CN110093601B - Method and device for laser cladding real-time thickness measurement and feedback - Google Patents
Method and device for laser cladding real-time thickness measurement and feedback Download PDFInfo
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- CN110093601B CN110093601B CN201910470166.2A CN201910470166A CN110093601B CN 110093601 B CN110093601 B CN 110093601B CN 201910470166 A CN201910470166 A CN 201910470166A CN 110093601 B CN110093601 B CN 110093601B
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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Abstract
The invention relates to the technical field of laser cladding, and particularly discloses a method and a device for laser cladding real-time thickness measurement and feedback. The method for laser cladding real-time thickness measurement and feedback is characterized by comprising the following steps: a laser displacement sensor is arranged near the laser processing head and is driven by the laser processing head, the measuring laser of the laser displacement sensor is vertical to the laser cladding layer of the workpiece, and the measuring point of the measuring laser is arranged on the same arc with the molten pool and close to the lap joint of the two laser cladding layers; the laser displacement sensor measures the height of the cladding layer, the measured value is fed back to the controller, the controller completes calculation, display and feedback of the numerical value, and then cladding parameters of the laser processing head are controlled, and the final size meets the requirements. According to the invention, laser processing parameters are adjusted through closed-loop control, the thickness of a cladding layer is accurately controlled, the manual measurement error is reduced, the powder waste is reduced, and the cladding efficiency and the qualified rate of processed finished products are effectively improved.
Description
(I) technical field
The invention relates to the technical field of laser cladding, in particular to a method and a device for laser cladding real-time thickness measurement and feedback.
(II) background of the invention
Laser Cladding (Laser Cladding), also known as Laser Cladding or Laser Cladding, is a new surface modification technique. The method is characterized in that a cladding layer which is metallurgically bonded with a base layer is formed on the surface of the base layer by adding a cladding material on the surface of the base layer and fusing the cladding material and a thin layer on the surface of the base layer by using a laser beam with high energy density. As a novel surface treatment technology, laser cladding is widely applied to the field of engineering machinery manufacturing and remanufacturing.
The application number of the application of the technology for measuring the thickness of the laser cladding layer is 201810766782.8, the patent name is 'a laser cladding closed-loop control method based on stereoscopic vision', and the application number is 201810766782.8, the method discloses that CCDs which are connected by a control system and move synchronously are respectively arranged on two opposite sides of a laser, the two CCDs are calibrated, a molten pool change image during laser cladding is obtained in real time through the two CCDs, then the control system is used for comparing with the shape of a preset standard molten pool forming layer, and the laser power or defocusing amount is adjusted according to errors, so that the size and the quality of the cladding layer are controlled.
The control technology has higher measurement accuracy, but laser cladding is a processing process influenced by multiple factors such as laser power, powder and matrix characteristics, and in an actual complex industrial production environment, a captured molten pool image is interfered by multiple factors and is easy to be shielded, the temperature around the molten pool is higher, more dust exists, and the requirements on long-time high-temperature stable operation of the CCD and lens cleaning are also higher; in addition, the CCD camera has high cost, increases the equipment cost, has complex calibration process and has certain limitation in large-scale industrial application.
At present, in the practical production of shaft laser cladding, manual measurement is mostly adopted, namely the outer diameter of a workpiece is clamped by calipers, and the size is measured on a ruler. In addition, the local cladding manual measurement difficulty of some large-scale workpieces is large, and the coating thickness can only be estimated by experience for some special-shaped surfaces or even can not be measured.
Disclosure of the invention
In order to make up for the defects of the prior art, the invention provides the method and the device for laser cladding real-time thickness measurement and feedback, which are simple and easy to implement, low in cost and high in measurement precision.
The invention is realized by the following technical scheme:
a method for laser cladding real-time thickness measurement and feedback is characterized in that: a laser displacement sensor is arranged near the laser processing head and is driven by the laser processing head, the measuring laser of the laser displacement sensor is vertical to the laser cladding layer of the workpiece, and the measuring point of the measuring laser is arranged on the same arc with the molten pool and close to the lap joint of the two laser cladding layers; the laser displacement sensor measures the height of the cladding layer, the measured value is fed back to the controller, the controller completes calculation, display and feedback of the numerical value, and then laser cladding parameters are controlled, so that the final size meets the requirements.
The invention is mainly applied to the measurement of the thickness of the coating in the laser cladding processing process and after the processing, is integrated with a machine tool, a powder feeder, a laser and the like, regulates and controls laser processing parameters in real time, ensures that the thickness of the coating meets the processing size requirement, improves the cladding efficiency and the qualification rate of processed finished products, and solves the problem that the thickness measurement is not accurate or can not be measured in the laser cladding processing process.
The more preferable technical scheme of the invention is as follows:
the laser measuring point of the laser displacement sensor is 2-10mm behind the molten pool, so that the precise control of the size of the laser cladding large-area coating is realized.
The controller collects measurement data through the control unit, calculates the thickness of the cladding layer through language algorithms such as Labview and the like, compares the actual thickness data with the preset thickness, feeds back a corresponding adjusting instruction to a powder feeder or a laser of the laser cladding equipment, and displays the thickness data of the cladding layer on the display.
The laser displacement sensor is a diffuse reflection type digital display laser displacement sensor; the laser displacement sensor has high measurement precision and high response speed, measures a cladding layer, can accurately reflect the thickness of the cladding layer, has less interference factors compared with means such as CCD (charge coupled device) and the like, and has more stable and efficient measurement.
The thickness calculation method of the control unit comprises the steps of determining the size of a preset cladding layer as a, calibrating c as a standard numerical value by using c as a standard numerical value on the premise that the reading of a laser displacement sensor is b when the laser displacement sensor is not clad, and satisfying the preset size, wherein the numerical value when the laser displacement sensor measures the cladding layer is displayed as d, the difference e between the actual cladding layer thickness and the preset thickness is = c-d, calculating the height difference e in real time through language algorithms such as Labview and the like, setting the allowable error range of the height difference e to be less than or equal to 0.3mm, and completing the display and feedback of the numerical value e by the control unit so as to control the cladding parameters.
The cladding parameters comprise the powder feeding amount of the powder feeder, the laser cladding speed and the laser power.
The device for realizing the method for measuring the thickness and feeding back in real time by laser cladding comprises a laser processing head of a laser cladding device and a workpiece corresponding to the laser processing head, wherein a laser displacement sensor which follows the laser processing head is arranged near the laser processing head, the laser displacement sensor is connected with a controller through a lead, and the controller is connected with the laser cladding device and a powder feeder of the laser cladding device; the laser of the laser displacement sensor is vertical to the cladding layer on the workpiece.
The controller includes a control unit and a display.
The real-time thickness measuring and feedback device forms a whole set of closed-loop system, ensures that the thickness of the cladding layer is consistent with the preset size, and avoids powder waste and secondary processing caused by insufficient machining allowance.
At present, no accurate on-line nondestructive measurement means exists for the thickness of the laser cladding coating, and the thickness of the cladding coating can be effectively controlled, the stability of parameters is ensured, and the product quality is further ensured.
The invention has low equipment cost, is suitable for industrial production, measures the height difference, has low requirements on the shape of the workpiece, and can be applied to the measurement of the sizes of cladding layers of various workpieces with different shapes and large manual measurement difficulty.
The whole device can be detached for use, in some temporary application occasions, the self-carried numerical value display of the sensor can be utilized, the height difference is calculated after the numerical value is read manually and is used as a reference for adjusting the processing parameters, and the device is suitable for field cladding, processing of differential products and the like.
According to the invention, laser processing parameters are adjusted through closed-loop control, the thickness of a cladding layer is accurately controlled, the manual measurement error is reduced, the powder waste is reduced, and the cladding efficiency and the qualified rate of processed finished products are effectively improved.
(IV) description of the drawings
The invention will be further described with reference to the accompanying drawings.
FIG. 1 is a schematic diagram of the apparatus of the present invention;
FIG. 2 is a schematic block diagram of the method of the present invention.
In the figure, 1 laser processing head, 2 laser displacement sensor, 3 workpiece, 4 laser cladding layer, 5 controller, 6 powder feeder, 7 control unit and 8 display.
(V) detailed description of the preferred embodiments
The present invention is further illustrated by the following specific examples.
As shown in the attached figure 1, the device comprises a laser displacement sensor 2 and a controller 5, wherein the laser displacement sensor 2 is arranged near a laser processing head 1 and follows the laser displacement sensor 2, the laser displacement sensor 2 measures the laser to be vertical to a laser cladding layer 4, and in order to ensure that the measuring position is the low point of the laser cladding layer 4, the measuring point is arranged on the same arc with a molten pool and close to the joint of the two laser cladding layers 4.
The laser displacement sensor 2 is a diffusion reflection type digital display laser displacement sensor, mainly has the function of measuring height, can radiate a laser line segment to an object based on the triangulation principle, receives diffuse reflection projection through a CMOS photosensitive element to obtain the heights of all points on the line segment, and feeds measured values back to the controller 5;
the controller 5 comprises a control unit 7 and a display 8.
The control unit 7 is used for collecting measurement data, the control unit 7 can be a PLC (programmable logic controller) or an embedded microprocessor and the like, the thickness of the cladding layer is calculated through algorithms such as Labview language and the like, the actual thickness data is compared with the preset thickness, and a corresponding adjusting instruction is fed back to the powder feeder 6 of the laser cladding equipment, so that the powder feeding amount is changed, and the thickness of the laser cladding layer 4 is further changed. The thickness of the laser cladding layer 4 can be changed by other processing parameters, such as feedback to a motion control unit, such as a machine tool or a robot, to increase or decrease the cladding speed.
The thickness calculation idea of the control unit 7: determining that the size of a preset laser cladding layer 4 is a, measuring the reading of a laser displacement sensor 2 when the laser cladding layer is not cladded to be b, on the premise that the preset size is met, the reading c = b-a of the laser displacement sensor 2, calibrating c as a standard numerical value, displaying the numerical value when the laser displacement sensor 2 measures the laser cladding layer 4 to be d, calculating the height difference e in real time through algorithms such as Labview language and the like, setting the allowable error range of the height difference e to be less than or equal to 0.3mm, and completing displaying and feeding back the numerical value e by a control unit 7 so as to control the cladding parameters such as powder feeding amount, cladding speed, laser power and the like, so that the final size meets the requirements.
The display 8 is used for displaying the thickness data of the laser cladding layer 4, so that the observation is convenient.
Claims (6)
1. A method for laser cladding real-time thickness measurement and feedback is characterized in that: a laser displacement sensor is arranged near the laser processing head and is driven by the laser processing head, the measuring laser of the laser displacement sensor is vertical to the laser cladding layer of the workpiece, and the measuring point of the measuring laser is arranged on the same arc with the molten pool and close to the lap joint of the two laser cladding layers; the laser displacement sensor measures the height of the cladding layer, the measured value is fed back to the controller, the controller completes the calculation, display and feedback of the numerical value, and then the laser cladding parameters are controlled, so that the final size meets the requirements;
the laser measuring point of the laser displacement sensor is 2-10mm behind the molten pool;
the controller collects measurement data through the control unit, calculates the thickness of the cladding layer through a Labview language algorithm, compares the actual thickness data with the preset thickness, feeds back a corresponding adjusting instruction to a powder feeder or a laser of the laser cladding equipment, and displays the thickness data of the cladding layer on the display.
2. The laser cladding real-time thickness measuring and feedback method of claim 1, wherein: the laser displacement sensor is a diffuse reflection type digital display laser displacement sensor.
3. The laser cladding real-time thickness measuring and feedback method of claim 1, wherein: the thickness calculation method of the control unit comprises the steps of determining the size of a preset cladding layer as a, calibrating c as a standard numerical value by using c as a standard numerical value on the premise that the reading of a laser displacement sensor is b when the laser displacement sensor is not clad, and satisfying the preset size, wherein the numerical value when the laser displacement sensor measures the cladding layer is displayed as d, the difference e between the actual cladding layer thickness and the preset thickness is = c-d, calculating the height difference e in real time through a Labview language algorithm, setting the allowable error range of the height difference e to be less than or equal to 0.3mm, and completing the display and feedback of the numerical value e by the control unit so as to control the cladding parameters.
4. The laser cladding real-time thickness measuring and feedback method of claim 1, wherein: the cladding parameters comprise the powder feeding amount of the powder feeder, the laser cladding speed and the laser power.
5. The device for realizing the laser cladding real-time thickness measuring and feedback method of claim 1 comprises a laser processing head (1) of a laser cladding device and a workpiece (3) corresponding to the laser processing head, and is characterized in that: a laser displacement sensor (2) which follows the laser processing head (1) is arranged near the laser processing head (1), the laser displacement sensor (2) is connected with a controller (5) through a lead, and the controller (5) is connected with a laser cladding device and a powder feeder (6) of the laser cladding device; the laser of the laser displacement sensor (2) is vertical to the laser cladding layer (4) on the workpiece (3).
6. The apparatus of claim 5, wherein: the controller (5) comprises a control unit (7) and a display (8).
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| WO2021036630A1 (en) | 2019-08-29 | 2021-03-04 | 山东大学 | Laser-cladding joining control method, and laser head dynamic height adjustment method and system |
| CN110408925B (en) * | 2019-08-29 | 2020-05-19 | 山东大学 | Laser head height dynamic adjusting method, device and system for laser cladding machine tool |
| CN111060026B (en) * | 2019-12-31 | 2021-06-22 | 天津镭明激光科技有限公司 | Method for detecting cladding quality based on laser displacement sensor coaxial powder feeding equipment |
| CN113909501B (en) * | 2021-09-23 | 2023-07-25 | 沈阳精合数控科技开发有限公司 | Thickness monitoring device and adjusting method of laser deposition layer and laser deposition equipment |
| CN114192809A (en) * | 2021-10-29 | 2022-03-18 | 江苏大学 | Device and method for correcting flatness of cladding layer based on three-dimensional imaging laser radar |
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| CN1356608A (en) * | 2001-12-15 | 2002-07-03 | 华中科技大学 | Automatic controller for laser coating and powder feeding system |
| EP1396556A1 (en) * | 2002-09-06 | 2004-03-10 | ALSTOM (Switzerland) Ltd | Method for controlling the microstructure of a laser metal formed hard layer |
| CN102794565B (en) * | 2012-09-04 | 2015-01-21 | 徐州工程学院 | LabView-based real-time monitoring system for laser cladding/laser re-melting process temperature field |
| CN203918225U (en) * | 2013-12-11 | 2014-11-05 | 乐清市佳速激光有限公司 | Laser real-time feedback control system |
| CN107328391A (en) * | 2017-06-28 | 2017-11-07 | 武汉理工大学 | A kind of multi-sensor cooperation monitoring device and method for broadband laser cladding |
| CN108189406B (en) * | 2018-03-16 | 2020-01-14 | 吉林大学 | Precise proportioning powder feeding system and dynamic control method for powder output and proportioning quantity |
| CN108247059B (en) * | 2018-04-23 | 2020-12-22 | 广东省智能制造研究所 | Layer height control system and method for coaxial powder feeding laser melting forming equipment |
| CN108624880B (en) * | 2018-08-10 | 2019-08-06 | 南通大学 | A kind of Laser Cladding Quality intelligence control system and its intelligent control method |
| CN109778182B (en) * | 2019-03-11 | 2020-06-19 | 西安交通大学 | Laser cladding additive forming height online monitoring device and closed-loop control method |
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Effective date of registration: 20200616 Address after: 250000 f4-2-202-35, No. 2016, Feiyue Avenue, high tech Zone, Jinan City, Shandong Province Applicant after: Shandong Leiyan Laser Technology Co., Ltd Address before: 272000 Block B, Building A3, Production, Education and Research Base, No. 9 Haichuan Road, Rencheng District, Jining City, Shandong Province Applicant before: Laser Institute of Shandong Academy of Science |
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