Large shaft part repair equipment and method of use

Abstract

This invention discloses a large shaft parts repair equipment and its usage method, relating to the fields of additive manufacturing and large shaft parts repair technology. It includes a housing, within which a machine bed main support is fixed. A spindle box housing is fixed to one end of the machine bed main support. A MIG wire feeder, a MIG welding power source, and a protective gas cylinder are respectively arranged at a corner of the housing away from the spindle box housing. A main rotary positioning assembly and a secondary rotary positioning assembly are respectively arranged at both ends of the machine bed main support, and the main rotary positioning assembly includes a spindle servo motor fixed to the other end of the machine bed main support. A precision machining assembly and a welding assembly are respectively arranged on the outer sides of the machine bed main support near the main and secondary rotary positioning assemblies. This invention achieves integrated and automated repair of large shaft parts of different specifications, with excellent repair results.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing and repair technology for large shaft parts, and in particular to a repair equipment for large shaft parts and its method of use. Background Technology

[0002] Large shaft components are crucial transmission and load-bearing parts in modern heavy industry and high-end equipment, primarily used in key areas such as energy and power (e.g., steam turbines, generator rotors), heavy machinery (e.g., rolling mills, mining equipment), ship propulsion, and major engineering projects (e.g., tunnel boring machines). Therefore, stringent requirements are placed on their mechanical performance, lifespan, and reliability. Under extreme service conditions, large shaft components are subjected to alternating loads, impacts, friction, vibration, and corrosive media, frequently exhibiting fatigue wear, pitting, fracture, or other defects on their surfaces, necessitating regular repair and replacement. However, due to the high manufacturing cost and long repair cycle of large shaft components, the development and application of shaft component repair and remanufacturing technologies are of great significance. Arc-wire additive manufacturing, as a direct energy deposition process, uses an arc-wire method to add new materials to repair damaged components. Its deposited layer has a dense structure, low porosity, high material utilization and deposition efficiency, and the equipment is simple to manufacture and inexpensive, making it an advanced method for component repair.

[0003] However, the surface roughness of parts repaired by arc additive manufacturing cannot meet the normal usage requirements of shaft parts. Precision turning and other machining processes are needed to ensure that the repaired parts meet the requirements for dimensional tolerances, geometric tolerances, and surface roughness. Currently, the process design for additive manufacturing repair of large shaft parts is segmented and discrete. The core repair processes are not continuous, and the pretreatment, additive manufacturing repair, machining, and quality assessment are disconnected and poorly connected. This relies heavily on manual intervention, resulting in low repair efficiency and long cycles. There is a lack of integrated and automated equipment for arc additive manufacturing repair of large shaft parts. Summary of the Invention

[0004] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0005] In view of the problems existing in the above and / or existing large shaft parts repair equipment and their usage methods, the present invention is proposed.

[0006] Therefore, the problem to be solved by this invention is how to solve the problems of arc additive manufacturing repair, precision machining and high-quality repair of large shaft parts.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a large shaft parts repair equipment, including a packaging shell, a bed main support fixed inside the packaging shell, a spindle box shell fixed at one end of the bed main support, and a MIG wire feeder, a MIG welding power source and a protective gas cylinder respectively arranged at a corner of the packaging shell away from the spindle box shell.

[0008] Furthermore, a main rotary positioning assembly and a secondary rotary positioning assembly are respectively provided at both ends of the main body support of the bed. The main rotary positioning assembly includes a spindle servo motor fixed at the other end of the main body support of the bed, and the secondary rotary positioning assembly includes a secondary spindle servo motor fixed on one side of the main body support of the bed.

[0009] Furthermore, a precision machining assembly and a welding assembly are respectively provided on the outer side of the main rotation positioning assembly and the auxiliary rotation positioning assembly near the main body support of the bed. The precision machining assembly includes a tool post servo motor fixed on the side of the main body support of the bed near the auxiliary spindle servo motor, and the welding assembly includes a gantry component servo motor fixed on the other side of the main body support of the bed.

[0010] As a preferred embodiment of the large shaft parts repair equipment described in this invention, the main rotary positioning assembly further includes a drive wheel sleeved on the output shaft of the main spindle servo motor, a driven wheel driven by a transmission belt on the outside of the drive wheel, and a main three-jaw self-centering chuck fixed on the inside of the driven wheel by a transmission shaft.

[0011] As a preferred embodiment of the large shaft parts repair equipment described in this invention, the secondary rotary positioning assembly further includes a secondary spindle moving lead screw fixed on the output shaft of the secondary spindle servo motor, a secondary spindle lead screw sleeve threadedly connected to the secondary spindle moving lead screw, a secondary spindle ball nut connecting plate fixed on the outer side of the secondary spindle lead screw sleeve, a secondary spindle moving guide rail fixed on the secondary spindle ball nut connecting plate, and a secondary spindle motor protective cover fixed on the secondary spindle moving guide rail.

[0012] As a preferred embodiment of the large shaft part repair equipment described in this invention, the auxiliary spindle motor protective cover is embedded with an auxiliary spindle stepper motor, and an auxiliary three-jaw self-centering chuck that matches the main three-jaw self-centering chuck is fixed on the output shaft of the auxiliary spindle stepper motor, and a large shaft part is clamped between the main three-jaw self-centering chuck and the auxiliary three-jaw self-centering chuck.

[0013] As a preferred embodiment of the large shaft parts repair equipment described in this invention, the precision turning assembly further includes a tool post moving ball screw fixed on the output shaft of the tool post servo motor, a tool post screw sleeve threadedly connected to the tool post moving ball screw, a tool post ball nut connecting plate fixed on the outside of the tool post screw sleeve, a tool post feed moving guide rail fixed on the tool post ball nut connecting plate, and a first static guide rail in the X direction fixed on the main body support of the bed, which slides with the secondary spindle moving guide rail and the tool post feed moving guide rail.

[0014] As a preferred embodiment of the large shaft parts repair equipment described in this invention, a tool post base is provided on the tool post feed guide rail, and a tool post stepper motor is embedded in the tool post base. A turret CNC tool post is fixed on the output shaft of the tool post stepper motor, and a turning tool is provided on the turret CNC tool post.

[0015] As a preferred embodiment of the large shaft component repair equipment described in this invention, the welding assembly further includes a gantry component ball screw fixed on the output shaft of the gantry component servo motor, a gantry component screw sleeve threadedly connected to the gantry component ball screw, a gantry component ball nut connecting plate fixed on the outside of the gantry component screw sleeve, a gantry component moving guide rail fixed on the gantry component ball nut connecting plate, and a second static guide rail in the X direction that slides with the gantry component moving guide rail fixed on the outside of the bed body support.

[0016] As a preferred embodiment of the large shaft component repair equipment described in this invention, the gantry component has a longitudinally arranged support connecting frame on the outer side of the moving guide rail, and a Y-direction motion module is arranged on the two support connecting frames, and a Z-direction motion module is arranged on the Y-direction motion module. A transition profile is arranged on the outer side of the Z-direction motion module, and a structured light sensor is fixed on one of the transition profiles, and a MIG welding gun is fixed on the other transition profile by a welding gun clamp.

[0017] As a preferred embodiment of the large shaft parts repair equipment described in this invention, the front side of the encapsulation housing is provided with a push-pull slide rail, and a push-pull front safety door is slidably mounted on the two push-pull slide rails via push-pull slide rail strips. A main control panel is fixed to the outside of the encapsulation housing, and a swing-open rear safety door and a swing-open welding machine safety door are respectively hinged to the rear side of the encapsulation housing.

[0018] A method for using a repair tool for large shaft parts includes the following steps: Step 1: Open all safety doors on the enclosure and the main control panel. Turn on the MIG wire feeder, MIG welding power supply and protective gas cylinder. Return all shafts to zero. Remove the oxide layer and oil from the parts of large shafts to be repaired, and clamp them correctly to ensure sufficient clamping force.

[0019] Step 2: Use the structured light sensor operated by the main control panel to scan the area to be repaired of the large shaft-like parts, obtain the three-dimensional morphological data map of the damaged area, and plan the additive repair deposition path.

[0020] Step 3: Set the additive repair process parameters on the main control panel, including deposition rate, voltage, wire feed rate, etc.; set the mechanical subtractive process parameters on the main control panel, including spindle speed, depth of cut, feed rate, tool selection, etc.; correctly edit the machining program, perform additive repair first, and then perform subtractive machining.

[0021] Step 4: Close all safety doors and start the machining program to repair large shaft parts.

[0022] Step 5: After the repair program is completed, the structured light sensor scans the surface of the repair area to obtain a three-dimensional surface topography data map, calculates the surface roughness Ra value, compares it with the standard value, and provides feedback on whether the surface quality meets the standard.

[0023] Step Six: If the surface quality of the repaired part of the large shaft part does not meet the standard, continue with precision turning; if the surface quality of the repaired part of the large shaft part meets the standard, the repair process is completed.

[0024] Step 7: Open the safety door, disassemble the parts, turn off the MIG wire feeder, MIG welding power supply and protective gas cylinder, turn off the main control panel, close all safety doors, and complete the repair and processing of large shaft parts.

[0025] The beneficial effects of this invention are as follows: Addressing the existing deficiencies in additive repair processes for large shaft parts, this invention integrates arc additive repair, precision machining, and high-precision repair into a unified design. This achieves integrated and automated repair processes for large shaft parts of different specifications, significantly improving the efficiency and precision of additive repair for large shaft parts. The dual-spindle design simultaneously meets the process requirements of arc additive repair and precision machining, thereby enhancing the repair accuracy. A structured light sensor with three-axis linkage displacement provides a visual monitoring mechanism, enabling closed-loop control of the repair process. Furthermore, the use of both precision turning and welding repair methods achieves effective additive repair for large shaft parts, with a wider repair scope. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. 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.

[0027] Figure 1This is a diagram showing the repair status of a large shaft-type parts repair equipment.

[0028] Figure 2 This is a diagram showing the activated state of a large shaft-type parts repair equipment.

[0029] Figure 3 This is a partial internal view of a repair tool for large shaft-type parts.

[0030] Figure 4 A side view of the main rotary positioning component of a large shaft-type parts repair equipment.

[0031] Figure 5 A bottom view of the secondary rotary positioning component of a large shaft-type parts repair equipment.

[0032] Figure 6 A bottom view of a precision-machined assembly for a large shaft-type parts repair equipment.

[0033] Figure 7 A side view of the welding assembly of a large shaft-type parts repair equipment.

[0034] In the diagram: 1. Encapsulation housing; 2. Bed main support; 3. Spindle box housing; 4. MIG wire feeder; 5. MIG welding power supply; 6. Protective gas cylinder; 71. Spindle servo motor; 72. Drive wheel; 73. Drive belt; 74. Driven wheel; 75. Drive shaft; 76. Main three-jaw self-centering chuck; 81. Sub-spindle servo motor; 82. Sub-spindle moving screw; 83. Sub-spindle screw sleeve; 84. Sub-spindle ball nut connecting plate; 85. Sub-spindle moving guide rail; 86. Sub-spindle motor protective cover; 87. Sub-spindle stepper motor; 88. Sub-three-jaw self-centering chuck; 89. Large shaft parts; 91. Tool post servo motor; 92. Tool post moving ball screw; 93. Tool post screw sleeve; 94. Tool holder ball nut connecting plate; 95. Tool holder feed guide rail; 96. Tool holder base; 97. Tool holder stepper motor; 98. Turret CNC tool holder; 99. Lathe tool; 101. Gantry component servo motor; 102. Gantry component ball screw; 103. Gantry component screw sleeve; 104. Gantry component ball nut connecting plate; 105. Gantry component moving guide rail; 106. Support connecting frame; 107. Y-direction motion module; 108. Z-direction motion module; 109. Adapter profile; 1010. Structured light sensor; 1011. Welding torch fixture; 1012. MIG welding torch; 11. X-direction first static guide rail; 12. X-direction second static guide rail; 13. Push-pull front safety door. Detailed Implementation

[0035] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0036] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0037] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0038] Example 1, referring to Figures 1 to 7 This is the first embodiment of the present invention, which provides a large shaft part repair equipment, including a housing 1, a bed main support 2 fixed inside the housing 1, a spindle box housing 3 fixed at one end of the bed main support 2, and a MIG wire feeder 4, a MIG welding power source 5 and a protective gas cylinder 6 respectively arranged at a corner of the housing 1 away from the spindle box housing 3. The MIG wire feeder 4 and the MIG welding power source 5 provide hardware support for the additive repair process of large shaft parts, and the protective gas cylinder 6 provides the necessary protective atmosphere for the additive repair process of large shaft parts.

[0039] A main control panel is fixed to the outside of the encapsulation housing 1. The main control panel contains multiple windows, namely, an additive repair process parameter setting window, a mechanical subtractive process parameter setting window, a window for planning the three-dimensional morphology and repair path of the damaged part, a window for inspecting the surface quality of the part, and a window for real-time monitoring of equipment operation program and data. These windows are used to plan repair schemes, control equipment operation, and detect repair data. A push-pull slide rail is horizontally placed on the front side of the encapsulation housing 1. A push-pull front safety door 13 is slidably moved between the two push-pull slide rails and the push-pull slide rail strip. The push-pull front safety door 13 can be flexibly pushed and pulled open and closed through the push-pull slide rail and the push-pull slide rail strip, which is convenient for operation from the front of the encapsulation housing 1. A swing-type rear safety door and a swing-type welding machine safety door are respectively hinged to the rear side of the encapsulation housing 1 for loading and unloading large shaft parts to be repaired.

[0040] Example 2, refer to Figures 1 to 7 This is the second embodiment of the present invention, which is based on the previous embodiment.

[0041] Specifically, a main rotary positioning assembly and a secondary rotary positioning assembly are respectively provided at both ends of the bed main support 2. The main rotary positioning assembly includes a spindle servo motor 71 fixed at the other end of the bed main support 2, a drive wheel 72 sleeved on the output shaft of the spindle servo motor 71, a driven wheel 74 driven by a transmission belt 73 on the outside of the drive wheel 72, and a main three-jaw self-centering chuck 76 fixed on the inside of the driven wheel 74 by a transmission shaft 75.

[0042] First, a lifting device is used to clamp one end of the large shaft part 89 to be repaired into the main three-jaw self-centering chuck 76 to pre-clamp and position one end of the large shaft part 89. When linear rotation of the large shaft part 89 is required, the main spindle servo motor 71 is turned on and drives the driven wheel 74 and the drive shaft 75 to rotate synchronously through the transmission belt 73 on the drive wheel 72. The drive shaft 75 drives the clamped end of the large shaft part 89 to rotate linearly through the main three-jaw self-centering chuck 76.

[0043] Specifically, the secondary rotary positioning assembly includes a secondary spindle servo motor 81 fixed to one side of the bed main support 2, a secondary spindle moving lead screw 82 fixed to the output shaft of the secondary spindle servo motor 81, a secondary spindle lead screw sleeve 83 threadedly connected to the secondary spindle moving lead screw 82, a secondary spindle ball nut connecting plate 84 fixed to the outside of the secondary spindle lead screw sleeve 83, a secondary spindle moving guide rail 85 fixed on the secondary spindle ball nut connecting plate 84, and a secondary spindle motor protective cover 86 fixed on the secondary spindle moving guide rail 85.

[0044] The control spindle servo motor 81 is turned on and drives the spindle moving screw 82 to rotate linearly forward. The spindle moving screw 82 drives the spindle moving guide rail 85 and the spindle motor protective cover 86 to move forward through the spindle ball nut connecting plate 84 on the spindle sleeve 83. At the same time, the spindle motor protective cover 86 drives the spindle three-jaw self-centering chuck 88 to move forward through the spindle stepper motor 87 and clamp the other end of the large shaft part 89. It is suitable for the effective clamping and positioning of large shaft parts 89 of different specifications. It has a wide range of applications, does not require replacement of the positioning mechanism, and is more efficient.

[0045] A secondary spindle motor protective cover 86 houses a secondary spindle stepper motor 87. A secondary three-jaw self-centering chuck 88, which mates with the primary three-jaw self-centering chuck 76, is fixed to the output shaft of the secondary spindle stepper motor 87. A large shaft-like part 89 is engaged between the primary three-jaw self-centering chuck 76 and the secondary three-jaw self-centering chuck 88. The effective diameter range of the primary three-jaw self-centering chuck 76 to the secondary three-jaw self-centering chuck 88 is 100mm to 500mm. The diameters of the two ends of the large shaft-like part 89 range from 100mm to 500mm, the maximum diameter of the middle section is 800mm, and the length ranges from 600mm to 2000mm, forming a dual-spindle structure that improves the positioning stability and machining accuracy of the large shaft-like part 89.

[0046] When linear rotation of a large shaft part 89 is required, the secondary spindle stepper motor 87 and the main spindle servo motor 71 are started synchronously and at the same speed. The secondary spindle stepper motor 87 drives the other end of the large shaft part 89, which is clamped in place, through the secondary three-jaw self-centering chuck 88, to rotate linearly at the same speed as the drive shaft 75. The drive shaft 75, through the main three-jaw self-centering chuck 76, drives one end of the large shaft part 89, which is clamped in place, to rotate synchronously and linearly, thus meeting the subsequent precision machining and repair needs of the large shaft part 89.

[0047] Example 3, referring to Figures 1 to 7 This is the third embodiment of the present invention, which is based on the first two embodiments.

[0048] Specifically, the main body support 2 of the bed is equipped with a precision machining assembly and a welding assembly on the outer side near the main rotary positioning assembly and the auxiliary rotary positioning assembly, respectively. The precision machining assembly includes a tool post servo motor 91 fixed on the side of the main body support 2 near the auxiliary spindle servo motor 81, and a tool post moving ball screw 92 fixed on the output shaft of the tool post servo motor 91. A tool post screw sleeve 93 is threaded onto the tool post moving ball screw 92, and a tool post ball nut connecting plate 94 is fixed on the outer side of the tool post screw sleeve 93. A tool post feed moving guide rail 95 is fixed on the tool post ball nut connecting plate 94, and an X-direction first static guide rail 11 is fixed on the main body support 2, which slides with the auxiliary spindle moving guide rail 85 and the tool post feed moving guide rail 95. The X-direction first static guide rail 11 plays a sliding limiting role for the auxiliary spindle moving guide rail 85 and the tool post feed moving guide rail 95, thereby improving their displacement stability.

[0049] The tool holder servo motor 91 is turned on and the tool holder moves the ball screw 92, which drives the tool holder ball nut connecting plate 94 and the tool holder feed guide rail 95 on the tool holder screw sleeve 93 to move synchronously.

[0050] Specifically, a tool post base 96 is provided on the tool post feed guide rail 95, and a tool post stepper motor 97 is embedded in the tool post base 96. A turret CNC tool post 98 is fixed on the output shaft of the tool post stepper motor 97, and a turning tool 99 is provided on the turret CNC tool post 98. When the turning tool 99 needs to be replaced, the turning tool 99 on the turret CNC tool post 98 is first moved away from the large shaft part 89, and then the tool post stepper motor 97 is controlled to drive the turning tool 99 on the turret CNC tool post 98 to rotate, so as to replace the next set of turning tools 99.

[0051] The tool post feed guide rail 95 drives the selected turning tool 99 on the turret CNC tool post 98 to move along the tool post stepper motor 97 on the tool post base 96. The selected turning tool 99 then performs precision turning repair on the repair part of the large shaft part 89 which is in linear rotation, thereby achieving automated and integrated precision turning repair of the large shaft part 89.

[0052] Specifically, the welding assembly includes a gantry component servo motor 101 fixed on the other side of the bed main support 2, a gantry component ball screw 102 fixed on the output shaft of the gantry component servo motor 101, a gantry component screw sleeve 103 threadedly connected to the gantry component ball screw 102, a gantry component ball nut connecting plate 104 fixed on the outside of the gantry component screw sleeve 103, a gantry component moving guide rail 105 fixed on the gantry component ball nut connecting plate 104, and a second static guide rail 12 in the X direction that slides with the gantry component moving guide rail 105 fixed on the outside of the bed main support 2, which plays a sliding limiting role for the gantry component moving guide rail 105 and improves the displacement stability of the gantry component moving guide rail 105.

[0053] The servo motor 101 of the gantry component drives the ball screw 102 of the gantry component to rotate linearly in both directions. The ball screw 102 of the gantry component drives the ball nut connecting plate 104 and the moving guide rail 105 of the gantry component to perform axial displacement along the X-axis through the ball screw sleeve 103 of the gantry component.

[0054] The effective stroke of the tool post moving ball screw 92, the sub-spindle moving ball screw 82, and the gantry component ball screw 102 is 2000mm, the linear motion speed is adjustable from 0 to 100mm / s, and the repeatability is ±0.01mm.

[0055] Specifically, a support connecting frame 106 is longitudinally mounted on the outer side of the gantry component moving guide rail 105. A Y-direction motion module 107 is mounted on the two support connecting frames 106, and a Z-direction motion module 108 is mounted on the Y-direction motion module 107. A transition profile 109 is mounted on the outer side of the Z-direction motion module 108. The repeatability of the Y-direction motion module 107 and the Z-direction motion module 108 is ±0.05mm, and the linear motion speed is adjustable from 0 to 80mm / s. The Y-direction linear motion module is model FKM120-S850-SG-1205, with a stroke of 850mm, and the Z-direction linear motion module is model FKM120-S350-SG-1605, with a stroke of 350mm.

[0056] A structured light sensor 1010 is fixed on one of the adapter profiles 109, and a MIG welding torch 1012 is fixed on the other adapter profile 109 via a welding torch clamp 1011. It is compatible with the MIG wire feeder 4 and the MIG welding power source 5 and is suitable for one-element and pulsed gas metal arc welding, MMA welding and argon arc welding.

[0057] The structured light sensor 1010 selected is the KEYENCE LJ-X8020 fully automatic laser scanning 3D vision sensor. The reference distance for the sensing head is 20mm, the effective measurement range is 4.4mm, the contour data interval is 2.5μm, and the surface detection accuracy is ±0.01mm. Before additive repair, the structured light sensor 1010 scans the 3D morphology of the defect, and the host control software plans the repair deposition path trajectory based on the defect's 3D morphology, ensuring minimal additive quality and improving efficiency while saving costs. After machining, the structured light sensor 1010 scans the machined surface to obtain the 3D morphology of the surface contour and calculates the surface roughness Ra. Feedback is provided to determine whether the machined surface quality meets the standards and whether further repair or finishing is needed, achieving closed-loop control.

[0058] The gantry component moving guide rail 105 drives the component on it to move axially along the X-axis through two support connecting frames 106, and the component on it is adjusted axially along the Y-axis by the Y-direction motion module 107. The Z-direction motion module 108 drives the structure light sensor 1010 and the MIG welding gun 1012 on the welding gun fixture 1011 to adjust axially along the Z-axis through two adapter profiles 109 until the structure light sensor 1010 and the MIG welding gun 1012 reach the repair area of ​​the large shaft part 89. The structure light sensor 1010 accurately scans the repair area of ​​the large shaft part 89, and the MIG welding gun 1012 welds and repairs the repair area of ​​the large shaft part 89, realizing the effectiveness and diversity of the repair of the large shaft part 89 and meeting the repair needs of the large shaft part 89 under different damage conditions.

[0059] A method for using a repair tool for large shaft parts includes the following steps: Step 1: Open all safety doors on the encapsulation housing 1, and open the main control panel. Turn on the MIG wire feeder 4, MIG welding power supply 5 and protective gas cylinder 6. Return all shafts to zero. Remove the oxide layer and oil from the large shaft parts 89 to be repaired, and clamp them correctly to ensure sufficient clamping force. Step Two: Using the main control panel, operate the structured light sensor 1010 to scan the area to be repaired on the large shaft part 89. During this process, first control the main spindle servo motor 71 and the auxiliary spindle stepper motor 87 to drive the repair area of ​​the large shaft part 89 to the welding horizontal zone of the structured light sensor 1010 via the main three-jaw self-centering chuck 76 and the auxiliary three-jaw self-centering chuck 88. Then, control the gantry component servo motor 101 to drive the gantry component ball screw 102 to rotate linearly in both directions. The gantry component ball screw 102, through the gantry component screw sleeve 103, drives the gantry component ball nut connecting plate 104 and the gantry component moving guide rail 105 to perform axial displacement along the X-axis. The gantry component moving guide rail 105 drives the component on it to move axially along the X-axis through two support connecting frames 106, and the component on it is adjusted axially along the Y-axis by the Y-direction motion module 107. The Z-direction motion module 108 drives the structure light sensor 1010 and the MIG welding gun 1012 on the welding gun fixture 1011 to adjust axially along the Z-axis through two adapter profiles 109 until the structure light sensor 1010 reaches the repair area of ​​the large shaft part 89. The structure light sensor 1010 accurately scans the repair area of ​​the large shaft part 89, obtains the three-dimensional morphological data map of the damaged area, and performs additive repair deposition path planning. Step 3: Set the additive repair process parameters on the main control panel, including deposition rate, voltage, wire feed rate, etc.; set the mechanical subtractive machining process parameters on the main control panel, including spindle speed, depth of cut, feed rate, tool selection, etc.; correctly edit the machining program, perform additive repair first, and then perform subtractive machining. Step 4: Close all safety doors and start the machining program to repair the large shaft part 89. Before this, use a lifting tool to clamp one end of the large shaft part 89 to be repaired into the main three-jaw self-centering chuck 76 and position it in the horizontal area of ​​the secondary three-jaw self-centering chuck 88. Then, control the secondary spindle servo motor 81 to start and drive the secondary spindle moving screw 82 to rotate linearly forward. The secondary spindle moving screw 82 drives the secondary spindle moving guide rail 85 and the secondary spindle motor protective cover 86 to move forward through the secondary spindle ball nut connecting plate 84 on the secondary spindle screw sleeve 83. At the same time, the secondary spindle motor protective cover 86 drives the secondary three-jaw self-centering chuck 88 to move forward through the secondary spindle stepper motor 87 and clamps the other end of the large shaft part 89. Step 5: Next, the main spindle servo motor 71 and the secondary spindle stepper motor 87 are started synchronously. The main spindle servo motor 71 drives the driven wheel 74 and the drive shaft 75 to rotate synchronously through the transmission belt 73 on the drive wheel 72. The drive shaft 75 drives one end of the large shaft part 89, which is clamped in place, to rotate linearly through the main three-jaw self-centering chuck 76. At the same time, the secondary spindle stepper motor 87 drives the other end of the large shaft part 89, which is clamped in place, to rotate linearly at the same speed as the drive shaft 75 through the secondary three-jaw self-centering chuck 88. Step Six: Simultaneously, first control the tool post servo motor 91 to start and move the tool post ball screw 92 to drive the tool post ball nut connecting plate 94 on the tool post screw sleeve 93 and the tool post feed guide rail 95 to move synchronously. The tool post feed guide rail 95 drives the selected turning tool 99 on the turret CNC tool post 98 to move accordingly through the tool post stepper motor 97 on the tool post base 96. The selected turning tool 99 then performs precision turning repair on the repair part of the large shaft part 89 that is in linear rotation. If it is necessary to replace the turning tool 99, first move the turning tool 99 on the turret CNC tool post 98 away from the large shaft part 89, and then control the tool post stepper motor 97 to drive the turning tool 99 on the turret CNC tool post 98 to rotate. After replacing the next set of turning tools 99, the same process is repeated to continue precision turning repair on the repair part of the large shaft part 89 that is in linear rotation. Step 7: When welding is required on the large shaft part 89 that has been clamped in place, the structured light sensor 1010 first accurately scans the repair area of ​​the large shaft part 89. Then, the main spindle servo motor 71 and the auxiliary spindle stepper motor 87 are controlled to move the repair area of ​​the large shaft part 89 to the welding horizontal zone of the MIG welding torch 1012 through the main three-jaw self-centering chuck 76 and the auxiliary three-jaw self-centering chuck 88, respectively. Then, the gantry component servo motor 101 is controlled to drive the gantry component ball screw 102 to rotate linearly in both directions. The gantry component ball screw 102 drives the gantry component ball nut connecting plate through the gantry component screw sleeve 103. 104 and the gantry component moving guide rail 105 are moved axially along the X-axis. The gantry component moving guide rail 105 drives the components on it to move axially along the X-axis through two support connecting frames 106. The components on it are adjusted axially along the Y-axis by the Y-direction motion module 107. The Z-direction motion module 108 drives the structure light sensor 1010 and the MIG welding gun 1012 on the welding gun fixture 1011 to adjust axially along the Z-axis through two adapter profiles 109 until the MIG welding gun 1012 reaches the repair part of the large shaft part 89. The MIG welding gun 1012 then welds and repairs the repair part of the large shaft part 89. Step 8: After the repair program is completed, the structured light sensor 1010 scans the surface of the repair area to obtain a three-dimensional surface topography data map, calculates the surface roughness Ra value, compares it with the standard value, and provides feedback on whether the surface quality meets the standard. Step Nine: If the surface quality of the repaired area of ​​the large shaft part 89 does not meet the standards, continue with precision turning; if the surface quality of the repaired area of ​​the large shaft part 89 meets the standards, the repair process is complete. Step 10: Open the safety door, disassemble the parts, turn off the MIG wire feeder 4, MIG welding power supply 5 and protective gas cylinder 6, turn off the main control panel, close all safety doors, and complete the repair and processing of large shaft parts 89.

[0060] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A repair equipment for large shaft parts, characterized in that: Includes a housing (1), in which a bed body support (2) is fixed, and a spindle box housing (3) is fixed on one side of the bed body support (2). The main body support (2) of the bed is provided with a main rotation positioning component and a secondary rotation positioning component. The main rotation positioning component includes a spindle servo motor (71) fixed on the outside of the main body support (2), and the secondary rotation positioning component includes a secondary spindle servo motor (81) fixed on one side of the main body support (2). The outer side of the main bed support (2) is provided with a precision machining assembly, including a tool post servo motor (91) fixed on one side of the main bed support (2), and the outer side of the auxiliary rotary positioning assembly is provided with a welding assembly, including a gantry component servo motor (101) fixed on the other side of the main bed support (2).

2. The large shaft-type parts repair equipment as described in claim 1, characterized in that: The main rotary positioning assembly also includes a drive wheel (72) sleeved on the output shaft of the main spindle servo motor (71), and a driven wheel (74) is driven on the outside of the drive wheel (72) via a transmission belt (73). A main three-jaw self-centering chuck (76) is fixed on the inside of the driven wheel (74) via a transmission shaft (75).

3. The large shaft-type parts repair equipment as described in claim 2, characterized in that: The secondary rotary positioning assembly also includes a secondary spindle moving screw (82) fixed on the output shaft of the secondary spindle servo motor (81), and a secondary spindle screw sleeve (83) threadedly connected to the secondary spindle moving screw (82). A secondary spindle ball nut connecting plate (84) is fixed on the outside of the secondary spindle screw sleeve (83). A secondary spindle moving guide rail (85) is fixed on the secondary spindle ball nut connecting plate (84), and a secondary spindle motor protective cover (86) is fixed on the secondary spindle moving guide rail (85).

4. The large shaft-type parts repair equipment as described in claim 3, characterized in that: The auxiliary spindle motor protective cover (86) is embedded with an auxiliary spindle stepper motor (87), and an auxiliary three-jaw self-centering chuck (88) is fixed on the output shaft of the auxiliary spindle stepper motor (87). A large shaft part (89) is engaged between the main three-jaw self-centering chuck (76) and the auxiliary three-jaw self-centering chuck (88).

5. The large shaft-type parts repair equipment as described in claim 4, characterized in that: The precision turning assembly also includes a tool post moving ball screw (92) fixed on the output shaft of the tool post servo motor (91), and a tool post screw sleeve (93) threadedly connected to the tool post moving ball screw (92). A tool post ball nut connecting plate (94) is fixed on the outside of the tool post screw sleeve (93), and a tool post feed moving guide rail (95) is fixed on the tool post ball nut connecting plate (94). A first static guide rail (11) in the X direction is fixed on the bed main support (2).

6. The large shaft-type parts repair equipment as described in claim 5, characterized in that: The tool post feed guide rail (95) is provided with a tool post base (96), and a tool post stepper motor (97) is embedded in the tool post base (96). A turret CNC tool post (98) is fixed on the output shaft of the tool post stepper motor (97), and a turning tool (99) is provided on the turret CNC tool post (98).

7. The large shaft-type parts repair equipment as described in claim 6, characterized in that: The welding assembly also includes a gantry component ball screw (102) fixed on the output shaft of the gantry component servo motor (101), and a gantry component screw sleeve (103) threaded onto the gantry component ball screw (102). A gantry component ball nut connecting plate (104) is fixed on the outside of the gantry component screw sleeve (103), and a gantry component moving guide rail (105) is fixed on the gantry component ball nut connecting plate (104). A second static guide rail (12) in the X direction is fixed on the outside of the bed body support (2).

8. The large shaft-type parts repair equipment as described in claim 7, characterized in that: The gantry component moving guide rail (105) is longitudinally provided with a support connecting frame (106), and a Y-direction motion module (107) is provided on the two support connecting frames (106). A Z-direction motion module (108) is provided on the Y-direction motion module (107), and two adapter profiles (109) are provided on the outside of the Z-direction motion module (108). A structure light sensor (1010) is fixed on one of the adapter profiles (109), and a MIG welding gun (1012) is fixed on the other adapter profile (109) by a welding gun clamp (1011).

9. The large shaft-type parts repair equipment as described in claim 8, characterized in that: The encapsulation housing (1) is provided with a MIG welding power source (5) on the inner side near the main support (2) of the bed, and a MIG wire feeder (4) is fixed on the MIG welding power source (5). A protective gas cylinder (6) is placed on the outer side of the MIG welding power source (5). A push-pull slide rail is horizontally placed on the front side of the encapsulation housing (1), and a push-pull front safety door (13) slides through the push-pull slide rail strip in the two push-pull slide rails. A main control panel is fixed on the outer side of the encapsulation housing (1), and a swing-type rear safety door and a swing-type welding machine safety door are respectively hinged on the rear side of the encapsulation housing (1).

10. A method of using a large shaft parts repair equipment, employing the large shaft parts repair equipment described in any one of claims 1-9, characterized in that: Includes the following steps: Step 1: Open all the safety doors on the encapsulation housing (1), and open the main control panel. Turn on the MIG wire feeder (4), MIG welding power supply (5) and protective gas cylinder (6). Operate all shafts to return to zero. Remove the oxide layer and oil stains from the parts of the large shaft parts (89) to be repaired, and clamp them correctly to ensure sufficient clamping force. Step 2: Use the structured light sensor (1010) operated by the main control panel to scan the part of the large shaft part (89) to be repaired, obtain the three-dimensional morphological data map of the damaged part, and plan the additive repair deposition path; Step 3: Set the additive repair process parameters on the main control panel, including deposition rate, voltage, wire feed rate, etc.; set the mechanical subtractive machining process parameters on the main control panel, including spindle speed, depth of cut, feed rate, tool selection, etc.; correctly edit the machining program, perform additive repair first, and then perform subtractive machining. Step 4: Close all safety doors and start the machining program to repair the large shaft part (89); Step 5: After the repair program is completed, the structured light sensor (1010) scans the surface of the repair area to obtain a three-dimensional surface morphology data map, calculates the surface roughness Ra value, compares it with the standard value, and provides feedback on whether the surface quality meets the standard. Step 6: If the surface quality of the repaired part of the large shaft part (89) does not meet the standard, continue with precision machining; if the surface quality of the repaired part of the large shaft part (89) meets the standard, the repair machining is completed. Step 7: Open the safety door, disassemble the parts, turn off the MIG wire feeder (4), MIG welding power supply (5) and protective gas cylinder (6), turn off the main control panel, close all safety doors, and complete the repair and processing of large shaft parts (89).

Images