WO2019228313A1 - 利用手动填料进行激光焊接修补的半自动装置 - Google Patents

利用手动填料进行激光焊接修补的半自动装置 Download PDF

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Publication number
WO2019228313A1
WO2019228313A1 PCT/CN2019/088681 CN2019088681W WO2019228313A1 WO 2019228313 A1 WO2019228313 A1 WO 2019228313A1 CN 2019088681 W CN2019088681 W CN 2019088681W WO 2019228313 A1 WO2019228313 A1 WO 2019228313A1
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signal generator
dimensional curve
dimensional
curve
semi
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PCT/CN2019/088681
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English (en)
French (fr)
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刘闻司
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Liu Wensi
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70—Auxiliary operations or equipment
    • B23K26/702—Auxiliary equipment

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  • the invention relates to laser surfacing technology, in particular to an apparatus and method for repairing irregular shapes by using laser surfacing technology.
  • the existing laser welding can be roughly divided into automatic welding and manual welding.
  • Automatic welding is suitable for mass production. For example, in a mobile phone, a small screw is welded to the metal sheet, as long as the metal is melted to ensure that the small screw is combined with the metal sheet, there is no problem. In this case, welding does not need to add materials such as welding rod, welding wire, powder and so on.
  • the laser repair welding technology used to repair the mold scratches and indentations and the processing errors of mechanical parts must first restore the shape of the defect, and secondly, the quality requirements for the bonding strength and compactness of the welding are very high, so it needs to be added.
  • Materials such as welding rods or wires or powders are not suitable for automatic welding in this case. The reason is that automatic welding cannot be stopped during the welding process, and the speed cannot be adjusted.
  • the laser light spot is very small, only a few tenths of a millimeter, and the solder is slightly off. The molten state is not good, it is easy to produce pores, and even the solder does not melt.
  • the feed angle, feed speed, and feed amount of the solder are all real-time indicators, and the welder needs to adjust in real time according to the actual situation to meet the repair requirements.
  • the repair of the defect of the workpiece is generally performed by manual laser welding.
  • manual laser welding is used to repair small workpieces
  • the workpiece can be placed on the work table with one hand rotating the mechanical hand wheel to control the X direction, Y direction, and Z direction of the work table to achieve the three-dimensional movement of the work piece.
  • the movement can only be independent movement in each direction, and can not be linked. Moreover, it can only move in a straight line.
  • Welding repair of complex shapes is very difficult. For the damage of slightly complicated workpieces, it is difficult to implement high-quality and rapid welding repair.
  • a 3D bracket When manual laser welding is used to repair large workpieces, you can only use an auxiliary device called a 3D bracket (although it is called a 3D bracket, but the Z axis and the X and Y axes cannot be linked).
  • the joystick By pulling the joystick, the X axis and Y axis can be seen on the surface.
  • the axes are moving at the same time.
  • the joystick is controlled by the swing angles of the joysticks in the X and Y directions.
  • the X and Y axes are controlled separately to achieve the curve movement. This operation is very difficult, and the actual direction of movement is difficult to match the direction of movement.
  • the purpose of the present invention is to provide a semi-automatic device for laser welding repair using manual fillers and a method of using the device, in order to solve the problem that it is difficult to implement three-dimensional control in the process of curve or surface repair, so that the repair of curve or surface follows a pre-designed trajectory Manual control is performed to improve repair efficiency and repair quality.
  • a semi-automatic device for laser welding repair by using manual fillers including an imaging system mounted on a three-axis moving frame, a control system for controlling the three-axis moving frame, the control system including a control for sending static commands A panel and a signal generator for sending dynamic commands, and also includes a motion control card, which is characterized in that the motion control card can execute the following commands: the positioning of irregular shapes of defects to be repaired by the imaging system, collecting n points, and using software The calculation forms a first three-dimensional curve that matches the shape of the defect to be repaired and is automatically stored in the motion control card; the signal generator can send commands to control the three-axis moving frame through the motion control card to follow the stored three-dimensional curve On this basis, the offset is formed along the first three-dimensional curve to form a second three-dimensional curve.
  • the signal generator can send commands to control the three-axis moving frame through the motion control card to move along the second three-dimensional curve.
  • N three-dimensional curves of different positions form a curved surface; the welding material is sent manually
  • the signal generator can send commands to control the three-axis moving frame to advance, retreat, stop at any time along the three-dimensional curve, and advance and Backward speed.
  • the imaging system of the above-mentioned semi-automatic device for manual laser welding repair using manual fillers includes a laser focusing device, a microscope, and a CCD camera device.
  • the imaging system is used to observe and determine the relative position of the defect of the part to be repaired.
  • the semi-automatic device for manual laser welding repair using manual fillers characterized in that the three-dimensional curve includes a straight line segment, a curved line segment, a circular arc, an elliptical arc, a parabolic arc, a hyperbolic arc, and any two or more of the above-mentioned line segments. curve.
  • the above-mentioned semi-automatic device for manual laser welding repair using manual fillers is characterized in that the degree of coincidence between the first three-dimensional curve generated by the motion control card and the defect to be repaired can be adjusted by increasing points, deleting points, and moving points. To perfect the first three-dimensional curve.
  • the above-mentioned semi-automatic device for laser welding repair using manual fillers is characterized in that the welding of curved surfaces is realized by multi-line welding of the first three-dimensional curve, the second three-dimensional curve, and even the N-th three-dimensional curve; based on this, Through multiple 3D curved surface welding, welding repair of 3D defects is realized.
  • the above-mentioned semi-automatic device for laser welding repair using manual filler is characterized in that the signal generator includes an electric pulse handwheel, a control rocker, a button switch, a foot switch, a toggle switch, a knob switch, or a combination thereof;
  • the signal generator can send commands to control the three-axis moving frame through the motion control card, and implement the offset along the first three-dimensional curve to form the second three-dimensional curve, or even the N-dimensional three-dimensional curve.
  • the above-mentioned semi-automatic device for repairing by laser welding using a manual filler is characterized in that the signal generator includes a first signal generator, a second signal generator, and a third signal generator; Movement, the second signal generator controls the offset of the trajectory, and the third signal generator controls the offset of other dimensions of the trajectory; the offset can be performed at any point at any time, and the direction and distance of the trajectory offset are adjusted .
  • the second signal generator and the third signal generator may also be implemented by switching the gear position of the first signal generator.
  • Step 1 Using the imaging system along the defect shape of the part to be repaired, the signal generator moves the X-axis, Y-axis, and Z-axis respectively to locate and collect n points through the control system;
  • Step 2 Use the control panel to make the preset software automatically generate the first three-dimensional curve track based on the n points collected in step 1.
  • Step 3 Compare the generated first three-dimensional curve track with the defect shape of the part to be repaired. If there is a deviation, you can set the increase of the point again, delete the point, and move the point to make the first three-dimensional curve track and The shape of the defect to be repaired completely matches;
  • Step 4 Turn on the laser welding machine, and control the movement of the laser through the signal generator 1, so that the emitted laser light advances, retreats, and stops along the first three-dimensional curved trajectory; the speed of the forward and backward movement is signaled by the signal generator Adjust the amount at any time;
  • Step 5 Use the second signal generator and the third signal generator to send offset value instructions to the motion control card; make the first three-dimensional curve can be offset in any direction and at any distance; it can be achieved after multiple offsets Motion along a three-dimensional surface. Based on this, three-dimensional surface welding is performed multiple times to realize welding repair of three-dimensional defects.
  • Step 6 Adjust the filling angle and the amount of filling in real time according to the speed of the laser moving along each three-dimensional curved track.
  • the welding path that needs to be controlled in real time is changed to a real-time control along a preset curve or curved track, which solves the problem of laser welding on curved or curved surfaces during manual welding.
  • Walking along the broken line it is necessary to rotate the workpiece angle multiple times and calibrate the position multiple times, avoiding the quality problem of the joint of the weld caused by multiple welding pauses, and greatly improving the welding efficiency and welding quality.
  • FIG. 1 is a schematic diagram of a semi-automatic device for laser welding repair using a manual filler according to the present invention.
  • FIG. 2 is a schematic diagram showing irregular shapes of molds and mechanical parts to be repaired according to the present invention.
  • FIG. 3 is a schematic diagram of a broken line used in a conventional welding method according to an embodiment of the present invention.
  • FIG. 4 is a schematic diagram of a curve used in a semi-automatic welding method according to an embodiment of the present invention.
  • FIG. 5 is a schematic diagram showing a trajectory of forming a mining point according to an embodiment of the present invention.
  • FIG. 6 is a schematic diagram of dimension Y offset according to an embodiment of the present invention.
  • FIG. 7 is a schematic diagram of a dimension Z offset according to an embodiment of the present invention.
  • FIG. 8 is a schematic diagram of a first welding seam of a first layer according to an embodiment of the present invention.
  • FIG. 9 is a schematic diagram of a first layer and a second welding seam according to an embodiment of the present invention.
  • FIG. 10 is a schematic diagram of the Nth welding seam of the first layer according to the embodiment of the present invention.
  • FIG. 11 is a schematic diagram of the Nth welding seam of the second layer according to the embodiment of the present invention.
  • FIG. 12 is a schematic diagram of the Mth and Nth welds of the embodiment of the present invention.
  • FIG. 1 shows an embodiment of a semi-automatic device for laser welding repair using manual fillers according to the present invention.
  • the control system includes a control panel 4 for sending static commands and a signal generation for sending dynamic commands
  • the signal generators 1, 6, and 7 can be electric pulse handwheels, control joysticks, button switches, foot switches, toggle switches, knob switches, etc., which can control the movement of the laser along the motion control card 5
  • Each generated three-dimensional curve track advances, retreats or stops halfway, and the speed of laser advance or retreat is adjusted at any time by the amount of signal emitted by the signal generator.
  • FIG. 2 is a schematic diagram of the irregularly shaped edge defect 21 of the workpiece 20.
  • the workpiece 20 ′ is a top view of the workpiece 20
  • 21 ′ is a top view of the irregular shape edge defect 21 of the workpiece 20
  • the workpiece 20 ′′ is a front view of the workpiece 20 View, 21 "is a front view of the irregularly shaped edge defect 21 of the workpiece 20.
  • FIG. 3 are partial enlarged diagrams of the fold lines 22 and 23 used in the conventional welding method.
  • this welding method the quality of the joints of the welds cannot be guaranteed.
  • welding multiple welds or even multi-layer welds rotating the workpiece and repositioning requires a lot of time, and the processing quality and work efficiency cannot be guaranteed.
  • FIG. 4 are partial enlarged diagrams of continuous smooth curves 24 and 25 used in the welding method of the present invention.
  • the welding seams are continuous and not connected. Welding multiple welding seams or even multi-layer welding seams does not need to rotate the workpiece and does not require repositioning. The processing quality and work efficiency are greatly improved.
  • the imaging system is used to locate the irregular shape defects of the repaired parts, and the control system is used to move the X-axis, Y-axis, and Z-axis to fix the points, randomly select a few different positions, and then use the control panel 4 to make the preset software 4 ′
  • the first three-dimensional curve track shown in FIG. 5 is automatically generated; 26 is an upper view of the three-dimensional curve track, 27 is a front view of the three-dimensional curve track, and 28 is an isometric view of the three-dimensional curve track. Compare the first three-dimensional curve trajectory with the defect shape of the part to be repaired. If there is a deviation, you can set the movement of the point, increase the point, and delete the point to make the first three-dimensional curve trajectory and the part to be repaired. The shape of the defect fits perfectly.
  • the welder controls the movement of the laser through the signal generators 1, 6, and 7.
  • the laser passes through the focusing lens 16 to focus the laser on the focal point 15.
  • the emitted laser light follows the first The trajectory advances or retreats.
  • the speed of its advance or retreat is adjusted at any time by the amount of the signal generators 1, 6, and 7.
  • the other hand of the welder holds the laser in accordance with the real-time progress of the forward or retreat speed along the first trajectory. Adjust the angle of the solder and the speed of the filler.
  • the signal generator 2 sends an offset signal in the Y dimension through the motion control card; the offset can be normal or parallel, and the first curve 26 is offset.
  • N three-dimensional curve trajectories are obtained so many times; the N three-dimensional curve trajectories are the first-layer curved surface of the defect to be repaired.
  • the signal generator 3 shifts the first-layer curved surface 27 to the second-layer curved surface 27 ′ and the third-layer curved surface 27 ′′ through the motion control card to send a Z-dimensional offset signal.
  • the three-dimensional curved surface of the M layer can be obtained through such multiple shifts.
  • the three-dimensional curved surface of the M layer can be welded to repair the three-dimensional defect.
  • 29 shown in FIG. 8 is the first weld of the first layer
  • 30 shown in FIG. 9 is the second weld of the first layer
  • 31 shown in FIG. 10 is the N of the first layer.
  • 32 shown in FIG. 11 is a second-layer curved surface formed by N welds of the second layer.
  • 33 shown in FIG. 12 is the M-th surface formed by the N welding seams of the M-th layer, that is, a three-dimensional welding meat is finally formed.

Abstract

一种利用手动填料进行激光焊接修补的半自动装置，包括安装于三轴移动架上的成像系统，用于控制三轴移动架的控制系统，还包括运动控制卡，其特征在于该运动控制卡可以执行以下命令：通过成像系统对待修补件不规则形状缺陷的定位，采集n个点，通过软件计算形成一条与待修补件缺陷形状相吻合的第一条三维曲线，自动存储于运动控制卡中；信号发生器通过该运动控制卡可发送命令控制三轴移动架，沿着被存储的三维曲线运动；在此基础上，沿第一条三维曲线实施偏移形成第二条三维曲线，信号发生器通过该运动控制卡可发送命令控制三轴移动架，沿着第二条三维曲线运动。还涉及一种使用该装置进行焊接修补的方法。采用该装置，避免因多次焊接停顿所导致的焊缝衔接处的质量问题，大大提高了焊接效率和焊接质量。

Description

利用手动填料进行激光焊接修补的半自动装置 技术领域
本发明涉及激光堆焊技术，尤其是利用激光堆焊技术进行修补不规则形状的装置和方法。
背景技术
现有的激光焊接大体上可分为自动焊和手工焊。自动焊接适用于批量生产。比如在手机内部，把一个小螺丝焊接到金属薄片上，只要金属熔化能够保证小螺丝与金属薄片结合就没有问题了。这种情况焊接不需要添加如焊条、焊丝、粉末等材料。
而利用激光堆焊技术对模具划伤和压痕以及机械零部件儿的加工失误的焊接修补，首先要恢复缺陷的形状，其次对于焊接的结合强度，致密性等质量要求很高，所以需要添加焊条或焊丝或粉末等材料，在这种情况下自动焊接不适用，其原因在于自动焊接途中不能停止，也不能进行速度的调整，激光的光点很小只有零点数毫米，焊料稍有偏离，熔化的状态不好，容易产生气孔，甚至焊料不熔化。再者，根据待焊接修补缺陷的形状，焊料的进给角度、进给速度、进给量等都是实时指标，焊工需要根据实际情况即时调整，以满足修补的要求。
鉴于以上原因，对工件缺陷处的修补一般都是采用手动激光焊接进行的。手动激光焊接修补小型工件时，可以把工件放在工作台上一支手旋转机械手轮，控制工作台的X方向，Y方向，Z方向，以实现工作台上工件的三维运动，但是这种三维运动只能是各自方向的单独运动，不能联动，况且只能走直线运动，复杂形状的焊接修补非常困难，对于形状稍微有点复杂的工件的损伤之处，就难以实施高质量， 快速焊接修补。手动激光焊接修补大型工件时，只能利用一种叫做3D支架的辅助设备(虽然叫做3D支架，但是Z轴和X，Y轴不能联动)，通过扳动摇杆，表面上看X轴，Y轴是在同时的运动，实际上摇杆是通过X，Y各自方向的摇杆摆动角度的大小，同一时间单独地控制着X轴和Y轴，来实现曲线的运动。这种操作非常困难，实际的运动方向和想要运动的方向很难吻合。并且，即使勉强能够实现曲线的运动也仅仅是二维的，三维的曲线运动根本无法实现。也就是说不规则形状的焊接修补非常困难。用现有的焊接方法焊接曲线或者曲面的时候，只能把曲线分成数个直线段，以折线的形式焊接。如此一来，工作效率大幅降低，焊接的质量难以保证。
发明内容
本发明的目的在于提供利用手动填料进行激光焊接修补的半自动装置，以及该装置的使用方法，以解决曲线或曲面修补过程中难以实施三维控制的问题，使曲线或曲面的修补沿预先设计的轨迹人工控制进行，以提高修补效率以及修补质量。
本发明技术方案：利用手动填料进行激光焊接修补的半自动装置，包括安装于三轴移动架上的成像系统，用于控制三轴移动架的控制系统，该控制系统包括用于发送静态命令的控制面板和用于发送动态命令的信号发生器，还包括运动控制卡，其特征在于该运动控制卡可以执行以下命令：通过成像系统对待修补件不规则形状缺陷的定位，采集n个点，通过软件计算形成一条与待修补件缺陷形状相吻合的第一条三维曲线，自动存储于运动控制卡中；信号发生器通过该运动控制卡可发送命令控制三轴移动架，沿着被存储的三维曲线运动；在此基础上，沿第一条三维曲线实施偏移形成第二条三维曲线，信号发生器通过该运动控制卡可发送命令控制三轴移动架，沿着第二条三维曲线 运动，按照此方法，不同位的N条三维曲线构成一个曲面；焊接材料通过人工送给的方式添加到每一条三维曲线对应的待修补件的缺陷处；所述信号发生器可发送命令控制三轴移动架沿着每一条三维曲线进行前进，后退，任意时刻的中途停止，以及前进和后退的速度。
上述的利用手动填料进行激光焊接修补的半自动装置，其成像系统包括激光聚焦装置，显微镜和CCD摄像头装置，该成像系统用于观察和确定待修补件缺陷处的相对位置。
上述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述三维曲线包括直线段，曲线段，圆弧，椭圆弧，抛物线弧，双曲线弧，以及上述任意两种以上线段所构成的曲线。
上述的利用手动填料进行激光焊接修补的半自动装置，其特征在于运动控制卡所生成的第一条三维曲线与待修补件缺陷的吻合度可通过点的增加，点的删除，点的移动进行调整以完善第一条三维曲线。
上述的利用手动填料进行激光焊接修补的半自动装置，其特征在于通过第一条三维曲线，第二条三维曲线，乃至第N条三维曲线的多行焊接，实现曲面的焊接；在此基础上，通过多次的三维曲面焊接，实现立体缺陷的焊接修补。
上述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述信号发生器包括电动脉冲手轮，控制摇杆，按钮开关，脚踏开关，拨动开关，旋钮开关，或其组合；所述信号发生器通过运动控制卡可发送命令控制三轴移动架，沿第一条三维曲线实施偏移形成第二条三维曲线，乃至第N条三维曲线的偏移。
上述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述信号发生器包括第一信号发生器，第二信号发生器，第三信号发生器；所述第一信号发生器控制轨迹的运动，所述第二信号发生器控制轨迹的偏移，所述第三信号发生器控制轨迹其他维度的偏移；可 随时在任意点进行偏移，并且调整轨迹偏移的方向和偏移距离。所述第二信号发生器，第三信号发生器也可以通过切换第一信号发生器档位的方式来实现。
一种使用权利要求1所述装置的方法，其特征在于：
步骤一：利用成像系统沿着待修补件缺陷形状，信号发生器通过控制系统，分别移动X轴，Y轴，Z轴来定位，采集n个点；
步骤二：通过控制面板使预设的软件根据步骤一采集的n个点，自动生成第一条三维曲线轨迹；
步骤三：将生成的第一条三维曲线轨迹与待修补件缺陷形状进行吻合度比较，若有偏差可通过再次设置点的增加，点的删除，点的移动，使第一条三维曲线轨迹与待修补件缺陷形状完全吻合；
步骤四：开启激光焊机，通过信号发生器1，控制激光的运动，使射出的激光沿着第一条三维曲线轨迹前进，后退，停止；其前进，后退的速度由信号发生器发出信号量的多少随时调节；
步骤五：通过第二信号发生器，第三信号发生器给运动控制卡发出偏移数值指令；使第一条三维曲线可向任意方向，以任意距离偏移；经过多次偏移后可实现沿三维曲面的运动。在此基础上，通过多次的三维曲面焊接，实现立体缺陷的焊接修补。
步骤六：根据激光沿每一条三维曲线轨迹前进，后退的速度，实时进行填料角度、填料量多少的调整。
采用本发明的上述利用手动填料进行激光焊接修补的半自动装置，将需实时控制的焊接路径改变为沿预设的曲线轨迹或曲面轨迹进行实时控制，解决了手工焊时激光在焊接曲线或曲面时走折线，需要多次旋转工件角度，多次校准位置，避免了因多次焊接停顿所导致的焊缝衔接处的质量问题，大大提高了焊接效率和焊接质量。
附图说明
图1所示为本发明利用手动填料进行激光焊接修补的半自动装置示意图。
图2所示为本发明针对模具以及机械零部件待修补件不规则形状缺陷的示意图。
图3所示为本发明实施例的传统焊接方法所采用的折线示意图。
图4所示为本发明实施例的半自动焊接方法所采用的曲线示意图。
图5所示为本发明实施例采点形成曲线轨迹示意图。
图6所示为本发明实施例维度Y偏移示意图。
图7所示为本发明实施例维度Z偏移示意图。
图8所示为本发明实施例的第一层第一条焊缝示意图。
图9所示为本发明实施例的第一层第二条焊缝示意图。
图10所示为本发明实施例的第一层第N条焊缝示意图。
图11所示为本发明实施例的第二层第N条焊缝示意图。
图12所示为本发明实施例的第M层第N条焊缝示意图。
具体实施方式
下面结合实施例对本发明作进一步详细的说明。
如图1所示为本发明利用手动填料进行激光焊接修补的半自动装置的实施例。包括具有X轴驱动器10、X轴电机17、Y轴驱动器8、Y轴电机18、Z轴驱动器9、Z轴电机19的三轴移动架X，Y，Z上的激光聚焦头14、显微镜11、CCD摄像头12，显示屏13等成像系统，用于控制三轴移动架X，Y，Z的控制系统，该控制系统包括用于发送静态命令的控制面板4和用于发送动态命令的信号发生器1，6，7，还包括运动控制卡5，该运动控制卡5可以执行、处理、发出以下命令：通过成像系统对待修补件不规则形状缺陷定位，然后采集n 个点，再通过软件4′计算形成一条与待修补件缺陷形状相吻合的第一条三维曲线，自动存储于运动控制卡5中，之后再根据实际情况进行任意量的偏移，生成第二条三维曲线，乃至第N条三维曲线，如此通过运行不同位的多条三维曲线就构成一曲面；该运动控制卡5可发送命令，通过各轴的驱动器、电机控制三轴移动架X，Y，Z按照所存储的三维曲线的轨迹运动；焊料通过人工给进到每一条三维曲线所对应的待修补件的缺陷处；所述信号发生器1，6，7可发送命令控制三轴移动架X，Y，Z沿每一条三维曲线的轨迹前进，后退或中途停止，以及前进和后退的速度；所述运动控制卡5可以被输入和发送偏移命令，可控制三轴移动架实现多条三维曲线的运动。所述信号发生器1，6，7可为电动脉冲手轮，控制摇杆，按钮开关，脚踏开关，拨动开关，旋钮开关等，可控制激光的运动，使其沿着运动控制卡5生成的每一条三维曲线轨迹前进，后退或中途停止，激光前进或后退的速度由信号发生器发出信号量的多少来随时调节。通过所述第一信号发生器1，第六信号发生器6，第七信号发生器7以外的第二信号发生器2，第三信号发生器3可随时调整轨迹偏移的大小。
图2所示的是工件20不规则形状边缘缺陷21的示意图，工件20′为工件20的上视图，21′为工件20不规则形状边缘缺陷21的上视图，工件20″为工件20的前视图，21″为工件20不规则形状边缘缺陷21的前视图。
图3所示22′和23′为传统的焊接方法所采用的折线22和23的局部放大示意图。通过这种焊接方法，焊缝的衔接处质量不能保障，此外，焊接多条焊缝乃至多层焊缝，旋转工件以及从新定位需要大量的时间，加工质量和工作效率都不能保证。
图4所示24′和25′为本发明的焊接方法所采用的连续平滑曲线24和25的局部放大示意图。通过这种焊接方法，焊缝是连贯的没有 衔接，焊接多条焊缝乃至多层焊缝，不需要旋转工件，不需要重新定位，加工质量和工作效率大幅度提高。
通过成像系统对待修补件不规则形状缺陷的定位，通过控制系统分别移动X轴、Y轴、Z轴来定点，任意选取数个不同位置的点，然后通过控制面板4使预设的软件4′自动生成第一条如图5所示的三维曲线轨迹；26为此三维曲线轨迹的上视图，27为此三维曲线轨迹的前视图，28为此三维曲线轨迹的等轴试图。将生成的第一条三维曲线轨迹与待修补件缺陷形状进行吻合度比对，若有偏差可通过设置点的移动，点的增加，点的删除，使第一条三维曲线轨迹与待修补件缺陷形状完全吻合。
开启激光焊机，图1所示，焊工一支手通过信号发生器1，6，7控制激光的运动，激光通过聚焦镜16，使激光聚焦于焦点15处，射出的激光沿着第一条轨迹前进或后退，其前进或后退的速度由信号发生器1，6，7发出量的多少来随时调节，焊工的另一支手持焊料根据激光沿第一条轨迹前进或后退速度的实时进程，可调整焊料的角度、填料的快慢。
然后如图6的曲线上视图所示，信号发生器2，通过运动控制卡发出Y维度的偏移量信号；偏移可以采取法向也可采取平行偏移，将第一条曲线26偏移至第二条曲线26′，第三条曲线26″，如此多次得到N条三维曲线轨迹；该N条三维曲线轨迹即为待修补件缺陷的第一层曲面。
然后如图7的曲线前视图所示，信号发生器3，通过运动控制卡发出Z维度的偏移量信号将第一层曲面27偏移至第二层曲面27′，第三层曲面27″，如此多次偏移可得到M层的三维曲面，通过M层的三维曲面的焊接，可以实现立体缺陷的修补。
图8所示的29为本发明实施例的第一层第一条焊缝，图9所示 的30为第一层第二条焊缝，图10所示的31为第一层的N条焊缝所形成的第一层曲面。图11所示的32为第二层的N条焊缝所形成的第二层曲面。图12所示的33为第M层的N条焊缝所形成的第M层曲面，也就是最终形成了立体的焊肉。
以上所述的仅是本发明的优选实施方式，应当指出，对于本领域的普通技术人员来说，在不脱离本发明创造构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。

Claims (9)

  1. 利用手动填料进行激光焊接修补的半自动装置，包括安装于三轴移动架上的成像系统，用于控制三轴移动架的控制系统，该控制系统包括用于发送静态命令的控制面板和用于发送动态命令的信号发生器，还包括运动控制卡，其特征在于该运动控制卡可以执行以下命令：通过成像系统对待修补件不规则形状缺陷的定位，采集n个点，通过软件计算形成一条与待修补件缺陷形状相吻合的第一条三维曲线，自动存储于运动控制卡中；信号发生器通过该运动控制卡可发送命令控制三轴移动架，沿着被存储的三维曲线运动；在此基础上，沿第一条三维曲线实施行偏移形成第二条三维曲线，信号发生器通过该运动控制卡可发送命令控制三轴移动架，沿着第二条三维曲线运动，按照此方法，不同位的N条三维曲线构成一个曲面；焊接材料通过人工送给的方式添加到每一条三维曲线对应的待修补件的缺陷处；所述信号发生器可发送命令控制三轴移动架沿着每一条三维曲线进行前进，后退，任意时刻的中途停止，以及前进和后退的速度。
  2. 根据权利要求1所述的利用手动填料进行激光焊接修补的半自动装置，其成像系统包括激光聚焦装置，显微镜和CCD摄像头装置，该成像系统用于观察和确定待修补件缺陷处的相对位置。
  3. 根据权利要求1或2所述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述三维曲线包括直线段，曲线段，圆弧，椭圆弧，抛物线弧，双曲线弧，以及上述任意两种以上线段所构成的曲线。
  4. 根据权利要求3所述的利用手动填料进行激光焊接修补的半自动装置，其特征在于运动控制卡所生成的第一条三维曲线与待修补件缺陷的吻合度可通过点的增加，点的删除，点的移动进行调整以完善第一条三维曲线。
  5. 根据权利要求1或权利要求3所述的利用手动填料进行激光焊接修补的半自动装置，其特征在于通过第一条三维曲线，第二条三维曲线，乃至第N条三维曲线的多条焊接，实现曲面的焊接；在此基础上，通过多次的三维曲面焊接，实现立体缺陷的焊接修补。
  6. 根据权利要求1或权利要求2所述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述信号发生器包括电动脉冲手轮，控制摇杆，按钮开关，脚踏开关，拨动开关，旋钮开关，或其组合；所述信号发生器通过运动控制卡可发送命令控制三轴移动架，沿第一条三维曲线实施偏移形成第二条三维曲线，乃至第N条三维曲线的偏移。
  7. 根据权利要求3所述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述信号发生器包括电动脉冲手轮，控制摇杆，按钮开关，脚踏开关，拨动开关，旋钮开关，或其组合；所述信号发生器通过运动控制卡可发送命令控制三轴移动架，沿第一条三维曲线实施偏移形成第二条三维曲线，乃至第N条三维曲线的偏移。
  8. 根据权利要求5所述的利用手动填料进行激光焊接修补的半自动装置，其特征在于所述信号发生器包括第一信号发生器，第二信号发生器，第三信号发生器；所述第一信号发生器控制轨迹的运动，所述第二信号发生器控制轨迹的偏移，所述第三信号发生器控制轨迹其他维度的偏移；可随时在任意点进行偏移，并且调整轨迹偏移的方向和偏移距离；所述第二信号发生器，第三信号发生器也可以通过切换第一信号发生器档位的方式来实现。
  9. 一种使用权利要求1所述装置的方法,其特征在于：
    步骤一：利用成像系统沿着待修补件缺陷形状，信号发生器通过控制系统，分别移动X轴，Y轴，Z轴来定位，采集n个点；
    步骤二：通过控制面板使预设的软件根据步骤一采集的n个点， 自动生成第一条三维曲线轨迹；
    步骤三：将生成的第一条三维曲线轨迹与待修补件缺陷形状进行吻合度比较，若有偏差可通过再次设置点的增加，点的删除，点的移动，使第一条三维曲线轨迹与待修补件缺陷形状完全吻合；
    步骤四：开启激光焊机，通过第一信号发生器，控制激光的运动，使射出的激光沿着第一条三维曲线轨迹前进，后退，停止；其前进，后退的速度由信号发生器发出信号量的多少随时调节；
    步骤五：通过第二信号发生器，第三信号发生器给运动控制卡发出偏移数值指令；使第一条三维曲线可向任意方向，以任意距离偏移；经过多次偏移后可实现沿三维曲面的运动。在此基础上，通过多次的三维曲面焊接，实现立体缺陷的焊接修补。
    步骤六：根据激光沿每一条三维曲线轨迹前进，后退的速度，实时进行填料角度、填料量多少的调整。
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