RU2736301C1 - Mobile high-performance robotic complex for repair of ship equipment - Google Patents

Abstract

FIELD: shipbuilding.

SUBSTANCE: invention relates to maintenance and repair of ship equipment, in particular, in sea or river ports. Mobile high-performance robot system for repair of ship equipment includes arranged in containers workstations equipped with communications, tools and equipment. Complex consists of two sea containers, one of which is process and consists of working and operator compartment, and the second is laboratory-transport and consists of laboratory and storage compartments. Equipment comprises powder laser welding and / or gas-thermal sputtering equipment, robot-manipulator and universal rotator. Operator compartment comprises workstation and robot control equipment, as well as equipment for complex control. In storage compartment abrasive blasting and electric arc metallisation equipment is arranged. Laboratory compartment houses laboratory equipment for monitoring coatings and built-up layers.

EFFECT: providing on-line production and repair of ship parts in sea or river port conditions using sputtering and surfacing technologies, robotics of ship building and ship repair production processes, upgrading and retrofitting of construction and lowering structures.

4 cl, 1 dwg

Description

The invention relates to the field of maintenance and repair of ship equipment, in particular in sea or river ports.

There are known methods of maintenance and repair in the field of deployment, based on the use of mobile repair and diagnostic systems and mobile repair shops. Examples of analogous methods are technical solutions according to patents RU No. 33066 U (10.10.2007), RU No. 66287 U (10.09.2007), RU No. 44602 U (27.03.2005). RU No. 2288113 (27.11.2006). RU No. 2376164 C1 (20.12.2009) -all of them are mobile and equipped with the appropriate equipment for repairs, maintenance, diagnostics. However, all of them relate to the repair of complex technical systems, or complex electronic systems.

Other auxiliary mobile systems are also known, for example, a marine geophysical container-laboratory based on a standard marine 20-foot container RU 180293 (06/08/2018) for placement, transportation, storage and intended use of equipment. It is a standard sea container, appropriately retrofitted into a container laboratory, designed to improve the quality of work performed.

The closest analogue of the proposed invention is the mobile repair and diagnostic complex RU 2288113 (11/27/2006), which includes workplaces, tools, equipment located in containers, equipped with communications. The mobile repair and diagnostic complex contains a container body relocatable by all modes of transport with installed technological workstations and cabinets for storing spare property, devices, tools and documents (spare parts cabinets), located inside the container body along its walls. However, the main attention in this invention is paid to unification and optimal distribution of workplaces, equipment and spare parts cabinets inside the container body, and not to the composition of equipment and applied technological processes, which is of particular importance in the maintenance and repair of ship equipment in a sea or river port. This complex, like those described above, is intended for monitoring, diagnostics, maintenance and repair of complex radio-electronic systems, which indicates the limited possibilities of its use for solving other problems, in particular for maintenance, diagnostics and repair of ship parts and ship hull elements.

The well-known mobile repair and diagnostic complex has limited capabilities for use in the field of ship repair for solving problems of maintenance and repair of ship parts and components due to limited repair and diagnostic capabilities and the lack of specialized equipment for diagnostics, repair and quality control and limited capabilities for their relocation over long distances. Also, it is not equipped with emergency lighting, fire extinguishing systems, etc.

The basis of the proposed invention was the task of ensuring the prompt repair of ship parts in a sea or river port to reduce the time for construction and repair of marine equipment and to ensure the survivability and safety of the use of marine equipment, as well as robotization of technological processes in shipbuilding and ship repair production, modernization and retrofitting of construction launching facilities with high-tech equipment.

The desired technical result is the provision of operational production and repair of ship parts in a sea or river port using spraying and surfacing technologies, robotization of technological processes in shipbuilding and ship repair production, modernization and retrofitting of construction and launching facilities.

The desired technical result is achieved by the fact that the complex consists of two sea containers, one of which is a technological one and consists of a working and an operator compartment, and the second is a laboratory transport and consists of a laboratory and storage compartments, while the working compartment contains equipment for a powder laser surfacing, a robot arm and a universal rotator, in the operator compartment there is a workstation and equipment for controlling the robot and equipment for controlling the complex, in the warehouse compartment there are equipment for abrasive blasting, electric arc metallization and thermal spraying, and in the laboratory compartment there is laboratory equipment for monitoring coatings and deposited layers.

The technological container is equipped with an auxiliary compartment to accommodate additional equipment.

The storage compartment houses equipment, spare property and fixtures and materials during the transportation of the complex.

The containers are equipped with electrical distribution boards, their own heating system, individual ventilation and air conditioning systems, and gas supply systems for work.

Powder laser cladding equipment, a robotic arm and a universal rotator allow you to repair parts such as propellers, ship rudders.

Dimensional and weight characteristics of parts repaired on the VRK laser complex:

- length of shaft-type parts up to 2500 mm;

- diameter of shaft-type parts up to 700 mm;

- height of body parts up to 500 mm;

- part weight no more than 500 kg.

Electric arc metallization equipment allows the application and repair of metal anti-corrosion coatings.

The laboratory compartment allows you to quickly control the quality of coatings and surfacing.

The operator's compartment allows you to monitor and control the laser cladding process.

A high-performance robotic complex allows for the repair of parts and elements of ship equipment using the technologies of thermal spraying and laser surfacing, it is two standard containers relocated by all modes of transport: 1) technological and 2) laboratory transport.

The laboratory transport container consists of two separate compartments: storage and laboratory. The storage compartment is used for placing equipment and storing spare parts and materials during the transportation of the complex. The laboratory compartment contains laboratory equipment for research and quality control of the repair performed or manufactured elements.

The technological container consists of three separate compartments: a work compartment, an operator compartment, and an auxiliary compartment.

The working compartment is designed for powder laser surfacing carried out on a robotic laser complex. The operator's compartment is designed to monitor and control the laser cladding process. The auxiliary compartment is designed to accommodate additional equipment that ensures the operation of the technological container.

When the complex is deployed at the work site, the equipment from the storage compartment is placed in the immediate vicinity of the technological and laboratory-transport container.

Specialized containers are made on the basis of standard 40-foot sea containers.

The construction of containers provides:

- strength and rigidity of its own design, with full equipment and equipment;

- safety of loading and unloading and transport operations;

- the possibility of transportation by road, sea and rail.

VRK communications:

- Both containers have special inputs for connecting to an external power supply, as well as connectors for connecting external consumers. Each container is equipped with an electrical switchboard, to which all pieces of equipment located in the container are connected.

- Each of the compartments of the technological container is equipped with an individual ventilation and air conditioning system.

- All compartments of both containers are equipped with an automatic fire extinguishing system.

- Both containers are equipped with a gas supply system: in the process container, the working gas is argon GOST 10157-2016 - for laser cladding, in the laboratory-transport container, the working gas is compressed air GOST R ISO 8573-1-2016.

- All equipment and furniture placed in the VRK are mounted in order to be able to transport containers by all types of transport - they are rigidly fixed to the floor and / or walls of containers.

The technological container is equipped with a laser complex for surfacing coatings, restoring geometry and manufacturing parts. Powder laser cladding technology makes it possible to restore and apply hardening coatings on parts that are subject to significant wear during operation, as well as to grow parts or their elements layer by layer. Laser surfacing methods have a high concentration of energy in focused beams, which minimizes the volume of the melt and, as a consequence, the heat input into the base metal.

Figure 1 shows an example of the layout of a propeller-driven propellant device in an assembled state.

1. - working compartment;

1.1. - powder laser cladding chamber;

1.2. - robot manipulator;

1.3. - universal rotator;

1.4. - jib crane;

1.5. - exhaust ventilation;

2. - operator compartment;

2.1. - remote control;

2.2. - robot control cabinet;

2.3. - complex control cabinet;

2.4. - powder feeder;

2.5. - a source of laser radiation;

2.6. - gas distribution board;

2.7. - workplace;

2.8. - console crane control panel;

3. - auxiliary compartment;

3.1. - chiller of the laser radiation source;

3.2. - chiller for cooling optics;

3.3. - compressor unit;

4. - laboratory compartment;

4.1. - complex for sample preparation;

4.2. - research complex;

4.3. - water recirculation system;

4.4. - sink;

4.5. - cabinet for working with chemicals;

4.6. - cabinet for the preparation of powder materials;

4.7. - workplace;

4.8. - cabinets for spare parts, consumables, etc.

5. - storage compartment;

5.1. - installation of electric arc metallization;

5.2. - installation of abrasive blasting;

5.3. - compressor installation;

5.4. - argon ramp.

The technological container is divided into 3 compartments: work (1), operator (2) and auxiliary (3). All compartments are equipped with exit (exhaust) windows and a supply ventilation system with the function of cooling the supplied air.

The working compartment (1) is a powder laser cladding chamber equipped with an optical laser head (1.1), which is the working element of the laser radiation source, has a lens system and water cooling, and is equipped with a powder nozzle. The optical head (1.1) is installed on a robotic arm (1.2), which is designed to move it. The robotic arm (1.2) itself is controlled from the robot control cabinet (2.2) located in the operator compartment (2).

Also in the working compartment there is a universal rotator (1.3), a jib crane (1.4) for moving workpieces and exhaust ventilation (1.5).

The universal rotator (1.3) can operate both in the mode of a horizontal part rotator of the shaft type, and in the mode of a rotary table with an inclination of the part rotation axis. The universal rotator (1.3) is controlled from the robot control cabinet (2.2), which is located in the operator compartment (2).

The cantilever crane (1.4) is intended for installing the repaired part on the universal rotator (1.3). The console crane (1.4) is controlled by the control panel (2.8), which is located in the operator compartment (2).

Exhaust ventilation (1.5) is designed to remove gaseous combustion products and fine metal dust formed during the surfacing process. Air with gaseous combustion products and fine metal dust is cleaned with a filter and discharged outside the container.

The operator's compartment (2) is equipped with a workstation, designed to monitor and control the laser cladding process.

The control panel (2.1) allows you to control all the necessary parameters of the surfacing technological process, it is equipped with a monitor.

The robot control cabinet (2.2) with an industrial computer and a remote control panel (2.1) is used to control the movement and create movement programs for the robot manipulator and the universal rotator.

The complex control cabinet (2.3) is designed to control auxiliary systems.

Powder feeder (2.4) is designed for uniform dosing of powders into the powder nozzle of the optical head (1.1). The feeder operates in remote control mode. Controlled from the control panel (2.1).

A laser radiation source (2.5) generates a laser beam and transports it through an optical fiber to a working body - an optical head (1.1).

The gas distribution board (2.6) is connected to an argon rail (5.4).

The compartment is also equipped with a workstation (2.7).

The auxiliary compartment (3) is designed to accommodate auxiliary equipment that ensures the operation of the process container, including a chiller for a laser radiation source (3.1), a chiller for cooling optics (3.2), and a compressor unit (3.3).

The laboratory transport container is designed for laboratory research and for placing equipment during transportation.

The laboratory transport container is divided into two compartments: laboratory (4) and storage (5).

The laboratory compartment houses workstations, laboratory equipment and related systems.

The laboratory equipment includes a complex for sample preparation (4.1) and research (4.2) to control the quality of coatings and surfacing. Allows to carry out metallographic studies, control of surface roughness, thickness of coatings and deposited layers. The equipment is placed and secured on tables along the walls or in cabinets.

The laboratory compartment is also equipped with a water recirculation system (4.3) for water supply and cleaning from impurities after use, a sink (4.4), a fume hood for working with chemicals (4.5), a drying cabinet (4.6) for preparing powder materials, a compressor for supplying compressed air on the machines, they are all located along the walls of the container.

The laboratory compartment contains: a workplace (4.7), cabinets (4.8) for spare parts, consumables, etc. Cabinet doors are equipped with locks.

The storage compartment (5) is used to accommodate equipment during transportation of the complex. It contains:

- Installation of electric arc metallization (EDM) (5.1), designed for the application of protective anticorrosive metal coatings by the method of electric arc metallization on the surface of samples, parts and assemblies, which is used outside containers.

- Installation of abrasive blasting (ASO) (5.2) for surface preparation of samples and parts for spraying and surfacing, which is used outside the containers.

- Compressor unit (5.3), which serves to supply compressed air to the ASO unit and the EDM unit.

- Argon ramp (5.4), is a complex of gas equipment, consisting of argon cylinders, reducers, connecting pipes and a frame. The argon ramp is used outside the containers and supplies the process container with argon.

The proposed invention is aimed at creating and using, for the first time in practice, mobile complexes for the maintenance and repair of ship equipment, in particular in sea or river ports, using the technologies of thermal spraying and surfacing, which will provide the possibility of immediate work to maintain their serviceable and combat- or operational state in ports in a short time. Proceeding from this, the technical result of this invention is to ensure the prompt repair of ship parts in a sea or river port to reduce the construction and repair time of marine equipment, as well as to ensure the survivability and safety of the use of marine and river technology, as well as robotization of technological processes in shipbuilding and ship repair production, modernization and retrofitting of construction and launching facilities.

This technical result is achieved due to the fact that the VRK has a high-tech robotic powder laser cladding unit that makes it possible to repair parts, an electric arc metallization unit that allows the application and repair of anti-corrosion coatings, a laboratory for quality control and experimental work, accompanying and auxiliary equipment, workstations and compartments for compact and reliable placement of equipment, spare parts, materials, all the necessary communications for the deployment and safe operation of the VRK in ports and the prompt maintenance and repair. All stationary equipment is rigidly fixed in containers, and equipment that is used outside the containers is fixed in the storage compartment during transportation or idle time. The VRK is represented by two standard sea containers redeployed by all modes of transport, which makes it possible to base the complex in different ports and provide robotization of technological processes of shipbuilding and ship repair production, as well as modernization and retrofitting of construction and launching facilities.

The invention is illustrated by the attached drawing, which shows an example of the arrangement of the FKM equipment in the assembled state.

Implementation of the invention.

VRK is completed with equipment, materials, spare parts. The complex is located in an operating sea (river) port, where it is delivered by road, rail or sea transport. Both containers are installed on a flat and solid base (prepared concrete area) in close proximity to each other. The complex is supplied with electric power. The argon ramp (5.4) is installed in the immediate vicinity of the process container in compliance with safety requirements. The gas distribution board (2.6) of the process container is connected to an argon rail (5.4). If necessary, the equipment is installed, transported in the storage compartment of the laboratory transport container (5), from the transport state to the working one. By means of a jib crane (1.4), the workpiece is mounted on the universal rotator (1.3). A program is drawn up for moving the working body (1.1) installed on the robotic arm (1.2), as well as moving the part on the universal rotator (1.3) using the control panel (2.1).

Application and repair of anticorrosive coatings is carried out manually outside the container using ASO (5.2) installations for surface cleaning and preparation and EDM (5.1) for metal coating application.

To confirm the quality of the work performed, metallographic and other studies of samples are carried out in the laboratory compartment (4). Upon completion of the work, the equipment is dismantled and installed in the storage compartment, after which the complex can be relocated.

The problem of this invention is solved by creating a mobile complex for the repair of ship equipment using the technologies of thermal spraying and surfacing - a high-performance robotic complex (RSC) for equipping sea or river ports in order to promptly repair and protect ship parts and components, as well as provide ports with modern service technologies. and repair. The VRK can be transported by road, air or sea transport. Mobility and the ability to quickly deploy will allow for urgent or scheduled repairs in the right place at the right time, which will reduce downtime, maintenance and repair costs of marine equipment and infrastructure.

Claims (4)

1. Mobile high-performance robotic complex for the repair of ship equipment, including workplaces located in containers, equipped with communications, tools and equipment, characterized in that the complex consists of two sea containers, one of which is a technological one and consists of a working and an operator compartment, and the second is laboratory and transport and consists of laboratory and storage compartments, while the working compartment contains equipment for powder laser surfacing, a robot arm and a universal rotator, the operator compartment contains a workplace and equipment for controlling the robot and equipment for controlling the complex, in the warehouse the compartment houses the equipment for abrasive blasting, electric arc metallization and gas-thermal spraying, and the laboratory compartment contains laboratory equipment for controlling coatings and deposited layers. 2. Mobile high-performance robotic complex for the repair of ship equipment according to claim 1, characterized in that the technological container is equipped with an auxiliary compartment to accommodate additional equipment. 3. Mobile high-performance robotic complex for the repair of ship equipment according to claim 2, characterized in that the storage compartment contains equipment, spare property and fixtures and materials during transportation of the complex. 4. Mobile high-performance robotic complex for the repair of ship equipment according to PP. 1-3, characterized in that the containers are equipped with electrical distribution boards, their own heating system, individual ventilation and air conditioning systems, and gas supply systems for work.

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