CN113523496A - Electric arc additive repair method and equipment for blades of water turbine - Google Patents
Electric arc additive repair method and equipment for blades of water turbine Download PDFInfo
- Publication number
- CN113523496A CN113523496A CN202110973460.2A CN202110973460A CN113523496A CN 113523496 A CN113523496 A CN 113523496A CN 202110973460 A CN202110973460 A CN 202110973460A CN 113523496 A CN113523496 A CN 113523496A
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- welding
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- surfacing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/0026—Arc welding or cutting specially adapted for particular articles or work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Laser Beam Processing (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
A welding gun of a welding machine is clamped on a repair welding robot, and the repair welding robot drives the welding gun to carry out surfacing repair on a blade to be repaired, which is arranged on a rotary worktable; a scanning camera arranged at a welding gun transmits a real-time image of a surfacing repair layer to a controller, the controller generates machining codes through a slicing program and a track generation program according to the comparison difference, and the machining codes drive a surfacing robot and a rotary worktable to move so that the welding gun and a blade to be repaired generate relative rotation and feeding welding actions; the real-time temperature of the surfacing repair layer is transmitted to the controller by a temperature detector arranged at the welding gun, and the controller controls the surfacing robot to be matched with the rotary worktable to perform surfacing repair on the next layer after the temperature of the surfacing repair layer is lower than a set temperature. The invention realizes the accurate dimension of the processed surface by monitoring and evaluating the information of the surface defect to be repaired in real time.
Description
Technical Field
The invention relates to the field of surface engineering, in particular to a method and equipment for repairing an electric arc additive of a water turbine blade.
Background
The blades of the water turbine are worn and cavitated by rivers and silt for a long time, so that the defects of fatigue cracks and silt corrosion are generated, and the blades of the water turbine need to be repaired on site regularly to improve the working efficiency of the water turbine. The repair of the water turbine blade usually adopts the modes of surfacing, cladding and the like. However, when the repair welding operation is performed on the blade at present, due to the lack of professional repair equipment, the repair welding operation is performed on the surface defect only by depending on the experience of an operator, the working efficiency is low, and the welding precision of the manual welding operation cannot be accurately regulated and controlled.
The published patents are reported as follows: an automatic surfacing device (201811650242.X) for repairing a guide vane of a water turbine improves welding efficiency and solves the problems that manual surfacing repair is high in labor intensity and difficult to guarantee surfacing quality. A method (201510549734.X) for repairing cracks of a water turbine blade is complex and repairs the cracks by means of X flaw detection and a laser beam method. The online laser strengthening device (201910205181.4) for the water turbine blade overcomes the problems of large heat affected zone of a base material, low bonding strength, difficulty in thickness control, environmental pollution, large operation space, low repairing efficiency and the like in the traditional electric arc welding defect repairing process of the water turbine blade. However, the blade repairing device or method lacks monitoring of repairing layer profile information and interlayer temperature, the thickness of the repairing layer cannot be accurately regulated and controlled, and the purpose of optimizing process parameters in real time cannot be achieved.
Disclosure of Invention
The invention aims to provide a method and equipment for repairing an electric arc additive material of a water turbine blade, which can realize the accurate size of a machined surface by monitoring and evaluating the information of surface defects to be repaired in real time.
In order to solve the technical problems, the invention adopts the specific scheme that: a method for repairing a blade of a water turbine by electric arc additive materials comprises the steps of clamping a welding gun of a welding machine on a repair welding robot, and driving the welding gun by the repair welding robot to carry out surfacing repair on the blade to be repaired, which is arranged on a rotary workbench;
the method comprises the steps that a scanning camera arranged at a welding gun transmits a real-time image of a surfacing repair layer to a controller, the controller compares the real-time image with a pre-stored model of a blade, generates a machining code through a slicing program and a track generation program according to a comparison difference, and drives a surfacing robot and a rotary workbench to move through the machining code so that the welding gun and the blade to be repaired generate relative rotation and feeding welding actions;
the real-time temperature of the surfacing repair layer is transmitted to the controller by a temperature detector arranged at the welding gun, and the controller controls the surfacing robot to be matched with the rotary worktable to perform surfacing repair on the next layer after the temperature of the surfacing repair layer is lower than a set temperature.
Preferably, the CMT power supply is used as a welding power supply, when the controller detects a short-circuit signal, the short-circuit signal is fed back to a wire feeder of the welding machine, and the wire feeder withdraws the welding wire so that the welding wire is separated from molten drops;
when the short-circuit current is generated, the welding power supply automatically monitors the short-circuit transition process, the welding power supply reduces the current when the molten drops are transited, the heat input quantity is close to zero, and the welding wire stops advancing and is automatically drawn back.
An electric arc additive repair device for a water turbine blade comprises a welding machine, a repair welding robot, a rotary workbench and a controller; a welding gun of the welding machine is arranged on the output end of the repair welding robot, and a scanning camera for shooting a real-time image of the surfacing repair layer and a temperature detector for measuring the real-time temperature of the surfacing repair layer are arranged on the welding gun;
the controller is in communication connection with the welding machine, the repair welding robot, the rotary workbench, the scanning camera and the temperature detector, is used for receiving the real-time images and comparing the real-time images with the pre-stored models of the blades, generates machining codes according to comparison differences, controls the repair welding robot and the rotary workbench to perform welding matching action by the machining codes, is used for receiving the real-time temperature, and controls the repair welding robot and the rotary workbench to match to perform the next layer of surfacing repair after the real-time temperature is lower than a set value.
Preferably, the welding machine further comprises a water cooling system, a welding power supply and a wire feeder for feeding the welding wire to the welding gun, and a wire pushing and pulling mechanism for controlling the transmission of the welding wire is further arranged between the wire feeder and the welding gun.
Preferably, the welding power supply is a CMT power supply.
Preferably, the temperature detector is an infrared light generator.
Preferably, the repair welding robot is a six-axis robot.
The electric arc additive repair method can be used for monitoring and evaluating the surface defect information to be repaired in real time, and effectively collecting the shape and temperature of the repair surface layer closely related to the repair quality. And finally, the machining surface size is accurate by matching welding current and welding speed.
The electric arc additive repair device is simple in structure, high in automation degree and high in machining precision. From the development angle of an equipment platform, the repairing layer contour information and the interlayer temperature are accurately regulated and controlled by the cooperation of a rotary workbench, a six-axis robot, a welding machine, a scanning camera, a temperature detector and a controller, and the problems that manual repair welding is poor in stability and the repairing layer is different from an expected shape are solved. The invention can realize real-time online monitoring of the repair layer profile information and the interlayer temperature, accurately control the shape of the repair layer, the surface repair and the machining quality precision, and conveniently optimize the process parameters.
In the preferred embodiment, the welding power supply adopts a CMT welding power supply, the movement of a welding wire is organically combined with the molten drop transition process, cold-heat exchange welding is realized in the welding process, the welding heat input is greatly reduced, the welding deformation is small, no splashing exists, the welding seam bridging capacity is good, the welding speed is high, and the operation cost is low.
Drawings
Fig. 1 is a schematic structural diagram of an electric arc additive repair device for a water turbine blade according to the invention;
the labels in the figure are: 1. the device comprises a welding machine, 101, a water cooling system, 102, a welding power supply, 103, a wire feeder, 104, a wire pushing and pulling mechanism, 105, a welding gun, 2, a repair welding robot, 3, a temperature measurer, 4, a scanning camera, 5, a rotary workbench, 6, a blade to be repaired, 7 and a controller.
Detailed Description
As shown in fig. 1, the electric arc additive repair device for the blades of the water turbine mainly comprises a welding machine 1, a repair welding robot 2, a rotary worktable 5 and a control system.
The main body of the welder 1 is a water cooling system 101, a welding power supply 102 and a wire feeder 103 which are sequentially distributed from bottom to top. The bottom of the water cooling system 101 is supported by a foot pad, and the welding wire is extended from a wire feeder 103 and fed to a welding gun 105 of the repair welding machine 1 through a wire feeding pipe. A wire pushing and pulling mechanism 104 for assisting in feeding the welding wire is provided between the welding torch 105 and the wire feeder 103. The welding power source 102 is CMT, and the welding power source 102 in this embodiment supplies power to the wire welding, and is electrically connected to and supplies power to the repair welding robot 2, the water cooling system 101, the scanning camera 4, the temperature detector 3, and the rotary table 5.
The repair welding robot 2 is a six-axis robot with six degrees of freedom, and a welding gun 105 of the welding machine 1 is clamped at the output end position of the repair welding robot 2, so that the welding gun 105 can obtain the multi-degree-of-freedom motion capability, and repair welding is carried out on the blade 6 to be repaired at each angle according to actual needs.
The rotary worktable 5 is provided with a clamping seat for clamping the blade 6 to be repaired, and the clamping seat is mainly used for supporting a workpiece and enabling the workpiece to rotate, adjust and feed.
The control system comprises a scanning camera 4, a temperature detector 3 and a controller 7, wherein the temperature detector 3 in the embodiment is an infrared light generator. The controller 7 can input the three-dimensional model file and output the processing code file, and the processing code file is provided for the repair welding robot 2, the welding machine 1 and the rotary worktable 5 to execute. Scanning camera 4, thermoscope 3 and aforementioned welding machine 1, repair welding robot 2 and swivel work head 5 all are connected with 7 communications of controller, scanning camera 4 and thermoscope 3 wherein transmit acquisition information to controller 7, controller 7 produces the processing code and sends respectively to welding machine 1 according to acquisition information through the procedure, repair welding robot 2 and swivel work head 5, by welding machine 1, repair welding robot 2 and swivel work head 5 cooperate and treat to restore blade 6 and repair the welding, it is specific:
the scanning camera 4 transmits a real-time image of a surfacing repair layer to the controller 7, the controller 7 compares the real-time image with a pre-stored model of a blade, generates a machining code through a slicing program and a track generation program according to the comparison difference, and drives the repair welding robot 2 and the rotary worktable 5 to move through the machining code so that the welding gun 105 and the blade 6 to be repaired generate relative rotation and feeding welding actions;
the temperature detector 3 transmits the real-time temperature of the surfacing repair layer to the controller 7, and the controller 7 controls the surfacing robot 2 and the rotary worktable 5 to cooperate to perform surfacing repair on the next layer after the temperature of the surfacing repair layer is lower than a set temperature, so that overlarge crystal grains caused by thermal circulation are avoided;
when the digital controller 7 detects a short-circuit signal, the short-circuit signal is fed back to the wire feeder 103, and the wire feeder 103 quickly responds to the drawing back of the welding wire, so that the welding wire is separated from the molten drops; when short-circuit current is generated, the welding power supply 102 can automatically monitor the short-circuit transition process, when molten drops transition, the welding power supply 102 reduces the current to enable the heat input quantity to be almost zero, and at the moment, the welding wire stops advancing and is automatically drawn back; the process of heat input of the electric arc is short, short circuit occurs, the electric arc is extinguished, and the heat input is rapidly reduced, so that the cold-heat exchange cycle is carried out repeatedly in the whole welding process. And further, the welding heat input is greatly reduced, the welding deformation is small, no splashing exists, the welding seam bridging capacity is good, the welding speed is high, and the operation cost is low.
Claims (7)
1. The electric arc additive repair method for the blades of the water turbine is characterized by comprising the following steps of: clamping a welding gun (105) of a welding machine (1) on a repair welding robot (2), and driving the welding gun (105) by the repair welding robot (2) to carry out surfacing repair on a blade (6) to be repaired arranged on a rotary workbench (5);
the method comprises the steps that a scanning camera (4) arranged at a welding gun (105) transmits a real-time image of a surfacing repair layer to a controller (7), the controller (7) compares the real-time image with a pre-stored model of a blade, generates a machining code through a slicing program and a track generation program according to the comparison difference, and drives a repair welding robot (2) and a rotary worktable (5) to move through the machining code so that the welding gun (105) and the blade (6) to be repaired generate relative rotation and feeding welding actions;
the real-time temperature of the surfacing repair layer is transmitted to the controller (7) by the temperature detector (3) arranged at the welding gun (105), and after the temperature of the surfacing repair layer is lower than the set temperature, the controller (7) controls the surfacing robot (2) to be matched with the rotary worktable (5) to perform surfacing repair on the next layer.
2. The electric arc additive repair method for the blades of the water turbine as claimed in claim 1, wherein: the CMT power supply is adopted as a welding power supply (102), when the controller (7) detects a short-circuit signal, the short-circuit signal is fed back to a wire feeder (103) of the welding machine (1), and the wire feeder (103) draws back the welding wire to separate the welding wire from molten drops;
when short-circuit current is generated, the welding power supply (102) automatically monitors the short-circuit transition process, the welding power supply (102) reduces the current during the molten drop transition, the heat input quantity is close to zero, and the welding wire stops advancing and is automatically drawn back.
3. The utility model provides a hydraulic turbine blade electric arc vibration material disk prosthetic devices which characterized in that: comprises a welding machine (1), a repair welding robot (2), a rotary worktable (5) and a controller (7); a welding gun (105) of the welding machine (1) is arranged on the output end of the repair welding robot (2), and a scanning camera (4) for shooting a real-time image of the surfacing repair layer and a temperature detector (3) for measuring the real-time temperature of the surfacing repair layer are arranged on the welding gun (105); controller (7) and welding machine (1), repair welding robot (2), swivel work head (5), scanning camera (4) and thermoscope (3) communication connection, controller (7) are used for receiving real-time image and compare with the prestore model of blade, generate the processing code according to the contrast difference, by the welding cooperation action of processing code control repair welding robot (2) and swivel work head (5), and controller (7) are used for receiving real-time temperature, and control repair welding robot (2) and swivel work head (5) cooperation in order to carry out the build-up welding restoration of next floor after real-time temperature is less than the setting value.
4. The electric arc additive repair device for the blades of the water turbine as claimed in claim 2, wherein: the welding machine (1) further comprises a water cooling system (101), a welding power supply (102) and a wire feeder (103) used for feeding welding wires to the welding gun (105), and a wire pushing and pulling mechanism (104) used for controlling the transmission of the welding wires is further arranged between the wire feeder (103) and the welding gun (105).
5. The electric arc additive repair device for the blades of the water turbine as claimed in claim 3, wherein: the welding power supply (102) is a CMT power supply.
6. The electric arc additive repair device for the blades of the water turbine as claimed in claim 2, wherein: the temperature detector (3) is an infrared light generator.
7. The electric arc additive repair device for the blades of the water turbine as claimed in claim 2, wherein: the repair welding robot (2) is a six-axis robot.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110973460.2A CN113523496A (en) | 2021-08-24 | 2021-08-24 | Electric arc additive repair method and equipment for blades of water turbine |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110973460.2A CN113523496A (en) | 2021-08-24 | 2021-08-24 | Electric arc additive repair method and equipment for blades of water turbine |
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| CN113523496A true CN113523496A (en) | 2021-10-22 |
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| CN202110973460.2A Pending CN113523496A (en) | 2021-08-24 | 2021-08-24 | Electric arc additive repair method and equipment for blades of water turbine |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116441851A (en) * | 2023-04-28 | 2023-07-18 | 中国长江电力股份有限公司 | Integrated repairing device and method for material increase and decrease of leakage-stopping ring of runner of large-sized water turbine |
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2021
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116441851A (en) * | 2023-04-28 | 2023-07-18 | 中国长江电力股份有限公司 | Integrated repairing device and method for material increase and decrease of leakage-stopping ring of runner of large-sized water turbine |
| CN116441851B (en) * | 2023-04-28 | 2024-05-10 | 中国长江电力股份有限公司 | Integrated repairing device and method for material increase and decrease of leakage-stopping ring of runner of large-sized water turbine |
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