CN117344261A - Multi-robot collaborative automatic spraying system and method for turbine guide blades - Google Patents
Multi-robot collaborative automatic spraying system and method for turbine guide blades Download PDFInfo
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- CN117344261A CN117344261A CN202311266723.1A CN202311266723A CN117344261A CN 117344261 A CN117344261 A CN 117344261A CN 202311266723 A CN202311266723 A CN 202311266723A CN 117344261 A CN117344261 A CN 117344261A
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- 238000005507 spraying Methods 0.000 title claims abstract description 63
- 238000000034 method Methods 0.000 title claims abstract description 25
- 239000004576 sand Substances 0.000 claims abstract description 157
- 238000007664 blowing Methods 0.000 claims abstract description 156
- 238000010285 flame spraying Methods 0.000 claims abstract description 78
- 238000007750 plasma spraying Methods 0.000 claims abstract description 65
- 238000000576 coating method Methods 0.000 claims abstract description 40
- 238000001514 detection method Methods 0.000 claims abstract description 38
- 239000011248 coating agent Substances 0.000 claims abstract description 37
- 238000004140 cleaning Methods 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims abstract description 4
- 239000007921 spray Substances 0.000 claims description 21
- 238000007689 inspection Methods 0.000 claims description 15
- 238000011179 visual inspection Methods 0.000 claims description 12
- 238000009529 body temperature measurement Methods 0.000 claims description 9
- 239000000428 dust Substances 0.000 claims description 9
- 238000004064 recycling Methods 0.000 claims description 9
- 238000012216 screening Methods 0.000 claims description 9
- 230000000007 visual effect Effects 0.000 claims description 9
- 238000009413 insulation Methods 0.000 claims description 7
- 238000004891 communication Methods 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 3
- 238000010926 purge Methods 0.000 claims description 3
- 239000002344 surface layer Substances 0.000 claims description 3
- 238000004804 winding Methods 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 claims description 2
- 239000012720 thermal barrier coating Substances 0.000 abstract description 16
- 238000004519 manufacturing process Methods 0.000 abstract description 11
- 238000002360 preparation method Methods 0.000 abstract description 10
- 238000012797 qualification Methods 0.000 abstract description 5
- 238000002679 ablation Methods 0.000 abstract description 3
- 230000010354 integration Effects 0.000 abstract description 3
- 238000005422 blasting Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000007306 turnover Effects 0.000 description 2
- 241001022572 Triplax Species 0.000 description 1
- SYCBLWWKDXQZRR-UHFFFAOYSA-N [Ni].[W].[Cr] Chemical compound [Ni].[W].[Cr] SYCBLWWKDXQZRR-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
Classifications
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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
- 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
- C23C4/129—Flame spraying
-
- 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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
A multi-robot collaborative automatic spraying system and a method for turbine guide vanes are provided, wherein the system is divided into an upper/lower material area, a sand blowing area, a spraying area and a coating thickness detection area; the method comprises the following steps: part online, sand blowing, cleaning after sand blowing, sand blowing surface state detection, surface structure light detection, supersonic flame spraying, atmosphere plasma spraying surface structure light detection and part offline. The multi-robot cooperative automatic spraying system and the method for the turbine guide blades realize multi-station integration of the turbine guide blades during preparation of the thermal barrier coating, the thermal barrier coating prepared on the surfaces of the turbine guide blades has the characteristics of high stability and high qualification rate through cooperative automatic spraying of the multiple robots, the service temperature of the turbine guide blades is improved, the high-temperature and high-pressure use working conditions of the turbine guide blades in an aeroengine are met, the scrappage of parts of the turbine guide blades caused by over-temperature ablation is avoided, and the production yield and the production efficiency of the thermal barrier coating are improved, so that the production cost of the turbine guide blades is reduced.
Description
Technical Field
The invention belongs to the technical field of aeroengine part manufacturing, and particularly relates to a multi-robot collaborative automatic spraying system and method for turbine guide vanes.
Background
Aeroengines are typically turbofan engines consisting of a fan, a compressor, a combustion chamber, a turbine and a tail nozzle in that order from front to back, wherein the turbine section is required to withstand high temperature, high pressure gas washout up to 2000 ℃. In order to ensure that the turbine guide vane can normally work under a severe service environment, MCrAlY/ZrO is generally prepared on the surface of a gas flow passage of the turbine guide vane 2 The thermal barrier coating is used for achieving the heat insulation effect and improving the high-temperature oxidation resistance of the turbine guide blade.
The traditional preparation method of the thermal barrier coating can be divided into sand blowing before spraying, supersonic spraying MCrAlY and atmospheric plasma spraying ZrO 2 Cooling, cleaning, etc., wherein the pre-spray blasting is generally manual blasting, and the supersonic spraying MCrAlY and atmospheric plasma spraying ZrO 2 All are single-procedure automatic spraying.
However, the conventional thermal barrier coating preparation method has several problems:
(1) the preparation process of the thermal barrier coating of the turbine guide blade needs to use different process equipment, and needs to carry out turnover among a plurality of working procedures, so that the surface of the turbine guide blade and the surface of the coating are easy to pollute, and the bonding force of the coating is reduced.
(2) The preparation of the thermal barrier coating of the turbine guide vane belongs to single-piece production, frequent disassembly and assembly are needed during turnover among working procedures, so that the production efficiency is low, and the spraying equipment needs to be started and stopped frequently, so that the service life of a spray gun of the spraying equipment is shortened.
(3) The turbine guide vane is a multi-curved complex-surface part, the coating thickness of the surface of the part cannot be directly detected, and the coating thickness is generally detected in a patch mode, so that a certain detection error exists, and the thickness of the detection position cannot represent the coating thickness of all the surface positions of the turbine guide vane.
The problems mentioned above are caused by the conventional thermal barrier coating preparation method, so that the turbine guide vane production cannot meet the increasing task and product quality requirements.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention provides the multi-robot cooperative automatic spraying system and the method for the turbine guide blade, which realize multi-station integration of the turbine guide blade during preparation of the thermal barrier coating, and the thermal barrier coating prepared on the surface of the turbine guide blade has the characteristics of high stability and high qualification rate through the cooperative automatic spraying of multiple robots, so that the service temperature of the turbine guide blade can be further improved, the high-temperature and high-pressure use working condition of the turbine guide blade in an aeroengine can be met, the scrapping of parts of the turbine guide blade caused by over-temperature ablation can be avoided, and the production cost of the turbine guide blade can be further reduced through improving the qualification rate and the production efficiency of the thermal barrier coating preparation.
In order to achieve the above purpose, the present invention adopts the following technical scheme: the multi-robot collaborative automatic spraying system for the turbine guide vane comprises an upper/lower material area, a sand blowing area, a spraying area and a coating thickness detection area;
the feeding/discharging area comprises a speed-multiplying chain, a part information visual acquisition subsystem, a PLC and a computer; the double-speed chain path sand blowing area, the spraying area and the coating thickness detection area; the part information visual acquisition subsystem is in communication connection with the PLC and the computer;
the sand blowing area is divided into a sand blowing station and an inspection station, and the sand blowing station and the inspection station are distributed in parallel; the sand blowing station comprises a sand blowing station robot, a sand blowing gun, a gravel screening and recycling device and a dust removing subsystem; the inspection station comprises a sand blowing surface state visual inspection subsystem; the sand blowing station robots are arranged adjacent to the speed doubling chain, the sand blowing guns are arranged adjacent to the sand blowing station robots, and the sand blowing guns are distributed along the circumferential direction; the gravel screening and recycling device is arranged adjacent to the sand blowing station robot; the dust removing subsystem is arranged adjacent to the gravel screening and recycling device; the visual inspection subsystem for the state of the sand blowing surface is arranged adjacent to the sand blowing station robot; the whole sand blowing area is sealed by adopting a sound insulation plate, and a linkage bin gate is arranged on the sound insulation plate between the sand blowing station robot and the speed doubling chain;
the spraying area is divided into a supersonic flame spraying station and an atmospheric plasma spraying station; the ultrasonic flame spraying station comprises a first ultrasonic flame spraying station robot, a second ultrasonic flame spraying station robot, a ultrasonic flame spray gun and a first thermal infrared imager temperature measuring subsystem; the first supersonic flame spraying station robot and the second supersonic flame spraying station robot are arranged in parallel, and the supersonic flame spray gun is arranged on the first supersonic flame spraying station robot; the first thermal infrared imager temperature measurement subsystem is arranged adjacent to the second supersonic flame spraying station robot, and the second supersonic flame spraying station robot is arranged adjacent to the speed doubling chain; the atmosphere plasma spraying station comprises a first atmosphere plasma spraying station robot, a second atmosphere plasma spraying station robot, an atmosphere plasma spray gun and a second thermal infrared imager temperature measuring subsystem; the first atmospheric plasma spraying station robot and the second atmospheric plasma spraying station robot are arranged in parallel, and the atmospheric plasma spray gun is arranged on the first atmospheric plasma spraying station robot; the second thermal infrared imager temperature measurement subsystem is arranged adjacent to the second atmospheric plasma spraying station robot, and the second atmospheric plasma spraying station robot is arranged adjacent to the speed multiplication chain;
the coating thickness detection area comprises a surface structure light scanner, and the surface structure light scanner is arranged adjacent to the supersonic flame spraying station and the atmospheric plasma spraying station.
The multi-robot collaborative automatic spraying method for the turbine guide vane adopts the multi-robot collaborative automatic spraying system for the turbine guide vane, and comprises the following steps:
step one: part winding
The method comprises the steps that an operator places a turbine guide blade on a double-speed chain, a part information visual acquisition subsystem identifies and acquires part types and batch numbers of the turbine guide blade, acquired information is automatically transmitted to a database of a PLC and a computer, and then the PLC sends instructions to equipment in a sand blowing area, a spraying area and a coating thickness detection area;
step two: sand blowing
Moving the turbine guide blade to the front of the linkage bin gate through the double-speed chain, then opening the linkage bin gate, grabbing the turbine guide blade by a sand blowing station robot, transferring the turbine guide blade from the double-speed chain to the sand blowing station, and then closing the linkage bin gate; four sand blowing guns are arranged in total, the first sand blowing gun is aligned with the upper edge plate of the turbine guide blade, the second sand blowing gun is aligned with the lower edge plate of the turbine guide blade, the third sand blowing gun and the fourth sand blowing gun are aligned with the blade body of the turbine guide blade, the four sand blowing guns are started to perform sand blowing treatment on the surface of the turbine guide blade, and a sand blowing station robot drives the turbine guide blade to rotate in the sand blowing treatment process until sand blowing is completed;
step three: cleaning after sand blowing
After the sand blowing is finished, closing the sand supply of the sand blowing gun, only keeping the compressed air supply of the sand blowing gun, and blowing residual gravel and dust on the surface of the turbine guide vane through the compressed air;
step four: sand blowing surface state detection
After purging, transferring the turbine guide blade into an inspection station through a sand blowing station robot, collecting pictures on the surface of the turbine guide blade through a sand blowing surface state visual inspection subsystem in the inspection station, and comparing the collected pictures with standard sand blowing pictures prestored in the sand blowing surface state visual inspection subsystem, wherein if the comparison result is in an allowable difference range, the sand blowing is judged to be qualified; otherwise, judging that the sand blowing station is unqualified, and re-transferring the turbine guide vane back to the sand blowing station for sand blowing again, and then re-detecting until the sand blowing station is judged that the sand blowing is qualified;
step five: surface structured light detection
After sand blowing is qualified, transferring the turbine guide blade to a double-speed chain through a sand blowing station robot, moving the turbine guide blade to the front of a supersonic flame spraying station through the double-speed chain, transferring the turbine guide blade to a coating thickness detection area through a second supersonic flame spraying station robot, and carrying out surface structure light scanning on the turbine guide blade through a surface structure light scanner to obtain a profile three-dimensional point cloud of the turbine guide blade before spraying;
step six: supersonic flame spraying
After the structured light scanning is completed, transferring the turbine guide blade back to a supersonic flame spraying station through a second supersonic flame spraying station robot, simultaneously clamping a supersonic flame spray gun by the first supersonic flame spraying station robot, and carrying out MCrAlY bottom spraying on the turbine guide blade by cooperating with the second supersonic flame spraying station robot according to a set program path; in the process of supersonic flame spraying, a first thermal infrared imager temperature measurement subsystem is used for monitoring the temperature of the turbine guide blade, and the temperature of the turbine guide blade is required to be not more than 380 ℃;
step seven: atmospheric plasma spraying
After the supersonic flame spraying is finished, transferring the turbine guide blade to a double-speed chain through a second supersonic flame spraying station robot, moving the turbine guide blade to the front of an atmospheric plasma spraying station through the double-speed chain, transferring the turbine guide blade to the atmospheric plasma spraying station through a second atmospheric plasma spraying station robot, simultaneously clamping an atmospheric plasma spray gun through a first atmospheric plasma spraying station robot, and carrying out ZrO on the turbine guide blade according to a set program path in cooperation with the second atmospheric plasma spraying station robot 2 Is sprayed on the surface layer; before atmospheric plasma spraying, the turbine guide vane needs to be preheated, and the preheating temperature is 150-170 ℃; in the atmospheric plasma spraying process, the temperature of the turbine guide blade is monitored through a second thermal infrared imager temperature measuring subsystem, and the temperature of the turbine guide blade is required to be not more than 380 ℃;
step eight: surface structured light detection
After spraying, transferring the turbine guide blade to a coating thickness detection area through a second supersonic flame spraying station robot, carrying out surface structure light scanning on the turbine guide blade through a surface structure light scanner to obtain the three-dimensional point cloud of the molded surface of the turbine guide blade after spraying, comparing the three-dimensional point cloud data of the molded surface of the turbine guide blade after spraying with the three-dimensional point cloud data of the molded surface of the turbine guide blade before spraying, and automatically obtaining the coating thickness of the surface spraying area of the turbine guide blade;
step nine: part offline
After the coating thickness detection is finished, the turbine guide blade is transferred to a double-speed chain through a second supersonic flame spraying station robot, the turbine guide blade is moved to the front of an operator through the double-speed chain, and the operator removes the turbine guide blade from the double-speed chain.
The invention has the beneficial effects that:
the multi-robot collaborative automatic spraying system and the method for the turbine guide blade realize multi-station integration of the turbine guide blade during preparation of the thermal barrier coating, and the thermal barrier coating prepared on the surface of the turbine guide blade has the characteristics of high stability and high qualification rate through the multi-robot collaborative automatic spraying, so that the service temperature of the turbine guide blade can be further improved, the high-temperature and high-pressure use condition of the turbine guide blade in an aeroengine can be met, the scrapping of parts of the turbine guide blade caused by over-temperature ablation is avoided, and the production cost of the turbine guide blade can be further reduced through improving the qualification rate and the production efficiency of the thermal barrier coating preparation.
Drawings
FIG. 1 is a schematic illustration of a turbine stator blade multi-robot collaborative automated spray system of the present invention;
FIG. 2 is a schematic diagram of a dual robot cooperative work;
FIG. 3 is a typical metallographic structure of a coating;
in the figure, a 1-speed chain, a 2-sand blowing station robot, a 3-first supersonic flame spraying station robot, a 4-second supersonic flame spraying station robot, a 5-supersonic flame spray gun, a 6-first atmosphere plasma spraying station robot, a 7-second atmosphere plasma spraying station robot, an 8-plane structured light scanner and 9-turbine guide vanes are shown.
Detailed Description
The invention will now be described in further detail with reference to the drawings and to specific examples.
In the embodiment, the model numbers of the sand blowing station robot 2, the first supersonic flame spraying station robot 3, the second supersonic flame spraying station robot 4, the first atmospheric plasma spraying station robot 6 and the second atmospheric plasma spraying station robot 7 are ABB-IRB-2600, the model number of the supersonic flame spraying gun 5 is WokASAR-610, and the model number of the atmospheric plasma spraying gun is Triplax; the spraying program path when the first supersonic flame spraying station robot 3 and the second supersonic flame spraying station robot 4 work cooperatively and the spraying program path when the first atmospheric plasma spraying station robot 6 and the second atmospheric plasma spraying station robot 7 work cooperatively are all non-interference spraying program paths which are automatically generated by taking the curved surface parameters of the turbine guide blade 9 as the basis and taking the spraying process parameters (spraying distance, spraying angle and the like) into consideration by adopting secondary development of UG software as a programming environment and matching with an Eigen matrix operation library and an Optode collision detection algorithm.
As shown in fig. 1, a multi-robot collaborative automatic spraying system for turbine guide vanes is divided into an upper/lower material area, a sand blowing area, a spraying area and a coating thickness detection area;
the feeding/discharging area comprises a speed chain 1, a part information visual acquisition subsystem, a PLC and a computer; the double-speed chain 1 is provided with a sand blowing area, a spraying area and a coating thickness detection area; the part information visual acquisition subsystem is in communication connection with the PLC and the computer;
the sand blowing area is divided into a sand blowing station and an inspection station, and the sand blowing station and the inspection station are distributed in parallel; the sand blowing station comprises a sand blowing station robot 2, a sand blowing gun, a gravel screening and recycling device and a dust removing subsystem; the inspection station comprises a sand blowing surface state visual inspection subsystem; the sand blowing station robot 2 is arranged adjacent to the speed doubling chain 1, the sand blowing guns are arranged adjacent to the sand blowing station robot 2, and a plurality of sand blowing guns are distributed along the circumferential direction; the gravel screening and recycling device is arranged adjacent to the sand blowing station robot 2; the dust removing subsystem is arranged adjacent to the gravel screening and recycling device; the visual inspection subsystem for the state of the sand blowing surface is arranged adjacent to the sand blowing station robot 2; the whole sand blowing area is sealed by adopting a sound insulation plate, and a linkage bin gate is arranged on the sound insulation plate between the sand blowing station robot 2 and the double-speed chain 1;
the spraying area is divided into a supersonic flame spraying station and an atmospheric plasma spraying station; the ultrasonic flame spraying station comprises a first ultrasonic flame spraying station robot 3, a second ultrasonic flame spraying station robot 4, a ultrasonic flame spray gun 5 and a first infrared thermal imager temperature measurement subsystem; the first supersonic flame spraying station robot 3 and the second supersonic flame spraying station robot 4 are arranged in parallel, and the supersonic flame spraying gun 5 is installed on the first supersonic flame spraying station robot 3; the first thermal infrared imager temperature measurement subsystem is arranged adjacent to the second supersonic flame spraying station robot 4, and the second supersonic flame spraying station robot 4 is arranged adjacent to the speed doubling chain 1; the atmosphere plasma spraying station comprises a first atmosphere plasma spraying station robot 6, a second atmosphere plasma spraying station robot 7, an atmosphere plasma spray gun and a second thermal infrared imager temperature measuring subsystem; the first atmospheric plasma spraying station robot 6 and the second atmospheric plasma spraying station robot 7 are arranged in parallel, and the atmospheric plasma spray gun is arranged on the first atmospheric plasma spraying station robot 6; the second thermal infrared imager temperature measurement subsystem is arranged adjacent to the second atmospheric plasma spraying station robot 7, and the second atmospheric plasma spraying station robot 7 is arranged adjacent to the double-speed chain 1;
the coating thickness detection area comprises a surface structure light scanner 8, and the surface structure light scanner 8 is arranged adjacent to the supersonic flame spraying station and the atmospheric plasma spraying station.
The multi-robot collaborative automatic spraying method for the turbine guide vane adopts the multi-robot collaborative automatic spraying system for the turbine guide vane, and comprises the following steps:
step one: part winding
The method comprises the steps that an operator places a turbine guide blade 9 on a double-speed chain 1, a part information visual acquisition subsystem identifies and acquires part types and batch numbers of the turbine guide blade 9, acquired information is automatically transmitted to a database of a PLC and a computer, and then the PLC sends instructions to equipment in a sand blowing area, a spraying area and a coating thickness detection area;
step two: sand blowing
The turbine guide vane 9 is moved to the front of a linkage bin gate through the double-speed chain 1, then the linkage bin gate is opened, the turbine guide vane 9 is grabbed by the sand blowing station robot 2, the turbine guide vane 9 is transferred into the sand blowing station from the double-speed chain 1, and then the linkage bin gate is closed; four sand blowing guns are arranged in total, the first sand blowing gun is aligned with the upper edge plate of the turbine guide blade 9, the second sand blowing gun is aligned with the lower edge plate of the turbine guide blade 9, the third sand blowing gun and the fourth sand blowing gun are aligned with the blade body of the turbine guide blade 9, the four sand blowing guns are started to perform sand blowing treatment on the surface of the turbine guide blade 9, and the sand blowing station robot 2 drives the turbine guide blade 9 to rotate in the sand blowing treatment process until sand blowing is completed; specifically, the linkage bin gate is automatically closed, so that gravel can be prevented from entering the double-speed chain 1 during sand blowing, and the double-speed chain 1 is prevented from being damaged due to the entering of the gravel;
step three: cleaning after sand blowing
After the blowing of the sand is completed, the sand supply of the sand blowing gun is closed, only the compressed air supply of the sand blowing gun is reserved, and the residual gravel and dust on the surface of the turbine guide vane 9 are purged through the compressed air;
step four: sand blowing surface state detection
After purging, transferring the turbine guide blade 9 into an inspection station through the sand blowing station robot 2, collecting pictures on the surface of the turbine guide blade 9 through a sand blowing surface state visual inspection subsystem in the inspection station, and comparing the collected pictures with standard sand blowing pictures prestored in the sand blowing surface state visual inspection subsystem, wherein if the comparison result is in an allowable difference range, the sand blowing is judged to be qualified; otherwise, judging that the sand blowing station is unqualified, and re-transferring the turbine guide vane 9 back to the sand blowing station for sand blowing again, and then re-detecting until the sand blowing is judged to be qualified;
step five: surface structured light detection
After sand blowing is qualified, transferring the turbine guide blade 9 to a double-speed chain 1 through a sand blowing station robot 2, moving the turbine guide blade 9 to the front of a supersonic flame spraying station through the double-speed chain 1, transferring the turbine guide blade 9 to a coating thickness detection area through a second supersonic flame spraying station robot 4, and carrying out surface structure light scanning on the turbine guide blade 9 through a surface structure light scanner 8 to obtain a molded surface three-dimensional point cloud of the turbine guide blade 9 before spraying;
step six: supersonic flame spraying
After the structured light scanning is completed, the turbine guide blade 9 is transferred back to the supersonic flame spraying station through the second supersonic flame spraying station robot 4, meanwhile, the supersonic flame spraying gun 5 is clamped by the first supersonic flame spraying station robot 3, and is cooperated with the second supersonic flame spraying station robot 4 according to a set program path to carry out MCrAlY bottom spraying on the turbine guide blade 9, and the MCrAlY coating technological parameters are shown in table 1; as shown in fig. 2, a schematic diagram of the cooperation of the first supersonic flame spraying station robot 3 and the second supersonic flame spraying station robot 4 is shown; in the process of supersonic flame spraying, the temperature of the turbine guide vane 9 is monitored through a first thermal infrared imager temperature measuring subsystem, the temperature of the turbine guide vane 9 is required to be not more than 380 ℃, and the phenomenon that a coating forms larger internal stress due to overhigh temperature to cause cracks or flaking is avoided;
table 1 coating process parameters of mcraly
| Aviation kerosene (l/h) | O 2 (NLPM) | Scraper type | Turntable speed (%) | Spray distance (mm) | |
| Nickel-chromium-tungsten | 18 | 830 | NL | 30 | 350 |
Step seven: atmospheric plasma spraying
After the supersonic flame spraying is completed, the turbine guide vane 9 is transferred to the double speed chain 1 through the second supersonic flame spraying station robot 4, the turbine guide vane 9 is moved to the front of the atmospheric plasma spraying station through the double speed chain 1, then the turbine guide vane 9 is transferred to the atmospheric plasma spraying station through the second atmospheric plasma spraying station robot 7, the atmospheric plasma spraying gun is clamped by the first atmospheric plasma spraying station robot 6, and the ZrO is carried out on the turbine guide vane 9 according to the set program path in cooperation with the second atmospheric plasma spraying station robot 7 2 Surface layer spraying of ZrO 2 The coating process parameters of (2) are as shown in Table 2; before atmospheric plasma spraying, the turbine guide vane 9 needs to be preheated, and the preheating temperature is 150-170 ℃ to improve the binding force of the coating; in the atmospheric plasma spraying process, the temperature of the turbine guide vane 9 is monitored through the second thermal infrared imager temperature measuring subsystem, the temperature of the turbine guide vane 9 is required to be not higher than 380 ℃, and the coating is prevented from forming larger internal stress due to overhigh temperature to cause cracks or peeling;
TABLE 2 ZrO 2 Coating process parameters of (2)
Step eight: surface structured light detection
After the spraying is finished, transferring the turbine guide blade 9 to a coating thickness detection area through the second supersonic flame spraying station robot 4, scanning surface structure light of the turbine guide blade 9 through a surface structure light scanner 8, obtaining the three-dimensional point cloud of the molded surface of the turbine guide blade 9 after spraying, comparing the three-dimensional point cloud data of the molded surface of the turbine guide blade 9 after spraying with the three-dimensional point cloud data of the molded surface of the turbine guide blade 9 before spraying, and automatically obtaining the coating thickness of the surface spraying area of the turbine guide blade 9;
step nine: part offline
After the coating thickness detection is finished, the turbine guide blade 9 is transferred to the double speed chain 1 through the second supersonic flame spraying station robot 4, the turbine guide blade 9 is moved to the front of an operator through the double speed chain 1, and the operator removes the turbine guide blade 9 from the double speed chain 1.
The turbine guide vane 9 is MCrAlY/ZrO prepared by the multi-robot collaborative automatic spraying method of the invention 2 The thermal barrier coating has uniform white surface, no overburning discoloration, no cracking, tilting, peeling and other phenomena. Subsequently, the sprayed turbine guide vane 9 was subjected to destructive sampling, and microscopic observation was performed, as shown in fig. 3, to a typical metallographic structure of the coating at 200 times magnification, and the detection results are shown in table 3, which meet the standard requirements.
TABLE 3 coating microstructural examination results
The embodiments are not intended to limit the scope of the invention, but rather are intended to cover all equivalent implementations or modifications that can be made without departing from the scope of the invention.
Claims (2)
1. A turbine guide vane multi-robot collaborative automation spray system, characterized in that: the device comprises an upper/lower material area, a sand blowing area, a spraying area and a coating thickness detection area;
the feeding/discharging area comprises a speed-multiplying chain, a part information visual acquisition subsystem, a PLC and a computer; the double-speed chain path sand blowing area, the spraying area and the coating thickness detection area; the part information visual acquisition subsystem is in communication connection with the PLC and the computer;
the sand blowing area is divided into a sand blowing station and an inspection station, and the sand blowing station and the inspection station are distributed in parallel; the sand blowing station comprises a sand blowing station robot, a sand blowing gun, a gravel screening and recycling device and a dust removing subsystem; the inspection station comprises a sand blowing surface state visual inspection subsystem; the sand blowing station robots are arranged adjacent to the speed doubling chain, the sand blowing guns are arranged adjacent to the sand blowing station robots, and the sand blowing guns are distributed along the circumferential direction; the gravel screening and recycling device is arranged adjacent to the sand blowing station robot; the dust removing subsystem is arranged adjacent to the gravel screening and recycling device; the visual inspection subsystem for the state of the sand blowing surface is arranged adjacent to the sand blowing station robot; the whole sand blowing area is sealed by adopting a sound insulation plate, and a linkage bin gate is arranged on the sound insulation plate between the sand blowing station robot and the speed doubling chain;
the spraying area is divided into a supersonic flame spraying station and an atmospheric plasma spraying station; the ultrasonic flame spraying station comprises a first ultrasonic flame spraying station robot, a second ultrasonic flame spraying station robot, a ultrasonic flame spray gun and a first thermal infrared imager temperature measuring subsystem; the first supersonic flame spraying station robot and the second supersonic flame spraying station robot are arranged in parallel, and the supersonic flame spray gun is arranged on the first supersonic flame spraying station robot; the first thermal infrared imager temperature measurement subsystem is arranged adjacent to the second supersonic flame spraying station robot, and the second supersonic flame spraying station robot is arranged adjacent to the speed doubling chain; the atmosphere plasma spraying station comprises a first atmosphere plasma spraying station robot, a second atmosphere plasma spraying station robot, an atmosphere plasma spray gun and a second thermal infrared imager temperature measuring subsystem; the first atmospheric plasma spraying station robot and the second atmospheric plasma spraying station robot are arranged in parallel, and the atmospheric plasma spray gun is arranged on the first atmospheric plasma spraying station robot; the second thermal infrared imager temperature measurement subsystem is arranged adjacent to the second atmospheric plasma spraying station robot, and the second atmospheric plasma spraying station robot is arranged adjacent to the speed multiplication chain;
the coating thickness detection area comprises a surface structure light scanner, and the surface structure light scanner is arranged adjacent to the supersonic flame spraying station and the atmospheric plasma spraying station.
2. A multi-robot collaborative automatic spray coating method for turbine guide vanes, which adopts the multi-robot collaborative automatic spray coating system for turbine guide vanes according to claim 1, and is characterized by comprising the following steps:
step one: part winding
The method comprises the steps that an operator places a turbine guide blade on a double-speed chain, a part information visual acquisition subsystem identifies and acquires part types and batch numbers of the turbine guide blade, acquired information is automatically transmitted to a database of a PLC and a computer, and then the PLC sends instructions to equipment in a sand blowing area, a spraying area and a coating thickness detection area;
step two: sand blowing
Moving the turbine guide blade to the front of the linkage bin gate through the double-speed chain, then opening the linkage bin gate, grabbing the turbine guide blade by a sand blowing station robot, transferring the turbine guide blade from the double-speed chain to the sand blowing station, and then closing the linkage bin gate; four sand blowing guns are arranged in total, the first sand blowing gun is aligned with the upper edge plate of the turbine guide blade, the second sand blowing gun is aligned with the lower edge plate of the turbine guide blade, the third sand blowing gun and the fourth sand blowing gun are aligned with the blade body of the turbine guide blade, the four sand blowing guns are started to perform sand blowing treatment on the surface of the turbine guide blade, and a sand blowing station robot drives the turbine guide blade to rotate in the sand blowing treatment process until sand blowing is completed;
step three: cleaning after sand blowing
After the sand blowing is finished, closing the sand supply of the sand blowing gun, only keeping the compressed air supply of the sand blowing gun, and blowing residual gravel and dust on the surface of the turbine guide vane through the compressed air;
step four: sand blowing surface state detection
After purging, transferring the turbine guide blade into an inspection station through a sand blowing station robot, collecting pictures on the surface of the turbine guide blade through a sand blowing surface state visual inspection subsystem in the inspection station, and comparing the collected pictures with standard sand blowing pictures prestored in the sand blowing surface state visual inspection subsystem, wherein if the comparison result is in an allowable difference range, the sand blowing is judged to be qualified; otherwise, judging that the sand blowing station is unqualified, and re-transferring the turbine guide vane back to the sand blowing station for sand blowing again, and then re-detecting until the sand blowing station is judged that the sand blowing is qualified;
step five: surface structured light detection
After sand blowing is qualified, transferring the turbine guide blade to a double-speed chain through a sand blowing station robot, moving the turbine guide blade to the front of a supersonic flame spraying station through the double-speed chain, transferring the turbine guide blade to a coating thickness detection area through a second supersonic flame spraying station robot, and carrying out surface structure light scanning on the turbine guide blade through a surface structure light scanner to obtain a profile three-dimensional point cloud of the turbine guide blade before spraying;
step six: supersonic flame spraying
After the structured light scanning is completed, transferring the turbine guide blade back to a supersonic flame spraying station through a second supersonic flame spraying station robot, simultaneously clamping a supersonic flame spray gun by the first supersonic flame spraying station robot, and carrying out MCrAlY bottom spraying on the turbine guide blade by cooperating with the second supersonic flame spraying station robot according to a set program path; in the process of supersonic flame spraying, a first thermal infrared imager temperature measurement subsystem is used for monitoring the temperature of the turbine guide blade, and the temperature of the turbine guide blade is required to be not more than 380 ℃;
step seven: atmospheric plasma spraying
After the supersonic flame spraying is finished, transferring the turbine guide blade to a double-speed chain through a second supersonic flame spraying station robot, moving the turbine guide blade to the front of an atmospheric plasma spraying station through the double-speed chain, transferring the turbine guide blade to the atmospheric plasma spraying station through a second atmospheric plasma spraying station robot, simultaneously clamping an atmospheric plasma spray gun through a first atmospheric plasma spraying station robot, and carrying out ZrO on the turbine guide blade according to a set program path in cooperation with the second atmospheric plasma spraying station robot 2 Is sprayed on the surface layer; before atmospheric plasma spraying, the turbine guide vane needs to be preheated, and the preheating temperature is 150-170 ℃; in the atmospheric plasma spraying process, the temperature of the turbine guide blade is monitored through a second thermal infrared imager temperature measuring subsystem, and the temperature of the turbine guide blade is required to be not more than 380 ℃;
step eight: surface structured light detection
After spraying, transferring the turbine guide blade to a coating thickness detection area through a second supersonic flame spraying station robot, carrying out surface structure light scanning on the turbine guide blade through a surface structure light scanner to obtain the three-dimensional point cloud of the molded surface of the turbine guide blade after spraying, comparing the three-dimensional point cloud data of the molded surface of the turbine guide blade after spraying with the three-dimensional point cloud data of the molded surface of the turbine guide blade before spraying, and automatically obtaining the coating thickness of the surface spraying area of the turbine guide blade;
step nine: part offline
After the coating thickness detection is finished, the turbine guide blade is transferred to a double-speed chain through a second supersonic flame spraying station robot, the turbine guide blade is moved to the front of an operator through the double-speed chain, and the operator removes the turbine guide blade from the double-speed chain.
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