JP2011195945A - Construction method and construction apparatus for thermal barrier coating - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a construction method performing thermal barrier coating with satisfactory quality for a stationary blade having a complicated shape.SOLUTION: A melt spraying gun 2 is attached to the distal end part of a robot 1 and a blade 100 is placed on a turn table 10. The turn table 10 is rotated in the clockwise direction and, at the same time, the distal end part of the robot 1 is moved horizontally in the counter-clockwise direction. Therein, when the curvature change of a blade surface opposite to the melt spraying gun 2 is small(the blade surface opposite to the melt spray gun is a blade pressure surface or a blade suction surface), a turn table 10 is rotated at a regulated rotational speed and the melt spraying gun 2 is moved at a regulated moving speed. When the curvature change of a blade surface opposite to the melt spraying gun 2 is large (the blade surface opposite to the melt spray gun is a blade leading edge surface), the rotational speed of the turn table 10 is made to be smaller than the regulated rotational speed and the moving speed of the melt spray gun 2 is made to be larger than the regulated moving speed in accordance with an increasing in the curvature change.

Description

  The present invention relates to a thermal barrier coating construction method and a thermal barrier coating construction apparatus, which can apply a thermal barrier coating with a good quality to a thermal sprayed object having a complicated shape and provide a good thermal barrier performance. It is devised so that the product which it has can be manufactured.

  In the gas turbine, in order to improve the efficiency, the temperature of the gas used is set high. A blade exposed to such a high-temperature gas is provided with a thermal barrier coating (TBC) in order to improve heat resistance. TBC is obtained by coating the surface of a blade, which is a sprayed object, with a heat shielding material having a low thermal conductivity (for example, a ceramic material having a low thermal conductivity) by thermal spraying.

  In order to apply TBC to the object to be sprayed, a thermal barrier coating apparatus in which a spray gun for plasma spraying is attached to the tip of a multi-axis robot is generally used. In such a thermal barrier coating construction apparatus, a thermal spray material is sprayed by spraying a heated and melted thermal spray material from the thermal spray gun to the sprayed object while driving the multi-axis robot to scan and move the thermal spray gun.

The main performance of the thermal barrier coating (TBC) thus obtained includes thermal barrier properties, durability, and film formation efficiency (cost).
In order to maintain such performance well, (1) current, (2) plasma gas flow rate, (3) spraying distance, (4) powder amount, (5) spray gun moving speed, (6) preheating It is necessary to optimize the temperature, (7) spraying angle, etc.

  Therefore, in order to realize a thermal barrier coating apparatus that satisfies the above required performances, the following design method is employed.

First, a combination of the above parameters that satisfies the required performance (heat insulation, durability, efficiency) at the test piece level is obtained.
Next, in order to trace the combination of parameters obtained in this way to actual parts, it is necessary to produce an appropriate program for driving the apparatus (robot).

The most important parameters related to robot movement are (3) spraying distance, (5) spraying gun movement speed, and (7) spraying angle. is there.
Among these, since the moving speed of the spray gun can be designated numerically to the robot, it is relatively easy to control except the error at the folded end. However, the speeds of the sudden angle change part, the turn-back part, etc., depending on the conditions, the acceleration of the robot is not in time, and the speed is difficult to be constant.
Although the moving speed of the thermal spray gun tends to directly influence the film thickness, the performance of the TBC film (heat cycle resistance, heat shield, etc.) can be obtained as long as it is within a certain speed range.
The spraying distance and spraying angle are particularly difficult to control because they are determined by the relative positions of the robot and the parts (sprayed object).

  FIG. 7 shows the flow of developing a robot program for applying a thermal barrier coating to an actual part manufactured as described above.

The spraying distance is a very important parameter. The longer the distance, the lower the temperature of the sprayed particles, so that it directly affects the structure and adhesion, and has a great influence on the heat shielding properties and durability.
On the other hand, when the spraying distance is short, the spraying angle may be shallow in order to avoid contact between the spraying gun and the object to be sprayed (work).
When the spray angle becomes extremely shallow, the film structure is deteriorated and the adhesion is deteriorated, and the durability of the film is likely to be lowered as shown in FIG. Here, as shown in FIG. 9, the spray angle (θ) refers to an angle formed between the spraying direction of the heat shielding material (direction indicated by an arrow in the figure) and the surface of the sprayed object.
After all, considering the above-mentioned conditions and situations, a robot program used for thermal spraying work is produced.

  Here, a conventional example in which the stationary blade of the gas turbine for power generation is thermally shielded by atmospheric plasma spraying will be described with reference to FIG.

As shown in FIG. 10, the thermal barrier coating construction apparatus includes a multi-axis robot 1, a spray gun 2, and a turntable 10.
A thermal spray gun 2 is attached to the tip of the multi-axis robot 1, and the thermal spray gun 2 sprays a heat shield material heated and melted onto the sprayed object.
The turntable 10 can be driven to rotate in a horizontal plane.

The stationary blade 100 of the gas turbine has a structure in which a shroud 101 is usually provided on the blade base side (upper side in FIG. 10) and a shroud 102 is provided on the blade tip side (lower side in FIG. 10). Furthermore, when performing thermal barrier coating, a jig 111 is attached to the shroud 101 side and a jig 112 is attached to the shroud 102 side in order to avoid the formation of a coating unnecessary portion.
Then, the stationary blade 100 is placed on the turntable 10 with the root side and the distal end side of the stationary blade 100 positioned vertically.
The blade surface of the stationary blade 100 includes a blade abdominal surface, a blade leading edge surface, a blade back surface, and a blade trailing edge surface, and has a complicated shape that is generally a teardrop shape.

In such an apparatus, the turntable 10 performs an indexing operation, which will be described later, and rotates so that the surface to which the thermal barrier coating is applied among the blade surfaces of the stationary blade 100 faces the multi-axis robot 1.
The multi-axis robot 1 scans and moves the thermal spray gun 2 to spray the opposite surfaces of the blade surfaces.

  Next, the operation of spraying by moving the multi-axis robot 1 and the turntable 10 will be described with reference to FIGS. 11 to 13 are plan views of the stationary blade 100 and the turntable 10 mounted in the state of FIG. 10 as viewed from above.

First, the turntable 10 is rotated, and the rotation of the turntable 10 is stopped at a rotational position where the blade surface of the stationary blade 100 faces the multi-axis robot 1 as shown in FIG.
At this time, scanning is performed along the lateral direction of the wing surface (a direction perpendicular to the vertical direction (vertical direction) connecting the root side and the tip side of the wing) with the tip of the multi-axis robot 1 facing the flank surface. By moving, the spray gun 2 is scanned and moved in the horizontal direction (horizontal direction) along the path indicated by the dotted arrow in the figure, and spraying is performed from the spray gun 2 toward the stationary blade 100 at each scanning movement position. To do.
In FIG. 11, a solid line arrow and a two-dot chain line arrow indicate the thermal spraying direction of the heat shielding material.

Next, after the multi-axis robot 1 is retracted, the turntable 10 is rotated again, and the blade leading edge surface of the stationary blade 100 faces the multi-axis robot 1 as shown in FIG. The rotation of the turntable 10 is stopped at the rotation position that has reached the state.
At this time, the thermal spray gun 2 is moved in the horizontal direction along the path indicated by the dotted arrow in the figure by scanning and moving along the horizontal direction of the blade surface with the tip of the multi-axis robot 1 facing the blade front edge surface. The scanning movement is performed, and spraying is performed from the spray gun 2 toward the stationary blade 100 at each scanning movement position.
In FIG. 12, the solid line arrow and the two-dot chain line arrow indicate the thermal spraying direction of the heat shielding material.

Thereafter, after the multi-axis robot 1 is retracted, the turntable 10 is rotated again, and the back surface of the stationary blade 100 faces the multi-axis robot 1 as shown in FIG. The rotation of the turntable 10 is stopped at the rotated position.
At this time, the multi-axis robot 1 is scanned and moved along the horizontal direction of the blade surface while the tip of the multi-axis robot 1 is opposed to the back surface of the blade. Thermal spraying is performed from the spray gun 2 toward the stationary blade 100 at each scanning movement position.
In FIG. 13, the solid line arrow and the two-dot chain line arrow indicate the thermal spraying direction of the heat shielding material.

  As described above, repeating the operation of rotating the turntable 10 and stopping when the blade surface to be sprayed faces the multi-axis robot 1, It is called “operation”.

International Publication WO 98/17837

[Problems related to deposition quality]
In the case where film formation is performed by spraying on the blade surface of the stationary blade, the most difficult part of film formation is the sudden curvature change portion of the blade leading edge surface. For this reason, conventionally, as shown in FIGS. 11 to 13, for example, the entire surface to be formed is applied by overlapping the film formation by a technique such as dividing the thermal spray path into three. Although the division pattern can be changed according to the shape and dimensions of the wing, here, for the sake of simplicity, the case of three divisions will be described as an example.
When film formation is repeated in this way, it is not possible to spray directly on all blade surfaces to be sprayed, and it is difficult to adjust the thickness of the overlapping part and the structure, There was a concern that the film was mixed with a seam portion, a shallow-angle film formation, or a film formation with a poor distance, and the durability of these portions was lowered.

  The reason for this will be described next in order for each state in each path of FIGS.

In the state shown in FIG. 11, the turntable 10 is stationary at a position where the blade surface of the stationary blade 100 faces the multi-axis robot 1, and only the tip (spray gun 2) of the multi-axis robot 1 is indicated by a dotted arrow. Thus, the film is formed by scanning.
The solid line arrows and the two-dot chain line arrows are the directions that the spray gun 2 is aiming at. In this case, the construction is almost 90 degrees with respect to the blade surface, but the direction of the spray gun 2 is abrupt. Therefore, a small amount of a film having a bad angle and a long spraying distance is undesirably formed on the blade leading edge surface.
In the case of thermal spraying, there is a certain degree of tolerance in film quality, and the above issues do not directly lead to fatal defects such as peeling, and when the durability of the coating part is sufficiently high for the usage environment Even if a small amount of such a film is mixed, the performance is hardly affected. However, it is necessary to increase the reliability by bringing the construction method closer to the ideal state as the use environment becomes severer.
Here, the solid line arrows indicate the state where thermal spraying is applied to the target blade surface, and the two-dot chain line arrow is a film that is deposited on the blade surface that is not the target blade surface. This shows the state.

In the state shown in FIG. 12, in order to form the blade leading edge surface of the stationary blade 100, the turntable 10 stops at a position where the blade leading edge surface faces the multi-axis robot 1 side. The (thermal spray gun 2) scans as indicated by the dotted arrow.
Also in this case, as shown by the two-dot chain line arrow, a film having a long distance and a shallow angle is undesirably formed on the blade surface side.

Similarly, in the state shown in FIG. 13, the film is formed on the blade back side, and the turntable 10 is stationary at a position where the blade back is directed toward the multi-axis robot 1 in order to form the blade back surface of the stationary blade 100. The tip (spray gun 2) of the multi-axis robot 1 scans as indicated by the dotted arrow.
Also in this case, as indicated by the two-dot chain line arrow, a film forming portion having a shallow angle and a long spraying distance is generated at the blade leading edge surface.

  In the case of thermal spraying construction, there is a certain degree of tolerance in film quality, and the above problems do not directly lead to fatal defects such as peeling, but the more severe the usage environment, the closer the above construction method becomes to the ideal state. Need to increase reliability.

  After all, in each spraying operation shown in FIG. 11 to FIG. 13, the surface spraying in which the spraying distance (distance from the spraying gun 2 to the blade surface to be sprayed) is constant and the spraying angle (see FIG. 9) is 90 °. It is difficult to always maintain such a state, and in particular, since the curvature of the wing leading edge surface having a teardrop shape changes suddenly, such a problem becomes remarkable.

[Problems associated with robot operation limits]
On the other hand, the blades of a gas turbine have a very complicated and narrow curved surface, and it is difficult to perform surface directing (maintaining the spraying angle at 90 ° with respect to the target surface), which is the basis of thermal spraying.
That is, since the wing surface has a generally teardrop-shaped complicated shape, if the thermal spray gun 2 at the tip of the multi-axis robot 1 is moved laterally along the teardrop-shaped curve, the multi-axis robot 1 at the time of thermal spraying Since the speed is generally higher than the speed of welding or the like, the posture of the multi-axis robot 1 is difficult to change, particularly in the sudden curvature change portion of the blade leading edge surface.
As a result, even if the multi-axis robot 1 stops or moves beyond the operating range of the axis of the multi-axis robot 1, film thickness non-uniformity occurs due to speed fluctuations, etc. Nonconformity is likely to occur, such as peeling off due to excessive film thickness.

The reason for this inconvenience is that
(1) The speed at the time of thermal spraying is faster than the welding process,
(2) Compared to painting, etc., in the case of ceramic thermal barrier coating by atmospheric plasma spraying, the film formation area is concentrated in the center, so the subtle movement instability (speed) of the multi-axis robot 1 Subtle differences in the quality) are easily reflected in the results (film thickness, etc.)
(3) The spraying distance of atmospheric plasma spraying is generally shorter than LPPS (low pressure plasma spraying method), HVOF (high-speed flame spraying method), etc., and the spraying distance and subtle shifts in position are easily reflected in the results, This is because they are combined.

[Problems when using vertical scanning]
Further, when constructing a particularly important blade surface portion, for example, in the example of the stationary blade 100, the vertical direction in which the curvature change is small (the direction connecting the root side and the tip side of the blade (vertical direction), the vertical direction in FIG. However, it is difficult to connect the paths because the upper and lower shrouds 101 and 102 are obstructive.

Furthermore, when it is necessary to shorten the spraying distance depending on the film forming specification, the spraying gun 2 is likely to interfere with the shrouds 101 and 102 and the jigs 111 and 112 as shown by dotted lines in FIG. From this point of view, the spray gun 2 cannot often be moved in the vertical direction.
Even when the spraying distance is not short, the depth of the shrouds 101, 102 and the jigs 111, 112 is generally long, so that the spray gun 2 easily interferes with the shrouds 101, 102 and the jigs 111, 112. Often, the spray gun 2 cannot be moved vertically.

[Problems when trying to adopt low thermal conductivity TBC]
On the other hand, low thermal conductivity ceramics with a pyrochlore crystal structure, which have been studied in various fields in recent years, generally have excellent heat insulation and phase stability, but maintain durability as before. In order to do so, some ingenuity is required. This is because the fracture toughness of the low thermal conductive ceramic is generally smaller than that of conventional YSZ or the like.
For this reason, when applying low thermal conductivity TBC, it is necessary to devise on the construction side in order to maintain durability, and it is possible to shorten the spraying distance to make a dense structure, possibly a structure containing fine vertical cracks, etc. , One of them. In general, a dense film tends to increase in thermal conductivity, so it is difficult to use as a batting hand. However, in the case of low thermal conductivity TBC, which is originally low in thermal conductivity, a balance between increased thermal conductivity and improved durability. Depending on the situation, it becomes an effective improvement means. However, in the conventional technology, as described above, it is difficult to construct a complicated and narrow blade shape with a short spray distance. As a result, conventionally, it has not been possible to form a low thermal conductivity type TBC in the best state using a thermal barrier coating apparatus as shown in FIG.

  In view of the above-described conventional technology, the present invention is a surface-directed construction in which a spraying distance is constant and a spraying distance is 90 ° even for a sprayed object such as a wing having a complicated shape having a sharply curved portion. An object of the present invention is to provide a thermal barrier coating construction method and thermal barrier coating construction apparatus that can perform the above process.

The configuration of the thermal barrier coating construction method of the present invention that solves the above problems is as follows.
While the sprayed material is placed, the turntable rotates in a horizontal plane,
In the thermal barrier coating construction method in which the thermal spray gun that sprays the thermal spray material that is heated and melted on the object to be sprayed is controlled in conjunction with the movement of the tip of the robot attached to the tip.
Rotate the turntable in a predetermined rotation direction,
While maintaining the spray gun facing the spray surface of the object to be sprayed while the spray distance is a predetermined distance and the spray angle with respect to the spray surface is 90 °, the tip of the robot, Move horizontally in the direction opposite to the direction of rotation,
When the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot is zero, the rotation speed of the turntable is determined in advance. As the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot increases, the rotation speed of the turntable is determined as described above. The rotation speed is slower than the rotation speed,
When the curvature change of the sprayed surface facing the tip of the robot is zero, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. The moving speed of the tip of the robot is set to a moving speed faster than the specified moving speed as the change in curvature of the sprayed surface increases.

The configuration of the thermal barrier coating construction method of the present invention is as follows:
The gas turbine blade is placed with the root side and tip side of the blade positioned vertically, and the turntable rotates in a horizontal plane,
In the thermal barrier coating construction method in which the thermal spray gun that sprays heated and melted thermal barrier material on the wings and sprays it controls the movement of the tip of the robot attached to the tip.
Rotate the turntable in a predetermined rotation direction,
While the spray gun is opposed to the blade surface of the wing and the spray distance is a predetermined distance and the spray angle with respect to the blade surface is 90 °, the tip of the robot is moved in the rotational direction. Move horizontally in the opposite direction,
Of the wing surfaces of the wings placed on the turntable, when the surface facing the tip of the robot is a wing belly surface or wing back surface, the rotation speed of the turntable is set to a predetermined specified rotation speed. When the surface facing the tip of the robot among the wing surfaces of the wings placed on the turntable is a wing leading edge surface, as the curvature change of the wing leading edge surface increases, The rotation speed of the turntable is a rotation speed slower than the specified rotation speed,
When the wing surface facing the tip of the robot is a wing belly surface or a wing back, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. When the blade surface is a blade leading edge surface, the moving speed of the tip of the robot is set to a moving speed faster than the specified moving speed as the curvature change of the blade leading edge surface increases. And

The configuration of the thermal barrier coating construction method of the present invention is as follows:
When spraying the lowermost part of the blade surface, the spray gun is directed obliquely downward, and when spraying the uppermost part of the blade surface, the spray gun is directed obliquely upward. It is characterized by.

The configuration of the thermal barrier coating construction apparatus of the present invention is as follows:
A turntable on which a sprayed object is placed and rotates in a horizontal plane,
A thermal spray gun that sprays the thermal spray material heated and melted on the object to be sprayed, and a robot attached to the tip,
A control unit that interlocks and controls the rotation of the turntable and the movement of the tip of the robot;
In thermal barrier coating construction equipment with
The controller is
Rotate the turntable in a predetermined rotation direction,
While maintaining the spray gun facing the spray surface of the object to be sprayed while the spray distance is a predetermined distance and the spray angle with respect to the spray surface is 90 °, the tip of the robot, Move horizontally in the direction opposite to the direction of rotation,
When the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot is zero, the rotation speed of the turntable is determined in advance. As the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot increases, the rotation speed of the turntable is determined as described above. The rotation speed is slower than the rotation speed,
When the curvature change of the sprayed surface facing the tip of the robot is zero, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. As the change in the curvature of the sprayed surface increases, interlocking control is performed in which the moving speed of the tip of the robot is set to be higher than the specified moving speed.

The configuration of the thermal barrier coating construction apparatus of the present invention is as follows:
The gas turbine blade is placed with the root side and tip side of the blade positioned vertically, and a turntable that rotates in a horizontal plane,
A spray gun that sprays heated and melted heat shield on the blades, and a robot attached to the tip;
A control unit that interlocks and controls the rotation of the turntable and the movement of the tip of the robot;
In thermal barrier coating construction equipment with
The controller is
Rotate the turntable in a predetermined rotation direction,
While the spray gun is opposed to the blade surface of the wing and the spray distance is a predetermined distance and the spray angle with respect to the blade surface is 90 °, the tip of the robot is moved in the rotational direction. Move horizontally in the opposite direction,
Of the wing surfaces of the wings placed on the turntable, when the surface facing the tip of the robot is a wing belly surface or wing back surface, the rotation speed of the turntable is set to a predetermined specified rotation speed. When the surface facing the tip of the robot among the wing surfaces of the wings placed on the turntable is a wing leading edge surface, as the curvature change of the wing leading edge surface increases, The rotation speed of the turntable is a rotation speed slower than the specified rotation speed,
When the wing surface facing the tip of the robot is a wing belly surface or a wing back, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. When the blade surface is a blade leading edge surface, interlocking control in which the moving speed of the tip of the robot is set to a moving speed faster than the specified moving speed as the curvature change of the blade leading edge surface increases. It is characterized by doing.

The configuration of the thermal barrier coating construction apparatus of the present invention is as follows:
The controller is
When spraying the lowermost part of the blade surface, the spray gun is directed obliquely downward, and when spraying the uppermost part of the blade surface, the spray gun is directed obliquely upward. It is characterized by.

According to the present invention, while keeping the operating range and speed of the robot within the allowable operating range and the allowable speed range, the spraying distance is kept constant and the spraying angle is kept at 90 °, the sprayed object is Can be sprayed horizontally. As a result, a high quality thermal barrier coating can be formed.
Further, the spraying distance can be shortened, and a high-quality and durable thermal barrier coating can be formed using a low thermal conductivity type TBC.

The block diagram which shows the thermal barrier coating construction apparatus based on the Example of this invention. Explanatory drawing which shows the operation state of an Example. The block diagram which shows the thermal barrier coating construction apparatus based on the Example of this invention. The block diagram which shows the thermal barrier coating construction apparatus based on the Example of this invention. The composition figure which shows the composition of TBC formed by the conventional indexing method. The composition diagram which shows the composition of TBC formed by the Example of this invention. Explanatory drawing which shows the flow of the program development of the robot for constructing a thermal barrier coating on an actual part. The characteristic view which shows the relationship between a thermal spray angle and a film | membrane composition. Explanatory drawing which shows a thermal spray angle. The block diagram which shows the conventional thermal barrier coating construction apparatus. Explanatory drawing which shows operation | movement of the conventional thermal barrier coating construction method. Explanatory drawing which shows operation | movement of the conventional thermal barrier coating construction method. Explanatory drawing which shows operation | movement of the conventional thermal barrier coating construction method.

  Hereinafter, embodiments of the present invention will be described in detail based on examples.

[Overall Configuration of Example 1]
FIG. 1 shows a thermal barrier coating apparatus according to Embodiment 1 of the present invention. The thermal barrier coating construction apparatus includes a multi-axis robot 1, a spray gun 2, a turntable 10, and a control unit 20.
A spray gun 2 is attached to the tip of the multi-axis robot 1. The thermal spray gun 2 performs thermal spraying by spraying a heated and melted heat shielding material on the sprayed object.
The turntable 10 is driven to rotate in a horizontal plane.

A stationary blade 100 of a gas turbine that is a sprayed object has a shroud 101 attached to the root side (upper side in FIG. 1) and a shroud 102 attached to the tip side (lower side in FIG. 1) of the blade. Further, when performing thermal barrier coating, a jig 111 is attached to the shroud 101 side, and a jig 112 is attached to the shroud 102 side.
Then, the stationary blade 100 is placed on the turntable 10 with the root side and the distal end side of the stationary blade 100 positioned vertically.
The blade surface (sprayed surface) of the stationary blade 100 is composed of a blade belly surface, a blade leading edge surface, a blade back surface, and a blade trailing edge surface, and has a complicated shape that is generally a teardrop shape.

The turntable 10 rotates according to control by the control unit 20.
The multi-axis robot 1 is driven in accordance with the control by the control unit 20 to scan and move the spray gun 2, and the spray gun 2 sprays the opposed surfaces of the stationary blade 100.

  The control unit 20 has an interlocking operation program that interlocks the rotation of the turntable 10 and the operation of the multi-axis robot 1 that scans and moves the thermal spray gun 2. Control that links the rotation and the operation of the multi-axis robot 1 that scans and moves the spray gun 2 is performed.

Next, a control method of the turntable 10 and the multi-axis robot 1 by the control unit 20 will be described.
In the following description, “turn table control” and “multi-axis robot control” among the interlocking operations will be described separately, and then “control for interlocking the turn table and multi-axis robot” will be described.

[Control of turntable]
The turntable 10 rotates in one predetermined rotation direction (for example, clockwise direction), and faces the tip of the multi-axis robot 1 on the blade surface of the stationary blade 100 placed on the turntable 10. The smaller the change in curvature of the surface being turned, the faster the rotation speed of the turntable 10. The larger the change in curvature of the surface of the blade surface facing the tip of the multi-axis robot 1 is, the greater the rotation of the turntable 10 is. The speed is slower.

  More specifically, when the change in curvature of the surface of the stationary blade 100 facing the tip of the multi-axis robot 1 is zero (when it is a plane), the rotational speed of the turntable 10 is The rotation speed of the turntable 10 is slower than the predetermined rotation speed as the curvature of the blade surface facing the tip of the multi-axis robot 1 increases. It becomes the rotation speed.

  For this reason, when the surface of the stationary blade 100 placed on the turntable 10 that faces the tip of the multi-axis robot 1 is the blade abdominal surface or the blade rear surface (the curvature variation of the blade surface is small). In this case, the rotation speed of the turntable 10 is almost the specified rotation speed (the specified rotation speed, or a rotation speed that is slightly slower with respect to the specified rotation speed in accordance with the curvature change of the blade surface).

On the other hand, when the surface of the stationary blade 100 facing the tip of the multi-axis robot 1 is the blade leading edge surface (when the curvature variation of the blade surface is large), the turntable 10 rotates. The speed becomes slower than the specified rotation speed according to the curvature change of the blade surface.
Thus, when the surface of the stationary blade 100 facing the tip of the multi-axis robot 1 is the blade leading edge surface,
(1) As the surface of the stationary blade 100 facing the tip of the multi-axis robot 1 moves in a direction approaching the blade leading edge of the blade leading edge surface, the rotation speed of the turntable 10 increases. Decreased,
(2) As the surface of the stationary blade 100 facing the tip of the multi-axis robot 1 moves away from the blade leading edge, the rotation speed of the turntable 10 increases. Will increase.
This is because the curvature variation increases as the blade leading edge surface approaches the blade leading edge.

[Control of multi-axis robot]
In the multi-axis robot 1, the thermal spray gun 2 provided at the tip of the robot faces the blade surface of the stationary blade 100 in the lateral direction of the blade surface (vertical direction (vertical direction) connecting the root side and the tip side of the blade. On the other hand, it operates so as to scan and move in an orthogonal direction. The moving direction in the lateral direction (horizontal direction) of the tip of the multi-axis robot 1 and thus the spray gun 2 is the direction (counterclockwise direction) opposite to the rotational direction (for example, clockwise direction) of the turntable 10.
Moreover, the smaller the change in curvature of the blade surface of the stationary blade 100 that the tip of the multi-axis robot 1 is facing, the slower the lateral movement speed of the tip of the multi-axis robot 1 becomes. The greater the change in curvature of the blade surface of the stationary blade 100 facing the part, the faster the lateral movement speed of the tip of the multi-axis robot 1 becomes.

  More specifically, when the curvature change of the wing surface facing the tip of the multi-axis robot 1 is zero (when it is a plane), the moving speed of the tip of the multi-axis robot 1 is determined in advance. The movement speed of the tip of the multi-axis robot 1 is faster than the predetermined movement speed as the curvature change of the blade surface facing the tip of the multi-axis robot 1 increases. It becomes speed.

  For this reason, when the tip of the multi-axis robot 1 faces the blade surface or back of the stationary blade 100 (when the change in curvature of the blade surface is small), the tip of the multi-axis robot 1 (spray gun) The moving speed of 2) is almost the specified moving speed (the specified moving speed, or a moving speed slightly increased in accordance with the curvature change of the blade surface with respect to the specified moving speed).

On the other hand, when the tip of the multi-axis robot 1 faces the blade leading edge surface of the stationary blade 100 (when the curvature change of the blade surface is large), the tip of the multi-axis robot 1 (thermal spray gun 2). The moving speed of becomes higher than the specified moving speed according to the curvature change of the blade surface.
Thus, when the tip of the multi-axis robot 1 faces the blade leading edge surface of the stationary blade 100,
(1) The moving speed of the tip of the multi-axis robot 1 as the blade surface of the stationary blade 100 opposed to the tip of the multi-axis robot 1 moves in a direction approaching the blade leading edge of the blade leading edge. Increased,
(2) The moving speed of the tip of the multi-axis robot 1 increases as the blade surface of the stationary blade 100 facing the tip of the multi-axis robot 1 moves away from the blade leading edge of the blade leading edge. It will decrease.
This is because the curvature variation increases as the blade leading edge surface approaches the blade leading edge.

  Further, the spraying direction of the heat shield material output from the spray gun 2 is orthogonal to the blade surface of the stationary blade 100, and the distance between the spray gun 2 and the blade surface of the stationary blade 100 is a predetermined distance. Thus, the position and orientation of the tip of the multi-axis robot 1 are controlled.

[Control for interlocking movement of turntable and multi-axis robot]
FIG. 2 is an explanatory diagram illustrating a state in which the turntable 10 and the multi-axis robot 1 are operating in conjunction with each other in the first embodiment.
In FIG. 2, positions P1, P2, P3, P4, P5, P6, P7, and P8 have rotation positions (rotation angles) of the turntable 10 of −50 °, −80 °, −90 °, and −100, respectively. The spray direction of the heat shield material blown out of the stationary blade 100 and the spray gun 2 at °, -110 °, -120 °, -150 °, and -190 ° (indicated by a bar-shaped arrow in the figure) Is shown in a plan view.

  As in positions P1 to P8, the table 10 rotates clockwise in the horizontal plane, and the tip of the multi-axis robot 1 (spray gun 2) moves laterally along the counterclockwise direction. That is, the rotation direction of the table 10 and the moving direction of the tip portion (spraying gun 2) of the multi-axis robot 1 are opposite to each other.

  At this time, when spraying the blade surface of the stationary blade 100 with the heat shielding material blown from the spray gun 2, the position and orientation of the tip of the multi-axis robot 1, that is, the position and orientation of the spray gun 2 are as follows. The spraying direction of the heat shield material output from the spray gun 2 is orthogonal to the blade surface of the stationary blade 100, and the distance between the spray gun 2 and the blade surface of the stationary blade 100 is a predetermined constant distance. In addition, it is controlled by the control unit 20.

When the blade surface of the stationary blade 100 faces the tip of the robot 1 as in the positions P1 to P3, the turntable 10 rotates in the clockwise direction at a substantially specified rotational speed (fast rotational speed), The tip of the multi-axis robot 1 moves sideways in the counterclockwise direction at a substantially specified moving speed (slow moving speed).
More specifically, since the curvature change of the wing belly surface is zero at the position P2, the rotation speed of the turntable 10 is the specified rotation speed, the moving speed of the tip of the multi-axis robot 1 is the specified moving speed, and the position P1 , P3, the curvature change of the wing belly surface becomes slightly larger, so the rotational speed of the turntable 10 is slightly slower than the specified rotational speed, and the moving speed of the tip of the multi-axis robot 1 is slightly faster than the specified moving speed. . At this time, the decrease rate of the specified rotational speed and the increase rate of the moving speed are the same.
When the change in curvature of the wing abdominal surface is small as a whole, the rotational speed of the turntable 10 is defined as the specified moving speed in the entire wing abdominal surface including positions P1 to P3, and the moving speed of the tip of the multi-axis robot 1 is specified. The moving speed may be set.

  With such an operation, thermal spraying can be performed along the lateral direction from the rear edge side to the front edge side of the blade belly surface of the stationary blade 100. In addition, the relative movement speed between the turntable 10 and the tip of the multi-axis robot 1 is the same over the positions P1 to P3, whereby the spraying speed along the lateral direction of the spray gun 2 (the movement speed of the spraying point; In the case of 2, the intersection point A in the target direction of the blade surface and the spray gun is the spray point.)

When the blade leading edge surface of the stationary blade 100 faces the tip of the robot 1 as in positions P4 to P6, the turntable 10 has a position facing the tip of the multi-axis robot 1 at the front of the blade. As the edge surface moves toward the blade leading edge, the rotation speed decreases from the specified rotation speed, and as the position facing the tip of the multi-axis robot 1 moves away from the blade leading edge of the blade front edge surface, the specified rotation speed is reached. It will increase towards.
On the other hand, as for the tip of the robot 1, the moving speed increases from the specified moving speed as the position where the tip faces is directed toward the blade leading edge of the blade leading edge surface, and the position where the tip faces is the blade leading edge. As the distance from the wing leading edge of the surface increases, the moving speed decreases toward the specified moving speed.
At this time, the decrease / increase rate of the specified rotational speed and the increase / decrease rate of the moving speed are the same.

  With this operation, thermal spraying can be performed along the lateral direction with respect to the blade leading edge surface of the stationary blade 100. In addition, the relative movement speed between the turntable 10 and the tip of the multi-axis robot 1 is the same over the positions P4 to P6, so that the spraying speed along the lateral direction by the spray gun 2 (spraying point moving speed; In the case of 2, the intersection point A in the target direction of the blade surface and the spray gun is the spray point.) Is constant.

When the back surface of the stationary blade 100 faces the tip of the robot 1 as in the positions P7 to P8, the turntable 10 rotates clockwise at a substantially specified rotational speed (fast rotational speed), The tip of the multi-axis robot 1 moves sideways in the counterclockwise direction at a substantially specified moving speed (slow moving speed).
More specifically, since the back surface of the wing is not a flat surface but has a gentle change in curvature as a whole, the rotational speed of the turntable 10 is slightly slower than the specified rotational speed, and the moving speed of the tip of the multi-axis robot 1 is Slightly faster than the specified movement speed. At this time, the decrease rate of the specified rotational speed and the increase rate of the moving speed are the same.
When the change in the curvature of the back surface of the wing is small as a whole, the rotational speed of the turntable 10 is defined as the specified moving speed and the moving speed of the tip of the multi-axis robot 1 is specified over the entire back surface including the positions P7 to P8. The moving speed may be set.

  With this operation, thermal spraying can be performed along the lateral direction from the front edge side to the rear edge side of the rear surface of the stationary blade 100. In addition, the relative moving speed between the turntable 10 and the tip of the multi-axis robot 1 is the same over the positions P7 to P8, so that the spraying speed along the lateral direction by the spray gun 2 (spraying point moving speed; In the case of 2, the intersection point A in the target direction of the blade surface and the spray gun is the spray point.) Is constant.

  Eventually, by rotating the turntable 10 and the lateral movement of the tip of the multi-axis robot 1, a multi-axis is used when spraying a blade leading edge surface having a large curvature change, such as positions P 4 to P 6. The movement of the robot 1 is performed at a high speed, but when the thermal spray is performed on the blade surface or the back surface of the blade having a small change in curvature as in positions P1 to P3 and positions P7 to P8, the movement of the multi-axis robot 1 is performed at a low speed. Scanning movement of the tip of the multi-axis robot 1 can be performed within this robot operating range (angle, position, speed).

  In this way, the control unit 20 controls the scanning movement along the lateral direction of the tip of the multi-axis robot 1 and the rotation of the turntable 10 in conjunction with each other, so that from the trailing edge side of the blade surface of the stationary blade 100. Surface construction with a constant spraying distance and a 90 ° spraying angle in the so-called “single stroke” state from the leading edge side, leading edge surface, and leading edge side to the trailing edge side of the blade back Thus, one-pass thermal spraying can be performed.

When the spraying of one pass is completed in this way, the positions of the turntable 10 and the multi-axis robot 1 are returned to the state of the position P1 in FIG. 2, and the vertical direction (vertical direction is 1) with respect to the position of the previous one pass. The position in the vertical direction (vertical direction) of the tip of the multi-axis robot 1 is adjusted so that spraying can be performed at a position shifted by a pitch (for example, 3 to 5 mm).
Thereafter, in the same manner as described above, the controller 20 performs the interlocking operation between the turntable 10 and the multi-axis robot 1 as shown in FIG.

  Thereafter, similarly, the path is sprayed at a position shifted by 1 pitch in the vertical direction (longitudinal direction), and the entire blade surface of the stationary blade 100 is sprayed to form the TBC.

In Example 1, since one pitch spraying can be performed in a so-called one-stroke state along the horizontal direction, there is no overlap of sprayed portions, and the quality of the thermal barrier coating formed by spraying is improved.
Further, the movement range of the multi-axis robot 1 can be within an operation range allowed for the multi-axis robot 1.
Furthermore, since the tip (spray gun 2) of the multi-axis robot 1 is moved in the lateral direction, the spray gun 2 can be prevented from interfering with the shrouds 101, 102 and the jigs 111, 112. Thermal spraying can be done by shortening.
Therefore, even if low thermal conductivity type TBC is adopted as the thermal spray material, thermal spraying can be performed at the end thermal spray distance, and a high quality and durable thermal barrier coating can be formed using the low thermal conductivity type TBC.

  Next, a second embodiment of the present invention will be described. In the second embodiment, the robot 1 and the spray gun 2 do not interfere with the upper and lower shrouds 101 and 102 and the jigs 111 and 112 when spraying the lowermost part and the uppermost part along the longitudinal direction of the blade surface. It is devised as such.

  When spraying the lowermost one pass along the longitudinal direction of the blade surface, as shown in FIG. 3, the direction of the spray gun 2 is inclined downward by about 20 ° with respect to the horizontal plane. In this way, with the spray gun 2 facing downward, the controller 20 performs an interlocking operation between the turntable 10 and the multi-axis robot 1 as shown in FIG. Spray one pass along the horizontal direction.

  By doing so, it is possible to prevent the robot 1 and the spray gun 2 from interfering with the shroud 102 and the jig 112.

  Further, when the spray angle is 70 °, as shown in FIG. 8, the same performance as that when the spray angle is 90 ° (ie, perpendicular) can be obtained. Even if the spray gun 2 is tilted 20 ° downward, the spray angle becomes 70 ° or more, and good spraying performance can be obtained.

  When one-pass spraying is performed in the central portion along the longitudinal direction of the blade surface, the orientation of the spray gun 2 is set to a horizontal plane as shown in FIG. In this way, the spray gun 2 is leveled and the control unit 20 performs the interlocking operation of the turntable 10 and the multi-axis robot 1 as shown in FIG. Spray one pass.

  When spraying the uppermost one pass along the longitudinal direction of the blade surface, as shown in FIG. 4, the direction of the spray gun 2 is tilted upward by about 20 ° with respect to the horizontal plane. In this manner, with the spray gun 2 facing upward, the control unit 20 performs an interlocking operation between the turntable 10 and the multi-axis robot 1 as shown in FIG. Spray one pass.

  By doing so, it is possible to prevent the robot 1 and the spray gun 2 from interfering with the shroud 101 and the jig 111.

  Further, when the spray angle is 70 °, as shown in FIG. 8, the same performance as that when the spray angle is 90 ° (ie, perpendicular) can be obtained. Even if the spray gun 2 is tilted 20 ° upward, the spray angle becomes 70 ° or more, and good spraying performance can be obtained.

FIG. 5 shows the composition of TBC formed by the conventional indexing method, and FIG. 6 shows the composition of TBC formed by Examples 1 and 2.
In the conventional method, since the film having a shallow angle repeatedly overlaps the same portion in the sudden curvature change portion of the blade, an abnormally porous structure is formed as shown in FIG. As can be seen from FIG. 6, a very good film can be obtained.

  The present invention can be applied not only to a stationary blade of a gas turbine, but also to a turbine blade of a gas turbine and other components to be sprayed to form a TBC.

DESCRIPTION OF SYMBOLS 1 Multi-axis robot 2 Thermal spray gun 10 Turntable 20 Control part 100 Stator blade 101,102 Shroud 111,112 Jig

Claims (6)

While the sprayed material is placed, the turntable rotates in a horizontal plane,
In the thermal barrier coating construction method in which the thermal spray gun that sprays the thermal spray material that is heated and melted on the object to be sprayed is controlled in conjunction with the movement of the tip of the robot attached to the tip.
Rotate the turntable in a predetermined rotation direction,
While maintaining the spray gun facing the spray surface of the object to be sprayed while the spray distance is a predetermined distance and the spray angle with respect to the spray surface is 90 °, the tip of the robot, Move horizontally in the direction opposite to the direction of rotation,
When the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot is zero, the rotation speed of the turntable is determined in advance. As the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot increases, the rotation speed of the turntable is determined as described above. The rotation speed is slower than the rotation speed,
When the curvature change of the sprayed surface facing the tip of the robot is zero, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. The thermal barrier coating method according to claim 1, wherein the moving speed of the tip of the robot is set to be higher than the specified moving speed as the change in curvature of the sprayed surface increases. The gas turbine blade is placed with the root side and tip side of the blade positioned vertically, and the turntable rotates in a horizontal plane,
In the thermal barrier coating construction method in which the thermal spray gun that sprays heated and melted thermal barrier material on the wings and sprays it controls the movement of the tip of the robot attached to the tip.
Rotate the turntable in a predetermined rotation direction,
While the spray gun is opposed to the blade surface of the wing and the spray distance is a predetermined distance and the spray angle with respect to the blade surface is 90 °, the tip of the robot is moved in the rotational direction. Move horizontally in the opposite direction,
Of the wing surfaces of the wings placed on the turntable, when the surface facing the tip of the robot is a wing belly surface or wing back surface, the rotation speed of the turntable is set to a predetermined specified rotation speed. When the surface facing the tip of the robot among the wing surfaces of the wings placed on the turntable is a wing leading edge surface, as the curvature change of the wing leading edge surface increases, The rotation speed of the turntable is a rotation speed slower than the specified rotation speed,
When the wing surface facing the tip of the robot is a wing belly surface or a wing back, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. When the blade surface is a blade leading edge surface, the moving speed of the tip of the robot is set to a moving speed faster than the specified moving speed as the curvature change of the blade leading edge surface increases. Thermal barrier coating construction method. In claim 4,
When spraying the lowermost part of the blade surface, the spray gun is directed obliquely downward, and when spraying the uppermost part of the blade surface, the spray gun is directed obliquely upward. Thermal barrier coating construction method characterized by A turntable on which a sprayed object is placed and rotates in a horizontal plane,
A thermal spray gun that sprays the thermal spray material heated and melted on the object to be sprayed, and a robot attached to the tip,
A control unit that interlocks and controls the rotation of the turntable and the movement of the tip of the robot;
In thermal barrier coating construction equipment with
The controller is
Rotate the turntable in a predetermined rotation direction,
While maintaining the spray gun facing the spray surface of the object to be sprayed while the spray distance is a predetermined distance and the spray angle with respect to the spray surface is 90 °, the tip of the robot, Move horizontally in the direction opposite to the direction of rotation,
When the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot is zero, the rotation speed of the turntable is determined in advance. As the change in curvature of the surface of the sprayed surface of the sprayed object placed on the turntable facing the tip of the robot increases, the rotation speed of the turntable is determined as described above. The rotation speed is slower than the rotation speed,
When the curvature change of the sprayed surface facing the tip of the robot is zero, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. The thermal barrier coating apparatus according to claim 1, wherein interlocking control is performed such that the moving speed of the tip of the robot is faster than the specified moving speed as the change in curvature of the sprayed surface increases. The gas turbine blade is placed with the root side and tip side of the blade positioned vertically, and a turntable that rotates in a horizontal plane,
A spray gun that sprays heated and melted heat shield on the blades, and a robot attached to the tip;
A control unit that interlocks and controls the rotation of the turntable and the movement of the tip of the robot;
In thermal barrier coating construction equipment with
The controller is
Rotate the turntable in a predetermined rotation direction,
While the spray gun is opposed to the blade surface of the wing and the spray distance is a predetermined distance and the spray angle with respect to the blade surface is 90 °, the tip of the robot is moved in the rotational direction. Move horizontally in the opposite direction,
Of the wing surfaces of the wings placed on the turntable, when the surface facing the tip of the robot is a wing belly surface or wing back surface, the rotation speed of the turntable is set to a predetermined specified rotation speed. When the surface facing the tip of the robot among the wing surfaces of the wings placed on the turntable is a wing leading edge surface, as the curvature change of the wing leading edge surface increases, The rotation speed of the turntable is a rotation speed slower than the specified rotation speed,
When the wing surface facing the tip of the robot is a wing belly surface or a wing back, the moving speed of the tip of the robot is set to a predetermined specified moving speed, and the tip of the robot is facing. When the blade surface is a blade leading edge surface, interlocking control in which the moving speed of the tip of the robot is set to a moving speed faster than the specified moving speed as the curvature change of the blade leading edge surface increases. Thermal barrier coating equipment characterized by In claim 5,
The controller is
When spraying the lowermost part of the blade surface, the spray gun is directed obliquely downward, and when spraying the uppermost part of the blade surface, the spray gun is directed obliquely upward. Thermal barrier coating equipment characterized by

Images