CN116695049A - Method for calibrating a spray coating system and spray coating system - Google Patents
Method for calibrating a spray coating system and spray coating system Download PDFInfo
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- CN116695049A CN116695049A CN202310694392.5A CN202310694392A CN116695049A CN 116695049 A CN116695049 A CN 116695049A CN 202310694392 A CN202310694392 A CN 202310694392A CN 116695049 A CN116695049 A CN 116695049A
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- coordinate system
- workpiece coordinate
- spraying
- deviation value
- spray coating
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- 238000005507 spraying Methods 0.000 title claims abstract description 82
- 238000000034 method Methods 0.000 title claims abstract description 50
- 239000007921 spray Substances 0.000 claims description 36
- 239000000463 material Substances 0.000 claims description 8
- 238000004590 computer program Methods 0.000 claims description 6
- 238000000576 coating method Methods 0.000 description 11
- 239000011248 coating agent Substances 0.000 description 8
- 239000000843 powder Substances 0.000 description 5
- 238000005524 ceramic coating Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000007750 plasma spraying Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
The present application relates to a method for calibration of a spray coating system, and a spray coating system and a computer readable storage medium, the method comprising: step S1, defining a theoretical workpiece coordinate system based on an initial reference coordinate system of a spraying system, wherein the direction of a coordinate axis of the theoretical workpiece coordinate system is consistent with the direction of the coordinate axis of the initial reference coordinate system; s2, spraying the fixed point positions by using a theoretical workpiece coordinate system to form spots with first centers; step S3, determining a first deviation value of a first center relative to an origin of a theoretical workpiece coordinate system; and step S4, if the first deviation value is larger than the threshold value, the theoretical workpiece coordinate system is compensated by using the first deviation value to obtain a calibrated workpiece coordinate system.
Description
Technical Field
The application relates to a method for calibrating a spray coating system and a spray coating system.
Background
The turbine blade of the gas turbine often needs to adopt a single-powder-feeding plasma spraying process to obtain higher coating roughness or improve spraying precision, and is suitable for not only rough metal coating but also porous ceramic coating. However, for single powder delivery spray systems, there are situations where there is an inconsistency in the projection of the nozzle center of the spray gun with the center of the spray flame stream (spot). The conventional coating process generally adopts planning more coating paths for avoiding the inconsistent situation, in the actual manufacturing process, an operator needs to perform multiple manual operations and repeated inputs on a spraying system for different workpieces so as to adjust the positioning of a nozzle of the spraying system relative to the workpiece according to the geometry of the current workpiece, and then the nozzle is operated to move and spray along multiple spraying paths on the workpiece, so that the spraying task for the current workpiece is completed, but the scheme can cause more coating spraying time and consumption of powder materials.
Disclosure of Invention
In view of the above, the embodiments of the present application provide a method for calibrating a spraying system using a single powder feeding plasma spraying process and a spraying system using the method. Therefore, the application provides a rapid spot calibration method, so that the actual spot center of spraying is consistent with the theoretical projection center of the spray gun nozzle, and the accurate spraying of the coating can be realized without complex processing in the aspects of programming and programming, the time for spraying the coating and the consumption of powder materials are reduced, and the efficiency of spraying and production is improved.
According to a preferred embodiment of the present application, there is provided in one aspect a method for calibration of a spray coating system employing a single feed plasma spray coating process, the method comprising: step S1, defining a theoretical workpiece coordinate system based on an initial reference coordinate system of a spraying system, wherein the direction of a coordinate axis of the theoretical workpiece coordinate system is consistent with the direction of the coordinate axis of the initial reference coordinate system; s2, spraying the fixed point positions by using a theoretical workpiece coordinate system to form spots with first centers; step S3, determining a first deviation value of a first center relative to an origin of a theoretical workpiece coordinate system; and step S4, if the first deviation value is larger than the threshold value, the theoretical workpiece coordinate system is compensated by using the first deviation value to obtain a calibrated workpiece coordinate system. Therefore, the calibration method provided by the application can obtain higher coating roughness or improve spraying precision, and is suitable for rough metal coatings and porous ceramic coatings. Meanwhile, the method provided by the application can realize accurate spraying of the coating without complex processing in the aspects of programming and programming, and can be flexibly applied to various workpieces and application scenes of manufacturing and processing of various workpieces. The method can avoid or obviously reduce the positioning of the spray nozzle relative to the workpiece for multiple times according to the field observation result of the spray nozzle by an operator and the multiple manual inputs and the multiple manual movements of the spray nozzle required by the spray system for different workpiece geometries, thereby realizing the adjustment of the workpiece coordinate system in the spray system for different workpiece geometries in an automatic mode without or with little manual intervention and fundamentally avoiding or reducing the multiple manual operations required by the operator of the spray system for different types of workpieces or different workpiece geometries.
According to an exemplary embodiment of the application, the method further comprises: s5, spraying the fixed point positions by using a calibration workpiece coordinate system to form spots with second centers; step S6, determining a second deviation value of a second center relative to an origin of the theoretical workpiece coordinate system; step S7, if the second deviation value is larger than the threshold value, the theoretical workpiece coordinate system is compensated by using the second deviation value to obtain a calibration workpiece coordinate system, and the step S5 is returned to; and step S8, if the second deviation value is smaller than or equal to the threshold value, the workpiece coordinate system is calibrated for spraying of the actual product. The calibration method provided by the application enables the actual spot center of spraying to be consistent with the theoretical projection center or be in an acceptable range, and avoids the problem of time consumption and material consumption of spraying caused by planning more spraying paths in actual spraying.
According to an exemplary embodiment of the present application, there is a protrusion formed of a spray material in the region of the spot, and the first center and the second center are defined as the highest points of the protrusions, respectively. This results in a significant improvement in the accuracy of the calibrated spray coating such that the actual spot center of the spray coating coincides with the theoretical projected center or is within a predetermined acceptable range.
According to an exemplary embodiment of the present application, the spray coating is performed for fixed spots on the test plate. Before the actual spraying is performed, spots of the spraying system can be calibrated on the test platform, so that more spraying paths are prevented from being planned in the actual spraying, and the spraying time and the material consumption are avoided.
According to an exemplary embodiment of the application, the nozzle center of the spray system is projected onto a fixed point location prior to spraying. The calibrated spray system can be such that the actual spot center of the spray coincides with the theoretical projected center or is within a predetermined acceptable range.
According to an exemplary embodiment of the present application, an image sensor is used to determine a first deviation value, a second deviation value, and a highest point. This improves the accuracy and efficiency of automated spot calibration of the spray system, enabling a rapid calibration process prior to actual product spraying.
According to an exemplary embodiment of the present application, the first deviation value, the second deviation value, and the highest point are determined visually using a scale. This reduces the cost of spot calibration of the spray system, increases the flexibility of the calibration process, and is suitable for more incompatible test or calibration environments.
According to an exemplary embodiment of the application, a spray coating system is used for spraying a gas turbine blade. The method according to the application is suitable for rough metal coatings as well as for porous ceramic coatings.
According to a preferred embodiment of the present application, there is also provided in a further aspect a computer readable storage medium having a computer program stored thereon, wherein the method described above is implemented when the computer program is executed by a processor.
There is also provided in accordance with a preferred embodiment of the present application, in another aspect, a spray coating system employing a single feed plasma spray coating process, wherein the spray coating system includes a processor and a computer readable storage medium as described above, wherein a computer program is executed by the processor prior to the spray coating system spraying an actual product, whereby the spray coating system sprays the actual product using a calibrated workpiece coordinate system.
Drawings
The above and other features and advantages of the present application will become more apparent to those of ordinary skill in the art by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a flow chart of a method for calibration of a spray coating system according to an embodiment of the application;
FIG. 2 is a schematic illustration of a workpiece coordinate system used by a method for calibration of a spray coating system in accordance with an embodiment of the application;
FIG. 3 is a flow chart of a method for calibration of a spray coating system according to an embodiment of the application.
Detailed Description
The following examples illustrate the application in further detail in order to make the objects, technical solutions and advantages of the application more apparent.
FIG. 1 is a flow chart of a method for calibration of a spray coating system according to an embodiment of the application. FIG. 2 is a schematic illustration of a workpiece coordinate system used by a method for calibration of a spray coating system in accordance with an embodiment of the application. In an embodiment of the application, a method for calibration of a spray coating system is used for a spray coating system employing a single powder feed plasma spray coating process, for example, the spray coating system is used for spraying gas turbine blades. The method according to the flow chart shown in fig. 1 comprises the following steps.
In step S1, a theoretical workpiece coordinate system is defined based on an initial reference coordinate system of the spray coating system. In this step, an initial working or reference coordinate system F0 is first defined (e.g., custom or redefined based on the spray system). After defining the initial reference coordinate system of the spray system, all programmed points and directions of the spray robot of the spray system are based on the reference coordinate system. Based on the reference coordinate system F0, another coordinate system or reference coordinate system is newly defined or copied as a theoretical workpiece coordinate system FA, the direction of which coincides with the direction of the coordinate axes of the initial reference coordinate system F0, which is suitable for theoretical trajectory programming of the actual product, i.e. plasma spray (APS) theoretical trajectory point calibration (APS gun spray center projection is aligned with the prescribed position of the workpiece (i.e. gun theoretical center) but which is not used for actual workpiece spray, in one embodiment, a directional programmed coordinate system or theoretical workpiece coordinate system fa=f (X0, Y0, Z0) is created based on the initial reference coordinate system FO, in which a spray program is created in a computer readable storage medium using the theoretical workpiece coordinate system FA for subsequent spray work, such that the gun spray center projection is on a fixed one point a, e.g. point a shown in the coordinate system shown in fig. 2, wherein the coordinate system has a horizontal axis X and a vertical axis with positive directions, respectively, and the Z axis (is depicted as a simple and vertical axis is not depicted).
In step S2, a spray is performed for a fixed point location using the theoretical workpiece coordinate system to form a spot having a first center. For example, in this step, one spot is sprayed using the spraying program created in step S1, for example, spraying is continued for a predetermined time (for example, several seconds or several minutes) for a fixed spot on the test panel. Subsequently, in one embodiment, the center or highest point B of the spot shown in fig. 2 is determined using an image sensor, or in another embodiment, the center or highest point B of the spot is determined by visual means using a scale. In the area of the spot there is a bulge formed by the spray material, the first centre being defined as the highest point of the bulge.
In step S3, a first deviation value of the first center with respect to the origin of the theoretical workpiece coordinate system is determined. For example, in step S3, the deviation values x1, y1, z1 of the origin or point location a of the spot center B shown in fig. 2 with respect to the theoretical workpiece coordinate system FA or the reference coordinate system FO in a defined direction are checked, for example, x1= -11.5mm, y1=16 mm, z1=0.
In step S4, if the first deviation value is greater than the threshold value, the theoretical workpiece coordinate system is compensated using the first deviation value to obtain a calibrated workpiece coordinate system. For example, in one embodiment, the threshold is set by the experience of the operator. Thus, if the operator empirically determines that the deviation value is too large, resulting in too large a deviation of the center of the spot from the intended center, in a subsequent operation, an assignment process is performed in the program such that the calibration workpiece coordinate system fb=fa+ (-x 1, -y1, -z 1) =f (x 0, y0, z 0) +(-x 1, -y1, -z 1). For example, by duplicating the theoretical workpiece coordinate system FA and redefining another workpiece coordinate system FB, the coordinate system is compensated based on the compensation values to obtain a calibrated workpiece coordinate system for use in an actual product or spot spraying process, so that the center of the spot sprayed by the spray gun is projected at the theoretical center of the original spray gun during the spraying process. In one embodiment, the theoretical workpiece coordinate system FA is replicated and the aligned workpiece coordinate system fb=f (x 0, y0, z 0) with the direction is renamed or defined.
FIG. 3 is a flow chart of a method for calibration of a spray coating system according to an embodiment of the application. The method according to an embodiment of the application further comprises the following steps.
Step S5, spraying is conducted on the fixed point positions by using a calibration workpiece coordinate system so as to form spots with second centers. In the area of the spot there is a bulge formed by the spray material, the second centre being defined as the highest point of the bulge. In one embodiment, the assigned calibration workpiece coordinate system FB or assignment program is applied to the blob calibration program and a blob is painted to re-determine if the blob center B coincides with the point A of the theoretical center.
Step S6, determining a second deviation value of the second center relative to the origin of the theoretical workpiece coordinate system.
Step S7, if the second deviation value is larger than the threshold value, the theoretical workpiece coordinate system is compensated by using the second deviation value to obtain a calibration workpiece coordinate system, and the step S5 is returned.
And S8, if the second deviation value is smaller than or equal to the threshold value, the calibration workpiece coordinate system is used for spraying of the actual product. If the center B of the repainted spot coincides with the point A of the theoretical center, the calibrated workpiece coordinate system FB may be applied to the actual product spray, and if there is a deviation, the process described above continues to be implemented for repeated calibration.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present application and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that embodiments of the application described herein may be implemented in sequences other than those illustrated or otherwise described herein.
The foregoing description of the preferred embodiments of the application is not intended to be limiting, but rather is intended to cover all modifications, equivalents, alternatives, and improvements that fall within the spirit and scope of the application.
Claims (10)
1. A method for calibration of a spray coating system employing a single feed plasma spray coating process, the method comprising:
step S1, defining a theoretical workpiece coordinate system based on an initial reference coordinate system of the spraying system, wherein the direction of a coordinate axis of the theoretical workpiece coordinate system is consistent with the direction of the coordinate axis of the initial reference coordinate system;
s2, spraying aiming at fixed points by using the theoretical workpiece coordinate system so as to form spots with a first center;
step S3, determining a first deviation value of the first center relative to an origin of the theoretical workpiece coordinate system; and
and S4, if the first deviation value is larger than a threshold value, compensating the theoretical workpiece coordinate system by using the first deviation value to obtain a calibrated workpiece coordinate system.
2. The method according to claim 1, wherein the method further comprises:
s5, spraying aiming at fixed points by using the calibration workpiece coordinate system so as to form spots with second centers;
step S6, determining a second deviation value of the second center relative to the origin of the theoretical workpiece coordinate system;
step S7, if the second deviation value is greater than the threshold value, compensating the theoretical workpiece coordinate system using the second deviation value to obtain a calibrated workpiece coordinate system, and returning to the step S5; and
and S8, if the second deviation value is smaller than or equal to the threshold value, using the calibration workpiece coordinate system for spraying of actual products.
3. The method according to claim 2, characterized in that in the area of the spot there is a bulge formed by the spray material, the first center and the second center being defined as the highest point of the bulge, respectively.
4. The method of claim 2, wherein the fixed spot is sprayed on a test plate.
5. The method of claim 2, wherein the nozzle center of the spray system is projected onto the fixed point location prior to spraying.
6. A method according to claim 3, characterized in that the first deviation value, the second deviation value and the highest point are determined using an image sensor.
7. A method according to claim 3, wherein the first, second and highest points are determined visually using a scale.
8. The method of claim 1, wherein the spray system is used to spray gas turbine blades.
9. A computer readable storage medium, on which a computer program is stored, characterized in that the method according to any one of claims 1 to 8 is implemented when the computer program is executed by a processor.
10. A spray coating system employing a single feed plasma spray coating process, wherein the spray coating system comprises a processor and a computer readable storage medium according to claim 9, wherein the computer program is executed by the processor prior to the spray coating system spraying an actual product, whereby the spray coating system sprays an actual product using the calibrated workpiece coordinate system.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310694392.5A CN116695049A (en) | 2023-06-09 | 2023-06-09 | Method for calibrating a spray coating system and spray coating system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310694392.5A CN116695049A (en) | 2023-06-09 | 2023-06-09 | Method for calibrating a spray coating system and spray coating system |
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| Publication Number | Publication Date |
|---|---|
| CN116695049A true CN116695049A (en) | 2023-09-05 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202310694392.5A Pending CN116695049A (en) | 2023-06-09 | 2023-06-09 | Method for calibrating a spray coating system and spray coating system |
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- 2023-06-09 CN CN202310694392.5A patent/CN116695049A/en active Pending
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