CN105710371A

CN105710371A - Plasma 3D printing remanufacturing equipment and method for train wheel

Info

Publication number: CN105710371A
Application number: CN201610121657.2A
Authority: CN
Inventors: 华云峰; 何伟; 程国君; 郝勇; 魏志宇
Original assignee: Sinoadditive Manufacturing Equipment Co Ltd
Current assignee: Sinoadditive Manufacturing Equipment Co Ltd
Priority date: 2016-03-03
Filing date: 2016-03-03
Publication date: 2016-06-29

Abstract

The invention discloses plasma 3D printing remanufacturing equipment and method for a train wheel. The plasma 3D printing remanufacturing equipment consists of a monitoring system, a plasma beam processing system, a machining device for machining a train wheel to be repaired, a triaxial moving mechanism used for driving the machining device to move and a horizontal printing platform used for placing the train wheel to be repaired, wherein the plasma beam processing system consists of a plasma generator, a printing position adjusting device, an air supply device and a powder feeder; and the monitoring system comprises a horizontal movement controller, a temperature detection unit, a distance detection unit, a printing distance adjustment controller and a rotation controller, and the temperature detection unit and the printing distance adjustment controller constitute a temperature adjustment and control device. The plasma 3D printing remanufacturing method comprises the following steps: firstly, detecting defects of the train wheel; and secondly, repairing the train wheel. The plasma 3D printing remanufacturing equipment is reasonable in design, simple and convenient to operate, high in efficiency and good in using effect, the repair process is directly carried out in the atmospheric environment without a closed molding room, the repaired train wheel is good in quality, and the repair efficiency is high.

Description

A kind of train wheel plasma 3D prints and remanufactures Apparatus and method for

Technical field

The invention belongs to rapid shaping technique field, especially relate to a kind of train wheel plasma 3D printing and remanufacture Apparatus and method for.

Background technology

Train wheel wheel rim, in train running, is susceptible to abrasion when particularly turning round；When train wheel wheel wear to a certain extent after it cannot be guaranteed that the stable operation of train, make igneous rock cracks entirety scrap, the igneous rock cracks more renewed.In order to reduce cost, improve resource utilization, have employing overlaying method that the train wheel wheel rim of dimension overproof is remanufactured at present.

When adopting overlaying method to manufacture train wheel wheel rim, it is primarily present following three aspect problems:

The first, built-up welding needs train wheel to be preheated and subsequent heat treatment, this is accomplished by disassembling train wheel from igneous rock cracks, owing to the equipment of wheel and axle is by producing to expand by wheel heating, then being inserted in axle, cooling after-contraction is firmly combined together, therefore, the unloading process of wheel and axle is complicated and must adopt specific purpose tool, disassembly cost is high, and meanwhile, the reliability of igneous rock cracks is inevitably produced impact with again assembling by dismounting；

The second, built-up welding needs train wheel to be preheated and subsequent heat treatment, it is necessary to disassembled from axle by bearing, and the unloading process of bearing is complicated and must adopt specific purpose tool, and disassembly cost is high；

3rd, built-up welding needs train wheel to be preheated and subsequent heat treatment, removing vehicle tyres and bearing, and manufacture process is complicated, required time is long, and built-up welding wheel rim efficiency is low.

It addition, with rail rolling friction process, train wheel wheel face also can wear and tear, simultaneously the foreign body on rail also can accelerating pulley surface wear, as produced pit etc..After running a period of time, it is necessary to taking turns facing to smooth state, for several times after turning, wheel face is excessively thin causes igneous rock cracks thoroughly to be scrapped, and causes resource to waste in a large number.For increasing the service life of train wheel, being typically on the wheel hub of train wheel and lay one layer of wearing layer, this wearing layer is wheel face surface layer, and the wheel face of train wheel is the outer surface of this wheel face surface layer.After turning for several times, the wheel face surface layer of train wheel is crossed and thin will be caused that igneous rock cracks is thoroughly scrapped.

At present, domestic and international metal parts rapid shaping technique is mainly precinct laser fusion rapid molding technology (Selectivelasermelting, SLM).The basic functional principle of precinct laser fusion rapid molding equipment is: first utilize Pro/e on computers, UG, the 3D sculpting softwares such as CATIA design the three-dimensional entity model (i.e. three-dimensional stereo model) of part, then pass through Slice Software and this threedimensional model is carried out hierarchy slicing, obtain the outline data in each cross section, generated by outline data and fill scanning pattern, tile certain thickness powder in working cylinder, control according to computer, laser beam optionally melts fore-put powder layer by the mode of vibration mirror scanning according to the slicing treatment result of three-dimensional parts figure；Subsequently, working cylinder decline certain distance also spreads powder again, and laser beam completes the manufacture of next layer of parts under the drive of galvanometer again according to the 3-D graphic of parts；So repeat degradation operation under paving powder, scanning and working cylinder, thus realizing the manufacture of three-dimensional parts.Nowadays, precinct laser fusion rapid molding technology is primarily present following three aspect problems: the first, precinct laser fusion rapid molding technology needs protective atmosphere or vacuum environment, to avoid the oxidation of metal parts in forming process.This makes precinct laser fusion rapid molding device structure complicated, and forming part size is restricted, and energy source Optical Maser System price is high, and former is expensive；The second, precinct laser fusion rapid molding technology needs the moulding cylinder system of paving powder.This makes precinct laser fusion rapid molding device structure complicated, and not only forming part size is restricted, and shaping efficiency is relatively low；3rd, in order to ensure part mechanical property, precinct laser fusion rapid molding technology needs the globular metallic powder of good fluidity.This makes precinct laser fusion rapid molding equipment operating cost significantly high.

It addition, metal parts rapid shaping technique also has electron beam rapid shaping technique.But at present, Selected area electron bundle rapid shaping technique is primarily present following three aspect problems: the first, electron beam rapid shaping technique needs vacuum environment, to form energy source electron beam and to avoid the oxidation of metal parts in forming process.This makes electron beam rapid forming equipment structure complicated, and forming part size is restricted, and former is expensive；The second, electron beam rapid shaping technique needs paving powder system or moulding material feed system.This makes electron beam rapid forming equipment structure complicated, and not only forming part size is restricted, and shaping efficiency is relatively low；3rd, in order to ensure part mechanical property, electron beam rapid shaping technique needs the globular metallic powder of good fluidity.This makes precinct laser fusion rapid molding equipment operating cost significantly high.

Summary of the invention

The technical problem to be solved is in that for above-mentioned deficiency of the prior art, there is provided a kind of train wheel plasma 3D to print and remanufacture equipment, its simple in construction, reasonable in design and use easy and simple to handle, efficiency is high, result of use good, without airtight forming room, repair process directly carries out under atmospheric environment, after reparation, train wheel quality is good, and remediation efficiency is high.

For solving above-mentioned technical problem, the technical solution used in the present invention is: a kind of train wheel plasma 3D prints and remanufactures equipment, it is characterised in that: the three axle travel mechanisms and the horizontal stamp pad placed for train wheel to be repaired that are moved by monitoring system, plasma beam system of processing, the machining set-up that train wheel to be repaired is machined out, drive machining set-up form；Described horizontal stamp pad includes horizontal support mechanism and the horizontal rotary mechanism being fixedly mounted in horizontal support mechanism and driving described train wheel to be repaired to rotate around the central axis of its wheel shaft, described horizontal rotary mechanism is positioned at above horizontal support mechanism, described wheel shaft be level lay and its be installed on horizontal rotary mechanism；Described machining set-up is arranged in three axle travel mechanisms and it is positioned at above horizontal rotary mechanism；

Described plasma beam system of processing is by being provided with shower nozzle and for producing the plasma generator of beam-plasma, the print position adjusting apparatus that the position of described plasma generator is adjusted, providing the feeder of working gas for described plasma generator and for forming to the powder feeder sending into printed material in described plasma generator continuously, and described plasma generator is positioned at above horizontal rotary mechanism；Described feeder is connected with the air inlet opened on described plasma generator by air supply pipe；The powder flow paths of described powder circulation it is provided in described plasma generator, described powder flow paths with communicate inside the arc chamber in described plasma generator and it connects with described air inlet, the external port of described powder flow paths is powder inlet, and the powder feeding mouth of described powder feeder is connected with powder inlet by powder feeding pipe；Horizontally moving device that described print position adjusting apparatus includes driving described plasma generator to move in the horizontal plane and the printing distance adjusting means that the distance between driving described plasma generator and described horizontally moving device synchronizing moving and tackling outlet and the wheel shaft of described shower nozzle mutually is adjusted, described plasma generator is arranged on described horizontally moving device, and described horizontally moving device is arranged in described printing distance adjusting means；

Described monitoring system includes moving horizontally controller to what described horizontally moving device was controlled, described plasma beam system of processing Working position place temperature on described train wheel to be repaired is carried out the temperature detecting unit of detection in real time, distance between outlet and wheel shaft or the horizontal support mechanism of described shower nozzle is carried out the distance detection unit of detection in real time, the printing distance regulable control device that described printing distance adjusting means is controlled, the rotation angle detecting unit that the anglec of rotation of the wheel shaft of described train wheel to be repaired is carried out detection in real time and the Rotation Controllers that horizontal rotary mechanism is controlled, the described controller that moves horizontally is connected with described horizontally moving device, the described distance regulable control device that prints is connected with described printing distance adjusting means, described distance detection unit and temperature detecting unit are all connected apart from regulable control device with printing, described temperature detecting unit forms temperature control device with printing distance regulable control device；Described rotation angle detecting unit is connected with Rotation Controllers.

Above-mentioned a kind of train wheel plasma 3D prints and remanufactures equipment, it is characterized in that: described train wheel to be repaired is the train wheel that there is wheel wear defect and/or wheel planar defect；There is abrasion in the wheel rim that described wheel wear defect is described train wheel to be repaired；Described planar defect of taking turns is wheel face local defect and/or wheel face wear-out defect, and described wheel face local defect is there is damaged or cracking on the wheel face of described train wheel to be repaired, and described wheel face wear-out defect is there is abrasion on the wheel face of described train wheel to be repaired；The ultrasonic detection device being provided above the defect existed on described train wheel to be repaired is detected of described horizontal rotary mechanism or three-dimensional laser scanner.

Above-mentioned a kind of train wheel plasma 3D prints and remanufactures equipment, it is characterized in that: described powder feeder includes the shell that top has charging aperture and the powder feeding wheel being arranged in described shell, and described powder feeding wheel is driven by drive motor；Described powder feeding mouth is positioned at described outer casing underpart；

Detection of gas flow rate unit that plasma generator controller that described monitoring system also includes described plasma generator is controlled, gas flow to air supply pipe carry out detection in real time and the gas flow controller that the flow control valve installed on air supply pipe is controlled, described plasma generator controller is connected with described plasma generator, and described detection of gas flow rate unit is connected with gas flow controller.

Above-mentioned a kind of train wheel plasma 3D prints and remanufactures equipment, it is characterized in that: described plasma generator includes plasma gun, and described shower nozzle is the anode nozzle of plasma gun front end；Described plasma gun includes having the gun body of described air inlet, being positioned at the anode nozzle of gun body dead ahead and be plugged in the negative electrode of gun body, described anode nozzle is positioned on front side of negative electrode, described arc chamber is positioned on front side of negative electrode and it is positioned at the posterior medial of anode nozzle, and the front inner of described anode nozzle is spout；

Angle between central axis and the vertical plane of the beam-plasma that described plasma generator produces is not more than 45 °；Described printing distance adjusting means is the adjusting apparatus up and down described shower nozzle adjusted up and down along the central axis of described beam-plasma.

Above-mentioned a kind of train wheel plasma 3D prints and remanufactures equipment, it is characterized in that: described horizontal rotary mechanism includes two, the left and right rotary support seat being all fixedly mounted in horizontal support mechanism and the rotary drive mechanism driving wheel shaft to rotate, and the two ends of described wheel shaft are separately mounted on two described rotary support seats and are attached each through bearing between its two ends and two described rotary support seats；Described rotary drive mechanism is that electronic rotation driving mechanism and itself and wheel shaft are in transmission connection, and described rotary drive mechanism is controlled by Rotation Controllers and it is connected with horizontal rotary mechanism；

Described horizontal support mechanism is the mobile platform that fixed supporting construction maybe can move up and down.

Meanwhile, the invention discloses the train wheel plasma 3D that a kind of method step is simple, reasonable in design and realization is convenient, result of use is good and print reproducing method, it is characterised in that: the method comprises the following steps:

Step one, train wheel defects detection: the defect existed on described train wheel to be repaired is detected, and the position detecting each defect is recorded respectively；

Described train wheel to be repaired is the train wheel that there is wheel wear defect and/or wheel planar defect；There is abrasion in the wheel rim that described wheel wear defect is described train wheel to be repaired；Described planar defect of taking turns is wheel face local defect and/or wheel face wear-out defect, and described wheel face local defect is there is damaged or cracking on the wheel face of described train wheel to be repaired, and described wheel face wear-out defect is there is abrasion on the wheel face of described train wheel to be repaired；

Step 2, train wheel reparation: adopting described train wheel plasma 3D to print and remanufacture equipment, the defect that the train wheel described to be repaired detected in step one exists is repaired respectively, process is as follows:

Step 201, wheel wear defect repair judge: according to the train wheel defects detection result in step one, judge whether to carry out wheel wear defect repair: when the wheel rim detecting described train wheel to be repaired in step one exists described wheel wear defect, described train wheel to be repaired need to be carried out wheel wear defect repair, and enter step 202；Otherwise, step 203 is entered；

Step 202, wheel wear defect repair: according to the train wheel defects detection result in step one, adopt described plasma beam system of processing, the eroded area of the wheel rim of described train wheel to be repaired is repaired, and the wheel rim completing described train wheel to be repaired remanufactures process；

Step 203, wheel face local defect reparation judge: according to the train wheel defects detection result in step one, judge whether to carry out wheel face local defect reparation: when the wheel face detecting described train wheel to be repaired in step one exists described wheel face local defect, described train wheel to be repaired need to be carried out wheel face local defect reparation, and enter step 204；Otherwise, step 205 is entered；

Step 204, wheel face local defect are repaired: according to the train wheel defects detection result in step one, the each wheel face local defect existed on described train wheel to be repaired is repaired respectively, until completing the repair process of all wheel face local defects existed on described train wheel to be repaired；

On described train wheel to be repaired, the restorative procedure of all wheel face local defects is all identical；When any one the described wheel face local defect existed on described train wheel to be repaired is repaired, comprise the following steps:

Step 2041, rejected region are removed: first pass through Rotation Controllers and horizontal rotary mechanism is controlled, and drive described train wheel to be repaired to rotate around the central axis of its wheel shaft, until current repaired wheel face local defect present position is rotated above the central axis of wheel shaft；Adopt described machining set-up that region residing for repaired wheel face local defect current on described train wheel to be repaired is removed again, it is thus achieved that the to be filled region corresponding with current repaired wheel face local defect；

Step 2042, plasma 3D print: adopt described plasma beam system of processing, region to be filled described in step 2041 is carried out plasma 3D printing, complete the repair process of current repaired wheel face local defect；

Step 205, wheel face wear-out defect reparation judge: according to the train wheel defects detection result in step one, judge whether to carry out wheel face wear-out defect reparation: when step one detects there is wheel face wear-out defect in described train wheel to be repaired time, described train wheel to be repaired need to be carried out wheel face wear-out defect reparation, and enter step 206；Otherwise, what complete described train wheel to be repaired remanufactures process；

Step 206, wheel face wear-out defect are repaired: according to the train wheel defects detection result in step one, adopt described plasma beam system of processing, the eroded area of the wheel face of described train wheel to be repaired is repaired, and what complete described train wheel to be repaired remanufactures process.

Above-mentioned plasma 3D that train wheel to be repaired is carried out prints the method remanufactured, it is characterized in that: when step one carries out train wheel defects detection, controlling horizontal rotary mechanism by Rotation Controllers drives wheel shaft to rotate around its center axis, and in wheel shaft rotary course, the defect that described train wheel to be repaired exists is detected by ultrasonic detection device or three-dimensional laser scanner that employing horizontal rotary mechanism is provided above；

After step 2 completes train wheel reparation, it is thus achieved that train wheel after reparation；Afterwards, control horizontal rotary mechanism by Rotation Controllers and drive wheel shaft to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up that train wheel after described reparation is carried out polish.

Above-mentioned plasma 3D that train wheel to be repaired is carried out prints the method remanufactured, and it is characterized in that: adopt described plasma beam system of processing in step 2022, and when region to be filled described in step 2021 carries out plasma 3D printing, process is as follows:

Step A, three-dimensional stereo model obtain and hierarchy slicing processes: the three-dimensional stereo model according to the train wheel finished product of described train wheel to be repaired, adopt data handling equipment and call the three-dimensional stereo model in the described region to be filled of image processing module acquisition, recall the hierarchy slicing module three-dimensional stereo model to described region to be filled and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

In this step, multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to described region to be filled carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the bottom to top；

Step B, scanning pattern are filled: adopt data handling equipment and call described image processing module, described layering cross-sectional images multiple in step A are respectively processed, and complete the scanning pattern filling process in multiple described layering cross section, it is thus achieved that the scanning pattern in multiple described layering cross sections；

Step C, printing path obtain: the described data handling equipment scanning pattern according to the multiple described layering cross section obtained in step B, it is thus achieved that the printing path in multiple described layering cross sections；The printing path in each described layering cross section is all identical with the scanning pattern in this layering cross section；

Step D, from the bottom to top successively printing: the printing path according to the multiple described layering cross section obtained in step C, successively described region to be filled is printed from the bottom to top, make described region to be filled be filled with by multiple shape layers stacking from the bottom to top；The quantity of described shape layer is identical with the quantity being layered cross section described in step A, the installation position of multiple described shape layers is all identical with the installation position one_to_one corresponding in multiple described layering cross sections and its thickness respectively, distance between the thickness of described shape layer two described layering cross sections adjacent with step A is identical, the printing path of multiple described shape layers in the printing path in multiple described layering cross sections respectively described region to be filled in step C；In described region to be filled, the Method of printing of multiple described shape layers is all identical；When described region to be filled is printed, process is as follows:

Step D1, bottom print: described in move horizontally the controller printing path according to current institute printing shaping layer acquired in step C, described horizontally moving device is controlled and drives described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto in described region to be filled by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer in described region to be filled；

In this step, current institute printing shaping layer is the shape layer being positioned at bottommost in described region to be filled in multiple described shape layers；

Step D2, last layer print, and comprise the following steps:

Step D21, horizontal support mechanism move down: horizontal support mechanism in the vertical direction is once moved down and moved down height identical with the thickness of described shape layer in described region to be filled；

Step D22, printing and synchronize temperature control: described in move horizontally the controller printing path according to current institute printing shaping layer acquired in step C, described horizontally moving device is controlled and drives described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the upper surface of the current printed described shape layer of the next one by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device to the upper surface temperature of the described shape layer of the next one current printed in described region to be filled by temperature detecting unit, detect the distance between unit outlet and horizontal support mechanism to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device that will detect；Described print temperature information that distance regulable control device detects according to temperature detecting unit and be adjusted by controlling the distance between described printing distance adjusting means outlet and horizontal support mechanism to described shower nozzle, making 0.6 times of the upper surface temperature of the currently printed described shape layer of the next one material fusing point not higher than described printed material；

When plasma generator described in step D1 and step D22 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft；In plasma generator moving process described in step D1 and step D22, described printed material is delivered in described plasma generator by described powder feeder continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；

Step D3, repeatedly repetition step D2, until completing the print procedure of all shape layers in described region to be filled.

Above-mentioned plasma 3D that train wheel to be repaired is carried out prints the method remanufactured, and it is characterized in that: described train wheel to be repaired includes middle part and has axis hole and the wheel hub being arranged on wheel shaft, and described wheel rim is laid in wheel hub and it is positioned at inside wheel hub；

When step one carries out train wheel defects detection, when detect there is wheel wear defect in described train wheel to be repaired time, the degree of wear also needing the wheel rim to described train wheel to be repaired judges: when the degree of wear judging wheel rim is part wears, and after adopting direct repairing method in step 202 or removing, repairing method carries out wheel wear defect repair again；When the degree of wear judging wheel rim is all wear and tear, when carrying out wheel wear defect repair in step 202, process is as follows:

Step 202-1, three-dimensional stereo model obtain and hierarchy slicing processes: adopt data handling equipment and call the three-dimensional stereo model of image processing module acquisition wheel rim, recall the hierarchy slicing module three-dimensional stereo model to wheel rim and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to wheel rim carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 202-2, scanning pattern are filled: adopt data handling equipment and call described image processing module, described layering cross-sectional images multiple in step 202-1 are respectively processed, and complete the scanning pattern filling process in multiple described layering cross section, it is thus achieved that the scanning pattern in multiple described layering cross sections；

Step 202-3, printing path obtain: the described data handling equipment scanning pattern according to the multiple described layering cross section obtained in step 202-2, it is thus achieved that the printing path in multiple described layering cross sections；The printing path in each described layering cross section is all identical with the scanning pattern in this layering cross section；

Step 202-4, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 202-3, successively print wheel rim from the inside to the outside, it is thus achieved that the wheel rim stacking from the inside to the outside by multiple shape layers on wheel hub；The quantity of described shape layer is identical with the quantity being layered cross section described in step 202-1, the installation position of multiple described shape layers is all identical with the installation position one_to_one corresponding in multiple described layering cross sections and its thickness respectively, distance between the thickness of described shape layer with adjacent two described layering cross sections is identical, the printing path of the printing path in multiple described layering cross sections respectively multiple described shape layers in step 202-3；When wheel rim is printed, process is as follows:

Step 202-401, bottom print: the printing path according to current institute printing shaping layer acquired in step 202-3, controlling horizontal rotary mechanism by Rotation Controllers drives wheel shaft to rotate around its center axis, and in wheel shaft rotary course, described in move horizontally controller and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of wheel hub by described plasma beam system of processing continuously；After wheel shaft rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, current institute printing shaping layer is the shape layer being positioned at inner side in multiple described shape layer；

Step 202-402, next layer print, and comprise the following steps:

Step 202-4021, plasma generator move: control described printing distance adjusting means by printing distance regulable control device, drive described plasma generator in the vertical direction once to move up and move up highly identical with the thickness of described shape layer；

After moving into place, the height of described plasma generator being recorded, now the height of described plasma generator is the basis printing height of current institute printing shaping layer；

Step 202-4022, printing and synchronization temperature control: the printing path according to current institute printing shaping layer acquired in step 202-3, controlling horizontal rotary mechanism by Rotation Controllers drives wheel shaft to rotate around its center axis, and in wheel shaft rotary course, described in move horizontally controller and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of a current printed upper described shape layer by described plasma beam system of processing continuously；After wheel shaft rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device to the hull-skin temperature of a current printed upper described shape layer by temperature detecting unit, detect the distance between unit outlet and wheel shaft to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device that will detect；Described print temperature information that distance regulable control device detects according to temperature detecting unit and be adjusted by controlling the distance between described printing distance adjusting means outlet and wheel shaft to described shower nozzle, making 0.6 times of the hull-skin temperature of the currently printed upper described shape layer material fusing point not higher than described printed material；

When plasma generator described in step 202-401 and step 202-4022 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft；In plasma generator moving process described in step 202-401 and step 202-4022, described printed material is delivered in described plasma generator by described powder feeder continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；Described printed material is dusty material；

Step 202-4023, plasma generator move reset: control described printing distance adjusting means by printing distance regulable control device, described plasma generator in the vertical direction is driven to move up and down, until being that in step 202-4021, the basis of current institute printing shaping layer prints height by the height adjustment of described plasma generator；

Step 202-403, repeatedly repetition step 202-402, until completing the print procedure of all shape layers of wheel rim；

When adopting described direct repairing method to carry out wheel wear defect repair in step 202, process is as follows:

Step 20211, three-dimensional stereo model obtain and hierarchy slicing processes: adopt described data handling equipment and call the three-dimensional stereo model of eroded area on described image processing module acquisition wheel rim, recall hierarchy slicing module and the three-dimensional stereo model of eroded area on wheel rim is carried out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image that the three-dimensional stereo model of eroded area on wheel rim obtains after carrying out hierarchy slicing multiple layering cross section, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 20212, scanning pattern are filled: the method described in step 202-2, it is thus achieved that the scanning pattern in multiple described layering cross sections in step 20211；

Step 20213, printing path obtain: the method described in step 202-3, it is thus achieved that the printing path in multiple described layering cross sections in step 20211；

Step 20214, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 20213, and the method described in step 202-4, successively print the eroded area on wheel rim from the inside to the outside；

When adopting in step 202 that repairing method carries out wheel wear defect repair again after described removal, process is as follows:

Step 20221, wheel rim are removed: control horizontal rotary mechanism by Rotation Controllers and drive wheel shaft to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up that the wheel rim of described train wheel to be repaired is removed；

Step 20222, according to step 202-1 to the method described in step 202-4, on the wheel hub of train wheel to be repaired described in step 20221 print wheel rim.

Above-mentioned plasma 3D that train wheel to be repaired is carried out prints the method remanufactured, and it is characterized in that: the outside of described wheel hub is along the circumferential direction laid with one layer of wheel face surface layer, the outer surface that wheel face is wheel face surface layer of described train wheel to be repaired；When step one carries out train wheel defects detection, when detect there is wheel face wear-out defect in described train wheel to be repaired time, the degree of wear also needing the wheel face surface layer to described train wheel to be repaired judges: when the degree of wear judging wheel face surface layer is part wears, and after adopting direct repairing method in step 206 or removing, repairing method carries out wheel face wear-out defect reparation again；When the degree of wear judging wheel face surface layer is all wear and tear, when step 206 carries out the reparation of wheel face wear-out defect, according to step 202-1 to the method described in step 202-4, the wheel hub of described train wheel to be repaired prints wheel face surface layer；

When adopting direct repairing method to carry out the reparation of wheel face wear-out defect in step 206, process is as follows:

Step 20611, three-dimensional stereo model obtain and hierarchy slicing processes: adopt described data handling equipment and call the three-dimensional stereo model of eroded area on described image processing module acquisition wheel face surface layer, recall hierarchy slicing module and the three-dimensional stereo model of eroded area on wheel face surface layer is carried out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image that the three-dimensional stereo model of eroded area on wheel face surface layer obtains after carrying out hierarchy slicing multiple layering cross section, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 20612, scanning pattern are filled: the method described in step 202-2, it is thus achieved that the scanning pattern in multiple described layering cross sections in step 20611；

Step 20613, printing path obtain: the method described in step 202-3, it is thus achieved that the printing path in multiple described layering cross sections in step 20611；

Step 20614, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 20613, and the method described in step 202-4, successively print the eroded area on wheel face surface layer from the inside to the outside；

When after adopting removal in step 206, repairing method carries out the reparation of wheel face wear-out defect again, process is as follows:

Step 20621, wheel face surface layer are removed: control horizontal rotary mechanism by Rotation Controllers and drive wheel shaft to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up that the wheel face surface layer of described train wheel to be repaired is removed；

Step 20622, according to step 202-1 to the method described in step 202-4, on the wheel hub of train wheel to be repaired described in step 20621 print wheel face surface layer.

The present invention compared with prior art has the advantage that

1, it is convenient that the train wheel plasma 3D that adopts prints and remanufactures that device structure is simple, reasonable in design and input cost is relatively low, processing and fabricating and installing is laid.

2, the train wheel plasma 3D adopted prints and remanufactures equipment without airtight forming room, and does not need protective atmosphere or vacuum environment, and repair process (namely remanufactures process) directly to carry out under atmospheric environment.Thus, structure is very simple, and it is unrestricted to remanufacture accessory size, and equipment price is relatively low.

3, train wheel plasma 3D prints the printed material supply of the equipment that remanufactures in energy source beam-plasma (the drop plasma beam of material), the moulding cylinder system that need not spread powder need not spread powder system, only needing a powder feeder, structure significantly simplifies.

4, the train wheel plasma 3D printing adopted remanufactures equipment easy and simple to handle, the intelligence degree of use and efficiency is high, result of use is good, and institute's molding train wheel quality is good.What the monitoring system adopted included horizontally moving device is controlled moves horizontally controller, to printing the temperature detecting unit that position temperature carries out detecting in real time, distance between outlet and wheel shaft or the horizontal support mechanism of shower nozzle is carried out the distance detection unit of detection in real time, to printing the printing distance regulable control device that distance adjusting means is controlled, the rotation angle detecting unit that the anglec of rotation of wheel shaft is carried out detection in real time and the Rotation Controllers that horizontal rotary mechanism is controlled, print distance regulable control device to be connected with printing distance adjusting means, temperature detecting unit and distance detection unit are all connected apart from regulable control device with printing；Temperature detecting unit forms temperature control device with printing distance regulable control device, and rotation angle detecting unit is connected with Rotation Controllers.

In actually used process, printing distance regulable control device in temperature control device is controlled printing distance adjusting means according to the detected information of temperature detecting unit, make to print distance energy Automatic adjusument, so can prevent because printing the problem that hypotelorism causes the shape layer printed to occur fusing again, and the formed precision caused because of printing hypertelorism also can be prevented relatively low, there is the problems such as solidification before a printable layer outer surface in molten melt drop on being sprayed onto, make forming process easily controllable, and realize conveniently, can effectively prevent the surface of train wheel wheel rim or wheel face from aoxidizing simultaneously, because of without arranging airtight vacuum environment.It addition, the monitoring system adopted also includes gas flow Automatic adjusument and powder mass flow Automatic adjusument function, intelligence degree is high.

5, train wheel plasma 3D prints the energy source remanufacturing equipment employing is beam-plasma, and beam-plasma power is up to tens of kilowatt, energy molten ceramic material, it is achieved the plasma casting rapid shaping of metal, ceramic metal and ceramic part.Producing plasma generator (specifically plasma gun) simple in construction of beam-plasma, operation expense is low, and plasma casting rapid forming equipment cost is low.

6, train wheel plasma 3D prints the drop remanufacturing equipment institute printed material in plasma beam; beam-plasma itself has protective effect; add the effect of working gas; can effectively prevent the oxidation of printed material; this equipment does not need protective atmosphere or vacuum environment; directly use under atmospheric environment, the advantage such as have that device structure is simple, operating cost is low, to remanufacture accessory size unrestricted.

7, train wheel plasma 3D prints and remanufactures equipment employing direct current generator drive powder wheel rotation and deliver in beam-plasma by working gas auxiliary by powder, can use a powder or prilling powder, it is not necessary to spherical powder.This equipment printed material cost is low.

8, when train wheel plasma 3D printing remanufactures equipment printing, materials behavior is become solid-state by settable liquid, and technical process simplifies, and reduces the 3D technology difficulty printed and cost.Simultaneously, under the effect of working gas (beam-plasma includes unionized working gas), powder enters in beam-plasma, and accelerate in described beam-plasma, heat and be fused into molten condition and form small drop, this drop sprays in the lump with beam-plasma, forms the interior plasma beam with molten melt drop；After the molten melt drop that powder is formed after fusing sprays with beam-plasma, formed by the microstream of the molten melt drop being evenly distributed with printed material, form casting type molding, the rounded constrictions phenomenon produced when avoiding molten drop cooled and solidified molding, part mechanical property is high, smooth surface, reduces the technology difficulty of rapid shaping.

9, adopted train wheel plasma 3D print remanufacture functions of the equipments comprehensively and use easy and simple to handle, occupation mode flexible, and has defects detection and machining function.This equipment less costly, in adopted plasma beam system of processing, plasma gun price is low, change, maintenance cost low, and use cost is low.Adopt the present invention local defect of train wheel to be repaired can be carried out printing to remanufacture, it also is able to that whole wheel rim, part wheel rim, whole wheel face or part wheel face are carried out printing remanufacture, polish can also be carried out to printing the wheel rim remanufactured with wheel face, make the train wheel that printing remanufactures be directly used on train.

10, the train wheel plasma 3D printing reproducing method adopted is simple, reasonable in design and realization is convenient, result of use is good, with taking turns planar defect, the wheel wear that train wheel exists can be carried out simplicity, quick and high-quality reparation.

11, the plasma 3D Method of printing step of adopted plasma beam system of processing simple, reasonable in design and realize convenient, result of use is good, improved by plasma gun structure and powder is sent directly in beam-plasma and makes powder smelting, the drop plasma beam of formation institute printed material.Beam-plasma has protective effect, it is not necessary to protective atmosphere or vacuum environment, directly prints under atmospheric environment.Further, printed material supplies in energy source beam-plasma (the drop plasma beam of material), it is not necessary to the moulding cylinder system of paving powder.It addition, adopt direct current generator drive powder wheel to rotate and deliver in beam-plasma by working gas auxiliary by powder, a powder or prilling powder can be used, it is not necessary to spherical powder.During printing, materials behavior is become solid-state by settable liquid, and technical process simplifies, and reduces the 3D technology difficulty printed and cost, and it is no longer size-limited to print part.As shown in the above, traditional plasma surfacing method is substantially improved by the present invention, the generally individually plasma arc voltage Height-adjusting device that is provided with of existing plasma surfacing method, and the distance of plasma gun and surface of the work is not more than 15mm, and the scope of application is limited.And in the present invention, print distance can on a large scale in be adjusted, adapting to unlike material prints demand, and can be effectively ensured the Forming Quality of workpiece (i.e. train wheel wheel rim or wheel face).

Adopt energy efficient solution of the present invention to determine the problems referred to above that precinct laser fusion rapid molding technology and electron beam rapid shaping technique exist, and provide a kind of brand-new train wheel reproducing method for train wheel, can effectively solve the various problems that existing laser cladding method exists, have that efficiency height, Forming Quality be good, between wheel hub and wheel rim and wheel face surface layer, bonding strength is high, repair after the advantages such as train wheel quality is good.

12, printed material (i.e. material used by train wheel wheel rim or wheel face surface layer) fusing in beam-plasma forms drop, beam-plasma has protection and purification effect, it is to avoid the material contamination in smelting and casting cycle, train wheel stable performance.Plasma 3D is adopted to print train wheel wheel rim and wheel face, beam-plasma energy source energy density is controlled, heat input is controlled, there is Temperature Feedback and control system simultaneously, in next layer of wheel rim and wheel face file printing process, last layer printed material can be carried out synchronizing heat treatment by plasma beam, print wheel rim and wheel face thermal stress is little, do not have micro-crack or cracking, therefore, train wheel need not be preheated and heat treatment, from without removing vehicle tyres and bearing, wheel rim and wheel face low cost of manufacture, efficiency is high, the reliability of igneous rock cracks will not be produced impact.

Additionally, adopt the present invention to be printed by train wheel face to recover to original size, avoid tradition to process reduction wheel diameter and the shortcoming to original size can not be recovered, the wheel making permutation train is identical to axis height, wheel diameter is identical, make train running steady, and can make wheel to life-span close, it is simple to life appraisal, reliability improve and be easy to management.Simultaneously, adopt the present invention that wheel rim and wheel face can be removed the pretreatment of defect, also being able to the wheel rim after printing and wheel face are carried out polish, complete train wheel wheel rim and wheel face are printed upon on a set of equipment to complete, and make the igneous rock cracks of printing wheel rim and wheel face be directly used on train.

When 13, adopting the present invention to print train wheel wheel rim and wheel face; beam-plasma has protective effect; power is big and heat input is controlled; beam-plasma atmosphere also has the feature of being synthesized; train wheel rim material can be designed and synthesizes, generate the second-phase such as graphite, hexagonal AlN, TiC etc. of low-friction coefficient, make the train wheel wheel rim of printing have Wear-resistant performance; further raising wheel rim service life, reduce the abrasion to rail simultaneously；Train wheel plane materiel material can be designed and synthesizes, generate coefficient of friction relatively low but do not reduce second-phase such as TiC, TiCN etc. of hardness, the train wheel wheel face making printing has Wear-resistant performance, further raising wheel face service life, reduces the abrasion to rail simultaneously.

When adopting the present invention to remanufacture train wheel, technical process is simple, and technological process is short, and equipment cost is low.And, plasma beam system of processing disclosed in this invention can directly use under atmospheric environment, train wheel wheel rim or wheel face material therefor can be fused into liquid stream during molding, realize continuous micro-casting rapid shaping, technical process simplifies, reduce technology difficulty and cost that conventional composite train wheel manufactures, improve the performance of compound train wheel.

14, printing and remanufacture process and can carry out under atmospheric environment, the handling of train wheel to be repaired are easy, and remediation efficiency is high.The present invention is adopted directly to print on the igneous rock cracks with wheel shaft, need not preheating when preparing wheel rim and wheel face of the tradition overlaying method and heat treatment process, train wheel need not be disassembled from wheel shaft, reduce manufacturing cost, improve manufacture efficiency, improve the reliability of igneous rock cracks, and the wheel rim printed and wheel face can be carried out polish, enable to directly apply on train.

Below by drawings and Examples, technical scheme is described in further detail.

Accompanying drawing explanation

Fig. 1 is the train wheel plasma 3D of the present invention structural representation printing the equipment that remanufactures.

Fig. 2 is the structural representation of plasma gun in the embodiment of the present invention 1.

Fig. 3 is the schematic block circuit diagram that the present invention monitors system.

Fig. 4 is the structural representation of air inlet ring of the present invention.

Fig. 5 is the structural representation of air inlet ring body of the present invention.

Fig. 6 is the train wheel plasma 3D of the present invention FB(flow block) printing reproducing method.

Fig. 7 is the structural representation of plasma gun in the embodiment of the present invention 2.

Description of reference numerals:

1 feeder；2 powder feeders；3-1 wheel shaft；

3-2 wheel rim；3-3 wheel face surface layer；3-4 wheel hub；

4 horizontal rotary mechanisms；5 air supply pipes；

6 powder feeding pipe；7 plasma generator controllers；

8 distance detection unit；9 temperature detecting units；

10 print distance regulable control device；11 detection of gas flow rate unit；

12 gas flow controllers；13 plasma guns；13-1 gun body；

13-2 anode nozzle；13-3 negative electrode；13-4 arc chamber；

13-5 spout；13-6 insulating barrier；14 powder flow paths；

15 Rotation Controllers；16 horizontal support mechanisms；About 17 adjusting apparatus；

18 powder mass flow detection unit；19 drive motors；20 powder feeding flow controllers；

21 air inlet rings；21-1 air inlet ring body；21-2 annular sealing cover；

21-3 annular air inlet duct；Air inlet outside 21-4；Air inlet inside 21-5；

22 powder inlets；23 PCs；24 move horizontally controller；

24-1 X-axis travel mechanism；24-2 Y-axis moving mechanism；

25 flow control valves；26 rotation angle detecting units；

27 machining set-ups；28 3 axle travel mechanisms.

Detailed description of the invention

Embodiment 1

A kind of train wheel plasma 3D as shown in Figure 1 prints and remanufactures equipment, monitoring system, plasma beam system of processing, the machining set-up 27 that train wheel to be repaired is machined out, drive machining set-up 27 the three axle travel mechanisms 28 and the horizontal stamp pad placed for train wheel to be repaired that move form.Described horizontal stamp pad includes horizontal support mechanism 16 and the horizontal rotary mechanism 4 being fixedly mounted in horizontal support mechanism 16 and driving described train wheel to be repaired to rotate around the central axis of its wheel shaft 3-1, described horizontal rotary mechanism 4 is positioned at above horizontal support mechanism 16, described wheel shaft 3-1 be level lay and its be installed on horizontal rotary mechanism 4.Described machining set-up 27 is arranged in three axle travel mechanisms 28 and it is positioned at above horizontal rotary mechanism 4.

Described plasma beam system of processing is by being provided with shower nozzle and for producing the plasma generator of beam-plasma, the print position adjusting apparatus that the position of described plasma generator is adjusted, providing the feeder 1 of working gas for described plasma generator and for forming to the powder feeder 2 sending into printed material in described plasma generator continuously, and described plasma generator is positioned at above horizontal rotary mechanism 4.Described feeder 1 is connected with the air inlet opened on described plasma generator by air supply pipe 5.The powder flow paths 14 of described powder circulation it is provided in described plasma generator, described powder flow paths 14 with communicate inside the arc chamber 13-4 in described plasma generator and it connects with described air inlet, the external port of described powder flow paths is powder inlet 22, and the powder feeding mouth of described powder feeder 2 is connected with powder inlet 22 by powder feeding pipe 6；Horizontally moving device that described print position adjusting apparatus includes driving described plasma generator to move in the horizontal plane and drive described plasma generator and described horizontally moving device synchronizing moving and tackle the printing distance adjusting means that the distance between the outlet of described shower nozzle and wheel shaft 3-1 is adjusted mutually, described plasma generator is arranged on described horizontally moving device, and described horizontally moving device is arranged in described printing distance adjusting means.Described printed material is dusty material (i.e. powder), and, described printed material is the material used by wheel rim 3-2 or the material used by its wheel face (i.e. wheel face surface layer 3-3) of train wheel to be repaired.

As shown in Figure 3, what described monitoring system included described horizontally moving device is controlled moves horizontally controller 24, described plasma beam system of processing Working position place temperature on described train wheel to be repaired is carried out the temperature detecting unit 9 of detection in real time, distance between outlet and wheel shaft 3-1 or the horizontal support mechanism 16 of described shower nozzle is carried out the distance detection unit 8 of detection in real time, the printing distance regulable control device 10 that described printing distance adjusting means is controlled, the rotation angle detecting unit 26 that the anglec of rotation of the wheel shaft 3-1 of described train wheel to be repaired is carried out detection in real time and the Rotation Controllers 15 that horizontal rotary mechanism 4 is controlled, the described controller 24 that moves horizontally is connected with described horizontally moving device, the described distance regulable control device 10 that prints is connected with described printing distance adjusting means, described distance detection unit 8 and temperature detecting unit 9 are all connected apart from regulable control device 10 with printing, described temperature detecting unit 9 forms temperature control device with printing distance regulable control device 10；Described rotation angle detecting unit 26 is connected with Rotation Controllers 15.

Described train wheel to be repaired includes middle part and has axis hole and the wheel hub 3-4 being arranged on wheel shaft 3-1, and described wheel rim 3-2 is laid in wheel hub 3-2 and it is positioned at inside wheel hub 3-2；The outside of described wheel hub 3-4 is along the circumferential direction laid with one layer of wheel face surface layer 3-3, the outer surface that wheel face is wheel face surface layer 3-3 of described train wheel to be repaired.Described wheel rim 3-2 and wheel face surface layer 3-3 all lays in coaxial with wheel shaft 3-1.Described wheel face surface layer 3-3 is wearing layer.

In the present embodiment, described train wheel to be repaired is the train wheel that there is wheel wear defect and/or wheel planar defect；There is abrasion in the wheel rim 3-2 that described wheel wear defect is described train wheel to be repaired；Described planar defect of taking turns is wheel face local defect and/or wheel face wear-out defect, and described wheel face local defect is there is damaged or cracking on the wheel face of described train wheel to be repaired, and described wheel face wear-out defect is there is abrasion on the wheel face of described train wheel to be repaired.

Meanwhile, being provided above the ultrasonic detection device that detects of defect existed on described train wheel to be repaired or three-dimensional laser scanner of described horizontal rotary mechanism 4.

In the present embodiment, adopt ultrasonic detection device that the defect existed on described train wheel to be repaired is detected.

And, described ultrasonic detection device and machining set-up 27 are installed in same three axle travel mechanisms 28, described three axle travel mechanisms 28 can drive described ultrasonic detection device and machining set-up 27 to synchronize the travel mechanism moved in X-axis, Y-axis and Z-direction, as three axle mobile platforms, three-dimensional mechanical hand, three axles regulate support, gimbal etc..In the present embodiment, described three axle travel mechanisms 28 are positioned at above horizontal rotary mechanism 4.

In the present embodiment, described three axle travel mechanisms 28 are that three axles regulate support, described three axles regulate supports include base, the Z axis regulating arm being arranged on described base, the X-axis regulating arm being arranged on described Z axis regulating arm and the Y-axis regulating arm that is arranged on described X-axis regulating arm, described Y-axis regulating arm is provided with a vertical mounting rod, and described machining set-up 27 and ultrasonic detection device are separately mounted to the left and right sides of described vertical mounting rod.

In the present embodiment, described temperature detecting unit 9 is that in Working position place (i.e. print position place or the reparation position) temperature of described train wheel to be repaired, described plasma beam system of processing is carried out the infrared temperature sensor of detection in real time.Described distance detection unit 8 is laser range sensor.

When actual laying is installed, described temperature detecting unit 9 is positioned at above wheel shaft 3-1.In the present embodiment, described temperature detecting unit 9 is positioned at the surface of wheel shaft 3-1.

The outlet of described shower nozzle is positioned at the surface of wheel shaft 3-1, and described plasma generator is laid on same vertical plane with wheel shaft 3-1.

It should be noted that: the distance between the outlet that distance is described shower nozzle and the central axis of wheel shaft 3-1 between outlet and the wheel shaft 3-1 of the described shower nozzle that described distance detection unit 8 detects.

In the present embodiment, X-axis travel mechanism 24-1 that described horizontally moving device includes driving described plasma generator to carry out in the X-axis direction moving horizontally and drive described plasma generator to carry out the Y-axis moving mechanism 24-2 moved horizontally in the Y-axis direction, thus described horizontally moving device is X-Y shaft moving device.

Further, described plasma generator is arranged on Y-axis moving mechanism 24-2, and described Y-axis moving mechanism 24-2 is arranged on X-axis travel mechanism 24-1, and described X-axis travel mechanism 24-1 is arranged in described printing distance adjusting means.In actually used process, described plasma generator is driven to move horizontally in the Y-axis direction by Y-axis moving mechanism 24-2, driven by X-axis travel mechanism 24-1 that Y-axis moving mechanism 24-2 is Tong Bu with described plasma generator moves horizontally in the X-axis direction, and described horizontally moving device is Tong Bu with described plasma generator moves on the central axis of described beam-plasma by the drive of described printing distance adjusting means.Wherein, X-direction is the central axial direction of wheel shaft 3-1.

In the present embodiment, described Y-axis moving mechanism 24-2, X-axis travel mechanism 24-1 and described printing distance adjusting means composition drive described plasma generator (specifically plasma gun 13) to carry out the mechanical hand of three-dimensional motion.

In the present embodiment, detection of gas flow rate unit 11 that plasma generator controller 7 that described monitoring system also includes described plasma generator is controlled, gas flow to air supply pipe 5 carry out detection in real time and the gas flow controller 12 that the flow control valve 25 installed on air supply pipe 5 is controlled, described plasma generator controller 7 is connected with described plasma generator, and described detection of gas flow rate unit 11 is connected with gas flow controller 12.

In the present embodiment, as in figure 2 it is shown, described plasma generator includes plasma gun 13, described shower nozzle is the anode nozzle 13-2 of plasma gun 13 front end；Described plasma gun 13 includes having the gun body 13-1 of described air inlet, being positioned at the anode nozzle 13-2 of gun body 13-1 dead ahead and be plugged in the negative electrode 13-3 of gun body 13-1, described anode nozzle 13-2 is positioned on front side of negative electrode 13-3, described arc chamber 13-4 is positioned on front side of negative electrode 13-3 and it is positioned at the posterior medial of anode nozzle 13-2, and the front inner of described anode nozzle 13-2 is spout 13-5.

Time actually used, described plasma gun 13 is arranged on Y-axis moving mechanism 24-2.

Time actually used, described horizontally moving device may also be only and drives described plasma generator to carry out the X-axis travel mechanism 24-1 moved horizontally in the X-axis direction.Now, described plasma gun 13 is arranged on X-axis travel mechanism 24-1.

In the present embodiment, described anode nozzle 13-2, negative electrode 13-3 and arc chamber 13-4 all lay in coaxial with gun body 13-1；Described powder flow paths 14 stretches in spout 13-5 with the inclined laying of gun body 13-1 and its front end, described powder flow paths 14 be straight channel and it include the back side walkway being laid in gun body 13-1 and the front side channel being laid in anode nozzle 13-2.

Further, described air inlet is positioned on rear side of gun body 13-1, and described spout 13-5 and gun body 13-1 lays in coaxial or lay in coaxial with powder flow paths 14.

In the present embodiment, between described anode nozzle 13-2 and gun body 13-1, it is provided with insulating barrier 13-6.

In the present embodiment, as in figure 2 it is shown, described spout 13-5 and gun body 13-1 lays in coaxial.

In the present embodiment, described air supply pipe 5 is connected with the air inlet opened on described plasma generator by air inlet ring 21.Further, uniformly supplied in described plasma generator by air inlet ring 21.

Such as Fig. 4, shown in Fig. 5, described air inlet ring 21 be annular and it include air inlet ring body 21-1 and lid be contained on air inlet ring body 21-1 annular sealing cover 21-2, described air inlet ring body 21-1 has an annular air inlet duct 21-3 on annular and its medial wall, described air inlet ring body 21-1 has an outside air inlet 21-4 connected with air supply pipe 5 and its inside have multiple inner side air inlet 21-5, multiple described inner side air inlet 21-5 along the circumferential direction uniformly lay and it is respectively positioned on inside annular air inlet duct 21-3, described outside air inlet 21-4 is positioned at outside annular air inlet duct 21-3, described outside air inlet 21-4 and multiple described inner side air inlet 21-5 all communicates with inside annular air inlet duct 21-3.

Further, described gun body 13-1 along the circumferential direction has multiple respectively with multiple described inner side air inlet 21-5 gun body air inlet communicated.

Time actually used, described powder flow paths 14 can also adopt same passage with the inlet channel of described working gas.

In the present embodiment, the meal outlet of described powder flow paths 14 is positioned on front side of arc chamber 13-4 and it is positioned at the inner back side of spout 13-5.

In plasma gun 13 use procedure as shown in Figure 2, producing plasma in described arc chamber 13-4, produced plasma forms beam-plasma and sprays through spout 13-5；Meanwhile, described powder is tilted towards entering spout 13-5 by powder flow paths 14, and described powder enters in described beam-plasma under the effect of described working gas, and accelerate in described beam-plasma, heat and be fused into molten condition and form small drop, this drop sprays in the lump with beam-plasma, forms the interior plasma beam with molten melt drop；After the molten melt drop that powder is formed after fusing sprays with beam-plasma, formed by the microstream of the molten melt drop being evenly distributed with printed material.Thus, described printed material is powder, to the shape of powder without particular/special requirement.

In the present embodiment, described working gas is noble gas or H₂Gas.

Wherein, noble gas is Ar gas, He gas and N₂Gas.

Time actually used, described horizontal support mechanism 16 is the mobile platform that fixed supporting construction maybe can move up and down.

When described horizontal support mechanism 16 is mobile platform, described monitoring system also includes the position adjustment controller that described mobile platform is controlled, and described position adjustment controller is connected with described mobile platform.Time actually used, described mobile platform can be three axis numerically controlled machine.Further, described position adjustment controller is the controller of three axis numerically controlled machine.Time actually used, described mobile platform can also adopt other can complete the device of X, Y and the motion of three directions of Z axis or can the vertically movable device that moves up and down of in the vertical direction.

In the present embodiment, described horizontal support mechanism 16 is the fixed fixed supporting construction in position.

In actually used process, the angle between central axis and the vertical plane of the beam-plasma that described plasma generator produces is not more than 45 °；Described printing distance adjusting means is adjusting apparatus 17 up and down described shower nozzle adjusted up and down along the central axis of described beam-plasma.When distance between outlet and the wheel shaft 3-1 of described shower nozzle is detected by described distance detection unit 8, the central axis along described beam-plasma is detected in real time from the distance exported between wheel shaft 3-1 of described shower nozzle.When distance between outlet and the horizontal support mechanism 16 of described shower nozzle is detected by described distance detection unit 8, the central axis along described beam-plasma is detected in real time from the distance exported between horizontal support mechanism 16 of described shower nozzle.Owing to the relative position of wheel shaft 3-1 Yu horizontal support mechanism 16 is constant, thus the distance between outlet and the wheel shaft 3-1 of the described shower nozzle that unit 8 detects is detected according to distance, and in conjunction with the position relationship of wheel shaft 3-1 Yu horizontal support mechanism 16, the distance between the outlet of described shower nozzle and horizontal support mechanism 16 can be immediately arrived at.

In the present embodiment, described upper and lower adjusting apparatus 17 is Z-direction adjusting apparatus, and wherein Z-direction is vertical direction.

Further, described upper and lower adjusting apparatus 17 is telescopic hydraulic cylinder.

In the present embodiment, the central axis of the beam-plasma that described plasma generator produces is in vertically to laying.Time actually used, can according to specific needs, the angle between central axis and the vertical plane of the beam-plasma that described plasma generator produces be adjusted accordingly.

In the present embodiment, described powder feeder 2 includes the shell that top has charging aperture and the powder feeding wheel being arranged in described shell, and described powder feeding wheel is driven by drive motor 19；Described powder feeding mouth is positioned at described outer casing underpart.

As shown in Figure 3, described monitoring system also includes the powder mass flow detection unit 18 that the powder feeding flow of powder feeding pipe 6 carries out detection in real time and the powder feeding flow controller 20 that drive motor 19 is controlled, and described powder mass flow detection unit 18 is connected with powder feeding flow controller 20.

In the present embodiment, described drive motor 19 is direct current generator.In actually used process, by changing the rotating speed of described direct current generator, the powder feeding flow of powder feeding pipe 6 is carried out simplicity, quickly adjusts.

In the present embodiment, described monitoring system also includes respectively to Y-axis moving mechanism 24-2 horizontal displacement in the Y-axis direction, carry out the first displacement detecting unit of detection, the second displacement detecting unit and triple motion detection unit in real time to X-axis travel mechanism 24-1 horizontal displacement in the X-axis direction with to the displacement in the Z-axis direction of upper and lower adjusting apparatus 17, described first displacement detecting unit and the second displacement detecting unit all with move horizontally controller 24 and be connected, described triple motion detection unit is connected apart from regulable control device 10 with printing.

In the present embodiment, described plasma generator controller 7, gas flow controller 12, Rotation Controllers 15, printing distance regulable control device 10, powder feeding flow controller 20 and move horizontally controller 24 and all connect with described data handling equipment, described data handling equipment is PC 23.Described feeder 1 is carried out on off control by PC 23.

In the present embodiment, described ultrasonic detection device and machining set-up 27 are all connected with described data handling equipment, described ultrasonic detection device is by its testing result synchronous driving to described data handling equipment, and described machining set-up 27 and ultrasonic detection device are controlled by described data handling equipment.Described three axle travel mechanisms are controlled by described data handling equipment and it is connected with data handling equipment.

In the present embodiment, described machining set-up 27 includes polishing utensil and removal tool, and described removal tool is drilling tool or cutting tool.

During actual installation, described polishing utensil and removal tool can be installed on a Multifunctional knife rack dish.

In the present embodiment, described horizontal rotary mechanism 4 includes two, the left and right rotary support seat 4-1 being all fixedly mounted in horizontal support mechanism 16 and drives the wheel shaft 3-1 rotary drive mechanism 4-2 rotated, and the two ends of described wheel shaft 3-1 are separately mounted on two described rotary support seat 4-1 and are attached each through bearing between its two ends and two described rotary support seat 4-1；Described rotary drive mechanism 4-2 is that electronic rotation driving mechanism and itself and wheel shaft 3-1 are in transmission connection, and described rotary drive mechanism 4-2 is controlled by Rotation Controllers 27 and it is connected with horizontal rotary mechanism 4.

Further, two described rotary support seat 4-1 are bearing block and both in vertically to laying, and described rotary drive mechanism 4-2 is arranged on a described rotary support seat 4-1 and one end of itself and wheel shaft 3-1 is in transmission connection.

Time actually used, the quantity of described rotary drive mechanism 4-2 can also be two, and two described rotary drive mechanism 4-2 are separately mounted on two described rotary support seat 4-1 and the two is in transmission connection with the two ends of wheel shaft 3-1 respectively.

A kind of train wheel plasma 3D as shown in Figure 6 prints reproducing method, comprises the following steps:

Described train wheel to be repaired is the train wheel that there is wheel wear defect and/or wheel planar defect；There is abrasion in the wheel rim 3-2 that described wheel wear defect is described train wheel to be repaired；Described planar defect of taking turns is wheel face local defect and/or wheel face wear-out defect, and described wheel face local defect is there is damaged or cracking on the wheel face of described train wheel to be repaired, and described wheel face wear-out defect is there is abrasion on the wheel face of described train wheel to be repaired；

Step 202, wheel wear defect repair: according to the train wheel defects detection result in step one, adopt described plasma beam system of processing, the eroded area of the wheel rim 3-2 of described train wheel to be repaired is repaired, and the wheel rim completing described train wheel to be repaired remanufactures process；Wherein, when the eroded area of wheel rim 3-2 is repaired, adopt described plasma beam system of processing that the eroded area of wheel rim 3-2 is carried out plasma 3D printing.

Step 2041, rejected region are removed: first pass through Rotation Controllers 15 and horizontal rotary mechanism 4 is controlled, and drive described train wheel to be repaired to rotate around the central axis of its wheel shaft 3-1, until current repaired wheel face local defect present position is rotated above the central axis of wheel shaft 3-1；Adopt described machining set-up 27 that region residing for repaired wheel face local defect current on described train wheel to be repaired is removed again, it is thus achieved that the to be filled region corresponding with current repaired wheel face local defect；

Step 206, wheel face wear-out defect are repaired: according to the train wheel defects detection result in step one, adopt described plasma beam system of processing, the eroded area of the wheel face of described train wheel to be repaired is repaired, and what complete described train wheel to be repaired remanufactures process.Wherein, when the eroded area of described wheel face is repaired, adopt described plasma beam system of processing that the eroded area of described wheel face is carried out plasma 3D printing.

In the present embodiment, the quantity of the train wheel described to be repaired that described wheel shaft 3-1 installs is two, two described train wheel to be repaired one igneous rock cracks of composition.Time actually used, the quantity that described wheel shaft 3-1 is installed train wheel to be repaired can also be one.

In the present embodiment, according to step one to the method described in step 2, two described train wheels to be repaired that described wheel shaft 3-1 installs are remanufactured respectively.

In the present embodiment, when step one carries out train wheel defects detection, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 to rotate around its center axis, and in wheel shaft 3-1 rotary course, the defect that described train wheel to be repaired exists is detected by ultrasonic detection device or three-dimensional laser scanner that employing horizontal rotary mechanism 4 is provided above.

Further, when step one carries out train wheel defects detection, only wheel shaft 3-1 need to be rotated a circle.When adopting ultrasonic detection device that the defect existed on described train wheel to be repaired is detected, ultrasonic detection method conventionally detects.

In the present embodiment, after step 2 completes train wheel reparation, it is thus achieved that train wheel after reparation；Afterwards, control horizontal rotary mechanism 4 by Rotation Controllers 15 and drive wheel shaft 3-1 to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up 27 that train wheel after described reparation is carried out polish.

After described reparation, the structure of train wheel is all identical with the structure of the train wheel finished product of train wheel to be repaired and size with size, and the train wheel finished product of described train wheel to be repaired is the train wheel being absent from any defect.Thus, adopt machining set-up 27 to when train wheel carries out polish after described reparation, specifically the size of train wheel after described reparation is carried out polish or the outer surface of train wheel after described reparation is polished, make its size can meet the dimensional requirement of train wheel finished product by the size of train wheel after described reparation is carried out polish, by the requirement making its surface roughness can meet train wheel finished product that the outer surface of train wheel after described reparation is polished, so that train wheel can directly apply on steel rolling production-line after described reparation.

In the present embodiment, adopt machining set-up 27 to, when train wheel carries out polish after described reparation, adopting machining set-up 27 only the outer surface of train wheel after described reparation to be polished so that it is surface roughness can meet the requirement of train wheel finished product.

In the present embodiment, when step one carries out train wheel defects detection, when detect there is wheel wear defect in described train wheel to be repaired time, the degree of wear also needing the wheel rim 3-2 to described train wheel to be repaired judges: when the degree of wear judging wheel rim 3-2 is part wears, and after adopting direct repairing method in step 202 or removing, repairing method carries out wheel wear defect repair again；When the degree of wear judging wheel rim 3-2 is all wear and tear, when carrying out wheel wear defect repair in step 202, process is as follows:

Step 202-1, three-dimensional stereo model obtain and hierarchy slicing processes: adopt data handling equipment and call the three-dimensional stereo model of image processing module acquisition wheel rim 3-2, recall the hierarchy slicing module three-dimensional stereo model to wheel rim 3-2 and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to wheel rim 3-2 carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 202-4, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 202-3, successively print wheel rim 3-2 from the inside to the outside, it is thus achieved that the wheel rim 3-2 stacking from the inside to the outside by multiple shape layers on wheel hub 3-4；The quantity of described shape layer is identical with the quantity being layered cross section described in step 202-1, the installation position of multiple described shape layers is all identical with the installation position one_to_one corresponding in multiple described layering cross sections and its thickness respectively, distance between the thickness of described shape layer with adjacent two described layering cross sections is identical, the printing path of the printing path in multiple described layering cross sections respectively multiple described shape layers in step 202-3；When wheel rim 3-2 is printed, process is as follows:

Step 202-401, bottom print: the printing path according to current institute printing shaping layer acquired in step 202-3, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 to rotate around its center axis, and in wheel shaft 3-1 rotary course, described in move horizontally controller 24 and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of wheel hub 3-4 by described plasma beam system of processing continuously；After wheel shaft 3-1 rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

Step 202-402, next layer print, and comprise the following steps:

Step 202-4021, plasma generator move: control described printing distance adjusting means by printing distance regulable control device 10, drive described plasma generator in the vertical direction once to move up and move up highly identical with the thickness of described shape layer；

Step 202-4022, printing and synchronization temperature control: the printing path according to current institute printing shaping layer acquired in step 202-3, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 to rotate around its center axis, and in wheel shaft 3-1 rotary course, described in move horizontally controller 24 and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of a current printed upper described shape layer by described plasma beam system of processing continuously；After wheel shaft 3-1 rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device 10 to the hull-skin temperature of a current printed upper described shape layer by temperature detecting unit 9, detect the distance between the unit 8 outlet and wheel shaft 3-1 to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device 10 that will detect；Described print temperature information that distance regulable control device 10 detects according to temperature detecting unit 9 and be adjusted by controlling the distance between described printing distance adjusting means outlet and wheel shaft 3-1 to described shower nozzle, making 0.6 times of the hull-skin temperature of the currently printed upper described shape layer material fusing point not higher than described printed material；

When plasma generator described in step 202-401 and step 202-4022 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft 3-1；In plasma generator moving process described in step 202-401 and step 202-4022, described printed material is delivered in described plasma generator by described powder feeder 2 continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；Further, described molten melt drop moves along the central axis of described beam-plasma under the effect of described working gas (beam-plasma includes unionized working gas)；Described printed material is dusty material；

Step 202-4023, plasma generator move reset: control described printing distance adjusting means by printing distance regulable control device 10, described plasma generator in the vertical direction is driven to move up and down, until being that in step 202-4021, the basis of current institute printing shaping layer prints height by the height adjustment of described plasma generator；

Step 202-403, repeatedly repetition step 202-402, until completing the print procedure of all shape layers of wheel rim 3-2；

Step 20211, three-dimensional stereo model obtain and hierarchy slicing processes: adopt described data handling equipment and call the three-dimensional stereo model of eroded area on described image processing module acquisition wheel rim 3-2, recall hierarchy slicing module and the three-dimensional stereo model of eroded area on wheel rim 3-2 is carried out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image that the three-dimensional stereo model of eroded area on wheel rim 3-2 obtains after carrying out hierarchy slicing multiple layering cross section, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 20214, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 20213, and the method described in step 202-4, successively print the eroded area on wheel rim 3-2 from the inside to the outside；

Step 20221, wheel rim are removed: control horizontal rotary mechanism 4 by Rotation Controllers 15 and drive wheel shaft 3-1 to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up 27 that the wheel rim 3-2 of described train wheel to be repaired is removed；

In this step, the wheel rim 3-2 of removal is the wheel rim 3-2 that there is abrasion on described train wheel to be repaired；

Step 20222, according to step 202-1 to the method described in step 202-4, on the wheel hub 3-4 of train wheel to be repaired described in step 20221 print wheel rim 3-2；

In this step, the wheel rim 3-2 of printing is the wheel rim 3-2 being absent from abrasion.

In the present embodiment, described wheel shaft 3-1 is cylindrical, and described wheel rim 3-2 is cylindrical shape, and in step 202-1, multiple described layering cross sections are the face of cylinder.

In the present embodiment, hierarchy slicing module described in step 202-1 is hierarchy slicing software.Described hierarchy slicing software is that 3D prints the conventional batch Slice Software adopted, such as Cura, Xbuilder, Makerbot etc..

In the present embodiment, step 202-401 and in plasma generator moving process described in step 202-4022, described plasma generator all moves left and right along the central axis of wheel shaft 3-1.And, in step 202-401 and step 202-4022, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 when its center axis rotates, described wheel shaft 3-1 is rotated for M time to rear point by elder generation, after being rotated in place each time, described wheel shaft 3-1 all stops the rotation, and moves horizontally controller 24 and described horizontally moving device is controlled and drives described plasma generator once to move to the left or to the right along the central axis of wheel shaft 3-1 described in afterwards.Wherein, the quantity of M and plasma generator described in the printing path of current institute printing shaping layer carry out identical with the total degree moved right to the left along the central axis of wheel shaft 3-1.

Thus, the quantity of M is determined according to the lap width between spray width (i.e. sweep length) two described plasma beams adjacent with front and back of the girth (namely printing overall width) of current institute printing shaping layer, described plasma beam.

When the plasma beam of melted for interior band liquid stream is sprayed onto on the outer surface of wheel hub 3-4 by plasma beam system of processing continuously described in step 202-401, the melted liquid stream of interior band synchronizes to flow on the outer surface of wheel hub 3-4.When the plasma beam of melted for interior band liquid stream is sprayed onto on the outer surface of a current printed upper described shape layer by plasma beam system of processing continuously described in step 202-4022, the melted liquid stream of interior band synchronizes to flow on the outer surface of a current printed upper described shape layer.

In the present embodiment, when step 202-1 obtains the three-dimensional stereo model of wheel rim 3-2, the three-dimensional stereo model according to the train wheel finished product (i.e. certified products) of described train wheel to be repaired, obtain the three-dimensional stereo model of wheel rim 3-2.

And, when step 20211 obtains the three-dimensional stereo model of eroded area on wheel rim, the three-dimensional stereo model of the train wheel finished product (i.e. certified products) of the three-dimensional stereo model according to described train wheel to be repaired and this train wheel to be repaired, obtains the three-dimensional stereo model of eroded area on wheel rim 3-2.

In the present embodiment, when step 20214 successively prints from the inside to the outside, process is as follows: the printing path according to the multiple described layering cross section obtained in step 20213, the eroded area of wheel rim 3-2 is successively printed by the wheel rim 3-2 of described train wheel to be repaired from the inside to the outside, it is thus achieved that repaired structure by the eroded area of the stacking from the inside to the outside wheel rim 3-2 of multiple shape layers；Shape layer described herein is the shape layer that described eroded area repairs in structure, the quantity of described shape layer is identical with the quantity being layered cross section described in step 20211, the installation position one_to_one corresponding in multiple described layering cross sections and its thickness are all identical with step 20211 respectively for the installation position of multiple described shape layers, distance between the thickness of described shape layer two described layering cross sections adjacent with step 20211 is identical, the printing path of the printing path in multiple described layering cross sections respectively multiple described shape layers in step 20213；When the eroded area of wheel rim 3-2 is printed, print to the method described in step 202-403 according to step 202-401.

In the present embodiment, when carrying out wheel wear defect repair in step 202, the printed material (namely powder feeder 2 sends into the printed material in described plasma generator) used by described plasma beam system of processing is the material used by wheel rim 3-2 of described train wheel to be repaired.

In the present embodiment, before step 202-4 successively prints from the inside to the outside, data handling equipment described in step 202-1 is first according to the material fusing point pre-build and printing range data storehouse, and combine the Material Name of described printed material pre-entered by parameter input unit, the basis of described printed material is printed distance and is determined；Described parameter input unit connects with described data handling equipment；

In described material fusing point and printing range data storehouse, storage has the material fusing point of various material and prints range information, and the material fusing point of every kind of described material and printing range information all include the title of this kind of material, fusing point and basis printing distance D；It is 5mm～1000mm that described basis prints distance D, and material fusing point is more high, and it is more near that basis prints distance D；

Step 202-401 carries out before bottom printing, distance between outlet and the wheel shaft 3-1 of described shower nozzle according to the range information detected apart from detection unit 8 and is adjusted to D+r by controlling described printing distance adjusting means by the described distance regulable control device 10 that prints, wherein r is the radius (being specially the radius at the installation position place of wheel rim 3-2 on wheel hub 3-4) of wheel hub 3-4, the distance between the outlet that distance is described shower nozzle and the central axis of wheel shaft 3-1 between outlet and the wheel shaft 3-1 of described shower nozzle；In step 202-401 in bottom print procedure, the distance between outlet and the wheel shaft 3-1 of described shower nozzle is D+r；

Before step 202-4022 carrying out print and synchronize temperature control, the described distance regulable control device 10 that prints according to the range information detected apart from detection unit 8 and combines the number of plies N currently having printed described shape layer, and by controlling described printing distance adjusting means, the distance between outlet and the wheel shaft 3-1 of described shower nozzle is adjusted to D+r+N × d, wherein d is the thickness of described shape layer；When distance between the outlet of described shower nozzle and wheel shaft 3-1 is adjusted by step 4022, described print temperature information that distance regulable control device 10 detects according to temperature detecting unit 9 and the distance that combines between range information that distance detection unit 8 detects outlet and the wheel shaft 3-1 to described shower nozzle is adjusted, make the hull-skin temperature of a current printed upper described shape layer control between 0.1 times～0.6 times of the material fusing point at described printed material；Further, when the distance between outlet and the wheel shaft 3-1 of described shower nozzle is adjusted, the amplitude of accommodation is 5mm～60mm, and material fusing point is more high, and the amplitude of accommodation is more little.

In the present embodiment, before step 202-4 successively prints from the inside to the outside, data handling equipment described in step 202-1 is first according to the gas pre-build and powder mass flow data base, and in conjunction with the thickness of described shape layer set in advance, the base gas flow of air supply pipe 5 and the powder feeding flow of powder feeding pipe 6 are determined；

Described gas and powder mass flow databases contain the powder feeding flow needed for the shape layer of multiple different thickness and base gas flow；Described base gas flow is 50ml/min～15000ml/min, and the powder feeding flow of powder feeding pipe 6 is more big, and described base gas flow is more big；

In plasma generator moving process described in step 202-401 and step 202-4022, the powder feeding flow of powder feeding pipe 6 is carried out detection in real time and detected synchronizing information is sent to powder feeding flow controller 20 by described powder mass flow detection unit 18, drive motor 19 is controlled by described powder feeding flow controller 20 according to powder feeding flow 18 detection information of combining powder flow detection unit of predetermined powder feeding pipe 6, and the powder feeding flow making powder feeding pipe 6 is all identical with predetermined powder feeding flow；

Carrying out in step 202-401 before bottom printing, the gas flow of air supply pipe 5 is adjusted to described base gas flow according to 11 detection information of detection of gas flow rate unit and by controlling flow control valve 25 by described gas flow controller 12；In step 202-401 in bottom print procedure, the gas flow of described air supply pipe 5 is described base gas flow；

Step 202-4022 carries out print and synchronize in temperature control process, described gas flow controller 12 is according to 11 detection information of detection of gas flow rate unit and combines distance detection 8 detecting distance information of unit, and by controlling flow control valve 25, the gas flow of air supply pipe 5 carries out increase and decrease adjustment；Further, the distance between outlet and the wheel shaft 3-1 of described shower nozzle is more big, and the gas flow of described air supply pipe 5 is more big.

In the present embodiment, when obtaining three-dimensional stereo model, utilize the three-dimensional graphics software such as pro/e, UG, CATIA to design three-dimensional stereo model (i.e. three-dimensional entity model), or utilize reverse engineering to solve three-dimensional stereo model；Again through described hierarchy slicing module, this three-dimensional stereo model is carried out hierarchy slicing, and obtain the outline data in each cross section, generated by outline data and fill scanning pattern, the corresponding printing path (i.e. the printing path in each layering cross section) obtaining described plasma beam system of processing.Thus, step 202-1 and the method adopted in step 202-2 are identical with the method that conventional laser selective melting molding or electron beam selective melting molding adopt.Afterwards, carrying out in the horizontal plane in X-direction motor process according to the printing path obtained, the interior plasma beam with molten melt drop is sprayed onto on wheel hub 3-4 or on the outer surface of a current printed upper described shape layer by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of a shape layer；Then, carrying out the printing of next shape layer, so successively printing, thus completing the print procedure of wheel rim 3-2.

Owing to horizontal support mechanism 16 can be three axis numerically controlled machine, thus plasma generator mobile route in the horizontal plane described in the printing path in each described layering cross section acquired in step 202-3 can also be the machining path of three axis numerically controlled machine 16, now described plasma beam system of processing is not moved in the horizontal plane, but be moved in the horizontal plane by horizontal support mechanism 16, thus complete the print procedure of each shape layer.

In the present embodiment, when step one carries out train wheel defects detection, when detect there is wheel face wear-out defect in described train wheel to be repaired time, the degree of wear also needing the wheel face surface layer 3-3 to described train wheel to be repaired judges: when the degree of wear judging wheel face surface layer 3-3 is part wears, and after adopting direct repairing method in step 206 or removing, repairing method carries out wheel face wear-out defect reparation again；When the degree of wear judging wheel face surface layer 3-3 is all wear and tear, when step 206 carries out the reparation of wheel face wear-out defect, according to step 202-1 to the method described in step 202-4, the wheel hub 3-4 of described train wheel to be repaired prints wheel face surface layer 3-3；

Step 20611, three-dimensional stereo model obtain and hierarchy slicing processes: adopt described data handling equipment and call the three-dimensional stereo model of eroded area on described image processing module acquisition wheel face surface layer 3-3, recall hierarchy slicing module and the three-dimensional stereo model of eroded area on wheel face surface layer 3-3 is carried out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image that the three-dimensional stereo model of eroded area on wheel face surface layer 3-3 obtains after carrying out hierarchy slicing multiple layering cross section, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 20614, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 20613, and the method described in step 202-4, successively print the eroded area on wheel face surface layer 3-3 from the inside to the outside；

Step 20621, wheel face surface layer are removed: control horizontal rotary mechanism 4 by Rotation Controllers 15 and drive wheel shaft 3-1 to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up 27 that the wheel face surface layer 3-3 of described train wheel to be repaired is removed；

In this step, the wheel face surface layer 3-3 of removal is the wheel face surface layer 3-3 that there is abrasion on described train wheel to be repaired；

Step 20622, according to step 202-1 to the method described in step 202-4, on the wheel hub 3-4 of train wheel to be repaired described in step 20621 print wheel face surface layer 3-3；

In this step, the wheel face surface layer 3-3 of printing is the wheel face surface layer 3-3 being absent from abrasion.

In actual mechanical process, when carrying out the reparation of wheel face wear-out defect in step 206, according to step 202-1 to the method described in step 202-4, when printing wheel face surface layer 3-3 on the wheel hub 3-4 of described train wheel to be repaired, process is as follows:

Step 2060-1, three-dimensional stereo model obtain and hierarchy slicing processes: adopt data handling equipment and call the three-dimensional stereo model of image processing module acquisition wheel face surface layer 3-3, recall the hierarchy slicing module three-dimensional stereo model to wheel face surface layer 3-3 and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to wheel face surface layer 3-3 carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 2060-2, scanning pattern are filled: adopt data handling equipment and call described image processing module, described layering cross-sectional images multiple in step 2060-1 are respectively processed, and complete the scanning pattern filling process in multiple described layering cross section, it is thus achieved that the scanning pattern in multiple described layering cross sections；

Step 2060-3, printing path obtain: the described data handling equipment scanning pattern according to the multiple described layering cross section obtained in step 2060-2, it is thus achieved that the printing path in multiple described layering cross sections；The printing path in each described layering cross section is all identical with the scanning pattern in this layering cross section；

Step 2060-4, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 2060-3, wheel face surface layer 3-3 is successively printed by wheel hub 3-4 from the inside to the outside, it is thus achieved that the wheel face surface layer 3-3 stacking from the inside to the outside by multiple shape layers；The quantity of described shape layer is identical with the quantity being layered cross section described in step 2060-1, the installation position of multiple described shape layers is all identical with the installation position one_to_one corresponding in multiple described layering cross sections and its thickness respectively, distance between the thickness of described shape layer with adjacent two described layering cross sections is identical, the printing path of the printing path in multiple described layering cross sections respectively multiple described shape layers in step 2060-3；When wheel face surface layer 3-3 is printed, process is as follows:

Step 2060-401, bottom print: the printing path according to current institute printing shaping layer acquired in step 2060-3, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 to rotate around its center axis, and in wheel shaft 3-1 rotary course, described in move horizontally controller 24 and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of wheel hub 3-4 by described plasma beam system of processing continuously；After wheel shaft 3-1 rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

Step 2060-402, next layer print, and comprise the following steps:

Step 2060-4021, plasma generator move: control described printing distance adjusting means by printing distance regulable control device 10, drive described plasma generator in the vertical direction once to move up and move up highly identical with the thickness of described shape layer；

Step 2060-4022, printing and synchronization temperature control: the printing path according to current institute printing shaping layer acquired in step 2060-3, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 to rotate around its center axis, and in wheel shaft 3-1 rotary course, described in move horizontally controller 24 and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of a current printed upper described shape layer by described plasma beam system of processing continuously；After wheel shaft 3-1 rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device 10 to the hull-skin temperature of a current printed upper described shape layer by temperature detecting unit 9, detect the distance between the unit 8 outlet and wheel shaft 3-1 to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device 10 that will detect；Described print temperature information that distance regulable control device 10 detects according to temperature detecting unit 9 and be adjusted by controlling the distance between described printing distance adjusting means outlet and wheel shaft 3-1 to described shower nozzle, making 0.6 times of the hull-skin temperature of the currently printed upper described shape layer material fusing point not higher than described printed material (i.e. wheel face surface layer 3-3 material therefor)；

When plasma generator described in step 2060-401 and step 2060-4022 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft 3-1；In plasma generator moving process described in step 2060-401 and step 2060-4022, described printed material is delivered in described plasma generator by described powder feeder 2 continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；Further, described molten melt drop moves along the central axis of described beam-plasma under the effect of described working gas (beam-plasma includes unionized working gas)；Described printed material is dusty material；

Step 2060-4023, plasma generator move reset: control described printing distance adjusting means by printing distance regulable control device 10, described plasma generator in the vertical direction is driven to move up and down, until being that in step 2060-4021, the basis of current institute printing shaping layer prints height by the height adjustment of described plasma generator；

Step 2060-403, repeatedly repetition step 2060-402, until completing the print procedure of the wheel face all shape layers of surface layer 3-3.

In the present embodiment, described wheel face surface layer 3-3 is cylindrical shape, and in step 2060-1, multiple described layering cross sections are the face of cylinder.

In the present embodiment, hierarchy slicing module described in step 2060-1 is hierarchy slicing software.Described hierarchy slicing software is that 3D prints the conventional batch Slice Software adopted, such as Cura, Xbuilder, Makerbot etc..

In the present embodiment, step 2060-401 and in plasma generator moving process described in step 2060-4022, described plasma generator all moves left and right along the central axis of wheel shaft 3-1.And, in step 2060-401 and step 2060-4022, controlling horizontal rotary mechanism 4 by Rotation Controllers 15 drives wheel shaft 3-1 when its center axis rotates, described wheel shaft 3-1 is rotated for m time to rear point by elder generation, after being rotated in place each time, described wheel shaft 3-1 all stops the rotation, and moves horizontally controller 24 and described horizontally moving device is controlled and drives described plasma generator once to move to the left or to the right along the central axis of wheel shaft 3-1 described in afterwards.Wherein, the quantity of m and plasma generator described in the printing path of current institute printing shaping layer carry out identical with the total degree moved right to the left along the central axis of wheel shaft 3-1.

When the plasma beam of melted for interior band liquid stream is sprayed onto on the outer surface of wheel hub 3-4 by plasma beam system of processing continuously described in step 2060-401, the melted liquid stream of interior band synchronizes to flow on the outer surface of wheel hub 3-4.When the plasma beam of melted for interior band liquid stream is sprayed onto on the outer surface of a current printed upper described shape layer by plasma beam system of processing continuously described in step 2060-4022, the melted liquid stream of interior band synchronizes to flow on the outer surface of a current printed upper described shape layer.

In the present embodiment, when step 2060-1 obtains the three-dimensional stereo model of wheel face surface layer 3-3, the three-dimensional stereo model according to the train wheel finished product (i.e. certified products) of described train wheel to be repaired, obtain the three-dimensional stereo model of wheel face surface layer 3-3.

And, when step 20611 obtains the three-dimensional stereo model of eroded area on wheel face surface layer 3-3, the three-dimensional stereo model of the train wheel finished product (i.e. certified products) of the three-dimensional stereo model according to described train wheel to be repaired and this train wheel to be repaired, obtains the three-dimensional stereo model of eroded area on wheel face surface layer 3-3.

In the present embodiment, when step 20614 successively prints from the inside to the outside, process is as follows: the printing path according to the multiple described layering cross section obtained in step 20613, the eroded area of wheel face surface layer 3-3 is successively printed by the wheel hub 3-4 of described train wheel to be repaired from the inside to the outside, it is thus achieved that repaired structure by the eroded area of the stacking from the inside to the outside wheel face surface layer 3-3 of multiple shape layers；Shape layer described herein is the shape layer that described eroded area repairs in structure, the quantity of described shape layer is identical with the quantity being layered cross section described in step 20611, the installation position one_to_one corresponding in multiple described layering cross sections and its thickness are all identical with step 20611 respectively for the installation position of multiple described shape layers, distance between the thickness of described shape layer two described layering cross sections adjacent with step 20611 is identical, the printing path of the printing path in multiple described layering cross sections respectively multiple described shape layers in step 20613；When the eroded area of wheel face surface layer 3-3 is printed, print to the method described in step 2060-403 according to step 2060-401.

In the present embodiment, when carrying out the reparation of wheel face wear-out defect in step 206, the printed material (namely powder feeder 2 sends into the printed material in described plasma generator) used by described plasma beam system of processing is the material used by wheel face surface layer 3-3 of described train wheel to be repaired.

In the present embodiment, before step 2060-4 successively prints from the inside to the outside, data handling equipment described in step 2060-1 is first according to the material fusing point pre-build and printing range data storehouse, and combine the Material Name of wheel face surface layer 3-3 pre-entered by parameter input unit, the basis of wheel face surface layer 3-3 is printed distance and is determined；Described parameter input unit connects with described data handling equipment；

Step 2060-401 carries out before bottom printing, distance between outlet and the wheel shaft 3-1 of described shower nozzle according to the range information detected apart from detection unit 8 and is adjusted to D+r by controlling described printing distance adjusting means by the described distance regulable control device 10 that prints, wherein r is the radius of wheel hub 3-4, the distance between the outlet that distance is described shower nozzle and the central axis of wheel shaft 3-1 between outlet and the wheel shaft 3-1 of described shower nozzle；In step 2060-401 in bottom print procedure, the distance between outlet and the wheel shaft 3-1 of described shower nozzle is D+r；

Before step 2060-4022 carrying out print and synchronize temperature control, the described distance regulable control device 10 that prints according to the range information detected apart from detection unit 8 and combines the number of plies n currently having printed described shape layer, and by controlling described printing distance adjusting means, the distance between outlet and the wheel shaft 3-1 of described shower nozzle is adjusted to D+r+n × d, wherein d is the thickness of described shape layer；When distance between the outlet of described shower nozzle and wheel shaft 3-1 is adjusted by step 4022, described print temperature information that distance regulable control device 10 detects according to temperature detecting unit 9 and the distance that combines between range information that distance detection unit 8 detects outlet and the wheel shaft 3-1 to described shower nozzle is adjusted, make the hull-skin temperature of a current printed upper described shape layer control between 0.1 times～0.6 times of the material fusing point at described printed material；Further, when the distance between outlet and the wheel shaft 3-1 of described shower nozzle is adjusted, the amplitude of accommodation is 5mm～60mm, and material fusing point is more high, and the amplitude of accommodation is more little.

In the present embodiment, before step 2060-4 successively prints from the inside to the outside, data handling equipment described in step 2060-1 is first according to the gas pre-build and powder mass flow data base, and in conjunction with the thickness of described shape layer set in advance, the base gas flow of air supply pipe 5 and the powder feeding flow of powder feeding pipe 6 are determined；

In plasma generator moving process described in step 2060-401 and step 2060-4022, the powder feeding flow of powder feeding pipe 6 is carried out detection in real time and detected synchronizing information is sent to powder feeding flow controller 20 by described powder mass flow detection unit 18, drive motor 19 is controlled by described powder feeding flow controller 20 according to powder feeding flow 18 detection information of combining powder flow detection unit of predetermined powder feeding pipe 6, and the powder feeding flow making powder feeding pipe 6 is all identical with predetermined powder feeding flow；

Carrying out in step 2060-401 before bottom printing, the gas flow of air supply pipe 5 is adjusted to described base gas flow according to 11 detection information of detection of gas flow rate unit and by controlling flow control valve 25 by described gas flow controller 12；In step 204-401 in bottom print procedure, the gas flow of described air supply pipe 5 is described base gas flow；

Step 2060-4022 carries out print and synchronize in temperature control process, described gas flow controller 12 is according to 11 detection information of detection of gas flow rate unit and combines distance detection 8 detecting distance information of unit, and by controlling flow control valve 25, the gas flow of air supply pipe 5 carries out increase and decrease adjustment；Further, the distance between outlet and the wheel shaft 3-1 of described shower nozzle is more big, and the gas flow of described air supply pipe 5 is more big.

In the present embodiment, when obtaining three-dimensional stereo model, utilize the three-dimensional graphics software such as pro/e, UG, CATIA to design three-dimensional stereo model (i.e. three-dimensional entity model), or utilize reverse engineering to solve three-dimensional stereo model；Again through described hierarchy slicing module, this three-dimensional stereo model is carried out hierarchy slicing, and obtain the outline data in each cross section, generated by outline data and fill scanning pattern, the corresponding printing path (i.e. the printing path in each layering cross section) obtaining described plasma beam system of processing.Thus, step 2060-1 and the method adopted in step 2060-2 are identical with the method that conventional laser selective melting molding or electron beam selective melting molding adopt.Afterwards, carrying out in the horizontal plane in X-direction motor process according to the printing path obtained, the interior plasma beam with molten melt drop is sprayed onto on wheel hub 3-4 or on the outer surface of a current printed upper described shape layer by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of a shape layer；Then, carrying out the printing of next shape layer, so successively printing, thus completing the print procedure of wheel face surface layer 3-3.

In the present embodiment, adopting described plasma beam system of processing in step 2022, when region to be filled described in step 2021 carries out plasma 3D printing, process is as follows:

Step D1, bottom print: described in move horizontally the controller 24 printing path according to current institute printing shaping layer acquired in step C, described horizontally moving device is controlled and drives described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto in described region to be filled by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer in described region to be filled；

Step D2, last layer print, and comprise the following steps:

Step D21, horizontal support mechanism move down: horizontal support mechanism 16 in the vertical direction is once moved down and moved down height identical with the thickness of described shape layer in described region to be filled；

Step D22, printing and synchronize temperature control: described in move horizontally the controller 24 printing path according to current institute printing shaping layer acquired in step C, described horizontally moving device is controlled and drives described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the upper surface of the current printed described shape layer of the next one by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device 10 to the upper surface temperature of the described shape layer of the next one current printed in described region to be filled by temperature detecting unit 9, detect the distance between the unit 8 outlet and horizontal support mechanism 16 to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device 10 that will detect；Described print temperature information that distance regulable control device 10 detects according to temperature detecting unit 9 and be adjusted by controlling the distance between described printing distance adjusting means outlet and horizontal support mechanism 16 to described shower nozzle, making 0.6 times of the upper surface temperature of the currently printed described shape layer of the next one material fusing point not higher than described printed material；

When plasma generator described in step D1 and step D22 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft 3-1；In plasma generator moving process described in step D1 and step D22, described printed material is delivered in described plasma generator by described powder feeder 2 continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；

In the present embodiment, before step D successively prints from the bottom to top, first the degree of depth in described region to be filled is judged, judge whether described sections bottom to be filled enters the wheel hub 3-4 of described train wheel to be repaired, when described sections bottom to be filled enters the wheel hub 3-4 of described train wheel to be repaired, in step D from the bottom to top successively in print procedure, when the region being positioned at described wheel hub 3-4 in described region to be filled is printed, the printed material (namely powder feeder 2 sends into the printed material in described plasma generator) used by described plasma beam system of processing material used by the wheel hub 3-4 of described train wheel to be repaired；When the region being positioned at described wheel face surface layer 3-3 in described region to be filled is printed, the material used by the wheel face surface layer 3-3 of described train wheel to be repaired of the printed material (namely powder feeder 2 sends into the printed material in described plasma generator) used by described plasma beam system of processing.Thus, the printed material used by described plasma beam system of processing need to be replaced.

Step D carry out from the bottom to top successively in print procedure, print at twice, wherein the region being positioned at wheel hub 3-4 in described region to be filled is printed by first time, and the region being positioned at wheel face surface layer 3-3 in described region to be filled is printed by second time.Further, when first time and second time print, all successively print from the bottom to top.

In the present embodiment, before step D successively prints from the bottom to top, data handling equipment described in step A is first according to the material fusing point pre-build and printing range data storehouse, and combine the Material Name of described printed material (material used by the wheel hub 3-4 or wheel face surface layer 3-3 of described train wheel to be repaired) pre-entered by parameter input unit, the basis of this printed material is printed distance and is determined；Described parameter input unit connects with described data handling equipment；

Carrying out in step D1 before bottom printing, the distance between outlet and the horizontal support mechanism 16 of described shower nozzle is adjusted to described basis printing distance apart from regulable control device 10 by controlling described printing distance adjusting means by described printing；In step D1 in bottom print procedure, the distance between outlet and the horizontal support mechanism 16 of described shower nozzle is that described basis prints distance；

Before carrying out in step D22 printing and synchronizing temperature control, the distance between the upper surface exporting the described shape layer of the next one current printed with described region to be filled of described shower nozzle is adjusted to described basis printing distance apart from regulable control device 10 by controlling described printing distance adjusting means by described printing；When distance between the outlet of described shower nozzle and horizontal support mechanism 16 is adjusted by step D22, also need by temperature-detecting device, the upper surface temperature of the current printed described shape layer of the next one to be detected in real time, the described distance printed between temperature information that distance regulable control device 10 detects according to described temperature-detecting device outlet and the horizontal support mechanism 16 to described shower nozzle is adjusted, the upper surface temperature making the described shape layer of the next one current printed in described region to be filled controls between 0.1 times～0.6 times of the material fusing point at described printed material；Further, when the distance between outlet and the horizontal support mechanism 16 of described shower nozzle is adjusted, the amplitude of accommodation is 5mm～60mm, and the material fusing point of described printed material is more high, and the amplitude of accommodation is more little.

In the present embodiment, before step D successively prints from the bottom to top, data handling equipment described in step A is first according to the gas pre-build and powder mass flow data base, and in conjunction with the thickness of shape layer described in described region to be filled set in advance, the base gas flow of air supply pipe 5 and the powder feeding flow of powder feeding pipe 6 are determined；

In plasma generator moving process described in step D1 and step D22, the powder feeding flow of powder feeding pipe 6 is carried out detection in real time and detected synchronizing information is sent to powder feeding flow controller 20 by described powder mass flow detection unit 18, drive motor 19 is controlled by described powder feeding flow controller 20 according to powder feeding flow 18 detection information of combining powder flow detection unit of predetermined powder feeding pipe 6, and the powder feeding flow making powder feeding pipe 6 is all identical with predetermined powder feeding flow；

Carrying out in step D1 before bottom printing, the gas flow of air supply pipe 5 is adjusted to described base gas flow according to 11 detection information of detection of gas flow rate unit and by controlling flow control valve 25 by described gas flow controller 12；In step D1 in bottom print procedure, the gas flow of described air supply pipe 5 is described base gas flow；

Step D22 carries out print and synchronize in temperature control process, described gas flow controller 12 is according to 11 detection information of detection of gas flow rate unit and combines distance detection 8 detecting distance information of unit, and by controlling flow control valve 25, the gas flow of air supply pipe 5 carries out increase and decrease adjustment；Further, the distance between outlet and the horizontal support mechanism 16 of described shower nozzle is more big, and the gas flow of described air supply pipe 5 is more big.

Embodiment 2

In the present embodiment, as it is shown in fig. 7, the train wheel plasma 3D adopted prints remanufactures equipment as different from Example 1: described spout 13-5 lays in coaxial with powder flow paths 14.

So, after the direction of described beam-plasma being changed by spout 13-5, can effectively reduce the plasma jet antianode nozzle 13-2 thermic load produced and impact, improve anode ablation situation.Simultaneously as spout 13-5 lays in coaxial with powder flow paths 14, thus without influence on the acceleration of powder, heating and fusion process, result of use is very good.

In the present embodiment, it is all identical with embodiment 1 that adopted train wheel plasma 3D printing remanufactures the remainder structure of equipment, annexation and operation principle.

In the present embodiment, it is identical with embodiment 1 that the train wheel plasma 3D adopted prints reproducing method.

The above; it it is only presently preferred embodiments of the present invention; not the present invention is imposed any restrictions, every any simple modification, change and equivalent structure change above example made according to the technology of the present invention essence, all still fall within the protection domain of technical solution of the present invention.

Claims

1. a train wheel plasma 3D prints and remanufactures equipment, it is characterised in that: the three axle travel mechanisms (28) and the horizontal stamp pad placed for train wheel to be repaired that are moved by monitoring system, plasma beam system of processing, the machining set-up (27) that train wheel to be repaired is machined out, drive machining set-up (27) form；Described horizontal stamp pad includes horizontal support mechanism (16) and is fixedly mounted on the horizontal rotary mechanism (4) that horizontal support mechanism (16) is upper and drives described train wheel to be repaired to rotate around the central axis of its wheel shaft (3-1), described horizontal rotary mechanism (4) is positioned at horizontal support mechanism (16) top, and described wheel shaft (3-1) is laid in level and it is installed on horizontal rotary mechanism (4)；Described machining set-up (27) is arranged in three axle travel mechanisms (28) and it is positioned at horizontal rotary mechanism (4) top；

Described plasma beam system of processing is by being provided with shower nozzle and for producing the plasma generator of beam-plasma, the print position adjusting apparatus that the position of described plasma generator is adjusted, providing the feeder (1) of working gas for described plasma generator and for form to the powder feeder (2) sending into printed material in described plasma generator continuously, and described plasma generator is positioned at above horizontal rotary mechanism (4)；Described feeder (1) is connected with the air inlet opened on described plasma generator by air supply pipe (5)；The powder flow paths (14) of described powder circulation it is provided in described plasma generator, described powder flow paths (14) communicates with arc chamber (13-4) inside in described plasma generator and it connects with described air inlet, the external port of described powder flow paths is powder inlet (22), and the powder feeding mouth of described powder feeder (2) is connected with powder inlet (22) by powder feeding pipe (6)；Horizontally moving device that described print position adjusting apparatus includes driving described plasma generator to move in the horizontal plane and drive described plasma generator and described horizontally moving device synchronizing moving and tackle the printing distance adjusting means that the distance between the outlet of described shower nozzle and wheel shaft (3-1) is adjusted mutually, described plasma generator is arranged on described horizontally moving device, and described horizontally moving device is arranged in described printing distance adjusting means；

What described monitoring system included described horizontally moving device is controlled moves horizontally controller (24), described plasma beam system of processing Working position place temperature on described train wheel to be repaired is carried out the temperature detecting unit (9) of detection in real time, distance between outlet and wheel shaft (3-1) or the horizontal support mechanism (16) of described shower nozzle is carried out distance detection unit (8) of detection in real time, printing distance regulable control device (10) that described printing distance adjusting means is controlled, the rotation angle detecting unit (26) that the anglec of rotation of the wheel shaft (3-1) of described train wheel to be repaired is carried out detection in real time and the Rotation Controllers (15) that horizontal rotary mechanism (4) is controlled, the described controller (24) that moves horizontally is connected with described horizontally moving device, described distance regulable control device (10) that prints is connected with described printing distance adjusting means, described distance detection unit (8) and temperature detecting unit (9) are all connected apart from regulable control device (10) with printing, described temperature detecting unit (9) forms temperature control device with printing distance regulable control device (10)；Described rotation angle detecting unit (26) is connected with Rotation Controllers (15).

2. a kind of train wheel plasma 3D described in claim 1 prints and remanufactures equipment, it is characterised in that: described train wheel to be repaired is the train wheel that there is wheel wear defect and/or wheel planar defect；There is abrasion in the wheel rim (3-2) that described wheel wear defect is described train wheel to be repaired；Described planar defect of taking turns is wheel face local defect and/or wheel face wear-out defect, and described wheel face local defect is there is damaged or cracking on the wheel face of described train wheel to be repaired, and described wheel face wear-out defect is there is abrasion on the wheel face of described train wheel to be repaired；The ultrasonic detection device being provided above the defect existed on described train wheel to be repaired is detected of described horizontal rotary mechanism (4) or three-dimensional laser scanner.

3. a kind of train wheel plasma 3D described in claim 1 or 2 prints and remanufactures equipment, it is characterized in that: described powder feeder (2) includes the shell that top has charging aperture and the powder feeding wheel being arranged in described shell, and described powder feeding wheel is driven by drive motor (19)；Described powder feeding mouth is positioned at described outer casing underpart；

Detection of gas flow rate unit (11) that plasma generator controller (7) that described monitoring system also includes described plasma generator is controlled, gas flow to air supply pipe (5) carry out detection in real time and the gas flow controller (12) that the upper flow control valve (25) installed of air supply pipe (5) is controlled, described plasma generator controller (7) is connected with described plasma generator, and described detection of gas flow rate unit (11) is connected with gas flow controller (12).

4. a kind of train wheel plasma 3D described in claim 1 or 2 prints and remanufactures equipment, it is characterized in that: described plasma generator includes plasma gun (13), described shower nozzle is the anode nozzle (13-2) of plasma gun (13) front end；Described plasma gun (13) includes having the gun body (13-1) of described air inlet, being positioned at the anode nozzle (13-2) of gun body (13-1) dead ahead and be plugged in the negative electrode (13-3) of gun body (13-1), described anode nozzle (13-2) is positioned at negative electrode (13-3) front side, described arc chamber (13-4) is positioned at negative electrode (13-3) front side and it is positioned at the posterior medial of anode nozzle (13-2), and the front inner of described anode nozzle (13-2) is spout (13-5)；

Angle between central axis and the vertical plane of the beam-plasma that described plasma generator produces is not more than 45 °；Described printing distance adjusting means is the adjusting apparatus up and down (17) described shower nozzle adjusted up and down along the central axis of described beam-plasma.

5. a kind of train wheel plasma 3D described in claim 1 or 2 prints and remanufactures equipment, it is characterized in that: described horizontal rotary mechanism (4) includes two rotary support seats (4-1) being all fixedly mounted in horizontal support mechanism (16) in left and right and the rotary drive mechanism (4-2) driving wheel shaft (3-1) to rotate, and the two ends of described wheel shaft (3-1) are separately mounted to two described rotary support seats (4-1) and above and are attached each through bearing between its two ends and two described rotary support seats (4-1)；Described rotary drive mechanism (4-2) is in transmission connection for electronic rotation driving mechanism and itself and wheel shaft (3-1), and described rotary drive mechanism (4-2) is controlled by Rotation Controllers (27) and it is connected with horizontal rotary mechanism (4)；

The mobile platform that described horizontal support mechanism (16) maybe can move up and down for fixed supporting construction.

6. one kind utilizes and remanufactures equipment as claimed in claim 1 and train wheel to be repaired carries out plasma 3D print the method that remanufactures, it is characterised in that: the method comprises the following steps:

Described train wheel to be repaired is the train wheel that there is wheel wear defect and/or wheel planar defect；There is abrasion in the wheel rim (3-2) that described wheel wear defect is described train wheel to be repaired；Described planar defect of taking turns is wheel face local defect and/or wheel face wear-out defect, and described wheel face local defect is there is damaged or cracking on the wheel face of described train wheel to be repaired, and described wheel face wear-out defect is there is abrasion on the wheel face of described train wheel to be repaired；

Step 202, wheel wear defect repair: according to the train wheel defects detection result in step one, adopt described plasma beam system of processing, the eroded area of the wheel rim (3-2) of described train wheel to be repaired is repaired, and the wheel rim completing described train wheel to be repaired remanufactures process；

Step 2041, rejected region are removed: first pass through Rotation Controllers (15) and horizontal rotary mechanism (4) is controlled, and drive described train wheel to be repaired to rotate around the central axis of its wheel shaft (3-1), until current repaired wheel face local defect present position is rotated above the central axis of wheel shaft (3-1)；Adopt described machining set-up (27) that region residing for repaired wheel face local defect current on described train wheel to be repaired is removed again, it is thus achieved that the to be filled region corresponding with current repaired wheel face local defect；

7. the plasma 3D that train wheel to be repaired is carried out described in claim 6 prints the method remanufactured, it is characterized in that: when step one carries out train wheel defects detection, controlling horizontal rotary mechanism (4) by Rotation Controllers (15) drives wheel shaft (3-1) to rotate around its center axis, and in wheel shaft (3-1) rotary course, the defect that described train wheel to be repaired exists is detected by ultrasonic detection device or three-dimensional laser scanner that employing horizontal rotary mechanism (4) is provided above；

After step 2 completes train wheel reparation, it is thus achieved that train wheel after reparation；Afterwards, controlling horizontal rotary mechanism (4) by Rotation Controllers (15) drives wheel shaft (3-1) to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up (27) that train wheel after described reparation is carried out polish.

8. the plasma 3D that train wheel to be repaired is carried out described in claim 6 or 7 prints the method remanufactured, it is characterized in that: step 2022 adopts described plasma beam system of processing, when region to be filled described in step 2021 carries out plasma 3D printing, process is as follows:

Step D1, bottom print: described in move horizontally the controller (24) printing path according to current institute printing shaping layer acquired in step C, described horizontally moving device is controlled and drives described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto in described region to be filled by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer in described region to be filled；

Step D2, last layer print, and comprise the following steps:

Step D21, horizontal support mechanism move down: horizontal support mechanism (16) in the vertical direction is once moved down and moved down height identical with the thickness of described shape layer in described region to be filled；

Step D22, printing and synchronize temperature control: described in move horizontally the controller (24) printing path according to current institute printing shaping layer acquired in step C, described horizontally moving device is controlled and drives described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the upper surface of the current printed described shape layer of the next one by described plasma beam system of processing continuously；After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device (10) to the upper surface temperature of the described shape layer of the next one current printed in described region to be filled by temperature detecting unit (9), detect the distance between the unit (8) outlet and horizontal support mechanism (16) to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device (10) that will detect；Described print temperature information that distance regulable control device (10) detects according to temperature detecting unit (9) and be adjusted by controlling the distance between described printing distance adjusting means outlet and horizontal support mechanism (16) to described shower nozzle, making 0.6 times of the upper surface temperature of the currently printed described shape layer of the next one material fusing point not higher than described printed material；

When plasma generator described in step D1 and step D22 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft (3-1)；In plasma generator moving process described in step D1 and step D22, described printed material is delivered in described plasma generator by described powder feeder (2) continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；

9. the plasma 3D that train wheel to be repaired is carried out described in claim 6 or 7 prints the method remanufactured, it is characterized in that: described train wheel to be repaired includes middle part and has axis hole and the wheel hub (3-4) being arranged on wheel shaft (3-1), described wheel rim (3-2) is laid in wheel hub (3-2) and it is positioned at wheel hub (3-2) inner side；

When step one carries out train wheel defects detection, when detect there is wheel wear defect in described train wheel to be repaired time, the degree of wear also needing the wheel rim (3-2) to described train wheel to be repaired judges: when the degree of wear judging wheel rim (3-2) is part wears, and after adopting direct repairing method in step 202 or removing, repairing method carries out wheel wear defect repair again；When the degree of wear judging wheel rim (3-2) is all wear and tear, when carrying out wheel wear defect repair in step 202, process is as follows:

Step 202-1, three-dimensional stereo model obtain and hierarchy slicing processes: adopt data handling equipment and call the three-dimensional stereo model of image processing module acquisition wheel rim (3-2), recall the hierarchy slicing module three-dimensional stereo model to wheel rim (3-2) and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to wheel rim (3-2) carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 202-4, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 202-3, wheel rim (3-2) is successively printed by wheel hub (3-4) from the inside to the outside, it is thus achieved that the wheel rim (3-2) stacking from the inside to the outside by multiple shape layers；The quantity of described shape layer is identical with the quantity being layered cross section described in step 202-1, the installation position of multiple described shape layers is all identical with the installation position one_to_one corresponding in multiple described layering cross sections and its thickness respectively, distance between the thickness of described shape layer with adjacent two described layering cross sections is identical, the printing path of the printing path in multiple described layering cross sections respectively multiple described shape layers in step 202-3；When wheel rim (3-2) is printed, process is as follows:

Step 202-401, bottom print: the printing path according to current institute printing shaping layer acquired in step 202-3, controlling horizontal rotary mechanism (4) by Rotation Controllers (15) drives wheel shaft (3-1) to rotate around its center axis, and in wheel shaft (3-1) rotary course, described in move horizontally controller (24) and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of wheel hub (3-4) by described plasma beam system of processing continuously；After wheel shaft (3-1) rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

Step 202-402, next layer print, and comprise the following steps:

Step 202-4021, plasma generator move: control described printing distance adjusting means by printing distance regulable control device (10), drive described plasma generator in the vertical direction once to move up and move up highly identical with the thickness of described shape layer；

Step 202-4022, printing and synchronization temperature control: the printing path according to current institute printing shaping layer acquired in step 202-3, controlling horizontal rotary mechanism (4) by Rotation Controllers (15) drives wheel shaft (3-1) to rotate around its center axis, and in wheel shaft (3-1) rotary course, described in move horizontally controller (24) and described horizontally moving device be controlled and drive described plasma generator to move in the horizontal plane；In described plasma generator moving process, the interior plasma beam with molten melt drop is sprayed onto on the outer surface of a current printed upper described shape layer by described plasma beam system of processing continuously；After wheel shaft (3-1) rotates a circle and described the sprayed molten melt drop of plasma beam system of processing all solidifies, complete the print procedure of current institute printing shaping layer；

In this step, in described plasma generator moving process, carry out detecting in real time and by detected temperature information synchronous driving to printing apart from regulable control device (10) to the hull-skin temperature of a current printed upper described shape layer by temperature detecting unit (9), detect the distance between the unit (8) outlet and wheel shaft (3-1) to described shower nozzle by distance simultaneously and carry out detection in real time the range information synchronous driving extremely printing distance regulable control device (10) that will detect；Described print temperature information that distance regulable control device (10) detects according to temperature detecting unit (9) and be adjusted by controlling the distance between described printing distance adjusting means outlet and wheel shaft (3-1) to described shower nozzle, making 0.6 times of the hull-skin temperature of the currently printed upper described shape layer material fusing point not higher than described printed material；

When plasma generator described in step 202-401 and step 202-4022 moves in the horizontal plane, described plasma generator all moves along the central axis of wheel shaft (3-1)；In plasma generator moving process described in step 202-401 and step 202-4022, described printed material is delivered in described plasma generator by described powder feeder (2) continuously, and the printed material sent in described plasma generator is sent in described plasma generator in the beam-plasma of generation and is molten into molten melt drop under the effect of described working gas, described molten melt drop is uniformly distributed in described beam-plasma, and forms the interior plasma beam with molten melt drop；Described printed material is dusty material；

Step 202-4023, plasma generator move reset: control described printing distance adjusting means by printing distance regulable control device (10), described plasma generator in the vertical direction is driven to move up and down, until being that in step 202-4021, the basis of current institute printing shaping layer prints height by the height adjustment of described plasma generator；

Step 202-403, repeatedly repetition step 202-402, until completing the print procedure of wheel rim (3-2) all shape layers；

Step 20211, three-dimensional stereo model obtain and hierarchy slicing processes: adopt described data handling equipment and call the three-dimensional stereo model of the upper eroded area of described image processing module acquisition wheel rim (3-2), recall the hierarchy slicing module three-dimensional stereo model to the upper eroded area of wheel rim (3-2) and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to the upper eroded area of wheel rim (3-2) carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 20214, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 20213, and the method described in step 202-4, successively print the eroded area on wheel rim (3-2) from the inside to the outside；

Step 20221, wheel rim are removed: control horizontal rotary mechanism (4) by Rotation Controllers (15) and drive wheel shaft (3-1) to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up (27) that the wheel rim (3-2) of described train wheel to be repaired is removed；

Step 20222, according to step 202-1 to the method described in step 202-4, the wheel hub (3-4) of train wheel to be repaired described in step 20221 prints wheel rim (3-2).

10. the plasma 3D that train wheel to be repaired is carried out described in claim 9 prints the method remanufactured, it is characterized in that: the outside of described wheel hub (3-4) is along the circumferential direction laid with one layer of wheel face surface layer (3-3), the outer surface that wheel face is wheel face surface layer (3-3) of described train wheel to be repaired；When step one carries out train wheel defects detection, when detect there is wheel face wear-out defect in described train wheel to be repaired time, the degree of wear also needing the wheel face surface layer (3-3) to described train wheel to be repaired judges: when the degree of wear judging wheel face surface layer (3-3) is part wears, and after adopting direct repairing method in step 206 or removing, repairing method carries out wheel face wear-out defect reparation again；When the degree of wear judging wheel face surface layer (3-3) is all wear and tear, when step 206 carries out the reparation of wheel face wear-out defect, according to step 202-1 to the method described in step 202-4, at the wheel hub (3-4) upper printing wheel face surface layer (3-3) of described train wheel to be repaired；

Step 20611, three-dimensional stereo model obtain and hierarchy slicing processes: adopt described data handling equipment and call the three-dimensional stereo model of the upper eroded area of described image processing module acquisition wheel face surface layer (3-3), recall the hierarchy slicing module three-dimensional stereo model to the upper eroded area of wheel face surface layer (3-3) and carry out hierarchy slicing, and obtain multiple layering cross-sectional image；

Multiple described layering cross-sectional images are the image obtaining multiple layering cross section after the three-dimensional stereo model to the upper eroded area of wheel face surface layer (3-3) carries out hierarchy slicing, and multiple described layering cross sections are uniformly laid from the inside to the outside；

Step 20614, from the inside to the outside successively printing: the printing path according to the multiple described layering cross section obtained in step 20613, and the method described in step 202-4, successively the eroded area on wheel face surface layer (3-3) is printed from the inside to the outside；

Step 20621, wheel face surface layer are removed: control horizontal rotary mechanism (4) by Rotation Controllers (15) and drive wheel shaft (3-1) to rotate around its center axis, and in described train wheel rotary course to be repaired, adopt machining set-up (27) that the wheel face surface layer (3-3) of described train wheel to be repaired is removed；

Step 20622, according to step 202-1 to the method described in step 202-4, the wheel hub (3-4) of train wheel to be repaired described in step 20621 is upper prints wheel face surface layer (3-3).