Laser powder cladding repair additive equipment

Abstract

The utility model relates to the technical field of additive repairing equipment, and discloses laser powder cladding additive repairing equipment which comprises an industrial robot, a double-shaft positioner, a laser scanner, a laser cladding head, a laser double-barrel powder feeder, a laser, a laser power voltage stabilizer, a double-temperature cooling water tank, an electrical control cabinet, a robot control cabinet and a robot base. According to the utility model, three-dimensional scanning, reverse modeling, off-line programming and laser cladding processing are organically integrated in one set of equipment system, and the laser scanner is carried by the industrial robot, so that on-line and in-situ scanning of workpieces is realized; errors and tedious processes caused by the fact that a workpiece needs to be moved to off-line equipment such as a three-coordinate measuring machine to be repeatedly measured and clamped in a traditional mode are avoided, automation of the whole process from damage identification to repair completion is achieved, dependence on experience of operators is greatly reduced, and the overall operation efficiency is improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of repair additive equipment, and specifically relates to a laser powder cladding repair additive equipment. BACKGROUND

[0002] Laser powder cladding is an advanced additive manufacturing and remanufacturing technology, which forms a dense cladding layer on the surface of the base material by rapidly melting and solidifying the synchronously delivered metal powder through a high-energy laser beam, thereby realizing high-performance repair, surface strengthening or three-dimensional additive manufacturing of parts; This technology has the advantages of small heat input, low dilution rate, high processing precision, wide material compatibility, etc., and is widely used in the repair and remanufacturing of key parts in the industrial fields of aerospace, energy power, mold manufacturing, etc.

[0003] At present, the equipment for realizing laser powder cladding has the following problems: a three-axis or multi-axis numerical control machine tool (CNC) is used as a motion execution mechanism, and the machine tool motion trajectory is controlled by programming to carry out cladding, the freedom of motion is limited, for the repair of complex curved surfaces (especially structures with pits, inner holes, etc.), multiple clamping or special fixtures need to be customized, the flexibility is insufficient, the equipment cost is high, and the working space is limited; an industrial robot is used to carry a laser cladding head, and a single-axis displacement machine is used for processing, which usually only has cladding processing capability, and before the repair operation, it seriously depends on the technology and experience of the operator, the whole process is time-consuming and long, the automation degree is low, and the repair efficiency and precision are seriously restricted; in the existing repair equipment, the scanning, modeling, path planning and processing execution function modules are often independent of each other, the scanner is not integrated on the processing equipment, multiple clamping and coordinate registration are needed, which introduces cumulative error, each subsystem (robot, laser, laser double-barrel powder feeder, scanner) is managed by different controllers, lacks a unified general control system for collaborative control and real-time monitoring, the system integration degree is low, the stability and reliability are difficult to guarantee, and the operation process is complex. UTILITY MODEL CONTENTS

[0004] The utility model aims at providing a laser powder cladding repair additive equipment, which has the effect of improving repair precision and quality.

[0005] The technical purpose is achieved by the following technical scheme: a laser powder cladding repair additive equipment, comprising an industrial robot, a double-shaft positioner, a laser scanner, a laser cladding head, a laser double-barrel powder feeder, a laser power stabilizer, a laser, a double-temperature cooling water tank, an electrical control cabinet, a robot control cabinet and a robot base, the industrial robot is fixedly installed at the top end of the robot base, the control end thereof is electrically connected with the robot control cabinet, the laser scanner and the laser cladding head are both installed on the end effector of the industrial robot, the double-shaft positioner is arranged in the working range of the industrial robot, the laser is connected with an external power supply through the laser power stabilizer, the light outlet of the laser is connected with the laser cladding head through an optical path system, the powder feeding pipeline of the laser double-barrel powder feeder is connected with the laser cladding head, and the double-temperature cooling water tank is respectively connected with the laser and the laser cladding head through cooling pipelines.

[0006] The laser scanner is used for scanning a workpiece to be processed to obtain point cloud data, the point cloud data is processed by reverse engineering software to generate an entity model and is imported into offline programming software, a robot machining track program is generated by the software and is downloaded into the robot control cabinet and the electrical control cabinet, and the industrial robot and the double-shaft positioner are controlled to move coordinately.

[0007] The double-shaft positioner comprises two rotating shafts and can realize horizontal rotation and inclined overturning of the workpiece, the control end thereof is electrically connected with the electrical control cabinet, and the double-shaft positioner is linked with the industrial robot to receive instructions.

[0008] The laser double-barrel powder feeder has a double-powder-barrel structure and can realize uninterrupted continuous powder feeding and automatic switching of powder materials.

[0009] The double-temperature cooling water tank adopts a double-temperature zone design and comprises a high-temperature cooling circuit and a low-temperature cooling circuit, the high-temperature cooling circuit is connected with the laser, and the low-temperature cooling circuit is connected with the laser cladding head.

[0010] The electrical control cabinet is electrically connected with the laser scanner, the laser, the laser double-barrel powder feeder, the double-temperature cooling water tank and the double-shaft positioner, the robot control cabinet is in communication connection with the electrical control cabinet, the electrical control cabinet is integrated with an industrial computer and a man-machine interaction interface and is used for displaying equipment running states, alarm information and providing a process parameter setting interface.

[0011] The industrial robot is a six-degree-of-freedom articulated robot.

[0012] In conclusion, the laser powder cladding repair additive equipment has the following beneficial effects:

[0013] 1. The three-dimensional scanning, reverse modeling, offline programming and laser cladding processing are integrated in a set of equipment systems, the industrial robot carries the laser scanner, realizes the online and in-situ scanning of the workpiece, avoids the error and tedious process caused by the repeated measurement and clamping of the workpiece in the traditional way, realizes the whole process automation from "damage identification" to "repair completion", greatly reduces the dependence on the experience of the operator, and improves the overall operation efficiency;

[0014] 2. The reverse modeling is carried out based on the real point cloud data obtained by scanning, the three-dimensional appearance of the workpiece can be accurately reconstructed, especially the geometric characteristics of the damage area, the machining track generated by the offline programming software according to the entity model has high matching degree with the actual appearance of the workpiece, and the path deviation caused by the traditional experience programming is avoided; meanwhile, the cooperative movement of the double-shaft positioner and the industrial robot ensures that the cladding head is always in the optimal working posture during the whole processing process, ensures that the cladding layer thickness is uniform and the metallurgical bonding is good, so that the size precision and comprehensive performance of the repaired part are greatly improved, and the repaired part can be machined or only a small amount of subsequent machining is needed;

[0015] 3. The scheme that the six-degree-of-freedom industrial robot cooperates with the double-shaft positioner constitutes a highly flexible processing system, provides motion freedom far exceeding that of traditional three-axis or five-axis machine tools, can easily realize multi-angle and omnidirectional cladding of complex curved surfaces, deep cavities, inner holes and other difficult-to-process parts, greatly expands the processing capacity and application range of the equipment, and is especially suitable for repairing precision parts with free curved surface characteristics such as aerospace blades and complex molds.

[0016] 4. The design of the laser double-barrel powder feeder realizes seamless switching or continuous replenishment of different powder materials, supports long-time uninterrupted repair or additive manufacturing operation of large components, avoids interruption of production due to addition of powder in the middle; the double-temperature cooling water tank provides independent and suitable cooling protection for the laser and the laser cladding head respectively, ensures the thermal stability of the core heat source components and optical components during long-time operation, thereby ensuring the stability of the laser output power and the consistency and reliability of the cladding process, and prolonging the service life of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0017] Fig. 1 It is a three-dimensional structure schematic view of the utility model;

[0018] Fig. 2 It is a three-dimensional structure schematic view of the utility model.

[0019] In the figure: 1, industrial robot; 2, double-shaft positioner; 3, laser scanner; 4, laser cladding head; 5, laser double-barrel powder feeder; 6, laser power stabilizer; 7, laser; 8, double-temperature cooling water tank; 9, electrical control cabinet; 10, robot control cabinet; 11, robot base. DETAILED DESCRIPTION

[0020] The utility model will be further explained in combination with the drawings in the embodiments of the utility model.

[0021] Please refer to Figs. 1-2 In the embodiments of the utility model, a laser powder cladding repair additive manufacturing equipment comprises an industrial robot 1, a double-shaft positioner 2, a laser scanner 3, a laser cladding head 4, a laser double-barrel powder feeder 5, a laser power stabilizer 6, a laser 7, a double-temperature cooling water tank 8, an electrical control cabinet 9, a robot control cabinet 10 and a robot base 11.

[0022] The industrial robot 1 is preferably a six-degree-of-freedom high-performance industrial robot, which is firmly installed on the heavy robot base 11 through a flange to ensure its stability during high-speed movement; the robot control cabinet 10 is connected to the body of the industrial robot 1 through power cables and control cables, drives the servo motors of each joint of the robot, and feeds back position information in real time.

[0023] The double-shaft positioner 2 is placed in the working range in front of the industrial robot 1, and its base is fixed to the ground through foundation bolts; the positioner adopts a double-shaft (i.e. A shaft and B shaft) design, and its chuck is used for clamping a workpiece to be repaired or additively manufactured; the control end of the double-shaft positioner 2 is connected to the electrical control cabinet 9 through a communication cable to receive movement instructions from the general control system.

[0024] The laser scanner 3 and the laser cladding head 4 are integrated and installed on the sixth shaft end flange of the industrial robot 1 through a special connecting clamp; the data output port of the laser scanner 3 is connected to the industrial computer in the electrical control cabinet 9 through a network cable; the laser scanner 3 is used for scanning a workpiece to be processed to obtain point cloud data; the point cloud data is processed by a reverse engineering software to generate an entity model and imported into an offline programming software; the software generates a robot machining trajectory program, which is downloaded to the robot control cabinet 10 and the electrical control cabinet 9 to control the industrial robot 1 and the double-shaft positioner 2 to move cooperatively; the input end of the laser cladding head 4 is connected to the light outlet of the laser 7 through an armored cable to conduct a high-energy laser beam.

[0025] The laser 7 is placed outside the equipment area; the laser power stabilizer 6 is connected to a three-phase industrial power grid to provide stable and pure power supply for the laser 7, preventing fluctuations in the power grid from affecting the stability of the laser output power.

[0026] The laser double-barrel powder feeder 5 is placed near the working area, and its powder outlet is connected with the powder inlet of the laser cladding head 4 through a flexible powder feeding pipeline; the two powder barrels inside the laser double-barrel powder feeder 5 can be loaded with the same or different metal powders, and automatic switching can be realized through program control to ensure the continuity of large-scale or long-time repair work; the control end of the laser double-barrel powder feeder 5 is connected to the electrical control cabinet 9.

[0027] The double-temperature cooling water tank 8 adopts a double-temperature zone precision design, and contains two independent cooling circulation systems inside; the high-temperature circulation loop is connected to the laser 7 through a cooling water pipe to provide cooling for the optical devices and pump sources inside the cavity of the laser; the low-temperature circulation loop is connected to the laser cladding head 4 through another set of cooling water pipes to ensure that the optical lenses and copper nozzles are fully cooled during the working process to prevent thermal damage; the monitoring signal line of the double-temperature cooling water tank 8 is connected to the electrical control cabinet 9.

[0028] The electrical control cabinet 9 is the control center of the device; it is integrated with an industrial computer (IPC), a programmable logic controller (PLC), various motion control cards, I / O modules, and a human-machine interface (HMI, usually a touch screen) inside; the electrical control cabinet 9 communicates with the robot control cabinet 10 through industrial Ethernet to coordinate the motion of the robot and the positioner; at the same time, it controls the start and stop of the laser 7 and its power, controls the powder feeding start and stop of the laser double-barrel powder feeder 5 and the powder feeding amount, monitors the running state (water temperature, flow, pressure alarm) of the double-temperature cooling water tank 8, and receives the data of the laser scanner 3.

[0029] When in use, the operator clamps and fixes the workpiece to be repaired on the chuck of the dual-shaft positioner 2. The scanning program is started through the human-machine interface on the electrical control cabinet 9; the industrial robot 1 receives instructions from the robot control cabinet 10, drives the laser scanner 3 installed at the end thereof to move along the predetermined path, scans the damaged area of the workpiece in all directions, and obtains high-precision three-dimensional point cloud data; these point cloud data are transmitted in real time to the industrial computer in the electrical control cabinet 9 through a data line;

[0030] Subsequently, the industrial computer runs a dedicated reverse engineering software to process the received point cloud data and reconstruct a three-dimensional entity model of the damaged area; the model is imported into the offline programming software and compared with the original ideal CAD model of the workpiece; the software automatically calculates the material area, volume, and shape that need to be filled, and automatically generates the motion trajectory of the industrial robot 1 and the coordinated rotation angle instruction of the dual-shaft positioner 2, while matching the process parameters such as laser power, scanning speed, and powder feeding amount, to form a complete machining program;

[0031] In the processing stage, the generated processing program is downloaded to the robot control cabinet 10 and the electrical control cabinet 9, and the operator confirms the safety and starts the processing cycle. The electrical control cabinet 9 serves as the central control center, and in turn starts the double-temperature cooling water tank 8 to provide cooling for the laser 7 and the laser cladding head 4, the laser power stabilizer 6 supplies power to the laser 7, and the laser generated by the laser 7 is transmitted to the laser cladding head 4 through the optical cable. At the same time, the laser double-barrel powder feeder 5 accurately delivers metal powder to the focal position of the laser cladding head 4 through the powder feeding pipeline according to the instructions.

[0032] The industrial robot 1 accurately executes the trajectory program to drive the laser cladding head 4 to move, and the double-axis positioner 2 synchronously cooperates to rotate the workpiece, so that the region to be processed is always in the best processing pose. The high-energy laser beam melts the metal powder delivered synchronously and forms a molten pool on the surface of the workpiece. With the movement of the laser beam, the molten pool rapidly solidifies to form a dense cladding layer that is metallurgically bonded to the substrate. Through layer-by-layer scanning and layer-by-layer accumulation, three-dimensional precise repair of damaged parts or near-net shape additive manufacturing of new parts is finally achieved.

[0033] The above is only the preferred embodiment of the present application, so any equivalent changes or modifications made according to the structure, features and principles of the present application patent application range are included in the present application patent application range.

Claims

1. A laser powder cladding repair additive manufacturing equipment, comprising an industrial robot (1), a double-axis positioner (2), a laser scanner (3), a laser cladding head (4), a laser double-barrel powder feeder (5), a laser power stabilizer (6), a laser (7), a double-temperature cooling water tank (8), an electrical control cabinet (9), a robot control cabinet (10), and a robot base (11), characterized in that, The industrial robot (1) is fixedly installed at the top end of a robot base (11), and a control end thereof is electrically connected with a robot control cabinet (10), the laser scanner (3) and the laser cladding head (4) are both installed on an end effector of the industrial robot (1), the dual-axis positioner (2) is arranged in a working range of the industrial robot (1), the laser (7) is connected with an external power supply through a laser power stabilizer (6), an outlet of the laser (7) is connected with the laser cladding head (4) through an optical path system, a powder feeding pipeline of the laser double-barrel powder feeder (5) is connected to the laser cladding head (4), and the dual-temperature cooling water tank (8) is respectively connected to the laser (7) and the laser cladding head (4) through cooling pipelines.

2. The laser powder cladding repair additive manufacturing apparatus of claim 1, wherein: The laser scanner (3) is used for scanning a workpiece to be processed to obtain point cloud data, the point cloud data is processed by a reverse engineering software to generate an entity model and is imported into offline programming software, a robot machining track program is generated by the software, and the program is downloaded into the robot control cabinet (10) and an electrical control cabinet (9), so that the industrial robot (1) and the dual-axis positioner (2) are controlled to move cooperatively.

3. The laser powder cladding repair additive manufacturing apparatus of claim 1, wherein: The dual-axis positioner (2) comprises two rotary shafts and can realize horizontal rotation and inclined overturning of the workpiece, and a control end thereof is electrically connected with the electrical control cabinet (9) to receive instructions and realize linkage with the industrial robot (1).

4. The laser powder cladding repair additive manufacturing apparatus of claim 1, wherein: The laser double-barrel powder feeder (5) has a double-powder-barrel structure and can realize uninterrupted continuous powder feeding and automatic switching of powder materials.

5. The laser powder cladding repair additive device of claim 1, wherein: The dual-temperature cooling water tank (8) adopts a dual-temperature zone design and comprises a high-temperature cooling circuit and a low-temperature cooling circuit, the high-temperature cooling circuit is connected to the laser (7), and the low-temperature cooling circuit is connected to the laser cladding head (4).

6. The laser powder cladding repair additive device of claim 1, wherein: The electrical control cabinet (9) is electrically connected with the laser scanner (3), the laser (7), the laser double-barrel powder feeder (5), the dual-temperature cooling water tank (8) and the dual-axis positioner (2), the robot control cabinet (10) is in communication connection with the electrical control cabinet (9), the electrical control cabinet (9) is integrated with an industrial computer and a man-machine interaction interface, and is used for displaying equipment running states and alarm information and providing a process parameter setting interface.

7. The laser powder cladding repair additive device of claim 1, wherein: The industrial robot (1) is a six-degree-of-freedom articulated robot.

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