CN115847000A

CN115847000A - Online repairing method for gear tooth surface damage in motor coupler of rolling mill production line

Info

Publication number: CN115847000A
Application number: CN202211613105.5A
Authority: CN
Inventors: 于斌; 娄家佳; 黄东保
Original assignee: Taier Anhui Industrial Technology Service Co ltd
Current assignee: Taier Anhui Industrial Technology Service Co ltd
Priority date: 2022-12-15
Filing date: 2022-12-15
Publication date: 2023-03-28

Abstract

The invention discloses an on-line repairing method for gear tooth surface damage in a motor coupler of a rolling mill production line, which comprises the following specific steps: (1) Closing a power and lubrication system of related equipment, disassembling accessory facilities around the equipment, removing power transmission and load loads of an input end and an output end of the equipment, disassembling parts matched with a target gear and exposing the target gear, and enabling the target gear and a shaft part matched with the target gear to be in an open space; (2) cleaning the tooth surface of the gear to be treated, and removing oil stains on the tooth surface; (3) detecting the gear to be processed; (4) Determining a gear tooth surface repairing scheme according to the detection result: and when the gear reaches the scrapping standard, the gear is repaired by using a material reducing scheme, and when the gear reaches the scrapping standard, the gear is repaired by using an additive scheme. According to the invention, two different methods are adopted to carry out targeted repair according to the detection result of the gear, so that the accurate size and tooth profile can be controlled, and further the repair processing of more tooth number or even all tooth number tooth surfaces can be completed.

Description

Online repairing method for gear tooth surface damage in motor coupler of rolling mill production line

Technical Field

The invention relates to the technical field of repair and reinforcement of gear surfaces of motor couplers of a rolling mill production line, in particular to a method for completing repair of the gear surfaces of the motor couplers of the rolling mill production line on line by applying a laser processing technology.

Background

Gears are common transmission elements, and have the advantages of multiple processing procedures, complex process, long production period and higher unit price. In complex working conditions, gear surfaces of gears often have serious abrasion, pitting corrosion and gluing. The transmission gear of large-scale equipment is expensive to manufacture, and the new gear after being scrapped has long period and great waste. Therefore, the normal operation of the equipment can be effectively guaranteed by repairing and strengthening the old parts in time, and the service life of the parts is prolonged.

After the tooth surface of a gear in a motor coupler of a production line of a rolling mill is damaged, the gear is repaired after being disassembled in a traditional repairing mode, but the production line is difficult to halt for long-time maintenance, so that the actual production requirement cannot be met; and the assembly mode of the gear and the matching parts adopts interference fit, so that the gear is not convenient to disassemble and repair, and if the matching surfaces of the matching parts are damaged by forcible disassembly, the online repair of the tooth surfaces of the gear in the coupler is one of the problems faced by the gear using manufacturers at present.

Patent CN 108555468B (granted publication No. 2020.10.9) discloses an on-line welding repair process for large spur gears, which is a welding repair performed after the gears generate broken teeth, and has the following disadvantages: 1. in the repairing process, manual welding and manual grinding depend on a tooth profile sample plate as a unique processing reference, the accurate size and tooth profile cannot be controlled in the processing process, and the repairing processing of tooth surfaces with more tooth numbers and even all tooth numbers cannot be finished; 2. the surfacing processing method has large heat input amount and large heat affected zone, the material structure of the repaired part is thick, the defects of inclusion, hydrogen embrittlement, welding cracks and the like are easy to occur, and the processing quality is difficult to meet the harsh working condition requirement of heavy-duty equipment; 3. an oxygen bottle and an acetylene bottle are used in a welding field, so that the probability of explosion risk is increased; 4. the gear is arranged in the box body, no protective measures are taken during welding, the heat of the gear can affect other parts, and residues can also fall into other parts or the box body, so that later use is influenced; 5. the manual repair seriously depends on the experience and the state of a skilled operator, and has low processing efficiency and unstable processing quality.

Disclosure of Invention

The invention aims to solve the problem of providing an on-line repairing method for gear tooth surface damage in a motor coupler of a rolling mill production line, which carries out targeted repairing by adopting two different methods according to the detection result of a gear, thereby ensuring the on-line repairing quality. The invention can control the accurate size and tooth shape, thereby completing the repair processing of tooth surfaces with more teeth and even all teeth.

The invention discloses an online repair method for gear tooth surface damage in a motor coupler of a rolling mill production line, which comprises the following specific steps: (1) Closing a power and lubrication system of related equipment, disassembling accessory facilities around the equipment, removing power transmission and load loads of an input end and an output end of the equipment, disassembling parts matched with a target gear and exposing the target gear, and enabling the target gear and a shaft part matched with the target gear to be in an open space; (2) cleaning the tooth surface of the gear to be treated, and removing oil stains on the tooth surface; (3) The gear to be processed is detected, and the detection items comprise: dimensional tooth profile measurement, wear measurement, tooth surface flaw detection, tooth surface hardness detection and the like; (4) Determining a restoration scheme of the gear tooth surface according to the detection result: and when the gear reaches the rejection standard, the gear is repaired by using an additive scheme.

Wherein, when the gear to be treated adopts the material reduction scheme to repair: (1) Manually polishing or mechanically processing the damaged area of the tooth surface to remove defects in the area, so that the tooth surface has no air holes, interlayers, rust, cracks and the like; checking the processed tooth surface by using a tooth profile sample plate to ensure that the tooth surface can be smoothly meshed; cleaning the gear tooth surface to remove oil stains on the gear tooth surface; (2) carrying out laser quenching strengthening treatment on the tooth surface: (1) installing and debugging movable modular laser processing equipment in the space outside the gear: fixing the laser processing equipment through the supporting base, confirming that the state of the laser is normal, and adjusting the pose of the industrial robot; (2) the height gauge is used as an observation and adjustment tool of the rotation positioning reference of the gear, and the consistency of the tooth surface processing reference is ensured by superposing and fixing positions one by one; (3) carrying out laser quenching on the tooth surface of one side of the gear: i, rotating and adjusting a circumferential corner of a gear to enable a first tooth surface (any tooth, mark identification) on any side to be machined of the gear to be in a horizontal position, measuring an angle and a distance between the tooth surface to be machined and a laser machining head, ensuring that a laser beam incident angle does not interfere with an adjacent tooth surface, and ensuring that the spot size and the focal length of the laser beam meet process requirements; II, arranging light shielding plates on two sides of a tooth surface to be processed, and extending the motion track of the laser beam scanning tooth surface beyond the edge of the tooth surface to ensure that the starting position and the ending position of the laser beam scanning are both positioned on the light shielding plates; III, jumping tooth processing is carried out after the laser quenching of the first tooth surface is finished until all the tooth surfaces on the same side of the gear are processed; (4) carrying out laser quenching on the tooth surface on the other side of the gear: repeating the steps I to III in the step (3) until the tooth surface on the other side of the gear is completely processed; (3) Cleaning the tooth surface, detecting the hardness and the roughness of the tooth surface, and performing nondestructive flaw detection on the tooth surface; checking the processed tooth surface by using a tooth profile sample plate to ensure that the tooth surface can be smoothly meshed; and delivering for use after the detection is qualified.

Wherein, when the tooth to be treated adopts the material increase scheme to repair: (1) Carrying out manual grinding or mechanical processing on the damaged region of the tooth surface to remove defects in the region, so that the tooth surface has no pores, interlayers, rust, cracks and the like; cleaning the tooth surface of the gear to remove oil stains on the tooth surface; (2) carrying out laser cladding repair treatment on the tooth surface: (1) installing and debugging movable modular laser processing equipment in the space outside the gear: fixing the laser processing equipment through the supporting base, confirming that the state of the laser is normal, and adjusting the pose of the industrial robot; (2) clamping the gear by using a horizontal numerical control rotary indexing table to ensure that the machining reference of the tooth surface is consistent; (3) carrying out laser cladding on the tooth surface of one side of the gear: i, before cladding, using a tooth-shaped induction heating head to perform local induction heating preheating; II, shooting a plurality of images of the part to be processed by using a calibrated industrial camera, inputting the image set into machine vision image processing software, outputting node coordinate data to a robot control system through processing operation of the image processing software, automatically calculating by running a pre-programmed program by the robot control system, generating a processing program, and checking; III, cladding layer extension plates are arranged on two sides of a tooth surface to be processed, the motion track of the laser beam scanning tooth surface extends to exceed the edge of the tooth surface, and the starting position and the ending position of the laser beam scanning are ensured to be positioned on the cladding layer extension plates; IV, performing laser cladding on the tooth surface by the robot by executing a laser cladding machining process, and performing jumping tooth machining after the first tooth surface is finished until the whole tooth surface on one side of the gear is machined; v, after cladding, synchronously performing local induction heating post-heat treatment by using a tooth-shaped induction heating head; (4) carrying out laser cladding on the tooth surface on the other side of the gear: repeating the steps I to V in the step (3) to complete laser cladding of the tooth surface on the other side; (5) carrying out vibration aging treatment on the cladding tooth surface; (3) Installing external shaft machining equipment, and performing gear tooth surface milling: (1) calibrating a part coordinate system, calibrating a vision camera to calibrate a tool coordinate system, shooting an initial image of the part, reading the image by image processing software, processing, outputting an actual coordinate value (relative to the tool coordinate system) of the gear contour to the industrial robot, comparing the actual coordinate value with an ideal coordinate value of the built-in gear contour by the robot, and automatically generating a machining program of the industrial robot; (2) the processing tool table of the external shaft processing equipment processes the tooth surface of the gear, and the tooth surface milling is completed tooth by tooth until all the tooth surfaces of the gear are processed; (3) manually grinding the edge rounding of the tooth surface by taking the tooth-shaped sample plate as a reference; (4) cleaning the tooth surface of the gear, detecting the tooth shape, the dimensional tolerance, the tooth surface hardness and the roughness, and performing nondestructive flaw detection on the tooth surface; and delivering for use after the detection is qualified.

The tooth surface damage area is polished in the step (1) in two ways: 1. manual grinding is carried out to remove defects in the area, the grinding pit is in an open state, and the edge of the pit is ground smoothly; 2. and (4) carrying out mechanical processing to remove the defective material layer, and carrying out smooth transition on the contact position of the processing removal area and the original tooth surface.

Wherein, the movable modularized laser processing equipment used in the step (2) is integrated by a plurality of equipment: for example, a laser LDM 6000-100ER, a laser head SN02099805845, a laser head D2009763041800503215, a powder feeder RC-PGF-D (004 #), a robot KR20R1810-2, a robot control cabinet KRC4, a laser water cooling machine MCWL-120DTR-01AES7Z1-3385; the laser head SN02099805845 is used for quenching, and the laser head D2009763041800503215 is used for cladding.

Wherein, when laser cladding is carried out in the step (2), the iron-based self-fluxing alloy powder comprises the following components in percentage by mass: 0.15-0.2% of C, 15-17% of Cr, 2% of Ni, 1% of Si, 1%B, 0.5% of Mo, 0.3% of Mn, 0.15% of Nb, 0.05V, 0.05Cu, ti < 0.02, P < 0.02, S < 0.02, and the balance Fe.

Wherein, in the step (2) of laser cladding, the step (3) comprises the following steps: calculating the heating temperature in the step I and the step VI according to the carbon equivalent of the base material and the cladding material:

CE＝W(c)+W(Mn)/6+[W(Cr)+W(Mo)+W(V)]/5+[W(Ni)+W(Cu)]/15(％)；

when CE is less than 0.45%, preheating is not needed; when the CE is between 0.45 and 0.60 percent, preheating to 100 to 200 ℃; when CE is more than 0.60%, preheating to 200-370 ℃.

And (3) when laser cladding is carried out in the step (2), a copper pipe nozzle is aligned to a laser spot irradiation molten pool to realize axial side powder feeding, and the optical head is protected by argon atmosphere.

When laser cladding is carried out in the step (2), planar large-area cladding is formed by overlapping a plurality of cladding layers; when the multiple layers are lapped, cleaning the layers after finishing each layer, polishing to remove surface oxides and hanging slag, and forming overlapping by staggering the lapping joints, polishing to form a slope angle and cladding the next layer.

Wherein, the extension plate is in a [ -shape, and two ends of the extension plate are respectively clamped at two sides of a tooth surface to be clad.

The on-line repairing method has the advantages that: 1. the gear is firstly subjected to relevant detection, and two different methods are adopted to carry out targeted repair according to the detection result, so that the repair quality is ensured, and the cost is saved; 2. when the gear does not reach the scrapping standard, a material reduction repairing method of laser quenching strengthening is adopted, so that the repairing quality is ensured, and the cost is saved; when the gear reaches the scrapping standard, a laser cladding metallurgy combined additive repairing method is adopted, the heat input is small, the heat influence is small, the machine vision is assisted to ensure the outline of the finally processed and formed gear, the processing precision is high, and full-tooth processing can be realized; the processing efficiency is high, the processing quality is good, and the energy is saved and the environment is protected; 3. when laser cladding is carried out in the additive repairing method, the extending plates are arranged on two sides of the tooth surface to be processed, so that the cladding layer on the edge of the tooth surface is full, and the cladding quality of the tooth surface is ensured; 4. the gear repaired on line is positioned in an open space, and protective measures are taken, so that heat and residues generated during repair are prevented from affecting other parts, and safety accidents cannot occur. Therefore, the method can accurately control the size and the tooth shape and finish the online repair processing of more tooth numbers and even all tooth surfaces.

Drawings

FIG. 1 is a flow chart of an online repair method of the present invention;

FIG. 2 is a flow chart of a subtractive scheme repair;

FIG. 3 is a flow chart of additive solution repair;

fig. 4 is a schematic view of an extension plate in an additive-solution repair;

FIG. 5 is a schematic view of the installation of the extension plate;

FIG. 6 is a front view of FIG. 5;

FIG. 7 is a right side view of FIG. 5;

fig. 8 is a top view of fig. 5.

Detailed Description

Example 1

The invention discloses an online repair method for gear tooth surface damage in a motor coupler of a rolling mill production line, which comprises the following specific steps:

(1) Closing a power and lubrication system of related equipment, disassembling accessory facilities around the equipment, removing power transmission and load loads of an input end and an output end of the equipment, disassembling parts matched with a target gear and exposing the target gear, and enabling the target gear and a shaft part matched with the target gear to be in an open space;

(2) Cleaning the tooth surface of a gear to be treated, and removing oil stains on the tooth surface;

(3) The gear to be processed is detected, and the detection items comprise: dimensional tooth profile measurement, wear measurement, tooth surface flaw detection, tooth surface hardness detection and the like;

(4) Determining a restoration scheme of the gear tooth surface according to the detection result: and when the gear reaches the scrapping standard, the gear is repaired by using a material reducing scheme, and when the gear reaches the scrapping standard, the gear is repaired by using an additive scheme.

Wherein the rejection standard of the gear is judged as follows: 1. the gear has cracks or teeth breaks; 2. the pitting damage of the tooth surface reaches 30 percent of the meshing tooth surface and the depth reaches 10 percent of the original tooth thickness, or the pitting area of the tooth surface exceeds 60 percent along the tooth width and the tooth height; 3. the worn tooth thickness of the gear is not less than 80% of the original tooth thickness; 4. the gear works abnormally loud, the vibration is obvious, the load is obviously raised.

Example 2

When the gear to be processed is repaired by adopting a material reduction scheme:

(1) Carrying out manual grinding or mechanical processing on the damaged region of the tooth surface to remove defects in the region, so that the tooth surface has no pores, interlayers, rust, cracks and the like; checking the processed tooth surface by using a tooth profile sample plate to ensure that the tooth surface can be smoothly meshed; cleaning the gear tooth surface to remove oil stains on the gear tooth surface;

(2) Carrying out laser quenching strengthening treatment on the tooth surface:

(1) installing and debugging movable modular laser processing equipment in the space outside the gear: fixing the laser processing equipment through the supporting base, confirming that the state of the laser is normal, and adjusting the pose of the industrial robot;

(2) the height gauge is used as an observation and adjustment tool of the rotary positioning reference of the gear, and the consistency of the tooth surface processing reference is ensured by the tooth-by-tooth superposition and fixing positions;

(3) carrying out laser quenching on the tooth surface of one side of the gear:

i, rotating and adjusting a circumferential corner of a gear to enable a first tooth surface (any tooth, mark identification) on any side to be machined of the gear to be in a horizontal position, measuring an angle and a distance between the tooth surface to be machined and a laser machining head, ensuring that an incident angle of a laser beam does not interfere with an adjacent tooth surface, and ensuring that the spot size and the focal length of the laser beam meet process requirements;

II, arranging light shielding plates on two sides of a tooth surface to be processed, and extending a laser beam scanning tooth surface motion track to exceed the edge of the tooth surface to ensure that the laser beam scanning initial and final positions are both positioned on the light shielding plates;

III, jumping tooth processing is carried out after the laser quenching of the first tooth surface is finished until all the tooth surfaces on the same side of the gear are processed;

(4) carrying out laser quenching on the tooth surface on the other side of the gear: repeating the steps I to III in the step (3) until the tooth surface on the other side of the gear is completely processed;

(3) Cleaning the tooth surface, detecting the hardness and the roughness of the tooth surface, and performing nondestructive flaw detection on the tooth surface; checking the processed tooth surface by using a tooth profile sample plate to ensure that the tooth surface can be smoothly meshed; and delivering for use after the detection is qualified.

Wherein, II in step (3) in step (2): since the size of the spot of the light beam is different at different focal lengths, if the laser beam is irradiated to other positions during processing, other tooth surfaces can be melted and burnt, and therefore, a protection measure is taken, namely, light shielding plates are arranged on two sides of the tooth surface to be processed.

Wherein, I in step (4) in step (2): after the gear is machined on one side of the tooth surface, the other side of the tooth surface of the gear is machined, and the starting position of the gear is determined according to the size of the working space: when the working space is limited and the robot can only work on one side of the workpiece, the circumferential rotation angle of the gear is rotationally adjusted at the moment, so that the first tooth surface (any tooth, mark identification) on the unprocessed side of the gear is in a vertical position; when the working space is large enough, the robot can work on the other side of the workpiece, and the circumferential rotation angle of the gear is adjusted in a rotating mode, so that the first tooth surface (any tooth, mark identification) on the unprocessed side of the gear is in a horizontal position. Machining horizontally on both sides of the gear is the preferred option.

Example 3

When the tooth to be treated adopts an additive scheme for repair:

(1) Manually polishing or mechanically processing the damaged area of the tooth surface to remove defects in the area, so that the tooth surface has no air holes, interlayers, rust, cracks and the like; cleaning the gear tooth surface to remove oil stains on the gear tooth surface;

(2) Carrying out laser cladding repair treatment on the tooth surface:

(2) clamping the gear by using a horizontal numerical control rotary indexing table to ensure that the machining reference of the tooth surface is consistent;

(3) carrying out laser cladding on the tooth surface of one side of the gear:

i, before cladding, using a tooth-shaped induction heating head to perform local induction heating preheating;

II, shooting a plurality of images of the part to be processed by using a calibrated industrial camera, inputting the image set into machine vision image processing software, outputting node coordinate data to a robot control system through processing operation of the image processing software, automatically calculating by running a pre-programmed program by the robot control system, generating a processing program, and checking;

III, cladding layer extension plates are arranged on two sides of a tooth surface to be processed, the motion track of the laser beam scanning tooth surface extends to exceed the edge of the tooth surface, and the starting position and the ending position of the laser beam scanning are ensured to be positioned on the cladding layer extension plates;

IV, performing laser cladding on the tooth surface by the robot by executing a laser cladding machining process, and performing jumping tooth machining after the first tooth surface is finished until all the tooth surfaces on one side of the gear are machined;

v, after cladding, synchronously performing local induction heating post-heat treatment by using a tooth-shaped induction heating head;

(4) carrying out laser cladding on the tooth surface on the other side of the gear: repeating the steps I to V in the step (3) to complete laser cladding of the tooth surface on the other side;

(5) carrying out vibration aging treatment on the cladding tooth surface;

(3) Installing external shaft machining equipment, and milling the tooth surface of the gear:

(1) calibrating a part coordinate system, calibrating a vision camera to calibrate a tool coordinate system, shooting an initial image of the part, reading the image by image processing software, processing, outputting an actual coordinate value (relative to the tool coordinate system) of the gear contour to the industrial robot, comparing the actual coordinate value with an ideal coordinate value of the built-in gear contour by the robot, and automatically generating a machining program of the industrial robot;

(2) the processing tool table of the external shaft processing equipment processes the tooth surface of the gear, and the tooth surface milling is completed tooth by tooth until all the tooth surfaces of the gear are processed;

(3) manually grinding the edge rounding of the tooth surface by taking the tooth-shaped sample plate as a reference;

(4) cleaning the tooth surface of the gear, detecting the tooth shape, the dimensional tolerance, the tooth surface hardness and the roughness, and performing nondestructive flaw detection on the tooth surface; and delivering for use after the detection is qualified.

Example 4

In the two methods of material reduction repair and material increase repair, the two modes of coping the damaged area of the tooth surface in the step (1) are as follows: 1. manual grinding is carried out to remove defects in the area, the grinding pit is in an open state, and the edge of the pit is ground smoothly; 2. and (4) carrying out mechanical processing to remove the defective material layer, and carrying out smooth transition on the contact position of the processing removal area and the original tooth surface.

The equipment used for mechanical processing can be an electric grinding head, an electric milling cutter and the like; the electric milling cutter has large cutting amount and high efficiency.

The concrete adopted mode mainly depends on the size of the grinding amount: when the grinding amount is small, manual grinding is adopted, and when the grinding amount is large, mechanical processing is adopted.

Example 5

The movable modular laser processing equipment used in the step (2) in the two methods of material reduction repair and material increase repair is integrated by a plurality of pieces of equipment: for example, a laser LDM 6000-100ER, a laser head SN02099805845, a laser head D2009763041800503215, a powder feeder RC-PGF-D (004 #), a robot KR20R1810-2, a robot control cabinet KRC4, a laser water cooler

MCWL-120DTR-01AES7Z1-3385; the laser head SN02099805845 is used for quenching, and the laser head D2009763041800503215 is used for cladding.

Example 6

When the gear machining reference is determined in the step (2) in the two methods of material reduction repair and material addition repair, the two methods are divided into two modes: 1. manually adjusting by using a height gauge; 2. mechanical adjustment using an indexing table.

The specific manner adopted mainly depends on the height of the positioning precision requirement: because the requirements of laser quenching on the processing reference are relatively low, manual adjustment can be adopted; because the mechanical processing after cladding has high requirement on the positioning precision of the gear, a numerical control indexing table is required to be used for indexing processing. In addition, the factors of gear size, structure, overall layout, whether the load of related matched parts is removed and the like need to be considered: even laser quenching requires mechanical adjustment using an indexing table if the gear is difficult to rotate manually.

Example 7

The tooth skipping processing in the step (3) in the two methods of material reduction repair and material increase repair is specifically as follows: after the first tooth surface of the gear is machined, the machining is continued at intervals of more than 2 tooth surfaces until all the tooth surfaces on one side of the gear are machined.

On one hand, the jumping processing considers heat dissipation, and avoids thermal deformation caused by heat accumulation and overlarge change of part process conditions; on the other hand, the negative effects of thermal deformation and thermal accumulation are dispersed in a tooth jumping processing mode, and the possible negative effects are balanced and counteracted through symmetrical configuration.

Example 8

When laser cladding is carried out in the step (2) of the additive repair method, cladding alloy powder is selected according to the material of a gear matrix and the technical requirements of working conditions, and the iron-based self-melting alloy powder comprises the following components in percentage by mass: 0.15-0.2% of C, 15-17% of Cr, 2% of Ni, 1% of Si, 1%B, 0.5% of Mo, 0.3% of Mn, 0.15% of Nb, 0.05V, 0.05Cu, ti < 0.02, P < 0.02, S < 0.02, and the balance Fe.

Example 9

Step (3) in step (2) in the additive repair method: calculating the heating temperature in the step I and the step VI according to the carbon equivalent of the base material and the cladding material;

CE＝W(c)+W(Mn)/6+[W(Cr)+W(Mo)+W(V)]/5+[W(Ni)+W(Cu)]/15(％)

Example 10

In step (3) of step (2) in the additive repair method: the copper pipe nozzle is adopted to aim at the laser spot irradiation melting pool to realize the axial side powder feeding and the optical head argon atmosphere protection.

Because cladding is carried out on line, the problems that the cladding space of the tooth surface is narrow, and turbulent flow is easily formed between the tooth surfaces by powder feeding carrier gas exist, so that the accurate powder feeding on the shaft side is realized by preferentially adopting a copper pipe nozzle; during laser cladding, the coaxial powder feeding and the axial side powder feeding can be switched at any time according to requirements.

Example 11

In step (3) of step (2) in the additive repair method: and step V, reducing the stress of the cladding part by adopting a slow heating and slow cooling mode.

Example 12

In step (3) of step (2) in the additive repair method: the plane large-area cladding is formed by overlapping a plurality of cladding layers; when the multiple layers are lapped, cleaning the layers after finishing each layer, polishing to remove surface oxides and hanging slag, and forming overlapping by staggering the lapping joints, polishing to form a slope angle and cladding the next layer.

Example 13

In step (5) of step (2) in the additive repair method: the vibrating head is adsorbed on the surface of a part through magnetic force, external stress is applied to a target part through mechanical vibration, the internal stress of the target part is changed, stress is released, local stress concentration is relieved, and therefore performance is stabilized, and subsequent deformation is reduced.

Example 14

The additive repair method comprises the following steps: the external shaft machining equipment is installed, and before the gear tooth surface milling machining is carried out, the movable modularized laser machining equipment can be removed: the same equipment used for milling can be adopted during mechanical coping.

Example 15

The additive repair method comprises the following steps: when laser cladding and machining equipment mill a gear face, an industrial camera shoots images of each angle of the end face and the side face of the gear in real time, the images are compared with design model data to obtain the size of a gear face machining allowance, and a machining program (a coordinate system, a node coordinate value, a track path, a motion program and a logic instruction) is automatically fed back and corrected.

Example 16

As shown in fig. 4, in the additive repair method: in step (3) iii of step (2), the extension plate 11 is "[" shaped, and both ends thereof are respectively clamped at both sides of the tooth surface to be clad.

As shown in fig. 5, 6, 7 and 8, the extension plate 11 is attached by a fixing bracket 12: the fixed bracket 12 is in a shape of Jiong, the lower part of the middle of a transverse bar is provided with a positioning tooth, the shape and the size of the positioning tooth are the same as those of the teeth of a gear to be repaired, the middle of two vertical bars is arc-shaped, the tail part of the two vertical bars is upwards tilted, and the distance between the inner sides of the two vertical bars is slightly wider than the thickness of the teeth of the gear; the extension plate 11 is placed on the tail of the two vertical bars of the fixed bracket.

Before cladding, the 12 positioning teeth of the fixed support are clamped in the tooth gaps of the gear, the two vertical bars are positioned at two ends of the tooth surface of the gear, then the extension plate 11 is placed on the tail parts of the two vertical bars of the fixed support and is flush with the tooth surface, and at the moment, the extension plate 11 tightly clamps two sides of the tooth surface. The starting and ending positions of the laser beam scanning tooth surface movement are positioned on the extension plate during cladding, the extension plate and the tooth surface are integrated into a whole when cladding is finished, and the fixed support can be taken down for reuse. And during subsequent gear tooth surface milling, removing the redundant parts on the teeth according to the final shape of the tooth surface.

When laser cladding is carried out in the additive repairing method: the extension plates are arranged on two sides of the tooth surface to be processed and have the following functions: 1. if the extension plate is not arranged, the edge of the cladding tooth surface can collapse, so that the subsequent machining allowance is insufficient; the use of the extension plate can ensure the plump cladding layer of the edge of the tooth surface; 2. other tooth surfaces may be protected. The extension plate has specific requirements on material and thickness: the material of the extension plate is consistent with or close to that of the gear, and the thickness of the extension plate is required to prevent the extension plate from being melted through by laser.

The online repair method has the advantages that: 1. the gear is firstly subjected to relevant detection, and then two different methods are adopted to carry out targeted repair according to the detection result, so that the repair quality is ensured, and the cost is saved; 2. when the gear does not reach the scrapping standard, a material reduction repairing method of laser quenching strengthening is adopted, so that the repairing quality is ensured, and the cost is saved; when the gear reaches the scrapping standard, a laser cladding metallurgy combined additive repairing method is adopted, the heat input is small, the heat influence is small, the machine vision is assisted to ensure the outline of the finally processed and formed gear, the processing precision is high, and full-tooth processing can be realized; the processing efficiency is high, the processing quality is good, and the energy is saved and the environment is protected; 3. when laser cladding is carried out in the additive repairing method, the extending plates are arranged on two sides of the tooth surface to be processed, so that the cladding layer on the edge of the tooth surface is full, and the cladding quality of the tooth surface is ensured; 4. the gear repaired on line is in an open space, and protective measures are taken, so that heat and residues generated during repair are prevented from affecting other parts, and safety accidents cannot occur. Therefore, the method can accurately control the size and the tooth shape and finish the online repair processing of tooth surfaces with more teeth and even all teeth.

The online repairing method is not limited to online repairing of damage of the gear tooth surface in the motor coupler of the rolling mill production line, and is applicable to other gears and heavy-duty gears which are inconvenient to detach from matched parts.

Claims

1. The on-line repairing method for the gear surface damage in the motor coupler of the rolling mill production line comprises the following specific steps:

(3) Detecting the gear to be processed, wherein the detection items comprise: dimensional tooth profile measurement, wear measurement, tooth surface flaw detection, tooth surface hardness detection and the like;

2. The on-line repair method of claim 1, wherein:

when the gear to be processed adopts a material reduction scheme for repairing:

(1) Manually polishing or mechanically processing the damaged area of the tooth surface to remove defects in the area, so that the tooth surface has no air holes, interlayers, rust, cracks and the like; checking the processed tooth surface by using a tooth profile sample plate to ensure that the tooth surface can be smoothly meshed; cleaning the gear tooth surface to remove oil stains on the gear tooth surface;

(2) Carrying out laser quenching strengthening treatment on the tooth surface:

(3) carrying out laser quenching on the tooth surface of one side of the gear:

II, arranging light shielding plates on two sides of a tooth surface to be processed, and extending the motion track of the laser beam scanning tooth surface beyond the edge of the tooth surface to ensure that the starting position and the ending position of the laser beam scanning are both positioned on the light shielding plates;

(4) carrying out laser quenching on the tooth surface on the other side of the gear: repeating the steps I-III in the step (3) until all the tooth surfaces on the other side of the gear are processed;

3. The on-line repair method of claim 1, wherein:

when the tooth to be treated adopts an additive scheme for repair:

(2) Carrying out laser cladding repair treatment on the tooth surface:

(3) carrying out laser cladding on the tooth surface of one side of the gear:

(5) carrying out vibration aging treatment on the cladding tooth surface;

(3) Installing external shaft machining equipment, and performing gear tooth surface milling:

4. The on-line repair method according to claim 2 or 3, wherein: the two modes of coping the damaged area of the tooth surface in the step (1) are specifically as follows: 1. manual grinding is carried out to remove defects in the area, the grinding pit is in an open state, and the edge of the pit is ground smoothly; 2. and (4) carrying out mechanical processing to remove the defective material layer, and carrying out smooth transition on the contact position of the processing removal area and the original tooth surface.

5. An online repair method according to claim 2 or 3, characterized in that: the movable modular laser processing equipment used in the step (2) is integrated by a plurality of pieces of equipment: such as laser LDM

6000-100ER, a laser head SN02099805845, a laser head D2009763041800503215, a powder feeder RC-PGF-D (004 #), a robot KR20R1810-2, a robot control cabinet KRC4, a laser water cooling machine MCWL-120DTR-01AES7Z1-3385; the laser head SN02099805845 is used for quenching, and the laser head D2009763041800503215 is used for cladding.

6. The on-line repair method of claim 3, wherein: when laser cladding is carried out in the step (2), the components of the iron-based self-fluxing alloy powder are as follows (in percentage by mass): 0.15-0.2% of C, 15-17% of Cr, 2% of Ni, 1% of Si, 1%B, 0.5% of Mo, 0.3% of Mn, 0.15% of Nb, 0.05V, 0.05Cu, ti < 0.02, P < 0.02, S < 0.02, and the balance Fe.

7. The on-line repair method of claim 3, wherein: step (2) laser cladding step (3): calculating the heating temperature in the step I and the step VI according to the carbon equivalent of the base material and the cladding material: CE = W (c) + W (Mn)/6 + [ W (Cr) + W (Mo) + W (V) ]/5+ [ W (Ni) + W (Cu) ]/15 (%); when CE is less than 0.45%, preheating is not needed; when the CE is between 0.45 and 0.60 percent, preheating to 100 to 200 ℃; when CE is more than 0.60%, preheating to 200-370 ℃.

8. The on-line repair method of claim 3, wherein: and (3) when laser cladding is carried out in the step (2), a copper pipe nozzle is adopted to aim at a laser spot irradiation melting pool to realize shaft side powder feeding, and the optical head is protected by argon atmosphere.

9. The on-line repair method of claim 3, wherein: when laser cladding is carried out in the step (2), planar large-area cladding is formed by overlapping a plurality of cladding layers; when the multiple layers are lapped, cleaning the layers after finishing each layer, polishing to remove surface oxides and hanging slag, and forming overlapping by staggering the lapping joints, polishing to form a slope angle and cladding the next layer.

10. The on-line repair method of claim 3, wherein: the extension plate (11) is in a [ -shape, and two ends of the extension plate are respectively clamped at two sides of a tooth surface needing to be clad.