JP2022105903A - Turbine component repair method, repair model creation device and control device - Google Patents

Abstract

To improve efficiency of turbine repair work in a manner that enables weld repair to be implemented on the basis of a model taking into consideration an adjustment after the weld repair.SOLUTION: A turbine component repair method comprises: a difference model creation process (S6) which creates a difference model corresponding to a difference between a repair object model created through measuring a three-dimensional shape of a turbine component to be a repair object and a reference model specifying a reference three-dimensional shape of the turbine component; a difference identification process (S7) which identifies a relative distance or a relative area between the difference model combined with the repair object model and another turbine component; and a repair model creation process (S10) which creates a repair model, when the relative distance or the relative area identified in the difference identification process does not correspond to a target value, by adding an adjustment margin to the difference model so that either the difference model or the adjustment margin includes a portion satisfying the target value with respect to the another component.SELECTED DRAWING: Figure 5

Description

Embodiments of the present invention relate to a method for repairing turbine parts, a repair model creating device, and a control device.

In the nozzle diaphragm, which is a stationary blade component of a steam turbine for thermal power generation, damage is likely to occur at the trailing edge of the nozzle plate. This damage can be caused primarily by erosion by solid particles passing through the vapor flow path during operation.

The above damage can change the state of the steam flow path and may significantly reduce the performance of the steam turbine. Therefore, for example, in the open inspection of the steam turbine, which is carried out regularly, when the nozzle plate having the above-mentioned damage is found, the nozzle plate is usually repaired. Then, the steam flow path formed by the nozzle plate is restored to a normal state.

In general nozzle plate repair work, a cutback step of a trailing edge including a damaged portion of the nozzle plate, a cutback amount and throat area measurement step, and a pass / fail determination step are carried out in this order. In the pass / fail determination step, it is determined whether or not the measured cutback amount and / or the throat area deviates from the permissible value. Then, if it deviates, a repair process is performed.

In the above repair step, usually, welding repair for adding a blade portion to the cut-back trailing edge portion is performed, and then shaping and throat area adjustment are performed. The shaping and throat area adjustment include the work of removing a part of the welded repaired part and adjusting the shape. Then, after such a repair step, the above-mentioned measurement step and pass / fail determination step are carried out again. In the general repair work as described above, each of the above-mentioned steps is performed manually by a worker.

In order to minimize the periodic inspection period of thermal power plants, it is necessary to shorten the lead time of various operations including repair work of nozzle plates. However, in the above-mentioned general repair work, the repair process, the measurement process, and the pass / fail determination process are repeatedly performed, and the work time is long because the work is manually performed by the worker.

As a method of shortening the lead time of repair work, the application of 3D modeling technology can be considered. Further, a technique of computer-generated a model of a repaired portion that fills the difference between a model generated by measuring the three-dimensional shape of a damaged part and a reference model with respect to the model may be applied.

However, even if the overlay corresponding to the model of the repaired portion that fills the difference as described above is simply added to the cut-back trailing edge of the nozzle plate, it is not always possible to efficiently obtain an appropriate repaired state. I can not say.

Specifically, in the repair of the nozzle plate, a reference value is generally defined for the throat area between the nozzle plate to be repaired and the adjacent nozzle plate. Here, since the nozzle plates are exposed to high temperature and high pressure, the state of change in the throat area may be different for each of a plurality of pairs of adjacent nozzle plates. Therefore, when a build-up that simply fills the difference as described above is added to the nozzle plate, a situation may occur in which the throat area of the nozzle plate after repair does not satisfy the reference value. Therefore, it is not always possible to obtain an appropriate repair condition.

Then, as described above, if the throat area of the repaired nozzle plate does not meet the reference value, adjustment is performed, but there is a situation in which such adjustment cannot be properly performed by simply filling the difference. Can occur. Therefore, a situation may occur in which an appropriate repair state cannot be efficiently obtained.

More specifically, when the throat area of the nozzle plate after repair is smaller than the reference value, a part of the built-up portion may be deleted, but a situation may occur in which an appropriate thickness cannot be secured. If such an appropriate thickness cannot be secured, further overlaying may be required. Further, when the throat area of the nozzle plate after repair is larger than the reference value, a situation may occur in which further overlaying is required. When these situations occur, the lead time required for repair may be longer than in general work. Especially when further overlaying is required, it is very troublesome.

Japanese Patent No. 5391658

Therefore, the problem to be solved by the present invention is a repair method and a repair model for turbine parts that can improve the work efficiency of turbine repair by enabling welding repair based on a model considering adjustment after welding repair. The purpose is to provide a creation device and a control device.

In one embodiment, the repair method of the turbine part includes a repair target model created by measuring the three-dimensional shape of the turbine part to be repaired and a reference model that defines the reference three-dimensional shape of the turbine part. The difference model creation process that creates the difference model corresponding to the difference of, and the difference amount specification that specifies the relative distance or relative area between the difference model coupled to the repair target model and other turbine parts. When the relative distance or the relative area specified in the step and the difference amount specifying step do not match the target value, an adjustment allowance is added to the difference model, and the adjustment allowance is added to either the difference model or the adjustment allowance. A repair model creating step of creating a repair model including a portion satisfying the target value with other turbine parts is provided.

Further, in one embodiment, the repair model creation device for the turbine parts defines the repair target model created by measuring the three-dimensional shape of the turbine parts to be repaired and the reference three-dimensional shape of the turbine parts. Specify the relative distance or relative area between the reference model to be used, the difference model creation unit that creates the difference model corresponding to the difference, the difference model coupled to the repair target model, and other turbine parts. When the relative distance or the relative area specified by the difference amount specifying unit and the difference amount specifying unit do not match the target value, an adjustment allowance is added to the difference model, and the difference model and the adjustment allowance are included. A repair model creating unit for creating a repair model including a portion satisfying the target value with the other turbine parts is provided.

Further, in one embodiment, the control device includes the repair model creating device for the turbine parts, and controls the welding repair device based on the repair model created by the repair model creating device.

According to the present invention, the work efficiency of turbine repair can be improved by enabling welding repair to be carried out based on a model in consideration of adjustment after welding repair.

It is a figure which shows the schematic structure of the repair system of the turbine parts which concerns on one Embodiment. It is a figure which conceptually explains the process performed by the difference model creation unit of the control device which constitutes the repair system shown in FIG. 1. It is a figure which conceptually explains the specification of the cutback amount performed by the difference amount specifying part of the control device which constitutes the repair system shown in FIG. 1. It is a figure which conceptually explains the specification of the throat area performed by the difference amount specifying part of the control device which constitutes the repair system shown in FIG. 1. It is a figure which conceptually explains the process performed by the repair model creation part of the control device which constitutes the repair system shown in FIG. 1, and is the repair model creation part when the throat area specified by the difference amount specification part is smaller than a target value. It is a figure explaining the repair model created by. It is a figure which conceptually explains the process performed by the repair model creation part of the control device which constitutes the repair system shown in FIG. 1, and is the repair model creation part when the throat area specified by the difference amount specification part is larger than a target value. It is a figure explaining the repair model created by. It is a flowchart which shows the example of the flow of the repair method which repairs a nozzle plate as a turbine component by using the repair system of FIG. It is a figure explaining the example which applied the repair system of FIG. 1 to the repair of a root fin as a turbine component.

Hereinafter, one embodiment will be described in detail with reference to the attached drawings.

FIG. 1 is a diagram showing a schematic configuration of a turbine component repair system S according to an embodiment. The repair system S shown in FIG. 1 includes a welding repair device 10 and a control device 100.

The repair system S repairs the turbine parts to be repaired by controlling the welding repair operation of the welding repair device 10 by the control device 100. In the present embodiment, the welding repair of the turbine component by the welding repair device 10 is performed by overlaying a metal material on the defective portion of the turbine component to be repaired by welding.

The welding repair device 10 includes a robot arm 11, an LMD head 12 and a three-dimensional shape measuring unit 13 provided on the arm tip side of the robot arm 11, and a turntable 14 for installing turbine parts to be welded. ing.

The robot arm 11 is an articulated arm, and positions the LMD head 12 and the three-dimensional shape measuring unit 13 provided on the tip end side of the arm at an arbitrary three-dimensional position.

The LMD (Laser Metal Deposition) head 12 is a built-up portion, and supplies a raw material powder made of metal particles or the like to a repair target portion, and melts the supplied raw material powder by irradiation with a laser beam and then solidifies it. Welding repair is performed at. In this case, welding repair can be efficiently performed even if the shape is three-dimensionally complicated. In addition, since welding repair with low heat input is possible, welding deformation and internal residual stress can be suppressed, and annealing for stress removal after welding repair can be omitted.

However, the overlay portion as described above is not limited to that of the LMD method. The overlay portion may be configured by, for example, a mechanism for supplying weld metal by a fused deposition modeling (FDM) method or the like.

The three-dimensional shape measuring unit 13 is a device that measures the three-dimensional shape of the turbine component to be repaired. The type of the three-dimensional shape measuring unit 13 includes, but is not limited to, a non-contact type and a contact type. The three-dimensional shape measuring unit 13 in the present embodiment is configured by a non-contact image pickup device as an example. However, the three-dimensional shape measuring unit 13 may be another optical type.

The turntable 14 has an installation surface on which turbine parts to be repaired are installed, and the installed turbine parts are rotated about the rotation axis C. In the present embodiment, the turbine component to be repaired is, for example, the nozzle plate 61 of the nozzle diaphragm 60, and the nozzle diaphragm 60 is such that the rotation axis C of the turntable 14 and the central axis of the nozzle diaphragm 60 are coaxial. Is installed on the turntable 14.

The nozzle diaphragm 60 has an inner ring 62, an outer ring 63, and a plurality of nozzle plates 61 held between the inner ring 62 and the outer ring 63. The plurality of nozzle plates 61 are arranged at equal intervals in the circumferential direction between the inner ring 62 and the outer ring 63.

In the present embodiment, the LMD head 12 sequentially welds and repairs a plurality of nozzle plates 61 on the nozzle diaphragm 60. Here, the turntable 14 rotates when the nozzle plate 61 for welding repair is switched. Further, the three-dimensional shape measuring unit 13 sequentially measures the three-dimensional shape of the nozzle plate 61 before welding repair in order to specify the nozzle plate 61 that needs to be repaired. Here, the turntable 14 rotates when the nozzle plate 61 to be measured is switched. By synchronizing the turntable 14 with the welding repair operation and the measurement operation as described above, the welding repair and the shape measurement can be efficiently advanced.

In the present embodiment, the robot arm 11 constitutes a positioning mechanism for the LMD head 12 and the three-dimensional shape measuring unit 13, and such a positioning mechanism is appropriately selected according to the turbine component to be repaired. Just do it. A three-axis stage (XYZ stage), a two-axis stage (XY stage), or the like may be used instead of the articulated robot arm 11 as long as the three-dimensional shape of the turbine component can be properly acquired.

Hereinafter, the control device 100 will be described. The control device 100 is electrically connected to the welding repair device 10 to control the operation of each part of the welding repair device 10, and information on the three-dimensional shape of the nozzle plate 61 before welding repair measured by the three-dimensional shape measuring unit 13. To get. Then, the control device 100 creates a repair model based on the three-dimensional shape of the nozzle plate 61 before welding repair acquired from the three-dimensional shape measuring unit 13 as described above, and the welding repair device 10 is based on the repair model. It is configured to control the weld repair operation.

As shown in FIG. 1, the control device 100 according to the present embodiment includes a repair target model creation unit 110, a difference model creation unit 120, a difference amount specifying unit 130, a repair necessity determination unit 140, and a repair model. It has a creation unit 150 and an operation control unit 160.

The repair target model creation unit 110 acquires the three-dimensional shape information of the repair target turbine component (nozzle plate 61 in this example) measured by the three-dimensional shape measurement unit 13, and based on the acquired three-dimensional shape information. , Create a repair target model for the turbine parts to be repaired.

The repair target model means information (data) expressing the three-dimensional shape of the turbine component to be repaired at coordinate points on three-dimensional coordinates in the virtual space. The concept called a model described below is also information (data) that expresses a shape with coordinate points on three-dimensional coordinates.

The difference model creation unit 120 creates a difference model corresponding to the difference between the repair target model created by the repair target model creation unit 110 as described above and the reference model that defines the three-dimensional shape of the reference of the turbine component. It is something to do. The reference model is held in advance in the control device 100, and may be design data of turbine parts or other arbitrary data that defines an appropriate shape.

FIG. 2 is a diagram conceptually explaining the processing of the difference model creating unit 120. 2A shows the repair target model Mt, FIG. 2B shows the reference model Ms, and FIG. 2C shows the difference model Md. In the present embodiment, the turbine component to be repaired is the nozzle plate 61, and more specifically, the trailing edge portion of the nozzle plate 61 is set as the repair target portion. Here, in the present embodiment, prior to the shape measurement of the nozzle plate 61, the trailing edge portion of the damaged nozzle plate 61 is cut back by being scraped toward the leading edge portion to a position where the damage is eliminated. In the following, the trailing edge portion after being cut back is referred to as a cutback trailing edge portion. The cutback is a work performed manually by a worker, but it may be automated. The trailing edge of the cutback described above is finished so as to extend, for example, along the blade height (with nozzle loss) of the nozzle plate 61. The blade height direction is a direction toward the inner ring 62 side and the outer ring 63 side, and is generally a radial direction. However, the trailing edge of the nozzle plate 61 or the trailing edge of the cutback may not match in the radial direction.

In FIG. 2A, the portion shown by the solid line corresponds to the repair target model Mt, and the portion shown by the broken line corresponds to the cutback portion Ct. In the model Mt to be repaired, the trailing edge of the cutback is represented. The difference model Md basically has a shape that fills the cutback portion Ct, and corresponds to the portion with hatching in FIG. 2C.

The reference numeral Ps in FIG. 2B indicates a plurality of alignment points defined in the reference model Ms, and the reference numeral Pt in FIG. 2A indicates the repair target model Mt corresponding to the plurality of alignment points Ps. It shows multiple correspondence points of. In the present embodiment, after the positions of the reference model Ms and the repair target model Mt are adjusted so that the total amount of deviation between the plurality of alignment points Ps and the plurality of corresponding points Pt is minimized, the difference is obtained. Model Ms is created. It is desirable that the position adjustment between the reference model Ms and the repair target model Mt is automatically performed by the function of the difference model creating unit 120.

The plurality of alignment points Ps include a contact point with the inner ring 62 and a contact point with the outer ring 63 of the leading edge portion of the nozzle plate 61 in the illustrated example. Further, the plurality of alignment points Ps are the inner ring 62 of the leading edge portion in the range up to the intermediate position in the chord direction on each of the ventral side of the nozzle plate and the dorsal side of the nozzle at the boundary between the nozzle plate 61 and the inner and outer rings. It also includes the point where the alignment point Ps corresponding to the contact point with the contact point with and the contact point with the outer ring 63 of the leading edge portion is moved. The nozzle plate 61 is liable to be damaged at the trailing edge, but the leading edge side is thick and is unlikely to be damaged. From such a viewpoint, in the present embodiment, the alignment point Ps is set on the front edge side.

The difference model Md is created after the positions of the reference model Ms and the repair target model Mt are adjusted so that the plurality of alignment points Ps and the plurality of corresponding points Pt completely match. Is desirable. However, the nozzle plate 61 is exposed to high temperature and high pressure, and a situation may occur in which the plurality of alignment points Ps and the plurality of corresponding points Pt do not match. Therefore, in this example, as described above, the difference model Md is rationally created at the positions of the reference model Ms and the repair target model Mt where the total amount of deviation between the alignment point Ps and the corresponding point Pt is minimized. ..

On the other hand, an expansion / contraction function for expanding / contracting the reference model is added to the control device 100, and when the plurality of alignment points Ps and the plurality of corresponding points Pt do not match, at least one of the plurality of alignment points Ps. By moving the model Ms on a computer (information processing device) to expand and contract the reference model Ms, the plurality of alignment points Ps and the plurality of corresponding points Pt may all be matched. A known CG technique may be used for the expansion / contraction function. As the expansion / contraction function, for example, a method of connecting a plurality of points on the model with links, expressing the model in a grid, and assuming each link as a spring, and predicting the expansion / contraction shape can be considered.

Returning to FIG. 1, the difference amount specifying unit 130 is based on the difference model Md and the like created by the difference model creating unit 120 as described above, and in the present embodiment, (1) the cutback amount and (2). The relative distance or relative area between the model Mt to be repaired and other turbine parts, and (3) the relative distance or relative area between the difference model Md coupled to the model Mt to be repaired and other turbine parts. To identify.

The cutback amount is the distance between the edge portion corresponding to the trailing edge portion of the nozzle plate in the difference model Md and the edge portion on the nozzle leading edge portion side in the difference model Md. On the other hand, in the present embodiment, the other turbine component is another nozzle plate 61 whose repair target nozzle plate 61 corresponding to the repair target model Mt is adjacent on the ventral side thereof, and the relative distance or relative area thereof is used. The throat area is specified.

FIG. 3A is a diagram conceptually explaining the specification of the cutback amount performed by the difference amount specifying unit 130. The reference numeral W in FIG. 3A indicates the cutback amount.

FIG. 3B is a diagram conceptually explaining the specification of the throat area performed by the difference amount specifying unit 130. The throat area is such that a straight line connecting the contact point of the trailing edge portion of the nozzle plate 61 with the inner ring 62 and the contact point of the trailing edge portion of the nozzle plate 61 with the outer ring 63 is between the dorsal surface of the adjacent nozzle plate 61. It is the minimum cross-sectional area of the gap cross-sectional area to be formed.

Reference numeral Mt'in FIG. 3B indicates a repair target model of another nozzle plate 61 to which the nozzle plate 61 to be repair is adjacent on the ventral side thereof. The range indicated by dots in FIG. 3B indicates the throat area Sa1 determined between the repair target model Mt and another adjacent repair target model Mt'. Further, the range shown with hatching indicates the throat area Sa2 determined between the difference model Md coupled to the repair target model Mt and another adjacent repair target model Mt'. In the present embodiment, the throat area Sa1 and the throat area Sa2 are specified by the difference amount specifying unit 130.

As described above, in the present embodiment, when the throat area Sa1 and the throat area Sa2 are specified by the difference amount specifying unit 130, another adjacent repair target model Mt'is used. Therefore, when the three-dimensional shape measuring unit 13 measures the three-dimensional shape of the nozzle plate 61 to be repaired in order to create the repair target model Mt, the three-dimensional shape measuring unit 13 uses another nozzle plate 61 adjacent to the three-dimensional shape measuring unit 13. It is also necessary to measure the three-dimensional shape of.

Subsequently, the repair necessity determination unit 140 determines the necessity of welding repair based on the cutback amount W and the throat area Sa1 specified by the difference amount identification unit 130 as described above. Specifically, in the present embodiment, the repair necessity determination unit 140 (1) when the cutback amount W exceeds a predetermined cutback threshold value, (2) the throat area Sa1 exceeds the predetermined throat area threshold value. In this case, and (3) when either the case where the cutback amount W exceeds the predetermined cutback threshold value and the throat area Sa1 exceeds the predetermined throat area threshold value is detected, it is determined that welding repair is necessary.

Then, the repair model creating unit 150 is configured to create a repair model Mr when it is determined by the repair necessity determination unit 140 that welding repair is necessary.

When the repair model creating unit 150 creates the repair model Mr, first, the difference model Md coupled to the repair target model Mt specified by the difference amount specifying unit 130 and another repair target model Mt'adjacent to the repair model Mt. It is determined whether or not the throat area Sa2 in between matches the target value. Then, when the throat area Sa2 does not match the target value, the repair model creation unit 150 creates the repair model Mr by adding the adjustment allowance AM to the difference model Md.

The repair model Mr is a model in which either the difference model Md or the adjustment allowance AM includes a portion that satisfies the target value with other turbine parts (other nozzle plates). If a build-up having a shape corresponding to such a repair model Mr is formed, a portion satisfying the target value can be formed by appropriately deleting a part.

The adjustment allowance AM added to the difference model Md is changed in size and / or shape according to the difference between the throat area Sa2 specified by the difference amount specifying unit 130 and the target value. That is, for example, when the throat area Sa2 is significantly larger than the target value, the adjustment allowance AM including the portion satisfying the target value becomes large. On the other hand, when the throat area Sa2 is slightly larger than the target value, the adjustment allowance AM including the portion satisfying the target value becomes small. As a result, the materials used and the labor of shaving can be suppressed.

Further, the repair model Mr created in the present embodiment is formed by adding an adjustment allowance AM to each of the ventral side of the nozzle plate and the dorsal side of the nozzle plate of the difference model Md. At this time, the direction in which the adjustment allowance AM is added to the difference model Md is changed depending on whether the throat area Sa2 specified by the difference amount specifying unit 130 is smaller than the target value or larger than the target value. That is, it is changed to add more adjustment allowance AM on the ventral side of the nozzle plate or add more adjustment allowance AM on the back side of the nozzle plate.

More specifically, when the throat area Sa2 specified by the difference amount specifying unit 130 is smaller than the target value, the thickness of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is on the back side of the nozzle plate. It is made smaller than the thickness of the added adjustment allowance AM. On the other hand, when the throat area Sa2 specified by the difference amount specifying unit 130 becomes larger than the target value, the thickness of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is added to the back side of the nozzle plate. It is made larger than the thickness of the adjustment allowance AM to be made.

FIG. 4A is a diagram illustrating a repair model Mr created by the repair model creating unit 150 when the throat area Sa2 specified by the difference amount specifying unit 130 is smaller than the target value.

In FIG. 4A (A), the target value is indicated by the reference numeral Tr, and the throat area Sa2 specified by the difference amount specifying unit 130 is smaller than the target value Tr. In this case, as shown by the adjustment allowance AM represented by the broken line in FIG. 4A (B), the thickness T1 of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is added to the back side of the nozzle plate. It is made smaller than the thickness T2 of the adjustment allowance AM.

If a build-up having a shape corresponding to the repair model Mr as shown in FIG. 4A (B) is formed, a portion satisfying the target value Tr can be formed by appropriately deleting a part. Further, an appropriate thickness can be secured in the portion on the trailing edge side of the nozzle plate. On the other hand, FIG. 4A (C) shows a repair model in which an adjustment allowance is added to the ventral side and the dorsal side of the nozzle plate of the difference model Md with an equal thickness. In this case, the amount of shaving to form the portion satisfying the target value increases, and the risk that further overlaying is required to secure an appropriate thickness increases.

Further, FIG. 4B is a diagram illustrating a repair model Mr created by the repair model creation unit 150 when the throat area Sa2 is larger than the target value. In FIG. 4B (A), the throat area Sa2 specified by the difference amount specifying unit 130 is larger than the target value Tr. In this case, as shown by the adjustment allowance AM represented by the broken line in FIG. 4B (B), the thickness T3 of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is added to the back side of the nozzle plate. It is made larger than the thickness T4 of the adjustment allowance AM.

In the above description, when the throat area Sa2 specified by the difference amount specifying unit 130 does not match the target value, the repair model creating unit 150 adds the adjustment allowance AM to the difference model Md to create the repair model Mr. create. However, even when the throat area Sa2 specified by the difference amount specifying unit 130 matches the target value, the repair model Mr may be created by adding the adjustment allowance AM to the difference model Md. In this case, as shown in FIG. 4A (C), a repair model with an equal thickness and an adjustment allowance may be created.

Further, the above-mentioned target value to be compared with the throat area Sa2 specified by the difference amount specifying unit 130 is a constant value such as a predetermined design value in the present embodiment. On the other hand, the target value may be a value obtained by adjusting a predetermined constant value such as a design value based on the total throat area which is the total of the throat areas for all of the nozzle plates. After repairing each nozzle plate, the throat area of each nozzle plate satisfies a certain value such as a design value, but the total throat area may not satisfy an allowable value. In such a case, the above-adjusted value as the target value becomes effective. In this case, the set target value may be a different value for each difference model Mt of the nozzle plate.

Then, the motion control unit 160 controls the operation of the welding repair device 10 by using the repair model Mr created by the repair model creation unit 150 as described above. Specifically, the operation control unit 160 adjusts the supply position of the raw material powder from the LMD 12 and the irradiation position of the laser beam by numerical control based on the repair model Mr. After that, the raw material powder is supplied to the repair target part (cut back part) of the damaged nozzle plate, and the supplied raw material powder is melted by irradiation with laser light and then solidified to be solidified. At least a part of the built-up portion having the shape corresponding to the above is formed on the nozzle plate 61.

In such a welding repair step, the image of the repair target portion where the raw material powder is supplied from the three-dimensional shape measuring unit 13 and the laser beam is irradiated may be acquired, and the welding conditions may be changed based on the image. .. Items for changing the welding conditions include laser output, laser focal length, metal melting position, raw material powder supply position, welding speed, shield gas flow rate, and the like.

In the control device 100 described above with reference to FIG. 1, the repair target model creation unit 110, the difference model creation unit 120, the difference amount specifying unit 130, the repair necessity determination unit 140, and the repair model creation unit 150 are used. The repair model creation device 101 may be configured. The repair system S may be configured in a state in which such a repair model creating device 101 and a control device including the above-mentioned operation control unit 160 are separated from each other.

Further, the control device 100 (repair model creation device 101) is composed of, for example, a computer (information processing device) including a CPU (Central Processing Unit). In this case, the various functions (functional units) described above are realized by reading the necessary program from the storage unit and executing the program. The storage unit is realized by, for example, a RAM (Random Access Memory), a semiconductor memory element such as a flash memory, a hard disk, an optical disk, or the like. Further, instead of the CPU, an integrated circuit for a specific application (Application Specific Integrated Circuit: ASIC), a programmable logic device (SPLD, CPLD), a field programmable gate array (Field Programmable Gate Array: FPGA) and the like can also be used.

Next, an example of a flow of a repair method for repairing a nozzle plate as a turbine component by using the repair system S will be described with reference to the flowchart shown in FIG.

First, in step S1, each nozzle plate 61 in the nozzle diaphragm 60 is inspected. Here, the nozzle plate 61 whose trailing edge is damaged is identified. This work may be performed visually by the worker, or may be performed by the control device 100 based on the information from the three-dimensional shape measuring unit 13.

Next, in step S2, the nozzle plate 61 with a damaged trailing edge identified in step S1 is cut back. Although this work is performed by an operator, a cutting and polishing device may be incorporated into the welding repair device 10 to automate the work.

Next, in step S3, the repair system S measures the three-dimensional shape of the nozzle plate 61, which is the part to be repaired (three-dimensional shape measurement step before repair). At this time, the control device 100 controls the control device 100 and sequentially measures the three-dimensional shape of each nozzle plate 61 in the nozzle diaphragm 60 by the three-dimensional shape measuring unit 13.

Next, in step S4, the repair target model creation unit 110 of the control device 100 acquires the information on the three-dimensional shape of each nozzle plate 61 measured by the three-dimensional shape measuring unit 13, and is based on the acquired three-dimensional shape information. Then, the repair target model Mt of each nozzle plate 61 is created (repair model creation step). Here, the repair target model Mt of each nozzle plate 61 is created, but for example, the repair target model Mt of only the cut-back nozzle plate 61 may be created.

Next, in step S5, the difference model creation unit 120 of the control device 100 obtains the repair target model Mt created by the repair target model creation unit 110 and the reference model Ms that defines the reference three-dimensional shape of the nozzle plate 61. compare. After that, in step S6, the difference model creating unit 120 creates a difference model Md corresponding to the difference between the repair target model Mt and the reference model Ms (difference model creation step). At this time, the repair target model Mt and the reference model Ms are appropriately aligned as described above. Then, in the present embodiment, the difference model Md of all the nozzle plates 61 is created.

Next, in step S7, the difference amount specifying unit 130 of the control device 100 relates to each nozzle plate 61 based on the difference model Md and the like created in step S6, and (1) cutback amount W and (2) repair. The throat area Sa1 between the target model Mt and the repair target model Mt'of the adjacent nozzle plate, (3) the difference model Md coupled to the repair target model Mt, and the repair target model Mt'of the adjacent nozzle plate. The throat area Sa2 between them is specified (difference amount specifying step).

Then, in step S8, the repair necessity determination unit 140 of the control device 100 determines the necessity of welding repair for each nozzle plate 61 based on the cutback amount W and the throat area Sa1 specified by the difference amount identification unit 130 in step S7. (Pass / fail judgment step). In the present embodiment, the repair necessity determination unit 140 determines (1) when the cutback amount W exceeds a predetermined cutback threshold value, (2) when the throat area Sa1 exceeds a predetermined throat area threshold value, and (3) When any of the cases where the cutback amount W exceeds the predetermined cutback threshold value and the throat area Sa1 exceeds the predetermined throat area threshold value is detected, it is determined that welding repair is necessary.

Then, in step S9 when it is determined in step S8 that welding repair is necessary, the difference model Md coupled to the repair target model Mt for the nozzle plate 61 for which welding repair is required and the repair target of the adjacent nozzle plate A target value (target throat area) is set for the throat area Sa2 between the model Mt'and the throat area Sa2 (target value setting step).

In the present embodiment, since the target value is a constant value such as a predetermined design value, the same value is set for each nozzle plate 61 that requires welding repair. On the other hand, when a predetermined constant value such as a design value adjusted based on the total throat area is used as the target value, for each nozzle plate 61 requiring welding repair. There can be situations where different target values are set.

Then, in step S10, the repair model creation unit 150 of the control device 100 creates the repair model Mr (repair model creation step). Here, in the repair model creating unit 150, first, the throat area Sa2 between the difference model Md coupled to the repair target model Mt specified by the difference amount specifying unit 130 and the adjacent other repair target model Mt'is set. , It is determined whether or not the target value set in step S9 is matched. Then, when the throat area Sa2 does not match the target value, the repair model creation unit 150 creates the repair model Mr by adding the adjustment allowance AM to the difference model Md.

In the repair model Mr created when the throat area Sa2 does not match the target value, as described above, the adjustment allowance AM added to the difference model Md is the throat area Sa2 specified by the difference amount specifying unit 130 and the target value. The size and / or shape is changed according to the difference from. More specifically, when the throat area Sa2 specified by the difference amount specifying unit 130 is smaller than the target value, the thickness of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is on the back side of the nozzle plate. It is made smaller than the thickness of the added adjustment allowance AM. On the other hand, when the throat area Sa2 specified by the difference amount specifying unit 130 becomes larger than the target value, the thickness of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is added to the back side of the nozzle plate. It is made larger than the thickness of the adjustment allowance AM to be made.

Next, in step S11, the operation control unit 160 of the control device 100 controls the operation of the welding repair device 10 using the above-mentioned repair model Mr created by the repair model creating unit 150, and welding repair is performed (welding repair). Process).
After the build-up is performed by welding repair, shaping and throat area adjustment may be performed by deleting a part of the welded repaired portion to adjust the shape. In this case, the repair model Mr is a shape that makes it easy to efficiently obtain a desired shape in consideration of the difference between the throat area Sa2 specified by the difference amount specifying unit 130 and the target value. Can be advanced efficiently.

Next, in the present embodiment, in step S12, the three-dimensional shape of the nozzle plate 61 after repair is measured (three-dimensional shape measurement step after repair). At this time, the control device 100 controls the control device 100 and sequentially measures the three-dimensional shape of each nozzle plate 61 in the nozzle diaphragm 60 by the three-dimensional shape measuring unit 13.

Next, in step S13, the repair target model creation unit 110 of the control device 100 acquires the information on the three-dimensional shape of each nozzle plate 61 measured by the three-dimensional shape measuring unit 13 in step S12, and the acquired three-dimensional shape. Based on the information, a post-repair target model MtP of each nozzle plate 61 after repair is created (post-repair model creation creation step).

Next, in step S14, the difference amount specifying unit 130 of the control device 100 specifies the throat area of each nozzle plate 61 based on each post-repair target model MtP created in step S13 (post-repair difference amount specifying step). ).

Then, in step S15, does the repair necessity determination unit 140 of the control device 100 satisfy both the throat area specified by the difference amount specifying unit 130 in step S14 and the total throat area calculated based on the throat area? Judgment of whether or not (second stage pass / fail judgment step). Even when it is determined in step S8 that welding repair is not necessary, the determination in step S15 is performed.

Then, when the allowable value is satisfied in step S16, the process is completed. On the other hand, if the permissible value is not satisfied in step S16, it is notified in step S16 that shaping and throat area adjustment are necessary, and in the present embodiment, the worker performs shaping and throat area adjustment. After that, the three-dimensional shape is measured again in step S14. In step S16, the target amount at the time of adjustment may be calculated and presented to the worker.

In the embodiment described above, the repair target model Mt created by measuring the three-dimensional shape of the nozzle plate 61 as the turbine component to be repaired and the reference defining the three-dimensional shape of the reference of the nozzle plate 61 are defined. The difference model creation process for creating the difference model Md corresponding to the difference between the model Ms, the difference model Md coupled to the repair target model Mt, and another nozzle plate 61 next to it (specifically, the repair target model thereof). When the difference amount specifying step for specifying the throat area Sa2 as the relative distance or the relative area between Mt') and the throat area Sa2 specified in the difference amount specifying step do not match the target value Tr, the difference model Md A repair model that adds an adjustment allowance AM to and creates a repair model Mr. that includes a portion of either the difference model Md or the adjustment allowance AM that satisfies the target value Tr with the other nozzle plate 61 adjacent to the difference model Md. It has a creation process.

When a build-up having a shape corresponding to the repair model Mr as described above is formed on the nozzle plate 61 to be repaired, a portion satisfying the target value Tr can be formed by appropriately deleting a part. Therefore, for example, it is possible to avoid a situation in which the target value Tr cannot be obtained in shaping the nozzle plate 61 after welding repair, and the work efficiency of turbine repair is improved. That is, the work efficiency of turbine repair can be improved by enabling welding repair based on the repair model Mr in consideration of adjustment after welding repair.

In particular, in the present embodiment, the size and / or the size of the adjustment allowance added to the difference model Md according to the difference between the throat area Sa2 specified in the difference amount specifying step (difference amount specifying unit 130) and the target value Tr. The shape is changed. That is, for example, when the throat area Sa2 is significantly larger than the target value, the adjustment allowance AM including the portion satisfying the target value becomes large. On the other hand, when the throat area Sa2 is slightly larger than the target value, the adjustment allowance AM including the portion satisfying the target value becomes small. As a result, the materials used and the labor of shaving can be suppressed.

Further, the repair model Mr created in the present embodiment is formed by adding an adjustment allowance AM to each of the ventral side of the nozzle plate and the dorsal side of the nozzle plate of the difference model Md. At this time, the direction in which the adjustment allowance AM is added to the difference model Md is changed depending on whether the throat area Sa specified by the difference amount specifying unit 130 is smaller than the target value Tr or larger than the target value Tr. That is, it is changed to add more adjustment allowance AM on the ventral side of the nozzle plate or add more adjustment allowance AM on the back side of the nozzle plate.

More specifically, when the throat area Sa2 specified by the difference amount specifying unit 130 is smaller than the target value, the thickness of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is on the back side of the nozzle plate. It is made smaller than the thickness of the added adjustment allowance AM. On the other hand, when the throat area Sa2 specified by the difference amount specifying unit 130 becomes larger than the target value, the thickness of the adjustment allowance AM added to the ventral side of the nozzle plate in the difference model Md is added to the back side of the nozzle plate. It is made larger than the thickness of the adjustment allowance AM to be made. As a result, a portion satisfying the target value can be formed by appropriately deleting a part, and an appropriate thickness can be secured at the trailing edge portion of the nozzle plate. As a result, re-building can be omitted, and the work efficiency of turbine repair is improved.

Further, in the difference model creation step (difference model creation unit 120), a plurality of alignment points Ps defined in the reference model Ms and a plurality of correspondence points Pt of the repair target model Mt corresponding to the plurality of alignment points Ps. After the positions of the reference model Ms and the repair target model Mt are adjusted so that the total deviation amount of the above is minimized, the difference model Md is created. According to this, a suitable difference model Md can be reasonably created.

Further, in the welding repair process, the raw material powder is supplied to the repair target portion of the damaged nozzle plate 61, and the supplied raw material powder is melted by irradiation with laser light and then solidified to form a repair model Mr. At least a part of the overlay portion having the corresponding shape is formed on the nozzle plate 61. By using such a so-called LMD, welding repair can be efficiently performed even with a complicated three-dimensional shape. In addition, since welding repair with low heat input is possible, welding deformation and internal residual stress can be suppressed, and annealing for stress removal after welding repair can be omitted.

Further, in the welding repair process, the operation control unit 160 adjusts the supply position of the raw material powder and the irradiation position of the laser beam by numerical control based on the repair model Mr, so that a shape corresponding to the repair model Mr is formed with high accuracy. can. At this time, the image of the repair target portion to which the raw material powder is supplied and the laser beam is irradiated is acquired, and the welding conditions are changed based on the image to accurately obtain the shape corresponding to the repair model Mr. And it can be formed efficiently.

In the following, an example in which the above-mentioned repair system S is applied to the repair of the packing ring 70 as a turbine component will be described with reference to FIG. In FIG. 6, reference numeral 71 indicates a seal portion 71 in the packing ring 70. The seal portion 71 faces the surface of the rotor 80, which is a component on the moving blade side, in the radial direction. The radial inner tip of the seal portion 71 may be chipped toward the radial outer side. The seal portion 71 shown in FIG. 6 has a defect cut back.

When the repair system S is applied to the repair of the packing ring 70, the repair target model Mt of the cut-back seal portion 71 is created. Then, the difference model Md and the repair model Mr corresponding to the hatched portion in FIG. 6 are created. As the relative distance or relative area between the difference model Md and other turbine parts, the inner diameter dimension (gap) of the tooth tip in the radial direction of the seal portion 71 indicated by the reference numeral Ra is specified. Then, when the tooth tip inner diameter dimension Ra specified for the difference model Md does not match the target value (typically, when it is small), a repair model Mr in which an adjustment allowance is added to the difference model Md is created.

The repair method according to the present embodiment can be applied not only to the packing ring 70, but also to a radial spill strip, a steam seal structure such as a root fin, and the like.

Although one embodiment and its modifications have been described above, the above embodiments and modifications are presented as examples and are not intended to limit the scope of the invention. This novel embodiment can be implemented in various other embodiments, and various omissions, replacements, and changes can be made without departing from the gist of the invention. Such embodiments and variations thereof are included in the scope and gist of the invention, and are also included in the scope of the invention described in the claims and the equivalent scope thereof.

S ... Welding system, 10 ... Welding repair device, 11 ... Robot arm, 12 ... LMD head, 13 ... Three-dimensional shape measuring unit, 14 ... Turntable, 60 ... Nozzle diaphragm, 61 ... Nozzle plate, 62 ... Inner ring, 63 ... Outer ring, 70 ... Packing ring, 100 ... Control device, 101 ... Repair model creation device, 110 ... Repair target model creation unit, 120 ... Difference model creation unit, 130 ... Difference amount identification unit, 140 ... Repair necessity determination unit, 150 ... Repair model creation unit, 160 ... Motion control unit, Mt ... Repair target model, Ms ... Reference model, Md ... Difference model, Mr ... Repair model, Ps ... Alignment point, Pt ... Correspondence point

Claims (16)

A difference model that creates a difference model corresponding to the difference between the repair target model created by measuring the three-dimensional shape of the turbine component to be repaired and the reference model that defines the reference three-dimensional shape of the turbine component. Creation process and
A difference amount specifying step for specifying a relative distance or a relative area between the difference model coupled to the repair target model and other turbine parts.
When the relative distance or the relative area specified in the difference amount specifying step does not match the target value, an adjustment allowance is added to the difference model, and the other turbine is added to either the difference model or the adjustment allowance. A method for repairing a turbine component, comprising a repair model creating step of creating a repair model including a portion satisfying the target value between the component and the component. In the repair model creating step, the size and / or shape of the adjustment allowance to be added is changed according to the difference between the relative distance or the relative area specified in the difference amount specifying step and the target value. The method for repairing a turbine component according to claim 1. In the repair model creating step, there are cases where the relative distance or relative area specified in the difference amount specifying step is smaller than the target value and cases where the relative area is larger than the target value, and there is a direction in which more adjustment allowance is added to the difference model. The method for repairing a turbine component according to claim 1, wherein the method is changed. In the repair model creating step, the adjustment allowance is added to each of the other turbine component side and the opposite side in the difference model, and the relative distance or the relative area specified in the difference amount specifying step is more than the target value. When is also smaller, the thickness of the adjustment allowance added to the other turbine component side in the difference model is made smaller than the thickness of the adjustment allowance added to the opposite side of the other turbine component side. When the relative distance or relative area specified in the difference amount specifying step becomes larger than the target value, the thickness of the adjustment allowance added to the other turbine component side in the difference model is set to the thickness of the other turbine. The method for repairing a turbine component according to claim 3, wherein the thickness is larger than the thickness of the adjustment allowance added to the opposite side of the component side. In the difference model creating step, the total amount of deviation between the plurality of alignment points defined in the reference model and the plurality of correspondence points of the repair target model corresponding to the plurality of alignment points is minimized. The method for repairing a turbine component according to any one of claims 1 to 4, wherein the difference model is created after the positions of the reference model and the model to be repaired are adjusted. In the difference model creating step, the reference model is such that the plurality of alignment points defined in the reference model and the plurality of correspondence points of the repair target model corresponding to the plurality of alignment points match. After the positions of the model and the model to be repaired are adjusted, the difference model is created, and when the plurality of alignment points and the plurality of corresponding points do not match, at least of the plurality of alignment points. The turbine component according to any one of claims 1 to 4, wherein the reference model is expanded and contracted by moving any of them on the information processing apparatus to match the plurality of alignment points with the plurality of corresponding points. Repair method. The turbine component is a nozzle plate of a nozzle dadiaphragm, and the other turbine component is another nozzle plate whose ventral side is adjacent to the nozzle plate as the turbine component to be repaired.
The relative distance or relative area characterized in the difference amount specifying step is a throat area.
The claim that the repair model is created by adding the adjustment allowance to each of the ventral side of the nozzle plate and the back side of the nozzle plate of the difference model corresponding to a part of the nozzle plate in the repair model creation step. The method for repairing turbine parts according to 1. In the repair model creating step, when the throat area specified in the difference amount specifying step is smaller than the target value, the thickness of the adjustment allowance added to the ventral side of the nozzle plate in the difference model is determined. When the thickness of the adjustment allowance added to the back side of the nozzle plate is smaller than the thickness of the adjustment allowance and the throat area specified in the difference amount specifying step becomes larger than the target value, the nozzle plate ventral side in the difference model is used. The method for repairing a turbine component according to claim 7, wherein the thickness of the adjustment allowance to be added is made larger than the thickness of the adjustment allowance added to the back side of the nozzle plate. The method for repairing a turbine component according to claim 8, wherein the target value is a predetermined constant value. The method for repairing a turbine component according to claim 8, wherein the target value is a value obtained by adjusting a predetermined constant value based on a total throat area which is a total of throat areas for all of the nozzle plates. The turbine component is a radial spill strip, root fin or packing ring, and the other turbine component is a blade-side component that faces the turbine component to be repaired in the radial direction.
The turbine according to claim 1, wherein the relative distance or relative area characteristic of the difference amount specifying step is the relative distance in the radial direction between the turbine component to be repaired and the moving blade side component. How to repair parts. Further equipped with a welding repair process for performing welding repair using the repair model,
In the welding repair step, the raw material powder is supplied to the damaged turbine component to be repaired, and the supplied raw material powder is melted by irradiation with a laser beam and then solidified to form the repair model. The method for repairing a turbine component according to any one of claims 1 to 11, wherein at least a part of a built-up portion having a corresponding shape is formed on the turbine component. The method for repairing a turbine component according to claim 12, wherein in the welding repair step, the supply position of the raw material powder and the irradiation position of the laser beam are adjusted by numerical control based on the repair model. The welding repair step according to claim 12 or 13, wherein an image of the repair target portion to which the raw material powder is supplied and the laser beam is irradiated is acquired, and the welding conditions are changed based on the image. How to repair turbine parts. A difference model that creates a difference model corresponding to the difference between the repair target model created by measuring the three-dimensional shape of the turbine component to be repaired and the reference model that defines the reference three-dimensional shape of the turbine component. With the creation department
A difference amount specifying unit that specifies a relative distance or a relative area between the difference model coupled to the repair target model and other turbine parts.
When the relative distance or the relative area specified by the difference amount specifying unit does not match the target value, an adjustment allowance is added to the difference model, and the other turbine is added to either the difference model or the adjustment allowance. A repair model creating device for turbine parts, comprising a repair model creating unit for creating a repair model including a portion satisfying the target value between the parts. The equipment for creating a repair model for a turbine component according to claim 15 is provided.
A control device that controls a welding repair device based on the repair model created by the repair model creation device.

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