High-energy beam repairing process based on data driving

Abstract

The invention discloses a high-energy beam repair process based on data driving, which comprises a pretreatment box, a pretreatment structure is mounted on the inner side of the pretreatment box, the pretreatment structure comprises a plurality of drum-type conveyors, a cleaning inner box and a polishing collection box, and the cleaning inner box and the polishing collection box are mounted on the inner side of the pretreatment box; a plurality of sawtooth-shaped lifting grooves are formed in the inner side of the pretreatment box; the invention relates to the technical field of high-energy beam repair, realizes one-time clamping and multi-degree-of-freedom accurate positioning of a workpiece, thoroughly avoids secondary positioning errors caused by traditional multi-process conversion, and fundamentally ensures the accuracy of a subsequent repair path. By integrating the functions of three-dimensional scanning, ultrasonic cleaning, automatic grinding, air drying and the like, the working efficiency and consistency are greatly improved; and meanwhile, the system can carry out dead-angle-free defect identification and self-adaptive posture adjustment on the complex curved surface workpiece, the repairing quality is remarkably improved, and the application range is remarkably widened.

Description

Technical Field

[0001] This invention relates to the field of high-energy beam repair technology, and in particular to a data-driven high-energy beam repair process. Background Technology

[0002] In the field of high-energy beam repair of metal components, traditional pretreatment and repair processes are typically completed by multiple discrete and independent workstations and equipment. This presents a series of prominent problems, including the need for multiple clamping and positioning of the workpiece, introducing secondary errors; difficulty in performing comprehensive 3D scanning of complex curved surfaces; insufficient flexibility of the fixture system to achieve precise multi-degree-of-freedom orientation adjustment; and a lack of integrated and coordinated control among various functional modules. These drawbacks severely restrict the accuracy of the repair path, the completeness of defect identification, and the automation level and overall efficiency of the entire repair system. While existing technologies may already offer solutions to these problems, this paper aims to provide an alternative or replacement technical solution. Summary of the Invention

[0003] The technical solution of the present invention to achieve the above objectives is: a data-driven high-energy beam repair process, comprising the following steps: Step S1, workpiece clamping and positioning: The metal material to be repaired is loaded into the pretreatment box and transported to the processing position by a roller conveyor. The workpiece is initially fixed by inflating the spiral-shaped air bladder in the inner wall of the coin-shaped limiting block.

[0004] Step S2, 3D scanning and defect identification: The fixed workpiece is scanned from all directions by a scanning detector; at the same time, the copper coin-shaped limiting block is rotated by an angle drive machine, and combined with the rotation of the horizontal telescopic wheel, the workpiece's multi-degree-of-freedom pose adjustment is realized to accurately locate the 3D shape and position of surface defects.

[0005] Step S3, Surface Pretreatment: Based on the defect identification results, the workpiece is sequentially sent into the cleaning chamber and the grinding collection box for processing. First, the roller conveyor transports the metal material to the top of the cleaning chamber. In the cleaning chamber, the area to be repaired is thoroughly cleaned using an ultrasonic vibrator and cleaning solvent to remove oil and moisture, and then dried by a dryer. Subsequently, at the grinding station, a grinder is used to mill or grind the identified defects to completely remove the defects and roughen the surface. The generated debris is collected by the dust collection box.

[0006] Step S4, High-energy beam repair: The pre-treated workpiece is moved to the repair station. Based on the three-dimensional defect information obtained in step S2, the high-energy beam repair path and process parameters are set. Repair materials are clad layer by layer in the defect area to complete the repair of the metal layer.

[0007] Step S5, Post-repair processing and quality inspection: Slowly cool the repaired area, relieve stress, or perform necessary surface finishing; use a scanning detector again to perform three-dimensional scanning and quality inspection on the repaired area to ensure that the repair layer meets the technical requirements.

[0008] Preferably, the scanning detector adjusts the position and angle of the 3D scanner and the defect detection probe through a rotatable and liftable scanning bracket to achieve blind-angle scanning of complex curved workpieces.

[0009] Preferably, the surface pretreatment in step S3 specifically includes an automated cleaning and polishing process, in which the start-up, shutdown and coordinated operation of the ultrasonic vibrator, hot air blower and polisher are centrally controlled by the central control unit.

[0010] A data-driven high-energy beam repair device includes a pretreatment box. A pretreatment structure is installed inside the pretreatment box. The pretreatment structure includes multiple roller conveyors, a cleaning inner box, and a polishing collection box. The cleaning inner box and the polishing collection box are installed inside the pretreatment box. Multiple serrated lifting slots are installed parallel to each other inside the pretreatment box. A pair of electric lifting rods are installed inside each serrated lifting slot, and serrated lifting mechanisms are mounted on the pair of electric lifting rods. The support block, the roller conveyor is mounted on a pair of sawtooth lifting support blocks, and multiple partition blocks are installed inside the pretreatment box, the cleaning inner box and the grinding collection box. The partition blocks have annular holes, and coin-shaped limiting blocks are installed inside the annular holes. The coin-shaped limiting blocks are inserted into the annular holes through bearings. An angle drive motor is installed on the partition block, and a conical ring rack is installed on the coin-shaped limiting blocks. A bevel gear is installed on the drive end of the angle drive motor, and the bevel gear meshes with the conical ring rack.

[0011] Preferably, the pretreatment structure further includes multiple horizontal telescopic wheels, multiple rotating grooves are formed on the inner side of the coin-shaped limiting block, two pairs of drive fine-tuning limiting shafts are installed on the coin-shaped limiting block, the two pairs of drive fine-tuning limiting shafts are respectively inserted into the multiple rotating grooves, the horizontal telescopic wheels are installed on the drive fine-tuning limiting shafts, multiple expanding convex grooves are formed on the horizontal telescopic wheels, expanding convex blocks are installed on the inner side of the expanding convex grooves, expanding spring columns are installed on the expanding convex grooves and the expanding convex blocks, a pair of U-shaped airbags are formed on the inner side of the coin-shaped limiting block, a pair of drainage inflation tubes are installed on the pair of U-shaped airbags, an inflation diversion tube is installed on the pretreatment box, multiple drainage inflation tubes are connected to the inflation diversion tube, a fine-tuning drive is installed on the drive fine-tuning limiting shaft, and an inflation pump is installed on the inflation diversion tube.

[0012] Preferably, multiple ultrasonic vibrators are installed inside the inner cleaning chamber, two pairs of lifting threaded tubes are installed on the pretreatment chamber, lifting threaded rods are installed inside the lifting threaded tubes, lifting connecting rods are installed on the lifting threaded rods, eye-shaped lifting support blocks are installed on the two pairs of lifting connecting rods, multiple support rollers are installed on the lifting support blocks, lifting gear sets are installed on the two pairs of lifting threaded tubes, and lifting drive motors are installed on the lifting gear sets.

[0013] Preferably, a fine-tuning device is installed inside the pretreatment box. The fine-tuning device includes a pair of loop-shaped limiting blocks. The pair of loop-shaped limiting blocks are installed inside the pretreatment box. A fine-tuning threaded rod assembly is installed on the pair of loop-shaped limiting blocks. A fine-tuning threaded tube assembly is installed on the partition block. The fine-tuning threaded tube assembly is movably fitted onto the fine-tuning threaded rod assembly. A fine-tuning gear assembly is installed on the fine-tuning threaded rod assembly. A fine-tuning drive motor is installed on the fine-tuning gear assembly.

[0014] Preferably, a scanning detector is installed inside the pretreatment box, the scanning detector including a 3D scanner and a defect detection probe; the 3D scanner is installed on the top inside of the pretreatment box via a rotatable and liftable scanning bracket and the defect detection probe.

[0015] Preferably, a dryer and a polisher are installed inside the pretreatment box. The dryer includes a hot air blower and an annular air outlet pipe. The annular air outlet pipe is installed on the upper inner side of the cleaning inner box, and the hot air blower is installed on the annular air outlet pipe. The polisher includes a polishing head, a dust suction hood, and a dust collection box.

[0016] Preferably, a central control unit is installed on the pretreatment box. The central control unit is connected to and centrally controls the roller conveyor, lifting electric push rod, angle drive, fine adjustment drive, ultrasonic vibrator, lifting drive, scanning detector, air dryer, grinder, and air pump.

[0017] The high-energy beam repair system for metal layers manufactured using the technical solution of this invention, compared with the prior art, achieves precise positioning of the workpiece in a single clamping and multiple degrees of freedom, completely avoiding secondary positioning errors caused by traditional multi-process conversion, and fundamentally ensuring the accuracy of subsequent repair paths; by integrating three-dimensional scanning, ultrasonic cleaning, automatic grinding and air drying into one system, it greatly improves work efficiency and consistency; at the same time, the system can perform defect identification and adaptive posture adjustment on complex curved workpieces without blind spots, significantly improving repair quality and applicability. Attached Figure Description

[0018] Figure 1 This is a three-dimensional cross-sectional schematic diagram of the data-driven high-energy beam repair process described in this invention.

[0019] Figure 2 This is a front cross-sectional view of the data-driven high-energy beam repair process described in this invention.

[0020] Figure 3 for Figure 2 Side view section of “AA” in the middle.

[0021] Figure 4 for Figure 2 Side view sectional view of “BB” in the middle.

[0022] Figure 5 for Figure 2 Side view sectional view of “CC” in the middle.

[0023] In the diagram: 1. Pre-treatment box; 2. Roller conveyor; 3. Cleaning inner box; 4. Grinding collection box; 5. Serrated lifting groove; 6. Lifting electric push rod; 7. Serrated lifting support block; 8. Divider block; 9. Circular hole; 10. Coin-shaped limit block; 11. Angle drive motor; 12. Conical ring rack; 13. Conical gear; 14. Horizontal telescopic wheel; 15. Rotary groove; 16. Drive fine-tuning limit shaft; 17. Extended convex groove; 18. Extended convex block; 19. Recurve airbag; 20. Lifting threaded tube; 21. Lifting threaded rod; 22. Eye-shaped lifting support block; 23. Support roller; 24. Lifting gear set; 25. Lifting drive motor; 26. Recurve limit block; 27. Fine-tuning threaded rod set; 28. Fine-tuning threaded tube set; 29. ​​Fine-tuning gear set; 30. Fine-tuning drive motor. Detailed Implementation

[0024] Those skilled in the art should connect all electrical components and their compatible power supplies in this case via wires, and should select appropriate controllers according to actual conditions to meet control requirements. The specific connection and control sequence should refer to the working principle described below, where the electrical components are connected in sequence. The detailed connection methods are well-known in the art. The following mainly introduces the working principle and process, without explaining the electrical control.

[0025] Example Please refer to Figure 1-5 In the field of metal component manufacturing and remanufacturing, high-energy beam (such as laser and electron beam) repair technology is widely used to repair defects such as cracks, wear, and corrosion on the surfaces of high-value-added components in aerospace and energy equipment due to its advantages such as high energy density, small heat-affected zone, and good bonding strength. A high-quality repair effect depends heavily on the quality of surface pretreatment and the precise planning of the repair path.

[0026] Currently, traditional pre-processing procedures are typically completed by multiple independent workstations and equipment, including manual or simple fixture clamping of the workpiece, defect location on a coordinate measuring machine, ultrasonic cleaning in a cleaning tank, and manual removal of defects at a grinding station. This discrete operation mode has significant drawbacks: First, the workpiece is repeatedly clamped and positioned between different devices, which is not only inefficient but also prone to introducing secondary positioning errors, resulting in a mismatch between the subsequent repair path and the actual defect location; second, for complex curved surfaces or large workpieces, it is difficult to fully acquire the three-dimensional morphology of defects using scanning equipment at a fixed angle, easily creating blind spots in inspection and affecting the completeness of defect identification; third, traditional fixture systems have poor flexibility, making it difficult to achieve precise multi-degree-of-freedom orientation adjustment of the workpiece during inspection and pre-processing, thus limiting the level of automation and intelligence in the process; Therefore, this application protects a data-driven high-energy beam repair device. By inserting a metal material into the inner side of a coin-shaped limiting block 10, the electric lifting rod 6 inside the serrated lifting groove 5 extends and retracts, driving the serrated lifting support block 7 on the pushing end of the electric lifting rod 6 to move stably up and down. The serrated lifting support block 7 moves stably up and down along the inner side of the serrated lifting groove 5, driving the roller conveyor 2 on it to move stably up and down, thereby achieving the lifting and loosening of the steel material's support. This is achieved through the extended spring column belt inside the extended convex groove 17 on the inner side of multiple horizontal telescopic wheels 14. The extended convex block 18 on the upper part of the steel material is compressed vertically and horizontally. Simultaneously, the fine-tuning drive 30 operates, driving the drive fine-tuning limit shaft 16 on its drive end. The drive fine-tuning limit shaft 16 drives the horizontal telescopic wheel 14, which in turn provides stable horizontal transport of the steel material. The angle drive 11 on the partition block 8 operates, driving the bevel gear 13 on its drive end to rotate. The bevel gear 13 drives the bevel ring rack 12, which meshes with it. The copper coin-shaped limiting block 10 on it is driven to rotate stably and vertically inside the annular hole 9. The air pump on the pretreatment box 1 is operated to inflate the air diversion pipe, which inflates multiple drainage air pipes, which inflates multiple loop-shaped airbags 19. The inflated loop-shaped airbags 19 expand and compress the steel material, thereby achieving multi-angle adjustable scanning of the steel material by changing its position below the scanning detector inside the pretreatment box 1. At the same time, multi-angle scanning can be performed according to different defects in the steel material. The steel material is transported to multiple support rollers 23 on the eye-shaped lifting support block 22. The lifting drive motor 25 is driven to drive the lifting gear set 24 on the drive end of the lifting drive motor 25, which drives the inner lifting threaded tube 20. The lifting threaded tube 20 drives the inner lifting threaded rod 21, which drives the lifting connecting rod on it. The lifting connecting rod drives the eye-shaped lifting support block 22 to lift stably. The area to be repaired is thoroughly cleaned with solvents such as acetone and alcohol to remove oil, grease and moisture. For cracks, milling and grinding methods must be used to completely remove them. In summary, after the operator feeds the metal material to be repaired into the pretreatment box 1, the roller conveyor 2, driven by the lifting electric push rod 6 and the serrated lifting support block 7, is responsible for the horizontal transport and initial height adjustment of the workpiece. Subsequently, the system achieves precise positioning and fixation of the workpiece through two core mechanisms: first, the air pump inflates the U-shaped airbag 19, causing it to expand and evenly grip the workpiece from the inside; second, multiple horizontal telescopic wheels 14, under the action of the internal extended spring columns, apply multi-directional extrusion force to the workpiece through the extended convex block 18, achieving initial centering and clamping, as well as clamping and horizontal pushing. To meet complex scanning requirements, the system integrates multi-degree-of-freedom pose adjustment functions: the angle drive motor 11 transmits power through the meshing of the bevel gear 13 and the bevel ring rack 12. The copper coin-shaped limiting block 10 drives the workpiece to rotate precisely in the vertical plane; at the same time, the fine-tuning threaded rod group 27 in the fine-tuner can drive the entire clamping unit to make fine adjustments to the horizontal position, thereby ensuring that the area of ​​the workpiece to be repaired can be presented to the grinding device at the best angle. The adjustment of the grinding position changes the clamping and fixing position. After clamping and posture adjustment are completed, the scanning detector starts to work, and performs an all-round, no-dead-angle scan on the surface of the workpiece to accurately obtain the three-dimensional shape and precise position of the defect, and transmits the data to the central control unit in real time. Based on the scanning results, the system automatically executes the surface pretreatment process: the workpiece is first transported to the cleaning chamber 3, where an ultrasonic vibrator, combined with chemical solvents, thoroughly cleans the defective areas. Subsequently, a hot air blower from a dryer rapidly dries the workpiece through a ring-shaped exhaust duct. After cleaning and drying, the workpiece is transferred to the grinding collection box 4, where the grinding head mills or grinds the defects to thoroughly remove cracks and roughen the surface. Debris generated during this process is collected simultaneously by a dust extraction hood and a dust collection box. The pretreated workpiece is then transferred to the high-energy beam repair station. The central control unit automatically sets the repair path and process parameters based on the previously obtained three-dimensional defect information, guiding the high-energy beam head to melt and coat the repair material layer by layer in the defective area, completing the remanufacturing of the metal layer. After repair, necessary post-processing can be performed on the workpiece, and the scanning detector is restarted to perform a three-dimensional scan and quality inspection of the repaired area, ensuring that the dimensional accuracy and performance of the repair layer meet the technical requirements. The entire process, from workpiece loading, positioning scanning, cleaning and polishing to repair quality inspection, is completed automatically under the centralized scheduling of the central control unit, forming an efficient, precise, and integrated intelligent repair system.

[0027] The above technical solutions only embody the preferred technical solutions of the present invention. Any modifications that may be made by those skilled in the art to certain parts thereof embody the principles of the present invention and fall within the protection scope of the present invention.

Claims

1. A data-driven high-energy beam repair process includes the following steps: Step S1, workpiece clamping and positioning: The metal material to be repaired is loaded into the pretreatment box (1) and transported to the processing position by the roller conveyor (2). The workpiece is initially fixed by the inflation of the spiral airbag (19) in the inner wall of the coin-shaped limiting block (10). Step S2, 3D scanning and defect identification: The fixed workpiece is scanned in all directions by scanning detector; at the same time, the copper coin-shaped limit block (10) is driven to rotate by angle drive machine (11), and combined with the rotation of horizontal telescopic wheel (14) to realize the multi-degree-of-freedom pose adjustment of the workpiece, so as to accurately locate the three-dimensional shape and position of surface defects. Step S3, Surface pretreatment: Based on the defect identification results, the workpiece is sequentially sent into the cleaning inner box (3) and the grinding collection box (4) for processing; First, the roller conveyor (2) transports the metal material to the top of the cleaning inner box (3). In the cleaning inner box (3), the area to be repaired is thoroughly cleaned with an ultrasonic vibrator and cleaning solvent to remove oil and moisture, and then dried by a dryer; Subsequently, the identified defects are milled or ground at the grinding station to thoroughly remove the defects and roughen the surface. The generated debris is collected by the dust collection box. Step S4, High-energy beam repair: The pre-treated workpiece is moved to the repair station. Based on the three-dimensional defect information obtained in step S2, the high-energy beam repair path and process parameters are set. Repair materials are clad layer by layer in the defect area to complete the repair of the metal layer. Step S5, Post-repair processing and quality inspection: Slowly cool the repaired area, relieve stress, or perform necessary surface finishing; use a scanning detector again to perform three-dimensional scanning and quality inspection on the repaired area to ensure that the repair layer meets the technical requirements.

2. The data-driven high-energy beam repair process according to claim 1, characterized in that, The scanning detector adjusts the position and angle of the 3D scanner and the defect detection probe through a rotatable and liftable scanning bracket, enabling it to perform blind-angle scanning of complex curved workpieces.

3. The data-driven high-energy beam repair process according to claim 2, characterized in that, The surface pretreatment in step S3 specifically includes automated cleaning and polishing processes, with the start-up, shutdown, and coordinated operation of the ultrasonic vibrator, hot air blower, and polisher centrally controlled by the central control unit.

4. The data-driven high-energy beam repair device according to claims 1-3, characterized in that, The system includes a pretreatment box (1), on the inner side of which a pretreatment structure is installed. The pretreatment structure includes multiple roller conveyors (2), a cleaning inner box (3), and a grinding collection box (4). The cleaning inner box (3) and the grinding collection box (4) are installed inside the pretreatment box (1). Multiple serrated lifting slots (5) are installed inside the pretreatment box (1). The multiple serrated lifting slots (5) are installed parallel to each other inside the pretreatment box (1). A pair of lifting electric push rods (6) are installed inside the serrated lifting slots (5). Serrated lifting support blocks (7) are installed on the pair of lifting electric push rods (6). The roller conveyors (2) are installed inside the pretreatment box (1). On a pair of sawtooth lifting support blocks (7), multiple partition blocks (8) are installed on the inner side of the pretreatment box (1), the cleaning inner box (3) and the grinding collection box (4). The partition blocks (8) have annular holes (9). A copper coin-shaped limiting block (10) is installed on the inner side of the annular hole (9). The copper coin-shaped limiting block (10) is inserted into the inner side of the annular hole (9) through a bearing. An angle drive motor (11) is installed on the partition blocks (8). A conical ring rack (12) is installed on the copper coin-shaped limiting block (10). A bevel gear (13) is installed on the drive end of the angle drive motor (11). The bevel gear (13) meshes with the conical ring rack (12).

5. The data-driven high-energy beam repair device according to claim 4, characterized in that, The pretreatment structure also includes multiple horizontal telescopic wheels (14), and multiple rotating grooves (15) are provided on the inner side of the coin-shaped limiting block (10). Two pairs of drive fine-tuning limiting shafts (16) are installed on the coin-shaped limiting block (10), and the two pairs of drive fine-tuning limiting shafts (16) are respectively inserted into the multiple rotating grooves (15). The horizontal telescopic wheels (14) are installed on the drive fine-tuning limiting shafts (16), and multiple extended convex grooves (17) are provided on the horizontal telescopic wheels (14). An extended convex block (18) is installed on the inner side of the expansion convex groove (17) and the extended convex block (18). An extended spring column is installed on the extended convex groove (17) and the extended convex block (18). A pair of spiral airbags (19) are opened on the inner side of the copper coin-shaped limiting block (10). A pair of drainage and inflation tubes are installed on the pair of spiral airbags (19). An inflation diversion tube is installed on the pretreatment box. Multiple drainage and inflation tubes are connected to the inflation diversion tube. A fine adjustment drive (30) is installed on the drive fine adjustment limiting shaft (16). An inflation pump is installed on the inflation diversion tube.

6. The data-driven high-energy beam repair device according to claim 5, characterized in that, Multiple ultrasonic vibrators are installed on the inner side of the cleaning inner box (3). Two pairs of lifting threaded tubes (20) are installed on the pretreatment box (1). Lifting threaded rods (21) are installed on the inner side of the lifting threaded tubes (20). Lifting connecting rods are installed on the lifting threaded rods (21). Eye-shaped lifting support blocks (22) are installed on the two pairs of lifting connecting rods. Multiple support rollers (23) are installed on the lifting support blocks. Lifting gear sets (24) are installed on the two pairs of lifting threaded tubes (20). Lifting drive motors (25) are installed on the lifting gear sets (24).

7. The data-driven high-energy beam repair device according to claim 6, characterized in that, A fine-tuner is installed inside the pretreatment box (1). The fine-tuner includes a pair of loop-shaped limit blocks (26). The pair of loop-shaped limit blocks (26) are installed inside the pretreatment box (1). A fine-tuning threaded rod assembly (27) is installed on the pair of loop-shaped limit blocks (26). A fine-tuning threaded tube assembly (28) is installed on the partition block (8). The fine-tuning threaded tube assembly (28) is movably fitted onto the fine-tuning threaded rod assembly (27). A fine-tuning gear assembly (29) is installed on the fine-tuning threaded rod assembly (27). A fine-tuning drive motor (30) is installed on the fine-tuning gear assembly (29).

8. The data-driven high-energy beam repair device according to claim 7, characterized in that, The pretreatment box (1) is equipped with a scanning detector, which includes a three-dimensional scanner and a defect detection probe. The three-dimensional scanner is mounted on the top inner side of the pretreatment box (1) via a rotatable and liftable scanning bracket and the defect detection probe.

9. The data-driven high-energy beam repair device according to claim 8, characterized in that, The pretreatment box (1) is equipped with a dryer and a polisher. The dryer includes a hot air blower and an annular air outlet pipe. The annular air outlet pipe is installed on the upper inner side of the cleaning inner box (3). The hot air blower is installed on the annular air outlet pipe. The polisher includes a polishing head, a dust suction hood and a dust collection box.

10. The data-driven high-energy beam repair device according to claim 9, characterized in that, The pretreatment box (1) is equipped with a central control unit, which is connected to and centrally controls the roller conveyor (2), the lifting electric push rod (6), the angle drive (11), the fine-tuning drive (30), the ultrasonic vibrator, the lifting drive (25), the scanning detector, the air dryer, the grinder, and the air pump.

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