A Novel Welding Method for Repairing Surface Defects of Large-Type Rotary Machinery Based on Line Structured Light Detection

IF 1 Q4 ENGINEERING, MANUFACTURING Journal of Micro and Nano-Manufacturing Pub Date : 2022-06-27 DOI:10.1115/msec2022-85527

Hao Fu, Hong Lu, Yongquan Zhang, Zidong Wu, He Huang, Shijie Liu, Shaojun Wang

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Abstract

Large-type rotary machinery is the core components of national major projects which is widely used aviation, electric power, metallurgy, energy and construction machinery industries. Surface defects of Large-type rotary machinery such as cracks and pits are usually processed into groove with a certain shape first, and then the processed groove is repaired by manual welding. This manual welding repair method has a low level of automation, and the repair quality of the groove is difficult to guarantee. Therefore, this paper proposes a novel welding method for repairing surface defects of Large-type rotary machinery which uses the Kollmorgen Joint Modular Robot to complete the welding repair of the processed groove. Firstly, the groove point cloud data collected by Line structured light sensor is processed by the designed algorithm to obtain the contour characteristics of the groove. Then, the arrangement of welding pass is completed based on contour characteristics of the groove. Finally, the trajectory of the welding robot is determined by the position of welding pass. The planned trajectory verification is completed on the simulation experiment platform and the result shows the accuracy and reliability of the planned trajectory which has certain theoretical and practical significance for realizing the automation of on-site maintenance of Large-type rotary machinery.

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基于线结构光检测的大型旋转机械表面缺陷修复新方法

大型回转机械是国家重大工程的核心部件，广泛应用于航空、电力、冶金、能源和工程机械等行业。大型旋转机械的表面缺陷如裂纹、凹坑等，通常先加工成一定形状的坡口，然后用手工焊接的方法对加工好的坡口进行修补。这种手工焊接修复方法自动化水平低，坡口的修复质量难以保证。因此，本文提出了一种大型旋转机械表面缺陷修复的新型焊接方法，利用Kollmorgen关节模块化机器人完成被加工槽的焊接修复。首先，利用所设计的算法对Line结构光传感器采集的凹槽点云数据进行处理，得到凹槽的轮廓特征;然后，根据坡口的轮廓特征完成焊道的布置。最后，根据焊接道的位置确定焊接机器人的运动轨迹。在仿真实验平台上完成了所规划轨迹的验证，结果表明所规划轨迹的准确性和可靠性，对实现大型回转机械现场维修自动化具有一定的理论和实际意义。

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来源期刊

Journal of Micro and Nano-Manufacturing ENGINEERING, MANUFACTURING-

CiteScore

2.70

自引率

0.00%

发文量

期刊介绍： The Journal of Micro and Nano-Manufacturing provides a forum for the rapid dissemination of original theoretical and applied research in the areas of micro- and nano-manufacturing that are related to process innovation, accuracy, and precision, throughput enhancement, material utilization, compact equipment development, environmental and life-cycle analysis, and predictive modeling of manufacturing processes with feature sizes less than one hundred micrometers. Papers addressing special needs in emerging areas, such as biomedical devices, drug manufacturing, water and energy, are also encouraged. Areas of interest including, but not limited to: Unit micro- and nano-manufacturing processes; Hybrid manufacturing processes combining bottom-up and top-down processes; Hybrid manufacturing processes utilizing various energy sources (optical, mechanical, electrical, solar, etc.) to achieve multi-scale features and resolution; High-throughput micro- and nano-manufacturing processes; Equipment development; Predictive modeling and simulation of materials and/or systems enabling point-of-need or scaled-up micro- and nano-manufacturing; Metrology at the micro- and nano-scales over large areas; Sensors and sensor integration; Design algorithms for multi-scale manufacturing; Life cycle analysis; Logistics and material handling related to micro- and nano-manufacturing.