate around its rotation connection point with the spraying worktable 1 through the connecting rod 3222. When the sliding seat 3221 moves toward the rotating disk 3211, the connecting rod 3222 pulls the positioning rod 311 to rotate inward into the working area, so that the positioning ends of the four positioning rods 311 move toward the edge of the fixed structure 2 and make contact, thus forming a multi-directional clamping and positioning of the fixed structure 2; when the sliding seat 3221 moves away from the rotating disk 3211, the connecting rod 3222 pushes the positioning rod 311 to rotate outward from the working area, and the positioning end gradually disengages from the fixed structure 2 and rotates to the avoidance position. At this time, the fixed structure 2 can enter the next working area under the drive of the conveying mechanism.

[0027] Furthermore, the fixed structure 2 is provided with inclined positioning surfaces at its four corners. When the positioning rod 311 rotates around its rotational connection point with the spraying worktable 1 into the working area, the positioning end of the positioning rod 311 can precisely fit with the inclined positioning surface. The design of the inclined positioning surface allows the positioning rod 311 to apply positioning force from the four corners of the fixed structure 2. Through surface contact, the positional error of the fixed structure 2 is dispersed and canceled in both the lateral and longitudinal directions, further improving the positioning accuracy. At the same time, the contact fit between the inclined positioning surface and the positioning end of the positioning rod 311 increases the friction between the two, effectively preventing the fixed structure 2 from undergoing slight displacement due to external forces during inspection, repair, and other operations. This ensures that the positioning repeatability accuracy of the fixed structure 2 in each working area can be controlled within 0.02mm, fully meeting the process requirements for high-precision repair of aerospace components.

[0028] Of course, in other possible embodiments, the positioning structure 3 can also adopt other structural forms, such as a pneumatically driven positioning pin structure, with a positioning hole preset at the bottom of the fixed structure 2. When the fixed structure 2 moves to the working area, the pneumatic cylinder drives the positioning pin to insert into the positioning hole to achieve rapid positioning; or an electromagnetic adsorption positioning method can be adopted, with an electromagnet set in the working area and a magnetic plate set at the corresponding position at the bottom of the fixed structure 2. The fixed structure 2 is adsorbed and fixed by the magnetic force generated by the electromagnet being energized.

[0029] Please see Figures 1 to 4 as well as Figure 6 In order to achieve stable bearing and fixation of aerospace components, in some possible embodiments, the fixing structure 2 includes a fixing platform 21, two sets of oppositely arranged clamping members, and a clamping drive 321 connecting the two sets of clamping members. The two sets of clamping members are slidably disposed on the upper surface of the fixing platform 21. The output end of the clamping drive 321 is connected to the two sets of clamping members respectively, and is used to drive the two sets of clamping members to move closer to each other along the lateral direction of the fixing platform 21 to clamp the workpiece or move away from each other to release the workpiece.

[0030] In one embodiment, the clamping component includes a clamping plate 22 and a sliding block 23. The clamping drive component 321 adopts a screw and nut transmission structure, including a bidirectional screw 24 and a handle 25. Specifically, two parallel movable grooves 211 are provided on both sides of the top of the fixed platform 21. The interior of the fixed platform 21 has a sliding groove 212 communicating with the movable grooves 211. The bidirectional screw 24 is rotatably installed in the sliding groove 212 along the transverse direction of the fixed platform 21, and its two ends pass through the two side walls of the fixed platform 21 and are fixedly connected to the handle 25. The bottom of the sliding block 23 is threadedly connected to the bidirectional screw 24, and its top passes through the movable groove 211 and is fixedly connected to the clamping plate 22. The sliding block 23 slides in cooperation with the movable groove 211. When the handle 25 is rotated, the bidirectional screw 24 synchronously drives the sliding blocks 23 on both sides to move towards or away from each other along the movable groove 211, thereby driving the two sets of clamping plates 22 to move closer or further away, realizing the clamping and fixing of aerospace components of different sizes.

[0031] Furthermore, the clamping surface of the clamping plate 22 is provided with replaceable elastic pads. These pads are made of polyurethane material, which has good cushioning performance and a high coefficient of friction. This not only prevents indentations or scratches on the surface of the aerospace parts during clamping, but also further enhances the stability of clamping.

[0032] Of course, in other possible embodiments, the fixing structure 2 can also adopt other structural forms, such as a fixing device based on the principle of vacuum adsorption, which has several adsorption holes on the surface of the fixing platform 21, and uses a vacuum pump to draw air to generate negative pressure in the adsorption holes, so as to adsorb and fix the aviation parts on the fixing platform 21; or a magnetic fixing structure 2 can be adopted, which has a strong magnet set on the inner side of the clamping plate 22, suitable for fixing aviation parts made of ferromagnetic materials.

[0033] In some possible embodiments, the detection unit 4 includes a 3D scanning module and a laser cleaning module. The 3D scanning module employs a high-precision blue light scanner, whose scanning head incorporates a high-resolution industrial camera and a blue light source, capable of acquiring point cloud data of the component surface at a rate of millions of points per second, with a scanning accuracy of up to 0.01 mm. This module utilizes multi-view stitching technology to perform omnidirectional scanning of the complex curved surfaces of aerospace components. After scanning, the system automatically compares and analyzes the point cloud data with the original 3D model of the component, quickly identifying the location, size, and depth information of damaged areas such as dents, cracks, and wear, and presenting the damage distribution in a visual manner, providing accurate digital basis for subsequent repair work. The laser cleaning module uses a 1064nm fiber laser. By controlling the laser's power density, scanning speed, and scanning path, it can efficiently remove oil, oxide layers, and other impurities from the component surface, avoiding interference from these contaminants on the accuracy of subsequent damage scanning results.

[0034] In some possible embodiments, the monitoring module includes an infrared thermal imager and a laser ultrasonic thickness gauge; the spraying module is a high-pressure cold spray gun equipped with an adjustable nozzle structure and a powder feeding device. The powder feeding device can precisely control the powder feeding rate of the metal powder to ensure a stable supply of spraying material. During the cold spraying process, the infrared thermal imager captures the temperature field distribution of the repair area in real time, and judges the energy transfer and bonding state during particle deposition by analyzing the temperature change trend, avoiding changes in material properties due to local overheating; the laser ultrasonic thickness gauge uses laser pulses to excite ultrasonic waves, and accurately measures the real-time thickness of the deposited layer by receiving the reflected wave signal. When the thickness reaches the preset value, it is promptly fed back to the control system, which automatically adjusts the working parameters of the spraying module or stops the spraying operation to ensure that the thickness of the repair layer meets the design requirements. The monitoring module compares the collected temperature, thickness, and other data with preset thresholds in real time. If an abnormal deviation occurs, an alarm is immediately issued and a corresponding adjustment mechanism is triggered, thereby realizing closed-loop control of the cold spraying repair process.

[0035] In some possible embodiments, the post-processing unit 6 employs a CNC grinding head or a laser cladding head to perform finishing on the repaired contour or pre-process special damage.

[0036] Please see Figure 1 and Figure 7In order to achieve flexible adjustment of the working position, in this embodiment, the cold spraying system for in-situ repair of aerospace components also includes a moving device 8 and several robotic arms 9. The moving device 8 is installed above the spraying workbench 1 and consists of a first guide rail 81 arranged along the conveying direction, three second guide rails 82 that slide with the first guide rail 81, and three moving seats 83 that slide with the three second guide rails 82 respectively. The first guide rail 81 is parallel to the length direction of the spraying workbench 1, and the second guide rails 82 are arranged perpendicular to the first guide rail 81. Each moving seat 83 is equipped with a robotic arm 9. The detection unit 4, the repair unit 5, and the post-processing unit 6 are respectively installed on the end effectors of the three robotic arms 9. Electric rollers 84 and motors are provided on both the movable seat 83 and the second guide rail 82. The motors drive the electric rollers 84 to move along the first guide rail 81 or the second guide rail 82. The sliding of the movable seat 83 on the second guide rail 82 can drive the robotic arm 9 to move laterally along the direction perpendicular to the conveying direction, while the sliding of the second guide rail 82 on the first guide rail 81 enables the robotic arm 9 to move longitudinally along the conveying direction. Through the adjustment of displacement in both the lateral and longitudinal directions, the robotic arm 9 can drive the detection unit 4, the repair unit 5 and the post-processing unit 6 to accurately cover any position of the aviation component to be processed within their respective work areas.

[0037] The robotic arm 9 employs a six-degree-of-freedom structure, possessing high flexibility and motion precision. Its end effector is equipped with a quick-change interface, allowing for rapid replacement of inspection probes, spray nozzles, or post-processing tools according to different operational needs. The quick-change interface features a switchable mounting plate with multiple tool mounting positions evenly distributed around its circumference. The tool mounting positions for the robotic arm 9 corresponding to the inspection positions are equipped with scanners and fiber lasers; those for the repair positions are equipped with infrared thermal imagers, laser ultrasonic thickness gauges, and high-pressure cold spray guns; and those for the post-processing positions are equipped with CNC grinding heads or laser cladding heads. The control system automatically controls the rotation of the mounting plate according to different process requirements, switching the corresponding tools to the working positions, enabling rapid tool changes for inspection, repair, and post-processing.

[0038] Secondly, embodiments of this application also provide a cold spraying method for in-situ repair of aerospace components, using a cold spraying system for in-situ repair of aerospace components as described in any of the above embodiments, the method comprising: S1. The aircraft component to be repaired is clamped in the fixed structure 2 and fed into the corresponding working area of ​​the detection unit 4 along the conveying direction; S2. The detection unit 4 performs a three-dimensional scan of the component surface, identifies the damaged area and generates a repair model, and then performs laser cleaning on the damaged area. S3. Move the fixed structure 2 to the corresponding working area of ​​the repair unit 5, use the spraying module to perform cold spraying deposition according to the repair model, and monitor the deposition process in real time through the monitoring module. At the same time, the spraying module dynamically adjusts the spraying parameters according to the online monitoring results fed back by the monitoring module. S4. Move the fixed structure 2 to the corresponding working area of ​​the post-processing unit 6, and use the post-processing unit 6 to perform fine processing on the repair area.

[0039] Furthermore, the monitoring of the deposition process in step S3 specifically includes: S31. Obtain the real-time temperature field of the deposition area using an infrared thermal imager, and extract the average impact temperature and temperature distribution uniformity index. S32. Measure the cumulative thickness of the current coating online using a laser ultrasonic thickness gauge; S33. The average impact temperature, temperature distribution uniformity index and cumulative thickness are compared with the preset target values ​​in the repair plan in real time.

[0040] S34. When the average impact temperature deviates from the preset target range, adjust the power of the carrier gas heater; when the temperature distribution uniformity index is lower than the preset threshold, adjust the scanning speed of the spray gun or the overlap rate of the scanning path; when the cumulative thickness reaches the preset layer thickness, control the multi-axis robot to raise the preset height and perform the next layer deposition.

[0041] The cold spraying system and method for in-situ repair of aerospace components provided by this invention constructs a fully automated production line platform by setting up at least three working areas arranged sequentially along the conveying direction, along with corresponding detection units 4, repair units 5, and post-processing units 6. This allows the aerospace components to be repaired to sequentially undergo automatic damage identification, controllable cold spraying deposition, and finishing treatment, achieving a complete repair closed loop from damage assessment to functional restoration. A movable fixed structure 2 stably supports the aerospace components and moves them sequentially through multiple working areas, allowing the components to enter the detection, repair, and post-processing stations in sequence, achieving continuous and automatic connection of processes. The positioning structure 3, when moving to each working area, precisely locks and calibrates the fixed structure 2, ensuring that the workpiece maintains the same reference attitude and spatial position as initially set throughout the key processes such as detection, spraying, and processing, thus providing a fundamental guarantee for high-precision operation throughout the entire process.

[0042] In the description of this application, it should be noted that the terms "upper" and "lower," etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0043] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A cold spray system for in-situ repair of an aerospace component, characterized by, include: The spraying workbench has at least three working areas sequentially formed along the workpiece conveying direction; A fixed structure for carrying aviation components and movable within each working section along the conveying direction; Several positioning structures are respectively set in each of the work areas to position and fix the fixed structures that enter the corresponding work areas; A detection unit is located in the working area of ​​the spraying workbench near the material feeding end, and is used to perform damage scanning on the parts. The repair unit is located in the working area behind the detection unit. It includes a spraying module and a monitoring module. The spraying module is used to perform cold spray repair on the area to be repaired, and the monitoring module is used to monitor the deposition process online. as well as The post-processing unit is located in the working area near the discharge end of the spraying workbench and is used to perform fine processing on the repaired area.

2. The cold spray system for in situ repair of an aerospace component of claim 1, wherein, The positioning structure includes at least two sets of positioning components and a driving component; At least two sets of positioning components are respectively disposed on both sides of the working area. Each positioning component includes two opposing positioning elements. One end of the positioning element is rotatably connected to the spraying worktable, and the other end forms a positioning end. The positioning element has a positioning state in which the positioning end rotates into the working area and a clearance state in which it rotates out of the working area. When the positioning element is in the positioning state, the positioning end contacts and engages with the edge of the fixed structure to limit and fix the fixed structure in the horizontal plane. The driving end of the driving component is connected to each of the positioning elements, and is used to synchronously drive the positioning elements to switch between positioning state and avoidance state.

3. The cold spray system for in situ repair of an aerospace component of claim 2, wherein, The driving component includes a driving element and two sets of transmission assemblies; The drive unit is mounted on the spraying worktable. The two sets of transmission components are respectively disposed on both sides of the driving member and are connected to the driving end of the driving member. Each set of transmission components is connected to two positioning members of a positioning component, which are used to drive the positioning component to rotate synchronously inward to the positioning state or outward to the avoidance state under the drive of the driving member.

4. The cold spray system for in situ repair of an aerospace component of claim 3, wherein, The driving component includes a rotary motor, a rotary disk, and two transmission rods. The rotary disk is rotatably mounted on the spraying worktable. The output shaft of the rotary motor is connected to the rotary disk. One end of each of the two transmission rods is rotatably connected to an eccentric position on the rotary disk. The transmission assembly includes a sliding seat and two connecting rods. The sliding seat can slide laterally along the spraying workbench. One end of each of the two connecting rods is rotatably connected to the sliding seat, and the other end is correspondingly connected to two positioning members of a set of positioning components. The end of the transmission rod away from the rotating disk is rotatably connected to the sliding seat. When the rotary motor drives the rotating disk to rotate, the two transmission rods respectively drive the corresponding sliding seats to slide in opposite directions along the lateral side of the spraying workbench, so as to drive the positioning component to switch between the positioning state and the avoidance state through the connecting rod.

5. The cold spray system for in situ repair of an aerospace component of claim 1, wherein, The fixing structure includes a fixed platform, two sets of oppositely arranged clamping members, and a clamping drive connecting the two sets of clamping members. The two sets of clamping members are slidably disposed on the upper surface of the fixed platform. The output end of the clamping drive is connected to the two sets of clamping members respectively, and is used to drive the two sets of clamping members to move closer to each other in the lateral direction of the fixed platform to clamp the workpiece or to move away from each other to release the workpiece.

6. The cold spraying system for in-situ repair of aerospace components according to claim 1, characterized in that, It also includes a conveying mechanism, which is installed on the spraying workbench or integrated into the fixed structure, for driving the fixed structure to move stepwise between adjacent work areas along the conveying direction.

7. The cold spraying system for in-situ repair of aerospace components according to claim 1, characterized in that, The detection unit includes a three-dimensional scanning module and a laser cleaning module. The three-dimensional scanning module is used to perform three-dimensional morphological scanning on the surface of the aerospace component, obtain morphological data of the damaged area, and generate a three-dimensional damage model. The laser cleaning module is used to perform laser cleaning treatment on the surface of the component to be repaired based on the damaged area determined by the three-dimensional damage model.

8. The cold spraying system for in-situ repair of aerospace components according to claim 1, characterized in that, The monitoring module includes an infrared thermal imager and a laser ultrasonic thickness gauge; the infrared thermal imager is used to monitor the temperature distribution of the repair area in real time during the cold spraying process; the laser ultrasonic thickness gauge is used to measure the thickness of the cold sprayed deposit layer in real time without contact.

9. The cold spraying system for in-situ repair of aerospace components according to claim 1, characterized in that, It also includes a mobile device and several robotic arms. The mobile device is installed above the spraying workbench. The number of robotic arms corresponds to the work area. One end of each robotic arm is connected to the mobile device, and the other end is respectively equipped with the corresponding functional module of the detection unit, repair unit or post-processing unit. The moving device is used to drive each robotic arm to perform multi-degree-of-freedom position adjustment along the length, width and / or height of the spraying workbench.

10. A cold spraying method for in-situ repair of aerospace components, characterized in that, Using the cold spray system for in-situ repair of aerospace components as described in any one of claims 1-9, the method comprises: The aircraft component to be repaired is clamped onto the fixed structure and fed into the corresponding working area of ​​the testing unit along the conveying direction; The detection unit performs a three-dimensional scan of the component surface, identifies the damaged area and generates a repair model, and then performs laser cleaning on the damaged area. The fixed structure is moved to the corresponding working area of ​​the repair unit, and the spraying module performs cold spraying deposition according to the repair model. At the same time, the deposition process is monitored in real time by the monitoring module, and the spraying module dynamically adjusts the spraying parameters according to the online monitoring results fed back by the monitoring module. The fixed structure is moved to the corresponding working area of ​​the post-processing unit, and the post-processing unit is used to perform fine processing on the repaired area.

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