Plasma powder centrifuge blade surfacing equipment

Abstract

The utility model relates to the technical field of surfacing equipment, and discloses plasma powder centrifugal machine blade surfacing equipment which comprises a base, a floor positioner, a running mechanism, an oscillator mechanism, a powder feeder, a plasma welding gun, a power supply control integrated cabinet, a cooling water tank and an upper computer system. The oscillator mechanism is mounted on a moving part of the running mechanism; all core units such as the landing positioner, the electric lead screw operating mechanism, the oscillator, the arc voltage heightening device, the powder feeder and the plasma power supply are integrally controlled through the upper computer system, full-automatic accurate control over the whole surfacing process is achieved, and dependence on skills of operators is greatly reduced; accurate execution and repeatability of process parameters are guaranteed, and stability and consistency of surfacing quality are improved fundamentally.

Description

Technical Field

[0001] This utility model relates to the field of surfacing equipment technology, specifically a surfacing equipment for plasma powder centrifuge blades. Background Technology

[0002] Centrifuges are core equipment in industries such as chemical, pharmaceutical, and food processing. Their blades, as key components, operate at high speeds for extended periods, enduring intense scouring from material particles and chemical erosion from corrosive media. This makes them highly susceptible to severe wear and corrosion on the working surfaces (especially the windward side and tips), leading to decreased equipment performance, increased energy consumption, and even safety accidents. Therefore, repairing failed centrifuge blades or strengthening new blades with wear-resistant and corrosion-resistant materials has significant economic and environmental value.

[0003] Currently, the main method for repairing and strengthening centrifuge blades is surfacing welding, which involves fusing a layer of high-performance alloy material onto the surface of the blade substrate to restore its dimensions and achieve wear and corrosion resistance superior to the substrate. However, existing plasma surfacing welding equipment has the following problems when applied to workpieces with complex curved surfaces (such as centrifuge blades): many devices lack highly integrated automated control systems, and the height tracking of the welding torch, the precise displacement of the workpiece, and the coordinated control of oscillation and powder feeding rely heavily on the operator's experience, making it difficult to achieve precise closed-loop control throughout the entire process, resulting in poor consistency of the surfacing layer; for complex curved workpieces such as centrifuge blades, ordinary positioners cannot achieve optimal workpiece posture adjustment, and ordinary triaxial welding mechanisms cannot ensure that the welding torch is always perpendicular to the tangential plane of the complex curved surface and maintains the optimal welding distance, which easily leads to uneven weld formation and increased defects. Utility Model Content

[0004] The purpose of this invention is to provide a plasma powder centrifuge blade overlay welding device, which has the effect of improving the quality and performance of the overlay layer.

[0005] The above-mentioned technical objective of this utility model is achieved through the following technical solution: a plasma powder centrifuge blade cladding equipment, comprising a base, a floor-mounted positioner, a running mechanism, a oscillating mechanism, a powder feeder, a plasma welding torch, a power control integrated cabinet, a cooling water tank, and a host computer system. The floor-mounted positioner and the running mechanism are installed on the top of the base. The oscillating mechanism is installed on the moving part of the running mechanism. The moving part of the oscillating mechanism is connected to the plasma welding torch through an arc voltage height regulator. A distance sensor is provided on one side of the plasma welding torch. The powder feeder is installed on the oscillating mechanism. The powder feeder's powder feeding pipeline is connected to the powder feeding port of the plasma welding torch. The power control integrated cabinet is connected to the plasma welding torch, the powder feeder, and the arc voltage height regulator through cables and pipelines, respectively. The cooling water tank is connected to the plasma welding torch through cooling pipelines. The host computer system is connected to the running mechanism, the oscillating mechanism, the arc voltage height regulator, the powder feeder, and the power control integrated cabinet through communication lines.

[0006] A further feature of this invention is that the operating mechanism is an electric lead screw mechanism, which includes a servo motor, a lead screw, and a slide table. The servo motor drives the lead screw to rotate, thereby causing the slide table to move in the vertical direction. The oscillator mechanism is fixedly installed on the slide table.

[0007] A further feature of this invention is that the oscillator mechanism is a servo motor-driven transverse oscillating slide, which drives the plasma welding torch to oscillate horizontally in order to widen the weld bead.

[0008] A further feature of this invention is that the arc voltage height regulator receives feedback signals from the distance sensor and instructions from the host computer system, and drives the plasma welding torch to perform real-time tracking compensation to maintain the stability of the welding arc voltage.

[0009] A further feature of this invention is that the powder feeder is a cylindrical powder feeder, which is connected to the pneumatic system in the integrated power control cabinet via a powder feeding air pipe, and the powder feeding rate is precisely controlled by the host computer system.

[0010] A further feature of this invention is that the integrated power control cabinet contains a plasma welding power supply, a powder feeder controller, an arc voltage adjustment controller, and a gas path control system.

[0011] A further feature of this invention is that the host computer system is an industrial computer with a built-in motion control card and control software, used to integrate and control the automated operation of the entire device.

[0012] In summary, this utility model has the following beneficial effects: By integrating all core units such as the floor-mounted positioner, electric screw running mechanism, oscillator, arc voltage height adjuster, powder feeder, and plasma power supply into a host computer system, this utility model achieves fully automatic and precise control of the entire welding process, greatly reducing reliance on operator skills, ensuring the precise execution and repeatability of process parameters, and fundamentally improving the stability and consistency of welding quality. The high energy density and concentrated heat input of the plasma arc, combined with precise powder feeding, effectively reduces the dilution rate of the base material and yields a high-performance alloy with a dense structure and uniform composition. The application of the oscillator in the weld layer widens the weld bead and makes the heat distribution more uniform, reducing the occurrence of defects. This results in excellent wear resistance and corrosion resistance of the weld overlay, meeting the stringent working requirements of centrifuge blades. The high-precision floor positioner can flexibly adjust the spatial posture of the blade workpiece, ensuring that the surface to be welded is always in the optimal position. Combined with the wide-range lifting of the electric screw running mechanism and the real-time micro-distance compensation of the arc voltage height adjuster, and feedback through the distance sensor, a constant optimal distance is maintained between the plasma welding torch and the complex curved surface workpiece. This enables precise overlay welding of complex curved surface parts such as centrifuge blades, resulting in uniform and aesthetically pleasing weld bead formation. Attached Figure Description

[0013] Figure 1 This is a three-dimensional structural schematic diagram of the present invention;

[0014] Figure 2 This is one of the structural schematic diagrams of the base, floor positioner, and running mechanism of this utility model;

[0015] Figure 3 This is the second structural schematic diagram of the base, floor positioner, and running mechanism of this utility model.

[0016] In the diagram: 1. Base; 2. Floor-mounted positioner; 3. Running mechanism; 4. Oscillator mechanism; 5. Powder feeder; 6. Arc voltage height regulator; 7. Plasma welding torch; 8. Distance sensor; 9. Power control cabinet; 10. Cooling water tank; 11. Host computer system. Detailed Implementation

[0017] The present invention will be further described below with reference to the accompanying drawings of the embodiments thereof.

[0018] Please see Figures 1-3In this embodiment of the invention, a plasma powder centrifuge blade surfacing equipment includes a base 1, a floor-mounted positioner 2, a running mechanism 3, a oscillating mechanism 4, a powder feeder 5, a plasma welding torch 7, a power control integrated cabinet 9, a cooling water tank 10, and a host computer system 11. The base 1 provides a stable foundation for the entire equipment and is welded from heavy steel and undergoes stress-relief treatment to ensure the rigidity and stability of the equipment during long-term operation. The floor-mounted positioner 2 and the running mechanism 3 are bolted to a platform at the top of the base 1. A high-torque, high-precision servo CNC positioner is adopted, with its headstock equipped with a three-jaw chuck or special tooling fixture for reliably clamping centrifuge blade workpieces. The floor-mounted positioner 2 can perform precise rotational movements under the control of the host computer system 11, thereby adjusting the blade's surface to be welded to the optimal welding posture. The oscillator mechanism 4 is mounted on the moving part of the running mechanism 3. The moving part of the oscillator mechanism 4 is connected to the plasma welding torch 7 through the arc voltage height adjuster 6. The arc voltage height adjuster 6 is fixedly mounted on the moving part of the oscillator mechanism 4 through a mounting plate. Therefore, it can perform large-range Z-axis lifting and lowering with the running mechanism 3, and also oscillate in the X-axis with the oscillator mechanism 4. The arc voltage height adjuster 6 contains a precision electric slide and controller. The plasma welding torch 7 is mounted on the moving part of the arc voltage height adjuster 6. The distance sensor 8 is mounted on an independent bracket. The detection head of the plasma welding torch 7 is fixedly installed on the oscillator mechanism 4 and aligned with the working surface in front of the tungsten electrode tip. The distance sensor 8 detects the distance between the welding torch and the workpiece surface in real time and feeds the signal back to the controller of the arc voltage height regulator 6 and the host computer system 11. The arc voltage height regulator 6 compares the set arc voltage value or distance value with the feedback from the distance sensor 8 and drives the plasma welding torch 7 to perform micro-distance lifting and lowering movements to overcome interference such as workpiece deformation and clamping errors, maintain a constant welding arc length, and ensure process stability. The powder feeder 5 is installed on the oscillator mechanism 4, and the powder feeder 5's powder feeder pipe is connected to the powder feed port of the plasma welding torch 7. The power control cabinet 9 is connected to the plasma welding torch 7, the powder feeder 5, and the arc voltage height regulator 6 through cables and pipes. The cooling water tank 10 is connected to the plasma welding torch 7 through cooling pipes. As an independent device, it is equipped with a water pump, deionized resin and heat exchanger. It forms a closed loop with the cooling water interface of the plasma welding torch 7 through a high-pressure cooling water pipe, continuously providing cooling for the plasma welding torch 7 under high load to prevent it from overheating and being damaged. The host computer system 11 is connected to the running mechanism 3, the oscillator mechanism 4, the arc voltage height regulator 6, the powder feeder 5 and the power control cabinet 9 through communication lines.

[0019] In this embodiment, preferably, the operating mechanism 3 is an electric lead screw mechanism, which includes a servo motor, a lead screw, and a slide table. The servo motor drives the lead screw to rotate, thereby driving the slide table to move in the vertical direction. The oscillator mechanism 4 is fixedly installed on the slide table. The oscillator mechanism 4 is fixedly installed on the slide table of the operating mechanism 3 through its base and rises and falls together with the slide table. The servo motor receives the instructions from the host computer system 11 and drives the lead screw to rotate, thereby driving the slide table to move precisely in the vertical direction, so as to realize a large adjustment of the welding torch in the height direction to adapt to workpieces of different sizes.

[0020] In this embodiment, preferably, the oscillator mechanism 4 adopts a servo motor driven transverse oscillating slide, whose moving parts can perform high-frequency, small-amplitude reciprocating linear motion. The oscillation frequency, amplitude and center position can be set by the host computer system 11. The oscillator mechanism 4 is used to drive the plasma welding gun 7 to oscillate laterally, thereby widening the weld bead, improving the weld bead formation and reducing the dilution rate of the base material.

[0021] In this embodiment, preferably, the arc voltage height regulator 6 receives feedback signals from the distance sensor 8 and instructions from the host computer system 11, and drives the plasma welding torch 7 to perform real-time tracking compensation to maintain the stability of the welding arc voltage.

[0022] In this embodiment, preferably, the powder feeder 5 is a cylindrical powder feeder, which is connected to the gas system in the power control cabinet 9 through a powder feeding gas pipe. The powder feeder 5 is fixedly installed on the side of the oscillator mechanism 4 by a support frame and moves together with the entire welding torch motion system to avoid powder feeding delay and instability caused by long-distance powder feeding pipeline. The working gas and powder feeding rate of the powder feeder 5 are controlled by the power control cabinet 9 and the host computer system 11 to ensure that the powder is accurately and continuously fed into the plasma arc.

[0023] In this embodiment, preferably, the power control cabinet 9 integrates a plasma welding power supply, a powder feeder controller, an arc voltage height controller, and a gas path control system. The plasma welding power supply provides the current and voltage required for welding to the plasma welding torch 7, and typically has functions such as slow rise and fall, and current waveform control. The powder feeder controller controls the speed (powder feeding rate) of the motor of the powder feeder 5 and the on / off state of the powder feeding gas. The arc voltage height controller processes the signal from the distance sensor 8 and drives the arc voltage height regulator 6 to operate. The gas path control system includes solenoid valves, flow meters, etc., for precisely controlling the flow rate and timing of the shielding gas, ion gas, and powder feeding gas. The power control cabinet 9 is connected to the plasma welding torch 7, the powder feeder 5, the arc voltage height regulator 6, and other actuators via multi-core cables and pipes.

[0024] In this embodiment, preferably, the host computer system 11 consists of an industrial computer, a motion control card, an I / O interface card, and dedicated control software. It is connected to the controllers of all subsystems, such as the running mechanism 3, the oscillating mechanism 4, the floor positioner 2, and the power control integrated cabinet 9, via communication methods such as Ethernet and RS485. Operators can preset the welding process program (including welding torch movement trajectory, positioner rotation speed, welding current, voltage, powder feeding amount, oscillation parameters, etc.) in the host computer software. The system can then automatically execute the entire welding process and monitor each parameter in real time to ensure the consistency and reliability of the weld layer quality.

[0025] When in use, the centrifuge blade workpiece to be welded is firmly clamped onto the chuck of the floor positioner 2. The operator sets a complete surfacing process program on the host computer system 11, including blade rotation speed, welding torch travel trajectory, welding current and voltage, powder feeding rate of powder feeder 5, swing parameters of oscillator mechanism 4, and preset arc voltage value. After the equipment is started, the host computer system 11 issues a command to control the rotation of the floor positioner 2, adjusting the part of the blade to be welded to the ideal horizontal surfacing position. At the same time, the servo motor in the running mechanism 3 starts, driving the electric screw mechanism to move, driving its slide and the entire welding torch motion system (including oscillator mechanism 4, arc voltage height adjuster 6, plasma welding torch 7, etc.) fixed on it to descend to the predetermined starting height. The surfacing process begins, the plasma welding power supply is started, and a high-temperature plasma arc is ignited between the tungsten electrode of the plasma welding torch 7 and the workpiece. Under precise control, the powder feeder 5 delivers alloy powder through the powder feeding pipeline to the nozzle outlet of the plasma welding torch 7. The powder is rapidly heated to a molten or semi-molten state by the high-temperature plasma arc. Meanwhile, the oscillator mechanism 4 drives the plasma welding torch 7 to oscillate laterally according to the set parameters to widen the weld bead. During the welding process, the distance sensor 8 monitors the actual distance between the plasma welding torch 7 and the surface of the blade workpiece in real time and feeds the measurement data back to the arc voltage height adjuster 6 and the host computer system 11. The arc voltage height adjuster 6 compares the real-time detected welding arc voltage with the system preset value. If there is a deviation, it immediately drives the internal fine adjustment mechanism to move, causing the plasma welding torch 7 to make a slight upward or downward movement, thereby dynamically compensating for the height caused by workpiece assembly errors, thermal deformation, or surface undulations. The system maintains a constant welding arc length and a stable arc; the floor positioner 2 rotates continuously at a uniform speed, driving the workpiece to move evenly, so that the molten alloy powder forms a uniform, dense, and high-quality weld overlay layer on the blade surface that is metallurgically bonded to the base material; the cooling water tank 10 continuously circulates cooling water to provide effective cooling protection for the plasma welding torch 7 under high load; the entire weld overlay process is fully automatically integrated and controlled by the host computer system 11, with each subsystem working in concert to finally complete one or more uniform, defect-free, high-performance weld overlay layers on the complex curved centrifuge blades; after the program ends, each mechanism automatically resets and the equipment stops running.

[0026] The above description is only a preferred embodiment of the present utility model. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present utility model patent application are included in the scope of the present utility model patent application.

Claims

1. A plasma powder centrifuge blade surfacing equipment, comprising a base (1), a floor positioner (2), a running mechanism (3), a swing mechanism (4), a powder feeder (5), a plasma welding torch (7), a power control integrated cabinet (9), a cooling water tank (10), and a host computer system (11), characterized in that, The floor positioner (2) and the running mechanism (3) are installed on the top of the base (1). The oscillator mechanism (4) is installed on the moving part of the running mechanism (3). The moving part of the oscillator mechanism (4) is connected to the plasma welding torch (7) through the arc voltage height regulator (6). A distance sensor (8) is provided on one side of the plasma welding torch (7). The powder feeder (5) is installed on the oscillator mechanism (4). The powder feeder (5) is connected to the powder feed port of the plasma welding torch (7) through the powder feeder pipe. The power control cabinet (9) is connected to the plasma welding torch (7), the powder feeder (5) and the arc voltage height regulator (6) through cables and pipes respectively. The cooling water tank (10) is connected to the plasma welding torch (7) through the cooling pipe. The host computer system (11) is connected to the running mechanism (3), the oscillator mechanism (4), the arc voltage height regulator (6), the powder feeder (5) and the power control cabinet (9) through the communication line.

2. The plasma powder centrifuge blade overlay apparatus of claim 1, wherein: The operating mechanism (3) is an electric lead screw mechanism, which includes a servo motor, a lead screw and a slide table. The servo motor drives the lead screw to rotate, thereby driving the slide table to move in the vertical direction. The oscillator mechanism (4) is fixedly installed on the slide table.

3. The plasma powder centrifuge blade overlay apparatus of claim 1, wherein: The oscillator mechanism (4) uses a servo motor-driven transverse oscillating slide to drive the plasma welding gun (7) to oscillate horizontally in order to widen the weld bead.

4. The plasma powder centrifuge blade overlay apparatus of claim 1, wherein: The arc voltage regulator (6) receives feedback signals from the distance sensor (8) and instructions from the host computer system (11) to drive the plasma welding torch (7) to perform real-time tracking compensation and maintain the stability of the welding arc voltage.

5. The plasma powder centrifuge blade overlay apparatus of claim 1, wherein: The powder feeder (5) is a cylindrical powder feeder, which is connected to the air circuit system in the power control cabinet (9) through a powder feeding air pipe, and the powder feeding rate is precisely controlled by the host computer system (11).

6. The plasma powder centrifuge blade cladding apparatus of claim 1, wherein: The power control cabinet (9) integrates a plasma welding power supply, a powder feeder controller, an arc voltage adjustment controller, and a gas path control system.

7. The plasma powder centrifuge blade cladding apparatus of claim 1, wherein: The host computer system (11) is an industrial computer with a built-in motion control card and control software, used to integrate and control the automated operation of the entire equipment.

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