CN107876261B - Flexible processing platform for thermal barrier coating of concatemer turbine guide blade and spraying method - Google Patents
Flexible processing platform for thermal barrier coating of concatemer turbine guide blade and spraying method Download PDFInfo
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- CN107876261B CN107876261B CN201710948446.0A CN201710948446A CN107876261B CN 107876261 B CN107876261 B CN 107876261B CN 201710948446 A CN201710948446 A CN 201710948446A CN 107876261 B CN107876261 B CN 107876261B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
- B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
- B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
- B05B13/0431—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with spray heads moved by robots or articulated arms, e.g. for applying liquid or other fluent material to 3D-surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
- B05B12/084—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to condition of liquid or other fluent material already sprayed on the target, e.g. coating thickness, weight or pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
- B05B12/10—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to temperature or viscosity of liquid or other fluent material discharged
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
- B05B12/12—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to conditions of ambient medium or target, e.g. humidity, temperature position or movement of the target relative to the spray apparatus
- B05B12/124—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to conditions of ambient medium or target, e.g. humidity, temperature position or movement of the target relative to the spray apparatus responsive to distance between spray apparatus and target
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
- B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
- B05B13/0221—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work characterised by the means for moving or conveying the objects or other work, e.g. conveyor belts
Abstract
A flexible processing platform for thermal barrier coatings of a concatemer turbine guide vane and a spraying method are provided, the platform comprises a spraying sound insulation room, a plasma spraying/supersonic flame spraying device, two manipulators, a workpiece conveying device and a spray gun, the manipulators comprise a base, arms and a controller, the arms are mounted on the base and connected with the controller, the spray gun is connected with one of the arms of the manipulators through a quick dismounting clamping device, the other manipulator is provided with a grabbing device, the two manipulators have a linkage function, the plasma spraying/supersonic flame spraying device is connected with the spray gun, the plasma spraying/supersonic flame spraying device, the workpiece conveying device and the grabbing device are respectively connected with the controller so as to feed powder for spraying, spray emergency stop, spray coating, And the integrated control of automatic grabbing and workpiece conveying is realized. The invention also discloses a spraying method of the platform.
Description
Technical Field
The invention relates to the technical field of special processing, in particular to a flexible processing platform for a thermal barrier coating of a guide blade of a multi-connected turbine and a spraying method.
Background
Thermal Barrier Coating (TBC) is widely used on the surface of hot end components of gas turbine engines, has good Thermal insulation, high temperature oxidation resistance and corrosion resistance, can significantly improve the service temperature and service life of the hot end components, and is one of the key technologies for manufacturing the essential turbine blades of modern gas turbine engines (gas turbines, aircraft engines and the like). Thermal spraying thermal barrier coating technology is applied to the surfaces of turbine blades in batches from the last 80 years, so far most of High-pressure turbine guide blades and low-pressure turbine guide blades of gas turbine engines are still prepared by adopting thermal spraying technology, wherein the most commonly used technology is to respectively prepare MCrAlY metal bonding layers and 8YSZ (6-8% Y) on the surfaces of the blades by using High velocity oxygen fuel spraying (HVOF) and Atmospheric Plasma Spraying (APS)2O3Partially stabilized ZrO2) And a ceramic functional layer.
The high-pressure turbine guide blade and the low-pressure turbine guide blade are basically sprayed in a duplex or a concatemer mode, most of the multi-connected guide blades have shielding problems due to the fact that blade bodies are small in size and complex in profile (blade body curvature changes are large), hundreds of cooling air film holes exist in the blade bodies of part of the guide blades, and throat among all the multi-connected guide blades is narrow, and the difficulty is high when high-performance coatings with stable coating thickness, binding force and quality at different positions of the blades are obtained. From the angle of the thermal spraying process, the closer the angle is to 90 degrees in the spraying process, and the more the spraying distance is controlled, the uniform and proper swing speed is controlled, so that the coating with high quality and high uniformity can be obtained. At present, the manual spraying mode is adopted at home, the quality consistency and stability of the blade coating are difficult to guarantee, even if the spraying mode of combining a manipulator clamping spray gun with a rotary turntable angle adjustment is improved, the quality consistency of the coating is further improved, and the following limitations still exist: 1) the platform precision is insufficient, the mutual positions of two independent individuals (a mechanical arm and a rotary table) are not fixed, and a three-dimensional processing model cannot be formed and quick off-line programming cannot be realized; 2) the spray gun clamping manipulator has higher degree of freedom, but the workpiece clamping rotary table generally only has a rotating function, so that relative degree of freedom of a part of areas difficult to spray is insufficient, and the optimal spraying angle, distance and track can not be controlled; 3) the original precision of a turntable or a manipulator mounting surface and the like and the repeated positioning precision of long-time use are insufficient, so that the consistency of the coating quality is difficult to achieve a higher control level; 4) when the multi-connected turbine guide blade with one specification is replaced, programming and system verification need to be carried out again, the spraying track and the spraying program are produced in a manual teaching mode, the spraying path is planned by approximating a curved surface to a plane, and the spraying path is low in precision, low in production efficiency and poor in effect.
Therefore, the flexible processing and high-quality processing of the thermal barrier coating of the multi-connected turbine guide blade are realized, the defects of the technology are overcome, a flexible high-precision manipulator spraying platform is developed, and a corresponding spraying method is established.
Disclosure of Invention
The invention aims to solve the technical problem of providing a high-precision flexible processing platform and a spraying method for thermal barrier coatings of a multi-connected turbine guide blade so as to realize flexible spraying of thermal barrier coatings on the surfaces of different workpieces; preparing a high-quality coating of the concatemer turbine guide blade; platform-based rapid automated programming and spray coating methods. The spraying quality and quality consistency can be ensured, the spraying efficiency can be ensured, and the flexible spraying processing of the concatemer turbine guide blade can be realized.
In order to achieve the above object, the present invention provides a flexible processing platform for thermal barrier coatings of a multi-connected turbine guide blade, wherein the flexible processing platform comprises: a spraying sound insulation room, a plasma spraying/supersonic flame spraying device, two manipulators, a workpiece conveying device and a spray gun, wherein each manipulator comprises a manipulator base, a manipulator arm and a manipulator controller, the mechanical arms are arranged on the mechanical arm base and connected with the mechanical arm controller, the spray gun is connected with one mechanical arm of the mechanical arm through a quick disassembling and clamping device, the other mechanical arm of the mechanical arm is provided with a gripping device, the two mechanical arms have a linkage function, the plasma spraying/supersonic flame spraying device is connected with the spray gun, and the plasma spraying/supersonic flame spraying device, the workpiece conveying device and the grabbing device are respectively connected with the manipulator controller so as to realize integrated control of powder feeding during spraying, emergency stop during spraying, automatic grabbing and workpiece conveying.
The flexible processing platform for the thermal barrier coating of the concatemer turbine guide blade is further provided with an offline programming simulation module, and the plasma spraying/supersonic flame spraying device, the workpiece conveying device and the gripping device are controlled by PLC controllers.
The flexible processing platform for the thermal barrier coating of the concatemer turbine guide blade further comprises a dust removal device, and the dust removal device is installed on the wall surface of the spraying soundproof room.
The mechanical arm has six degrees of freedom, the load capacity of the mechanical arm is greater than or equal to 16Kg, the repeated positioning precision of the mechanical arm is smaller than or equal to +/-0.1 mm, the mechanical arm base has six-degree-of-freedom adjustment and horizontal-direction movement adjustment functions, and the repeated positioning precision of the mechanical arm base is +/-0.1 mm.
The flexible processing platform for the thermal barrier coating of the concatemer turbine guide blade is characterized in that the workpiece conveying device is provided with six stations, a positioning block is arranged on a blade tool of the workpiece conveying device, the positioning precision of the positioning block is +/-0.2 mm, and the workpiece conveying device is provided with an automatically opened dust cover.
The flexible processing platform for the thermal barrier coating of the concatemer turbine guide vane comprises a spraying sound insulation room, a workpiece conveying device, a plasma spraying/supersonic flame spraying device and a manipulator controller, wherein the spraying sound insulation room comprises an operation room and a processing room which are arranged separately, the workpiece conveying device, the plasma spraying/supersonic flame spraying device and the manipulator controller are arranged in the operation room, a manipulator base and a manipulator arm are arranged in the processing room, the concatemer vane to be processed is clamped and taken out in the operation room, and the manipulator arm meets continuous spraying in the processing room in an automatic grabbing mode.
According to the flexible processing platform for the thermal barrier coating of the concatemer turbine guide blade, the repeated positioning precision of the front end surface of the spray gun and any point on the concatemer blade to be processed on the spatial position is +/-1 mm, and the repeated positioning precision of the posture is +/-1 degree.
In order to better achieve the aim, the invention also provides a spraying method of the thermal barrier coating flexible processing platform of the concatemer turbine guide blade, wherein the spraying method comprises the following steps:
s100, inputting a multi-connected turbine guide blade to be machined and a protection tool three-dimensional model thereof by combining a flexible machining platform three-dimensional model;
s200, determining constraint rules of different spraying areas, relative starting angles of a spray gun and a workpiece, spraying angles, spraying distances, starting/ending points, stepping, swing speeds of the spray gun at different tracks, a workpiece rotating direction and a spray gun walking direction according to a programming rule of a concatemer turbine guide blade and a spraying track optimization confirmation principle;
s300, setting a spraying track and a spraying program according to the constraint rule;
s400, preparing a coating on the to-be-processed multi-connected turbine guide blade by using the flexible processing platform of the multi-connected turbine guide blade thermal barrier coating and the spraying program.
The spraying method of the thermal barrier coating flexible processing platform of the concatemer turbine guide blade further comprises the following steps after the step S300:
and S350, checking the actual part, checking the spraying program according to spraying temperature control, area thickness control and transition continuous control, and determining and optimizing the segmentation, the spraying pass number and the transition area walking track of the spraying program.
The spraying method of the thermal barrier coating flexible processing platform for the concatemer turbine guide blade comprises the following steps of:
① spraying the blade body of the concatemer turbine guide blade and then spraying the edge plate of the concatemer turbine guide blade, wherein the blade body spraying sequence is determined according to the characteristics of the concatemer turbine guide blade;
② according to the optimization result, in the non-shielding area, the supersonic flame spray gun swing speed is 400 mm-500 mm/s, the plasma spray gun swing speed is 300mm/s, the step is 5mm of supersonic flame spraying metal bonding layer, the plasma spraying ceramic surface layer is 3mm, when the spray gun enters the spraying surface and the spraying surface track moves from the starting point, the spray gun swing speed is 500mm/s, the blade duplex throat area, the blade and the spray gun follow up, the parallel position of the spray gun and the upper and lower edge plates close to the center of the lower edge plate and just opposite to the rotating shaft is set as the starting spraying position, the concatemer turbine guide blade is set to uniformly swing around the tool shaft of the workpiece conveying device by +/-15 degrees, the spray gun and the concatemer turbine guide blade follow up spraying, the relative speed is 400mm/s, the step is 4mm of supersonic flame spraying metal bonding layer from the starting position of the lower edge plate of the concatemer turbine guide blade to the upper edge plate close to the concatemer turbine guide blade, and the plasma spraying ceramic layer is 2 mm;
③ when spraying different areas of the multi-body turbine guide vane, the spraying distance when spraying the metal bonding layer with oxygen-kerosene supersonic flame is set to 300-330 mm, the spraying distance when spraying the metal bonding layer with oxygen-gas supersonic flame is set to 180-220 mm, the spraying distance when spraying the surface layer with plasma is set to 75-95 mm, and the set angle is 90 degrees;
④ the blade body of the concatemer turbine guide blade is 5mm away from the two side edge plates to be used as the starting position and the ending position of a single spraying track;
⑤ setting start/end positions for different spraying areas of the concatemer turbine guide blade, wherein the distance between the start/end positions and the tool of the concatemer turbine guide blade is more than 3cm, and the direction of the spray gun is set to be parallel to the edge plate of the concatemer turbine guide blade;
⑥, setting different spraying areas of the concatemer turbine guide blade to be adjusted to rotate depending on the rotating axis of the workpiece conveying device, wherein the spray gun and the blade in the throat area between the concatemer turbine guide blade links with each other, and adjusting the follow-up depending on the posture of the spray gun and the posture of the rotating axis around a tool;
⑦ setting the required thickness according to the accumulated spraying distance, angle, swinging speed of the spray gun and the influence data of the spraying times on the thickness of the coating layer, so as to obtain initial values of the spraying times in different initial areas.
The spraying method of the thermal barrier coating flexible processing platform of the concatemer turbine guide blade comprises the following steps of:
a) ensuring that the temperature of a spraying surface does not exceed 200 ℃ during supersonic flame spraying, and the temperature does not exceed 300 ℃ during plasma spraying, and the preparation of a special structure coating does not exceed 700 ℃; if the temperature exceeds the temperature, the spraying track of a single spraying area is divided according to the temperature monitoring condition, the spraying process returns to the initial/final value point, the retention time is set, and the spraying process returns to the track division point again for initial spraying after the temperature of the workpiece is reduced;
b) the surface coating of the workpiece is continuous, uniform and free of steps, the thickness meets the requirement, the spraying track of the transition section of the region is used after being corrected, and the spraying pass of each region is checked to meet the spraying requirement of the multi-connected turbine guide blade.
The invention has the technical effects that:
compared with the prior art, the method has the advantages that the high-precision manipulator base is fully utilized while the two manipulators are cooperatively sprayed, the high repeated positioning precision is realized, the flexible processing platform three-dimensional visual model is established on the basis of the high repeated positioning precision, the function of offline programming simulation software is fully utilized, the tooling rotating and clamping rod is taken as the axis, the profile characteristics of the multi-connected turbine guide blade are taken as objects, the double-mechanical follow-up spraying track and program can be quickly and conveniently established under the determined programming rule and the spraying track optimization principle, the degree of freedom, the precision and the flexibility of the platform are improved, and the quick preparation of thermal barrier coatings on the surfaces of different workpieces can be realized. In addition, the invention fully utilizes the I/O interface of the manipulator, realizes the linkage of the workpiece conveying device, the automatic gripping device and the spraying device, realizes the construction of flexible processing platforms of different types of concatemer turbine guide blades, simultaneously realizes the continuous automatic spraying processing of the blades by taking groups as units, simultaneously reduces the accidental risk of the system through linkage control, and effectively protects the high-value blades. The invention has the advantages of low cost, compact arrangement, high flexibility, simple control mode and high safety, greatly improves the development and production efficiency, the spraying precision, the coating thickness uniformity and the quality consistency, and has better social and economic benefits.
The invention is described in detail below with reference to the drawings and specific examples, but the invention is not limited thereto.
Drawings
FIG. 1 is a schematic view of a platform for flexible processing of thermal barrier coatings of a guide vane of a multi-connected turbine according to an embodiment of the invention;
FIG. 2A is a schematic structural diagram of a workpiece conveying apparatus according to an embodiment of the present invention;
FIG. 2B is an external view of FIG. 2A;
FIG. 3 is a schematic view of a twin guide vane to be processed according to an embodiment of the present invention;
FIG. 4 is a schematic view of a dual guide vane and its center of rotation according to an embodiment of the present invention;
FIG. 5 is a schematic view of a first spray area of a two-piece turning vane in accordance with one embodiment of the present invention;
FIG. 6 is a schematic view of a second spray area of a two-piece turning vane in accordance with an embodiment of the present invention;
FIG. 7 is a schematic view of a third spray area of a dual guide vane in accordance with an embodiment of the present invention;
FIG. 8 is a schematic view of the attitude adjustment of the lance according to the variation of the blade curvature in accordance with one embodiment of the present invention.
Wherein the reference numerals
1 spraying sound insulation room
2 plasma spraying/supersonic flame spraying device
3 manipulator controller
4 workpiece conveying device
41 locating block
42 dust cover
43 tooling shaft
44 center position of tool mounting and clamping shaft
5 mechanical arm base
6 mechanical arm
7 spray gun
8. Gripping device
9. Dust removing device
10 concatemer blade to be processed
101 near the exhaust edge area, relatively straight area
102 near the inlet edge region, region with large curvature change and small curvature radius
103 double-body guide throat area
104 upper edge plate
105 lower edge plate
106 leaf basin noodle
Back of 107 leaves
108 double-body blade upper connection
109 double-body blade lower connection
110 air inlet side
111 exhaust edge
Detailed Description
The invention will be described in detail with reference to the following drawings, which are provided for illustration purposes and the like:
referring to fig. 1, fig. 1 is a schematic view of a platform for flexibly processing a thermal barrier coating of a multi-connected turbine guide blade according to an embodiment of the present invention. The invention relates to a flexible processing platform for a thermal barrier coating of a concatemer turbine guide blade, which comprises: spraying sound insulation room 1, plasma spraying supersonic speed flame spraying device 2, two manipulators, work piece conveyor 4 and spray gun 7, every manipulator includes manipulator base 5, robotic arm 6 and manipulator controller 3, robotic arm 6 installs on manipulator base 5 and with manipulator controller 3 is connected, spray gun 7 is connected through quick dismantlement clamping device and one of them robotic arm 6 of manipulator, another install grabbing device 8 on robotic arm 6 of manipulator, two the manipulator has the linkage function, plasma spraying supersonic speed flame spraying device 2 with spray gun 7 is connected, plasma spraying supersonic speed flame spraying device 2, work piece conveyor 4 and grabbing device 8 respectively with manipulator controller 3 is connected, so as to realize integrated control of spraying powder feeding, spraying emergency stop, automatic grabbing and workpiece conveying. The spraying sound insulation room 1 comprises an operation room and a processing room which are arranged in a separated mode, the workpiece conveying device 4, the plasma spraying/supersonic flame spraying device 2 and the manipulator controller 3 are arranged in the operation room, the manipulator base 5 and the mechanical arm 6 are arranged in the processing room, the concatemer blade 10 to be processed is clamped and taken out in the operation room, the mechanical arm 6 meets continuous spraying in the processing room in an automatic grabbing mode, and dust suction damage caused when people enter the processing room in the spraying process is avoided.
In this embodiment, an off-line programming simulation module is further provided, and the plasma spraying/supersonic flame spraying device 2, the workpiece conveying device 4 and the gripping device 8 are all controlled by a PLC controller. The spraying sound insulation room further comprises a dust removal device 9, and the dust removal device 9 is installed on the wall of the spraying sound insulation room 1.
In this embodiment, it is preferable that the robot arm 6 has six degrees of freedom, the load capacity of the robot arm 6 is greater than or equal to 16Kg, the repeated positioning accuracy of the robot arm 6 is less than or equal to ± 0.1mm, the robot base 5 has six-degree-of-freedom adjustment and horizontal-direction movement adjustment functions, has distance and angle sensors (three groups) for X, Y, Z three-direction relative spatial position data testing, is provided with a human-computer interface with an embedded algorithm, can implement position information and position alignment adjustment suggestions, and the repeated positioning accuracy of the robot base 5 itself is ± 0.1 mm.
Referring to fig. 2A and 2B, fig. 2A is a schematic structural diagram of a workpiece conveying device according to an embodiment of the invention, and fig. 2B is an external view of fig. 2A. This embodiment work piece conveyor 4 is provided with six stations, be provided with locating piece 41 on work piece conveyor 4's the blade frock, locating piece 41 one end and carousel contact and location, one end are used for robotic arm 6 to snatch the location automatically, the positioning accuracy of locating piece 41 is 0.2mm, work piece conveyor 4 is provided with automatic dust cover 42 of opening, avoids the pollution of spraying blade is treated to the dust between the spraying. The repeated positioning precision of the front end face of the spray gun 7 and any point on the multi-connected blade 10 to be processed on the spatial position is +/-1 mm, and the repeated positioning precision of the posture is +/-1 degree.
Referring to fig. 3 to 8, fig. 3 is a schematic view of a double-body guide vane to be processed according to an embodiment of the present invention, fig. 4 is a schematic view of a double-body guide vane and a rotation center thereof according to an embodiment of the present invention, fig. 5 is a schematic view of a first spraying region of the double-body guide vane according to an embodiment of the present invention, fig. 6 is a schematic view of a second spraying region of the double-body guide vane according to an embodiment of the present invention, fig. 7 is a schematic view of a third spraying region of the double-body guide vane according to an embodiment of the present invention, and fig. 8 is a schematic view of an attitude adjustment of a spray gun according to a change in a curvature of. In fig. 3, different regions of the plurality of machining positions of the concatemer blade 10 to be machined are illustrated as follows: a relatively flat area 101 near the discharge edge area, an area 102 with a large curvature change and a small radius of curvature near the inlet edge area, a double-body guide throat area 103, an upper edge plate 104, a lower edge plate 105, a vane basin 106, a vane back surface 107, a double-body vane upper link 108, a double-body vane lower link 109, an inlet edge 110 and a discharge edge 111.
The spraying method of the flexible processing platform for the thermal barrier coating of the concatemer turbine guide blade comprises the following specific operation steps of:
s100, inputting a multi-connected turbine guide blade to be machined and a protection tool three-dimensional model thereof by combining a flexible machining platform three-dimensional model;
s200, determining constraint rules of different spraying areas, relative starting angles of the spray gun 7 and the workpiece, spraying angles, spraying distances, starting/ending points, stepping, swing speeds of the spray gun 7 at different tracks, rotation directions of the workpiece and walking directions of the spray gun 7 according to a programming rule of the concatemer turbine guide vanes and a spraying track optimization confirmation principle;
step S300, setting a spraying track and a spraying program (including spraying tracks at different positions) according to the constraint rule;
and S400, preparing a coating on the to-be-processed concatemer turbine guide blade by using the concatemer turbine guide blade thermal barrier coating flexible processing platform and the spraying program.
The following steps may be further included after step S300:
and S350, checking the actual part, checking the spraying program according to the requirements of spraying temperature control, area thickness control, transition continuous control and the like required by the process, and determining the segmentation, the spraying pass number and the transition area walking track for optimizing the spraying program.
The programming rule and the spraying track optimization confirmation principle of the concatemer turbine guide vane comprise:
① spraying the blade body of the concatemer turbine guide blade and then spraying the edge plate of the concatemer turbine guide blade, wherein the blade body spraying sequence is determined according to the characteristics of the concatemer turbine guide blade;
② according to the optimization result, in the non-shielding area, the swing speed of the supersonic flame spray gun 7 is 400 mm-500 mm/s, the swing speed of the plasma spray gun 7 is 300mm/s, the steps are respectively supersonic flame spraying metal bonding layer 5mm, plasma spraying ceramic surface layer 3mm, when the spray gun 7 enters the spraying surface and the single track of the spraying surface from the starting point moves, the swing speed of the spray gun 7 is 500mm/s, the throat area 103 between the blade pair, the blade and the spray gun 7 follow up, the parallel position of the spray gun 7 and the upper and lower edge plates 104, 105 close to the lower edge 105 and just opposite to the rotating shaft center is set as the starting spraying position, the concatemer turbine guide blade is set to uniformly swing around the tooling shaft 43 of the workpiece conveying device 4 by +/-15 degrees, the spray gun 7 and the concatemer turbine guide blade follow up to spray, the relative speed is 400mm/s, from the starting position of the lower edge plate 105 of the concatemer turbine guide blade to the ending position of the upper edge plate 104 close to the concatemer turbine guide blade, the step is supersonic flame spraying metal bonding layer 4 mm;
③ when spraying different areas of the multi-body turbine guide vane, the spraying distance when spraying the metal bonding layer with oxygen-kerosene supersonic flame is set to 300-330 mm, the spraying distance when spraying the metal bonding layer with oxygen-gas supersonic flame is set to 180-220 mm, the spraying distance when spraying the surface layer with plasma is set to 75-95 mm, and the set angle is 90 degrees;
④ the blade body of the concatemer turbine guide blade is 5mm away from the two side edge plates to be used as the starting position and the ending position of a single spraying track;
⑤ setting start/end positions for different spraying areas of the concatemer turbine guide blade, wherein the distance between the start/end positions and the tool of the concatemer turbine guide blade is more than 3cm, and the direction of the spray gun 7 is set to be parallel to the edge plate of the concatemer turbine guide blade;
⑥, setting different spraying areas of the concatemer turbine guide blade to be adjusted to rotate by depending on the rotating axis of the workpiece conveying device 4, wherein the spray gun 7 and the blade of the throat area 103 between each pair of the concatemer turbine guide blade follow up, and the follow-up is adjusted by depending on the posture of the spray gun 7 and the posture of the rotating axis around a tool;
⑦ setting the required thickness according to the accumulated spraying distance and angle, the swinging speed of the spray gun 7 and the influence data of the spraying times on the thickness of the coating layer, so as to obtain initial values of the spraying times in different initial areas.
Wherein, after generating according to setting for the spraying orbit, the real part check-up step includes:
step a) ensuring that the temperature of a spraying surface does not exceed 200 ℃ during supersonic flame spraying, and the temperature does not exceed 300 ℃ during plasma spraying, and the preparation of a special structure coating does not exceed 700 ℃; if the temperature exceeds the temperature, the spraying track of a single spraying area is divided according to the temperature monitoring condition, the spraying process returns to the initial/final value point, the retention time is set, and the spraying process returns to the track division point again for initial spraying after the temperature of the workpiece is reduced;
and b) continuously and uniformly coating the surface of the workpiece in the step b) without steps, wherein the thickness meets the requirement, the coating track of the transition section of the region is corrected and then used, and the number of spraying passes of each region is checked to meet the spraying requirement of the guide vane of the multi-connected turbine.
The invention provides a programming rule and a spraying track optimization confirmation principle for preparing a thermal barrier coating on the surface of a multi-connected turbine guide blade according to a spraying process optimization result and an off-line simulation programming software function (taking a duplex blade illustrated in figures 3 and 4 as an example), wherein a dust removing device in a flexible processing platform is arranged on the wall surface of a spraying sound insulation room 1, a mechanical arm is connected with a mechanical arm controller 3, a spray gun 7 is connected with the spraying device, a controller of a grabbing device 8, a spraying device 2, a workpiece conveying device 4 and the mechanical arm controller 3 are connected, the spray gun 7 is connected with a mechanical arm 6 through a quick disassembling and clamping device, and the turbine guide blade with a tool protection is connected with the mechanical arm 6 through the grabbing device 8:
spraying a blade body firstly and then spraying a flange plate, wherein the spraying sequence of the blade body is a) visible blade basin surfaces 106 of an upper connection 108 and a lower connection 109 (see figure 5); b) the positions of the back surface 107 of the upper blade and the basin surface 106 (close to the exhaust edge 111) of the lower blade between the two (the visible area of the two from the direction of the air inlet edge 110) (see fig. 6); c) the relatively flat area 101 of the blade back of the upper link 108 and the lower link 109 (see fig. 7); the flange plate is sprayed to the junction with the blade body from the outer side;
according to the optimized process result, in the first spraying area and the third spraying area, the swing speed of the supersonic flame spray gun 7 is 400-500 mm/s, the swing speed of the plasma spray gun 7 is 300mm/s (a section shown in fig. 5), the first spraying area and the third spraying area respectively spray 5mm of the supersonic flame spraying metal bonding layer and 3mm of the plasma spraying ceramic surface layer, and the swing speed of the spray gun 7 is 500mm/s in the process from the section b and the starting/ending point of the first spraying area and the third spraying area to the spraying surface; in the second spraying area, the blades follow the spray gun 7, the parallel position of the spray gun 7 and the upper and lower edge plates, which is close to the center of the lower edge plate opposite to the rotating shaft, is set as the initial spraying position, the blades are set to uniformly swing around the tool shaft at an angle of 43 +/-15 degrees, the spray gun 7 and the blades perform follow-up spraying, the relative speed is 400mm/s, the metal bonding layer is sprayed by supersonic flame in a stepping mode from the initial position of the lower edge plate to the binding position close to the upper edge plate, and the ceramic layer is sprayed by plasma in a stepping mode by 4mm (see figure;
when spraying is carried out in different areas, the optimal spraying distance when the oxygen-kerosene supersonic flame is used for spraying the metal bonding layer is set to be 300-330 mm, the optimal spraying distance when the oxygen-fuel supersonic flame is used for spraying the metal bonding layer is set to be 180-220 mm, the optimal spraying distance when the surface layer is sprayed by plasma is set to be 75-95 mm, and the optimal spraying angle is set to be 90 degrees;
because the blade body and the edge plate have a larger included angle, the phenomenon that the blade body spraying and the edge plate spraying can spray the boundary position of the included angle to cause the coating at the boundary position to be too thick is avoided, and the positions of the blade body 5mm away from the edge plates on two sides are used as the starting position and the ending position of a single spraying track;
setting starting/ending positions of different spraying areas, such as a point 1 and a point 2 shown in fig. 5, aiming at the different spraying areas, wherein the position is more than 3cm away from the blade tool, and simultaneously setting the direction of a spray gun 7 at the position to be parallel to the edge plate; the speed of the spray gun 7 on the spraying surface is set to be 500mm/s when the spray gun 7 is removed from the spraying surface to the starting/ending position, and the speed is set to be slowly reduced to 0 when the spray gun leaves the spraying surface, so that the influence of the inertia of a manipulator on the precision of the system is avoided;
all the tracks with the curvature surfaces are set as shown in fig. 8, and under the set rules of distance, angle, speed and stepping when spraying in different areas, the movement track of the spray gun 7 on the blade profile is given by taking the center position 44 (the rotation change center position) of the tool clamping shaft as a rotation center point and the actual curvatures a, b, c and d of the blade;
setting the required thickness according to the accumulated spraying distance and angle, the swing speed of the spray gun 7 and the influence data of the spraying times on the thickness of the coating so as to obtain initial values of the spraying times in different initial areas;
after the set spraying track is generated, actual piece verification is carried out:
a) ensuring that the temperature of a spraying surface does not exceed 200 ℃ during supersonic flame spraying, and the temperature does not exceed 300 ℃ in general and the temperature does not exceed 700 ℃ during the preparation of a special structure coating during plasma spraying; if the temperature is exceeded according to the process target, the spraying track of the single spraying area is divided according to the temperature monitoring condition, the spraying process returns to the initial/final value point, the retention time is set, and the spraying process returns to the track division point again for initial spraying after the temperature of the workpiece is reduced;
b) the surface coating of the workpiece is continuous, uniform and free of steps, the thickness meets the requirement, the spraying track of the transition section of the region can be properly corrected and used in combination with the process requirement according to the actual part checking condition, and the spraying times of each region are properly checked to meet the blade spraying requirement.
When the multi-connected blades such as the triplet, the quadruplet and the like are sprayed, the processing is carried out according to the duplex spraying method of the embodiment, namely, the duplex blade has one throat area 103, and the triplet blade needs to be sprayed through two throat areas and then is finally sprayed.
When spraying the triplet guide vane, the spraying sequence is that the vane body is firstly sprayed and then the flange plate is sprayed, and the spraying sequence of the vane body is a) the triple visible vane basin surface; b) the back of the upper blade and the basin surface (close to the exhaust edge 111) of the lower blade between the two-blade connection (the visible area from the direction of the air inlet edge 110 between the two-blade connection, namely the throat area 103); c) the back of the upper and lower blade is relatively straight; the flange plate is sprayed to the junction with the blade body from the outer side; the control of the rest areas is basically consistent with that of the guide vane of the double-body, except that a throat area is added for spraying.
The invention relates to a flexible processing platform and a spraying method for a thermal barrier coating of a concatemer turbine guide blade, which relate to the technical field of special processing, wherein the platform is mainly used for flexible processing of the thermal barrier coating on the surface of the turbine guide blade of a gas turbine engine; the double manipulators respectively clamping the spray gun and the blade have a linkage function; the manipulator base has a six-degree-of-freedom adjusting function and a position and angle sensor between bases; the spraying device, the grabbing device and the workpiece conveying system realize linkage control based on an I/O interface of a manipulator controller. The flexible spraying processing method based on the platform comprises a programming rule, a spraying track optimization confirmation principle and operation steps. The platform and the method have the advantages of low cost, compact arrangement, high flexibility, simple control mode and high safety, and greatly improve the efficiency, the spraying precision, the coating thickness uniformity and the quality consistency
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it should be understood that various changes and modifications can be effected therein by one skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (10)
1. A spraying method of a thermal barrier coating flexible processing platform of a concatemer turbine guide blade is characterized by comprising the following steps:
s100, inputting a multi-connected turbine guide blade to be machined and a protection tool three-dimensional model thereof by combining a flexible machining platform three-dimensional model;
s200, determining constraint rules of different spraying areas, relative starting angles of a spray gun and a workpiece, spraying angles, spraying distances, starting/ending points, stepping, swing speeds of the spray gun at different tracks, a workpiece rotating direction and a spray gun walking direction according to a programming rule of a concatemer turbine guide blade and a spraying track optimization confirmation principle;
s300, setting a spraying track and a spraying program according to the constraint rule;
s400, preparing a coating on the to-be-processed multi-connected turbine guide blade by utilizing the flexible processing platform of the multi-connected turbine guide blade thermal barrier coating and the spraying program;
the programming rule and the spraying track optimization confirmation principle of the concatemer turbine guide vane comprise:
① spraying the blade body of the concatemer turbine guide blade and then spraying the edge plate of the concatemer turbine guide blade, wherein the blade body spraying sequence is determined according to the characteristics of the concatemer turbine guide blade;
② according to the optimization result, in the non-shielding area, the supersonic flame spray gun swing speed is 400 mm-500 mm/s, the plasma spray gun swing speed is 300mm/s, the step is 5mm of supersonic flame spraying metal bonding layer, the plasma spraying ceramic surface layer is 3mm, when the spray gun enters the spraying surface from the starting point and moves with the spraying surface track, the spray gun swing speed is 500mm/s, the blade duplex throat area, the blade and the spray gun follow up, the parallel position of the spray gun and the upper and lower edge plates close to the center of the lower edge plate just opposite to the rotating shaft is set as the starting spraying position, the concatemer turbine guide blade is set to uniformly swing around the tool shaft of the workpiece conveying device by +/-15 degrees, the spray gun and the concatemer turbine guide blade follow up spraying, the relative speed is 400mm/s, the step is 4mm of supersonic flame spraying metal bonding layer from the starting position of the lower edge plate of the concatemer turbine guide blade to the position close to the upper edge plate of the concatemer turbine guide blade, and the plasma spraying ceramic;
③ when spraying different areas of the multi-body turbine guide vane, the spraying distance when spraying the metal bonding layer with oxygen-kerosene supersonic flame is set to 300-330 mm, the spraying distance when spraying the metal bonding layer with oxygen-gas supersonic flame is set to 180-220 mm, the spraying distance when spraying the surface layer with plasma is set to 75-95 mm, and the set angle is 90 degrees;
④ the blade body of the concatemer turbine guide blade is 5mm away from the two side edge plates to be used as the starting position and the ending position of a single spraying track;
⑤ setting start/end positions for different spraying areas of the concatemer turbine guide blade, wherein the distance between the start/end positions and the tool of the concatemer turbine guide blade is more than 3cm, and the direction of the spray gun is set to be parallel to the edge plate of the concatemer turbine guide blade;
⑥, setting different spraying areas of the concatemer turbine guide blade to be adjusted to rotate depending on the rotating axis of the workpiece conveying device, wherein the spray gun and the blade in the throat area between the concatemer turbine guide blade links with each other, and adjusting the follow-up depending on the posture of the spray gun and the posture of the rotating axis around a tool;
⑦ setting the required thickness according to the accumulated spraying distance, angle, swinging speed of the spray gun and the influence data of the spraying times on the thickness of the coating layer, so as to obtain initial values of the spraying times in different initial areas.
2. The method for spraying the thermal barrier coating flexible processing platform of the concatemer turbine guide blade according to claim 1, further comprising the following steps after the step S300:
and S350, checking the actual part, checking the spraying program according to spraying temperature control, area thickness control and transition continuous control, and determining and optimizing the segmentation, the spraying pass number and the transition area walking track of the spraying program.
3. The spraying method of the thermal barrier coating flexible processing platform of the concatemer turbine guide blade according to claim 2, wherein after the generation of the set spraying track, the actual part verification step comprises:
a) ensuring that the temperature of a spraying surface does not exceed 200 ℃ during supersonic flame spraying and does not exceed 300 ℃ during plasma spraying; if the temperature exceeds each temperature under the corresponding condition, the spraying track of a single spraying area is divided according to the temperature monitoring condition, the spraying process returns to the initial/final value point, the retention time is set, and the spraying process returns to the track division point again for initial spraying after the temperature of the workpiece is reduced;
b) the surface coating of the workpiece is continuous, uniform and free of steps, the thickness meets the requirement, the spraying track of the transition section of the region is used after being corrected, and the spraying pass of each region is checked to meet the spraying requirement of the multi-connected turbine guide blade.
4. A flexible processing platform for thermal barrier coatings of a concatemer turbine guide blade is characterized in that flexible processing is carried out by adopting the spraying method of the flexible processing platform for thermal barrier coatings of the concatemer turbine guide blade as claimed in any one of the claims 1 to 3, and the flexible processing platform for thermal barrier coatings of the concatemer turbine guide blade comprises: a spraying sound insulation room, a plasma spraying/supersonic flame spraying device, two manipulators, a workpiece conveying device and a spray gun, wherein each manipulator comprises a manipulator base, a manipulator arm and a manipulator controller, the mechanical arms are arranged on the mechanical arm base and connected with the mechanical arm controller, the spray gun is connected with one mechanical arm of the mechanical arm through a quick disassembling and clamping device, the other mechanical arm of the mechanical arm is provided with a gripping device, the two mechanical arms have a linkage function, the plasma spraying/supersonic flame spraying device is connected with the spray gun, and the plasma spraying/supersonic flame spraying device, the workpiece conveying device and the grabbing device are respectively connected with the manipulator controller so as to realize integrated control of powder feeding during spraying, emergency stop during spraying, automatic grabbing and workpiece conveying.
5. The flexible processing platform for the thermal barrier coating of the guide vane of the concatemer turbine as claimed in claim 4, wherein an off-line programming simulation module is further provided, and the plasma spraying/supersonic flame spraying device, the workpiece conveying device and the gripping device are all controlled by a PLC controller.
6. The flexible processing platform for the thermal barrier coating of the guide vane of the multi-connected turbine as claimed in claim 4 or 5, further comprising a dust removing device, wherein the dust removing device is installed on the wall surface of the spraying soundproof room.
7. The flexible processing platform for the thermal barrier coating of the guide vane of the multi-connected turbine as claimed in claim 4 or 5, wherein the robot arm has six degrees of freedom, the load capacity of the robot arm is greater than or equal to 16Kg, the repeated positioning precision of the robot arm is less than or equal to ± 0.1mm, the robot base has six-degree-of-freedom adjustment and horizontal direction movement adjustment functions, and the repeated positioning precision of the robot base is ± 0.1 mm.
8. The flexible processing platform for the thermal barrier coating of the guide blade of the multi-connected turbine as claimed in claim 4 or 5, wherein the workpiece conveying device is provided with six stations, a positioning block is arranged on a blade tool of the workpiece conveying device, the positioning precision of the positioning block is +/-0.2 mm, and the workpiece conveying device is provided with an automatically-opened dust cover.
9. The flexible processing platform for the thermal barrier coating of the concatemer turbine guide vane as claimed in claim 4 or 5, wherein the spraying soundproof room comprises an operating room and a processing room which are separately arranged, the workpiece conveying device, the plasma spraying/supersonic flame spraying device and the manipulator controller are arranged in the operating room, the manipulator base and the manipulator arm are arranged in the processing room, the concatemer vane to be processed is clamped and taken out in the operating room, and the manipulator arm meets continuous spraying in the processing room in an automatic grabbing manner.
10. The flexible processing platform for the thermal barrier coating of the guide blade of the multi-body turbine as claimed in claim 4 or 5, wherein the repeated positioning precision of the front end face of the spray gun and any point on the multi-body blade to be processed on the spatial position is +/-1 mm, and the attitude repeated positioning precision is +/-1 °.
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| CN113600365B (en) * | 2021-06-30 | 2023-02-28 | 北京航星机器制造有限公司 | Equipment and method for protecting and cleaning surface of hollow titanium alloy wing rudder |
| CN114086107B (en) * | 2021-12-28 | 2023-07-14 | 河北复朗施纳米科技有限公司 | Nanometer antibacterial coating device |
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