JP2000282214A - Method and device for thermal spray - Google Patents

Abstract

PROBLEM TO BE SOLVED: To securely form sprayed coating of required thickness, to eliminate the measurement of the thickness of the sprayed coating by manpower, to improve the reliability of the quality of the sprayed coating film and to stably form the uniform and clean sprayed coating film. SOLUTION: In the formation of sprayed coating film executed by jectting a high temp. melted thermal spraying material from a thermal spraying torch 1 together with a high temp. air flow and applying it on a thermal spraying base material 6, a carriage 2 is equipped with the thermal spraying torch 1 and a distance measuring head 5, prior to the thermal spraying, each distance of the plural points in the thermal spraying base material is measured by the head 5, the value in which the objective value of the thickness of the sprayed coating film is subtracted from the measured value of the distance is stored into a memory as the objective value of the distance, in the process of the thermal spraying, the thermal spraying base material is scanned by the torch 1, furthermore, the measured value of the distance by the head 5 in the surface directly after the thermal spraying is read in, and by the fact whether or not the measured value is shorter than the objective value of the distance on the memory, the condition whether or not the thickness of the sprayed coating has reached to the objective value is judged.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of spraying a material to be processed (sprayed substrate) to a sprayed torch from a sprayed torch together with a high-heated or semi-melted sprayed material together with a high-heated airflow. In particular, the present invention relates to confirmation of a thermal spray coating thickness during a thermal spraying operation.

[0002]

2. Description of the Related Art Thermal spraying methods for forming various functional coatings on the surface of an object by high thermal spraying include gas spraying, arc spraying, plasma spraying, and high-speed frame spraying. Generally, the required thickness of the sprayed coating is about 100 to 500 μm.
The film thickness formed per time (one pass) varies depending on the thermal spraying method, but is about 10 to 30 μm. In order to obtain a required film thickness, thermal spraying of several layers (several passes) needs to be repeated. . Therefore, in any of the spraying methods, in order to obtain a desired film thickness, conventionally, the spraying conditions and the obtained film thickness (one-pass film thickness) are obtained in advance, and the given film thickness and one-pass film for the required spraying conditions are obtained. Calculate the required number of passes from the film thickness,
The spraying of the number of passes is repeated. When this is done,
The film thickness was measured with a data sheet or the like and confirmed. If high film thickness accuracy and / or high reliability is required, measure the film thickness for each pass and repeat one-pass spraying until the desired film thickness is reached, or adjust the spraying conditions during the process. Is being done.

[0003]

The manual measurement of film thickness using a micrometer or the like may damage the sprayed coating, and may cause problems in measurement accuracy and reliability. Furthermore, since the temperature of the sprayed base material changes during measurement and the surface atmosphere changes, performing random film thickness measurement during several passes of thermal spraying may hinder the stable formation of a uniform functional coating. is there. In any case, manual measurement of the film thickness requires a large amount of labor, and when the film thickness is measured for each pass, the labor required to obtain a film having a required thickness becomes enormous. Not only that, this also contributes to low productivity of film formation. In particular, when a vacuum coating or a non-oxidizing gas atmosphere is to be formed around the spraying apparatus to form a clean film, the sprayed substrate is carried out from the space, the film thickness is measured, and the film is again carried into the space. When a measurement worker enters and exits the space, it takes time to control and adjust the atmosphere, not only greatly reducing the productivity, but also highly likely to contaminate the film.

A first object of the present invention is to reliably form a sprayed coating having a required thickness, and a second object to realize this without manual measurement of the thickness of the sprayed coating. A third object is to enhance the reliability of quality, and a fourth object is to stably form a uniform and clean thermal spray coating.

[0005]

Means for Solving the Problems (1) According to the present invention, a sprayed torch (1) is sprayed with a high-heat or semi-melted thermal spray material together with a high-temperature air stream, and the spray stream is applied to the thermal spray substrate (6, 36). To form a thermal spray coating on the surface thereof, prior to the thermal spraying operation, at least a torch support member (2) for supporting the thermal spray torch (1) and a thermal spray substrate (6, 36). One of them is driven relatively to the other, and each distance of a plurality of points of the sprayed substrate (6, 36) is measured by a distance measuring device (5) carried by the torch support member (2); During the spraying operation, the torch support member (3) is so arranged that the jet stream of the spraying torch (1) scans the sprayed substrate (6, 36).
And at least one of the sprayed substrates (6, 36) is driven relative to the other, and the distance of the surface of the sprayed substrate scanned by the jet stream is measured by the torch support member (2). The sprayed coating thickness has reached the target value in accordance with the value measured before the spraying operation (the value of the pre-spray measurement value table), the current measurement value and the target value of the sprayed coating thickness. Judge;
It is characterized by the following. In addition, in order to facilitate understanding, symbols or corresponding items of the corresponding elements of the embodiment shown in the drawings and described later are additionally provided in the parentheses for reference. The same applies to the following.

According to this, the sprayed base material (6, 3
The difference between the distance measurement value of 6) and the distance measurement value after the start of thermal spraying is the thermal spray coating thickness.Comparing this difference with the thermal spray coating thickness target value, the required film thickness is obtained with the difference ≧ target value. It can be assumed. Since both the distance measurement before the spraying operation and the distance measurement during the spraying operation are automatically performed, and the determination of the difference ≧ the target value is performed in real time during the spraying operation,
The labor for managing the thickness of the sprayed coating is drastically reduced, and the sprayed coating having the required thickness can be reliably formed. After starting the thermal spraying work, the space around the thermal spraying equipment can be shut off until the required film thickness is obtained, so that contamination of the thermal sprayed coating can be avoided. Can be formed stably.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS (2) The target distance of each point is calculated from the distance measured before the spraying operation and the target value of the thickness of the sprayed coating and written into a memory (target value table). The measured value at a point where the target distance is present in the memory is compared with the target distance to determine whether the sprayed coating thickness has reached the target value (see FIG. 6).
89-91, 101-103).

Since this process can be performed at a high speed by a computer, even when the scanning speed is high, the distance measurement sampling points can be determined with high density, and the automatic control of the sprayed coating thickness can be performed densely. (3) A spray torch (1) for injecting a high-heat-melted or semi-melted thermal spray material together with a high-temperature air stream; a torch support member (2) for supporting the spray torch; Scanning means for driving at least one of the torch support member (2) and the thermal spray substrate (6, 36) relative to the other so that the thermal spray substrate (6, 36) scans. FIG. 3); and a measuring instrument (5) supported by the torch support member (2) for detecting the thickness of the sprayed coating on the surface of the sprayed substrate scanned by the jet flow.

Using this thermal spraying apparatus, the above (1) and (2)
And the above-described functions and effects can be obtained. (4) A member (32) that is supported by the torch support member (2) so as to be rotatable about the spray nozzle with respect to the spraying torch (1) and that supports the measuring instrument (5). A thermal spraying device further comprising:

According to this, when the spraying torch (1) is scanned in the x direction, the spraying torch (1) and the measuring instrument (5) are arranged in the x direction and the spraying torch is scanned in the scanning direction. The rotation angle of the measuring instrument support member (32) can be set so as to be located behind (1), and when the spraying torch (1) is changed to scanning in the y direction, the spraying is performed. The turning angle of the measuring instrument support member (32) is set so that the torch (1) and the measuring instrument (5) are arranged in the y direction and located behind the spraying torch (1) in the scanning direction. Therefore, the degree of freedom in selecting the scanning direction is increased. (5) An electric spraying device further comprising an electric mechanism (FIG. 7) for driving the measuring instrument support member (32) to rotate about the injection nozzle of the spraying torch (1).

According to this, for example, a short y forward scan is performed next to a long y forward scan, a long y backward scan is performed, and then a short x forward scan is performed. Thus, y forward scan + x forward scan + y When the backward scanning is repeated and scanning is performed along the arc-shaped trajectory, the measuring instrument supporting member (32) is moved 180 degrees at the end point of the y forward scanning (or the starting point of the y backward scanning).
By rotating the measuring unit 5 degrees, the measuring instrument (5) which was located behind the scan in the y forward scan can be automatically driven backward in the y backward scan.

Other objects and features of the present invention will become apparent from the following description of embodiments with reference to the drawings.

[0013]

FIG. 1 shows the appearance of a first embodiment of the present invention. In this embodiment, there are two horizontal y-beams 4a and 4b above the floor, and a horizontal x-beam 3 is movably connected in the y-direction to these horizontal x-beams 3 and is movably in the x-direction. A torch carriage 2 is connected, and the plasma spraying torch 1 is supported by the carriage 2. The carriage 2 and the horizontal x-beam 3 are equipped with an electric x-drive device for driving the carriage 2 in the x direction, but the mechanism is not shown. The electric motor of the electric x-drive device is simply denoted by M in FIG.
Above, it is described as Mx.

The horizontal x-beam 3 and the horizontal y-beams 4a, 4b are equipped with an electric y-drive for driving the horizontal x-beam 3 in the y-direction, but their mechanisms are not shown. The electric y
The electric motor of the driving device is simply denoted by M on FIG. 2 and My on FIG. With these x, y driving devices, the plasma spraying torch 1 (downward plasma injection nozzle) can be positioned at an arbitrary point on an x, y plane of a predetermined size at a predetermined position.

In the embodiment shown in FIG. 1, a roll support stand (not shown) is provided on the floor, and a shaft chuck having an electric rotary drive mechanism is provided on the floor. Shafts 7a and 7b are fixedly supported.
Electric motor of electric rotary drive mechanism (Mr on FIGS. 2 and 3)
As a result, the shaft chuck is driven to rotate, whereby the roll 6 serving as the sprayed base material is rotated. Plasma spraying torch 1
Is above the top (apex) of the drum-shaped peripheral surface of the roll 6.

An arm 32 is fixed to the torch carriage 2, and a measuring head 5 of a laser distance meter is fixed to a tip of the arm 32. The aim line of the distance measurement of the measuring head 5 (the center line of the head 5) is orthogonal to the center line of the roll 6. The center line of the injection nozzle of the torch 1 and the center line of the head 5 are on the same y, z plane. At the time of thermal spraying, the roll 6 is driven to rotate in the direction of the arrow near the reference numeral 7a (hereinafter referred to as the counterclockwise direction). At that time, the roll surface facing the nozzle of the torch 1 is rolled. -Rule 6 is angle Dr
(°) reaches the target line of the measuring head 5 when rotated,
And cross it. In other words, the measurement head 5 is located behind (rotation angle Dr ° rearward) with respect to the rotation of the roll 6 serving as the sprayed substrate, that is, the scanning of the sprayed substrate.

The thermal spraying mechanism shown in FIG. 1 is a part of the thermal spraying system shown in FIG. A personal computer 41 is connected to the electric device of the junction box 30 as a host, and the personal computer 41 gives welding conditions and control commands to the electric device of the junction box 30 in accordance with the thermal spraying schedule.

FIG. 3 shows an outline of the electric elements of the junction box 30. The above-mentioned x, y drive mechanisms of the torch 1 have start-end limit switches Lxo, Ly for respectively defining the movement range.
and the end limit switches Lxe and Lye are provided. When the torch 1 is at the position corresponding to the start end of each mechanism, the start end limit switch is open, the end limit switch is closed, and the torch 1 is at the position corresponding to the start end. When the torch 1 is at a position corresponding to the end of each mechanism, the start limit switch is closed and the end limit switch is open when the torch 1 is at the position corresponding to the end of each mechanism.

Rotary encoders Rx, Ry, and Rr are coupled to the rotating shafts of the electric motors Mx, My, and Mr of the x, y moving mechanism and the substrate rotation driving mechanism, respectively. These generate one electric pulse per predetermined small angle rotation of the electric motor. The substrate rotation drive mechanism is provided with a rotary encoder Rh for detecting a rotation angle base point for generating one electric pulse per one rotation of the roll 6.

When driving the torch 1, when the controllers 21x and 21y including the microprocessor are energizing the electric motors Mx and My in the forward direction, the rotary encoders Rx and Ry are provided. Counts the electric pulses generated by the rotary encoder Rx, Ry when the reverse rotation is energized, and counts down the electric pulses generated by the rotary encoder Rx, Ry.
When the start limit switches Lxo and Lyo are open, the count value is cleared (count data is set to 0). For example, when power is supplied to the controller 21x, the controller 21x checks whether the start limit switch Lxo is open (the x position of the torch 1 is the start position) and closes it (at the start position). If no, the motor driver 22x is instructed to rotate the motor in the reverse direction, and the motor driver 22x closes the reverse rotation energizing circuit. The reverse rotation energizing circuit includes a start end limit switch Lxo and is closed, so that a reverse current flows through the electric motor Mx and the electric motor M
x rotates in reverse. By this reverse rotation, the starting end limit switch L
When xo opens, the reverse rotation energizing circuit opens and the electric motor
The reverse current to the motor Mx is cut off, and the electric motor Mx stops. On the other hand, when the start end limit switch Lzo is switched from the closed state to the open state, the controller 1x operates the motor driver 22x.
Is canceled, and the x movement position register (one area of the internal RAM of the microprocessor) is cleared. Here, the x movement position of the torch 1 is at the beginning of the x movement range, and x
The data of the movement position register indicates 0 (base point).

The operation of the controller 21y is the same as that of the controller 21x, and the operation of the motor driver 22y is also the same as that of the controller 22x. When the roll 6 is rotationally driven,
A controller 21R including a microprocessor is
The electric pulse generated by the tari encoder Rr is counted up, and when the rotary encoder Rh generates an electric pulse, the count value is initialized to zero. The count value is
Represents the rotation angle of the file 6 from the rotation angle base point.

In response to an instruction from the CPU 24, the controller 21c gives a signal for designating a spray current / voltage and ON (energization) / OFF (energization stop) to the thermal spraying power source 16 to which the torch 1 is connected, and supplies the fluid supply device. A signal for instructing on (gas supply) / off (stop supply) is given to 17, and a feed rate is supplied to a powder feeding device 18 for feeding a spray material powder, which is a raw material of a sprayed film, to the torch 1. And a signal instructing ON (supply) / OFF (supply stop). The CPU 24 is connected to the controller 21 via an input / output (I / O) port 23.
x, 21y, 21R and 21c, and the operation pendant 8 are selectively connected. This connection is specified by the CPU 24 via the system controller 25. CPU
A ROM 26 and a RAM 27 are connected to 24 address buses and data buses. System controller 2
5 is a control signal which the CPU 24 instructs the ROM 26, R
AM 27 and operation pendant 8.

Referring again to FIG. 2 for PC 41
A three-dimensional display 42, a keyboard and a mouse 43 are connected, and the entire computer system is configured as a control panel, and a personal computer 41 generates a thermal spraying schedule in response to an operator input. And a program for driving a spraying mechanism in accordance with a spraying schedule to perform spraying.

FIG. 4 shows the functions realized by the program according to the operation flow of the operator. Control panel 4
When the power is turned on to 0 and the personal computer 41 completes the initialization of the power-on response, the program is started and the spraying operation menu is displayed on the display. The main items on this menu are spraying condition creation and editing (spraying condition creation and spraying condition editing) Target thickness and pitch input Measurement before spraying Spraying Measurement data editing. The operator selects “spray condition creation / edit” in the display menu of the personal computer 41, and generates or edits the spray condition in the submenu “spray condition creation” or “spray condition edit”. And then select "Target thickness and pitch input" to set the target value of the thickness of the sprayed coating, the x-axis start position Xs, the end position Xe, the circumferential sampling pitch Pr and the x direction of the spray. The sampling pitch Px is input.

Next, the input key of the operation pendant 8 is operated to set the torch 1 to the x-axis start position Xs, and "measurement before thermal spraying" is selected and its execution (start) is instructed. I do. In response to this, the personal computer 41 executes “distance measurement before thermal spraying” 5. That is, a program for measuring the distance before thermal spraying is started, and the laser distance meter (head 5 + measuring circuit 5p) is started.
The distance is measured on the peripheral surface of the roll 6 according to c), and the measured value is written in the measured value table before thermal spraying (one area of the memory inside the personal computer 41). This content will be described later with reference to FIG. When this measurement is completed, the personal computer 41 automatically executes the "target distance calculation" 6, sequentially reads out the respective measured values of the measured value table before spraying, and subtracts the sprayed film target value from the read value. Is written in the target value table. When this is completed, the personal computer 41 notifies the completion of the target distance setting.

When the operator selects "spraying" and instructs the execution (start), the personal computer 41 starts the "spraying".
Execute This content will be described later with reference to FIG.
The "edit measurement data" 8 includes a distance before spraying (data of a measured value table before spraying) and a distance (i) immediately after each pass i of spraying in accordance with an operator's instruction (interactive input). Table data) is edited for output, and / or the sprayed coating thickness of each pass and the total coating thickness of all passes are calculated based on the data and edited for output. The data before and after editing is displayed on the display 42 and printed out by an externally connected printer in response to a print output instruction.

The contents of the "measurement before spraying" 5 will be described with reference to FIG. In this process, the personal computer 41 waits for a measurement start instruction from the input board 43 or the operation pendant 8. During this time, if there is an x, y drive input of the torch 1 from the operation pendant 8, the personal computer 41 receives this command. Is permitted to the CPU 24 (steps 51 and 52).
Hereinafter, the word “step” is omitted in parentheses, and step No. Write only numbers.

When there is a measurement start instruction, the personal computer 41
Instructs the relay box 30 to perform constant-speed rotation at the roll rotation speed (specified value) Vro in the thermal spraying conditions, and the CPU 24 designates this constant-speed rotation to the controller 21R (step 5).
3). The controller 21R starts the rotation drive of the roller 6, and when the rotation speed reaches approximately Vro, the constant speed control is started.
The speed ready is notified to the CPU 24,
The PU 24 notifies this to the personal computer 41 via the communication controller 9 (step 54). In response, the personal computer 41 instructs the relay box 30 (the CPU 24 thereof) to drive the torch to Xs (step 55), and the rotary encoder
Waiting for the pulse Rh to generate the angle reference pulse PRh (56), and when that occurs, counting up the pulse PRr generated by the rotary encoder Rr is started (5).
7) Wait for the count value to reach Dr (58). That is, the control waits until the position of the roll 6 in the circumferential direction (rotation angle base) reaches the target line of the measuring head 5.

When the count value reaches Dr, the personal computer 41
Instructs the relay box 30 to rotate at a constant speed at the x-direction torch drive speed (specified value) Vxo under the spraying conditions (59). Next, the personal computer's own Rr, Rx interrupt processing for counting up the number of generated pulses in response to the pulses generated by the rotary encoders Rr, Rx is permitted (set) (6).
0), the write address Ad of the pre-spray measurement value table is initialized (61). Then, the write address Ad is advanced to the first write address, where the laser distance meter (5 + 5)
The measured distance data of pc) is written (62). Rr, Rx
By permitting the interrupt processing, the count data of the count register CRr is incremented by one when the rotary encoder Rr generates one pulse, and the count register CRx is generated when the rotary encoder Rx generates one pulse.
Is incremented by one. The count data of the register CRr indicates the amount of rotation of the roll 6, and the count data of the register CRx indicates the amount of movement of the torch 1 in the x direction.

Thereafter, this rotation amount data (data CRr of the register CRr) is initialized for each rotation amount of the roll 6 in the circumferential direction by one pitch (Pr °) (63, 63). 6
4) The write address Ad of the pre-spray measurement value table is advanced next, and the measurement distance data of the laser distance meter (5 + 5 pc) is written there (65). By this repetition, the distance data between the head 5 and the roll surface on one round (first line) of the roll 6 is written in the pre-spray measurement value table at the Pr pitch.

When the writing for one round is completed, the rotary encoder Rh generates one pulse and the register CRx
Of the data CRx becomes 1. In response to this, the personal computer 41 prohibits the count-up (pulse PRr interruption) of the pulse generated by the rotary encoder Rr (6).
7, 68), and waits for the data of the register CRx to become equal to the pitch Px in the x direction (69). If so, the registers CRr and CRx are cleared (70), and the pulse PRr
The interrupt is permitted (71), the write address Ad of the pre-spray measurement value table is advanced, and the laser distance meter (5 + 5) is stored there.
The measured distance data of pc) is written (62).

Thereafter, the rotation amount data (data CRr of the register CRr) is initialized for each rotation amount of the roll 6 in the circumferential direction for one pitch (Pr °) (63, 63). 6
4) The write address Ad of the pre-spray measurement value table is advanced next, and the measurement distance data of the laser distance meter (5 + 5 pc) is written there (65). By this repetition, the distance data between the head 5 and the roll surface on one round (second line) of the roll 6 is written in the pre-spray measurement value table at the Pr pitch. The distance between the first line and the second line in the x direction is an x pitch Px.

The personal computer 41 repeats the writing of the above-mentioned measured value table before spraying of the measured distance value for each round until the torch 1 (head 5) is at the Xe position on the x-axis. And Xe
When the position is reached, the personal computer 41 stops the x drive of the torch 1 and stops the rotation drive of the roll 6.

Next, the personal computer 41 executes a “target distance calculation” 6
Proceeding to FIG. 4, the measured values of the measured value table before thermal spraying are sequentially read out, and a value obtained by subtracting the thermal spray coating target value from the measured value is used as a distance target value as a target value table (memory in the personal computer 41). Area). Next, the contents of the “spraying” 7 will be described with reference to FIG. Here, first, the spraying of the spray material plasma (the high-temperature gas flow in which the spray material powder is melted by the high-temperature plasma and contained in the plasma airflow) is started from the head 1 and the spray material plasma is injected under the spraying conditions (73, 7).
4). Then, when there is a start instruction, the roll 6 is driven to rotate at the rotation speed Vro within the spraying conditions (75, 76).

When the rotation speed of the roll 6 reaches Vro, the measured value table after the first pass spraying is set to write the measured distance value (77, 78), and the torch 1 is moved to the start position Xs. It drives (79) and clears the register PFF (80). In the following, data 0 of the register PFF means that the thermal spraying of the thermal spray coating thickness target value or more has been completed, and data 1 means that the thermal spray coating thickness is less than the target value (continuation of thermal spraying is necessary). .

Thereafter, the torch 1 (and the head 5) is driven in the x direction at the x drive speed Vxo in the thermal spraying conditions (81 to 84), as in the above-described distance measurement before thermal spraying. At a Pr pitch in the circumferential direction of the roll 6, the distance measurement value is written in the measurement value table after the first pass spraying (85 to 88), and at the same time, the distance target value at the corresponding position is read from the target value table. (89) It is checked whether the current distance measurement value> distance target value (spraying of the target thickness of the sprayed coating is not completed) (9)
0), if so, 1 in register PFF (need to continue thermal spraying)
Is written (91). Hereinafter, similarly to the above-described distance measurement before thermal spraying, the above-described distance measurement value is written to the table at the pitch Pr in the circumferential direction and the pitch Px in the x direction, and the distance measurement value> check of the target distance value (87 to 100) ).

When the torch 1 reaches the end position Xe, the personal computer 41 checks the data of the register PFF (101), and when the value is 1 (spraying of the target thickness of the sprayed coating has not been completed). If there is, the measured value table after spraying for the next pass
Then, the torch 1 is returned to the start position Xs, and the above-described one-pass spraying process (80 to 101) is performed again at step 80 and thereafter. At the start of the one-pass spraying process, the register PFF is cleared (80), and the data is set to 0.
(The spraying of the target thickness of the sprayed coating is completed). If the spraying is not completed (distance measurement value> distance target value) even at one of the sampling points of one-pass spraying (start points Xs to Xe), the register is set. Write 1 (spray not completed) to PFF (90, 9)
1) In this case, the process proceeds to the next pass of thermal spraying (101-).
102-79). Distance measurement value at all sampling points for 1-pass spraying ≤ target distance value (sprayed coating thickness is greater than target value)
, The writing of data 1 to the register PFF in step 91 is not executed, so that the data of the register PFF becomes 0.
(The thickness of the sprayed coating is more than the target value). At this time,
At the end of the pass, the thermal spraying is stopped (101, 1
03).

In the "editing of measurement data" 8, the personal computer 4
1 displays a measurement data edit menu on the display 42. Among them, there are the sprayed coating thickness calculation for each pass and the total coating thickness calculation. When the operator specifies the total coating thickness calculation, the personal computer 41 firstly calculates the distance measurement value table of the final pass (i is the maximum value). By specifying the distance measurement value table before spraying, the difference between the measurement values of the corresponding sampling points (same Ad) on both tables, that is, the total film thickness, is calculated and written in the total film thickness table. Display on the display. The thermal spray coating thickness calculation for each pass is specified, and the pass No. When j is input,
The personal computer 41 calculates the distance measurement value table of i = j and i = j
A distance measurement value table of -1 is designated, and the difference between the measurement values of the corresponding sampling points on both tables, that is, the thickness of the jth pass sprayed coating is calculated and written into the jth pass coating thickness table. And display it on the display. The operator designates a table (data group) being displayed on the display and a table (data group) on the memory and designates a layout and a quantity display form (numerical display, graph display) on the display. ) Can be edited and printed.

Second Embodiment FIG. 7 shows an outline of the mechanism of the second embodiment. In the second embodiment, the thermal spray base 36 is scanned two-dimensionally in x and y by the plasma spraying torch 1. A two-dot chain line on the thermal spray substrate 36,
An example of a bow-shaped two-dimensional scanning trajectory is shown. In order to measure the sprayed coating thickness (distance between the head 5 and the base material 36) immediately after each thermal spraying pass (in real time) during thermal spraying, the head 5 for distance measurement must be positioned behind the travel of the head 1. Must. In the case of the scanning trajectory shown in FIG. 7, after scanning in the + y direction is completed, driving is performed for a predetermined distance in the x direction, and when scanning is performed in the -y direction, the arm 32 supporting the distance measuring head 5 of the laser distance meter. Must be rotated 180 degrees around the torch 1 injection nozzle. In order to automatically and smoothly perform such a rotational drive at a high speed, a ring-shaped spur gear is rotatably rotated around the torch 1 and suspended and supported by the torch carriage 2, and a head supporting arm is mounted on the spur gear. The small diameter gear meshed with the spur gear is rotationally driven by the electric motor Mr.

The thermal spraying system of the second embodiment is substantially the same as that shown in FIG. 2, except that the rotary drive mechanism 12 shown in FIG. 2 is used to rotate the arm 32 shown in FIG. The spur gear, the small diameter gear and the electric motor Mr) described above are replaced. The relay box 30 used in the thermal spraying system of the second embodiment is the same as that shown in FIG. 3, but the motor Mr and the rotary encoders Rr and Rh in FIG. 3 are the same as those shown in FIG. Becomes

FIG. 8 shows the function of the personal computer 41 of the thermal spraying system according to the second embodiment in accordance with the operation flow of the operator. The main items of the spraying operation menu displayed on the display are the creation and editing of spraying conditions (spraying condition creation, spraying condition editing) Target thickness input Spraying trajectory creation Pre-spray measurement Spraying Measurement data editing. The difference from the first embodiment is that the spray trajectory creation is added. The operator inputs the starting point (Xs, Ys) and the ending point (Xe, Ys) of the spraying area, and inputs coordinates or tees defining the spraying trajectory.
Set the spray trajectory by inputting the pitch. Here, the thermal spraying area is a motion area of the nozzle of the torch 1,
The teaching input is performed using the operation pendant 8.
Switch 1 is driven x and y by manual switch operation,
Numeral 1 is for reading the position of the torch 1. When the spraying trajectory is set, the operator sets the position (position on the spraying trajectory) and the swivel angle of the measuring head 5 so that the measuring head 5 is positioned behind the torch 1 in the moving direction.
Input on the spray trajectory.

"Distance measurement before thermal spraying" 5 in the second embodiment
In the same manner as in the thermal spraying operation, while automatically driving the torch 1 along the thermal spray locus, the head 5 is rotated and driven at the set position, and the laser distance meter (head 5 + measurement circuit) is set at the set sampling pitch. 5pc) is read and written into the memory. However, the torch 1 is not energized by thermal spraying. The sampling area is a rectangular area having a spraying area starting point (Xs, Ys) and an ending point (Xe, Ys) as a diagonal corner, and the other area is a measurement value sampling mask area. Then, the head position is calculated from the torch position, and the distance measurement value is read on condition that the head position is within the rectangular area.

The "spraying" 7 in the second embodiment automatically drives the torch 1 along the spraying trajectory while injecting the spraying flow from the torch 1, and performs the "measurement of distance before spraying". In the same manner as in 5, the measurement value of the laser distance meter (head 5 + measuring circuit 5pc) is read and written into the memory, and is compared with the target distance. Other configurations and functions of the thermal spraying system of the second embodiment are the same as those of the thermal spraying system of the first embodiment.

As shown in FIG. 7, the torch 1 scans forward in the -y direction, scans forward in the + x direction at the end point, scans back in the + y direction, scans forward in the + x direction at the end point, and When two-dimensional scanning is performed in an arc shape by repeating scanning (or in the case of an arc type scanning in which y in this expression is replaced with x and x is replaced with y), as shown in FIG. By setting the distance measuring head 5 behind (in the y direction), even if the scanning direction of the torch 1 changes, the turning drive for placing the head 5 behind in the scanning direction becomes unnecessary. If only the mode shown in FIG. 9 is sufficient, the head support arm 32 is fixed to the torch carriage 2 and the mechanism for rotating and driving the arm 32 is omitted. This simplifies the mechanism around the torch 1.

7 and 9 are shown by two-dot chain lines.
The bow-shaped scanning trajectory for the torch 1 is set, and the spraying area start point (X
s, Ys) and the end point (Xe, Ys) as diagonal corners, and if a mask area for sampling distance measurement values is used, the torch 1 moves substantially within the rectangular area.
The distance measurement of the area inside the boundary of the rectangular area by the distance between the torch 1 and the head 5 is not performed. In order to perform this distance measurement, the torch 1 must be moved from the rectangular area to the torch 1
It may be moved extra to the outside by the distance between the heads 5.
However, the practicality of the thermal spraying apparatus is not impaired even if a measured value of the thickness of the thermal spray coating in a part of the scanning movement area (the rectangular area) of the torch 1 is not obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an outline of a mechanism according to a first embodiment of the present invention.

FIG. 2 is a block diagram illustrating a configuration of a thermal spraying system that drives the mechanism illustrated in FIG.

3 shows an electric element of the junction box 30 shown in FIG. 2 and an electric motor and a rotary encoder incorporated in the mechanism shown in FIG. 1;
FIG. 4 is a block diagram showing a configuration in combination with a damper.

FIG. 4 is an operator using the thermal spraying system shown in FIG.
2 is a flowchart showing the functions of the personal computer 41 shown in FIG.

FIG. 5 is a flowchart showing the content of “distance measurement before thermal spraying” 5 shown in FIG. 4;

6 is a flowchart showing the contents of "spraying" 7 shown in FIG.

FIG. 7 is a perspective view showing an outline of a mechanism according to a second embodiment of the present invention.

8 is a flowchart showing the function of the thermal spraying system for driving the mechanism shown in FIG. 7 in accordance with the operation flow of the operator.

FIG. 9 is a perspective view showing a state in which the mechanism shown in FIG. 7 is set in a mode for performing simple distance measurement.

[Description of Signs] 1: Thermal spraying torch 2: Torch carriage 3: X beam 4a, 4b: Y beam 5: Distance measuring head 6: Roll (sprayed substrate) 7a, 7b: Axis M, Mx, My, Mr: Electric motor Rx, Ry, Rr, Rh: Rotary encoder Lxo, Lxe, Lyo, Lye: Limit switch 32: Head support arm 36: Thermal spray substrate

Continued on the front page (72) Inventor Osamu Ichimura 7-6-1 Higashi Narashino, Narashino-shi, Chiba F-term in the Nippon Steel Welding Industry Co., Ltd. Equipment Division 4K031 AB02 DA04 EA01 EA03 EA12 EA12

Claims (5)

[Claims] 1. A method for spraying a high-temperature or semi-molten thermal spray material from a thermal spray torch together with a high-temperature air stream and exposing a thermal spray substrate to the thermal spray stream to form a thermal spray coating on the surface thereof. At least one of the torch support member and the spray substrate supporting the spraying torch is relatively driven with respect to the other, and the distance measuring device carried by the torch support member is used to measure the spray substrate. Measure each distance at multiple points; during the spraying operation, so that the jet stream of the spraying torch scans the sprayed substrate,
At least one of the torch support member and the sprayed substrate is driven relative to the other, and the distance of the surface of the sprayed substrate scanned by the jet flow is measured by a distance measuring device carried by the torch support member. And determining whether the sprayed coating thickness has reached a target value in accordance with a value measured prior to the spraying operation, a current measured value, and a target value of the sprayed coating thickness. 2. A target distance of each point is calculated from a distance measured prior to a spraying operation and a target value of a sprayed coating thickness and written in a memory. During the spraying operation, a measured value of a point having a target distance in the memory is measured. The thermal spraying method according to claim 1, wherein it is determined whether the thermal sprayed coating thickness has reached a target value by comparing with the target distance. 3. A spraying torch for spraying a high-temperature or semi-molten thermal spray material together with a high-temperature air stream; a torch supporting member for supporting the spraying torch; Scanning means for driving at least one of the torch support member and the sprayed substrate relative to the other so as to scan; and the sprayed film thickness of the sprayed substrate surface scanned by the jet stream. A measuring device supported by the torch support member for detection. 4. A thermal spraying apparatus according to claim 3, further comprising a member supported by a torch support member and supporting said measuring device so as to be rotatable about the spray nozzle with respect to the spraying torch. apparatus. 5. The thermal spraying apparatus according to claim 4, further comprising: an electric mechanism for rotating said measuring instrument support member around a spray nozzle of a thermal spraying torch.