阅读说明：本技术 一种深水管道复合铣削增减材原位修复设备与方法 (deepwater pipeline composite milling material increase and decrease in-situ repair equipment and method ) 是由 杨永强 翁昌威 秦文韬 李阳 宋长辉 于 2019-09-29 设计创作，主要内容包括：本发明公开了一种深水管道复合铣削增减材原位修复设备,包括修复舱、装备舱、刀具库、本地控制系统、六轴机器人、增材修复系统、减材处理系统和监控系统。本发明利用水下高压干法进行水下金属增材制造,使得修复后零件孔洞少、裂纹少、致密度高、强度高、力学性能好。本发明采用等离子熔融沉积、激光熔融沉积结合减材制造可以满足多种条件下的修复工作,通过激光预沉积的方式解决了等离子熔融沉积第一层界面结合的问题,可以实现异种材料的修复；本发明在修复完成后,通过激光熔融沉积一层抗腐蚀层,可以大大提高修复后的零件质量。(the invention discloses a deepwater pipeline composite milling material increase and decrease in-situ repair device which comprises a repair cabin, an equipment cabin, a cutter library, a local control system, a six-axis robot, a material increase repair system, a material decrease processing system and a monitoring system. The invention utilizes the underwater high-pressure dry method to carry out underwater metal additive manufacturing, so that the repaired part has fewer holes, fewer cracks, high density, high strength and good mechanical property. The plasma melting deposition and laser melting deposition combined material reduction manufacturing method can meet repair work under various conditions, solves the problem of interface combination of the first layer of plasma melting deposition in a laser pre-deposition mode, and can realize repair of dissimilar materials; after the repair is finished, the laser melting deposition of the anti-corrosion layer can greatly improve the quality of the repaired part.)

1. The deepwater pipeline composite milling material-increasing and material-decreasing in-situ repair equipment is characterized by comprising a repair cabin, an equipment cabin, a cutter library, a local control system, a six-axis robot, a material-increasing repair system, a material-decreasing processing system and a monitoring system;

both sides of the repair cabin are provided with a replaceable cabin door and a sealing cabin door which are used for loading the pipeline to be repaired into the repair cabin and ensuring the air tightness in the cabin; the top of the repair cabin is provided with a protective gas pipe interface used for providing high-pressure protective gas for the cabin to remove liquid in the cabin through a gas cylinder equipped on the water surface; the bottom of the repair cabin is provided with a movable cabin bottom and a sealing gasket, and the movable cabin bottom and the sealing gasket are used for sealing the repair cabin after liquid in the repair cabin is emptied;

an equipment cabin door and a sealing strip are arranged between the equipment cabin and the repair cabin and are used for keeping a closed state when the drainage work of the repair cabin is not finished; the top of the equipment cabin is provided with a comprehensive pipeline joint for leading in a power line, an air pipe and a communication line from the water surface;

The tool magazine, the six-axis robot, the material increase repair system, the material reduction processing system, the monitoring system and the control system are all arranged in the equipment cabin;

The additive repair system comprises a coaxial wire-feeding plasma welding gun, a coaxial wire-feeding laser cladding head, a wire feeder, a laser, a plasma welding machine and a laser water cooling machine;

the wire feeder is respectively connected with the coaxial wire feeding plasma welding gun and the coaxial wire feeding laser cladding head and is used for providing metal wires with different diameters for the coaxial wire feeding plasma welding gun and the coaxial wire feeding laser cladding head;

The material reducing processing system comprises a polishing disc, a three-dimensional scanner, an electric spindle and a milling cutter; the three-dimensional scanner is used for acquiring three-dimensional image data of a processing surface; the polishing disc is used for carrying out pretreatment work of derusting the processing plane and removing shellfish;

The monitoring system comprises a high-definition camera and a molten pool monitoring camera; the high-definition camera is used for acquiring a high-definition image of the whole equipment cabin; the molten pool monitoring camera is provided with a photodiode and is used for acquiring molten pool image data in the material increase process in real time;

The coaxial wire-feeding plasma welding gun, the coaxial wire-feeding laser cladding head, the polishing disc, the three-dimensional scanner and the milling cutter are all arranged in the cutter library;

the six-axis robot is provided with a welding module, and clamps and switches a coaxial wire feeding plasma welding gun, a coaxial wire feeding laser cladding head, a polishing disc, a three-dimensional scanner and a milling cutter through an electric spindle;

the tool magazine, the six-axis robot, the material increase repair system, the material reduction processing system and the monitoring system are all connected to the local control system through signal lines and are cooperatively controlled by the local control system.

2. the apparatus of claim 1, wherein the local control system can transmit the data to the control system on the water surface by introducing a signal line through the integrated line connector, so that the personnel on the water surface can observe and control the whole apparatus conveniently.

3. A repair method based on the device of claims 1-2, comprising the steps of:

(1) Hoisting the repair equipment to a specified working place to enable the repair cabin to cover the pipeline to be repaired;

(2) closing the replaceable cabin door and the sealed cabin door, introducing argon into the repair cabin to empty water, closing the movable cabin bottom after the water is emptied, and opening the equipment cabin door;

(3) the six-axis robot clamps the three-dimensional scanner, scans the part to be repaired, acquires accurate image data and transmits the accurate image data to the control system;

(4) comparing the acquired image data with a process database, and automatically adapting to make a repair scheme;

(5) The six-axis robot switches, clamps and clamps the polishing disc or the milling cutter to preprocess the plane to be repaired;

(6) the six-axis robot switches and clamps the coaxial wire-feeding plasma welding gun or the coaxial wire-feeding laser cladding head, and performs fused deposition on the area to be repaired until the deposition repair work is completed;

(7) The six-axis robot switches the clamping polishing disc or the milling cutter to carry out post-treatment on the deposition layer;

(8) the six-axis robot switches and clamps the coaxial wire feeding laser cladding head to clad the repaired surface with the corrosion-resistant material;

(9) the six-axis robot switches and clamps the three-dimensional scanner, three-dimensional scanning is carried out on the repaired area, high-definition three-dimensional image data are obtained and transmitted to the water surface, and a technician confirms whether the repairing is finished or not;

(10) And after the restoration is finished, restoring the equipment in the equipment cabin to the original position, closing the equipment cabin door, opening the movable cabin bottom, the sealing cabin door and the replaceable cabin door, and lifting the restoration equipment out of the water surface.

4. the method of claim 3, wherein the plasma fusion deposition repair using a coaxial wire feed plasma torch is performed by a number of non-wire, low current preheats prior to processing the first layer.

5. a method according to claim 3, characterized in that when plasma fused deposition repair is performed using dissimilar materials, a layer may first be deposited using laser fused deposition of the first layer.

6. the method according to claim 3, characterized in that the post-processing in step (7) is: when the surface is found to have overlarge undulation and poor quality in the deposition repairing process, the surface can be replaced by a polishing disc or a milling cutter to be leveled, and then the repairing is continued.

Technical Field

The invention relates to the technical field of deep water metal part additive manufacturing repair, in particular to deep water pipeline composite milling material increase and decrease in-situ repair equipment and a method.

background

with the continuous development of natural resources, offshore oil and natural gas have become one of the main energy sources of human beings today. Ocean oil and gas pipelines and the like are the first choice for transportation, the first oil pipeline in the world is built in 1865 American Pennsylvania, and after second war, the long-distance ocean oil and gas pipelines are built in large scale in the United states, and the seabed oil and gas pipelines laid in China at present exceed 6000 km. The deep sea oil and gas pipeline has important significance in repairing the pipeline due to the fact that seawater continuously erodes the pipeline. With the emergence and development of additive manufacturing technology, underwater additive manufacturing technology becomes a key technology for manufacturing and repairing deep sea pipelines.

The metal melting deposition technology is a 3D printing technology formed by directly melting and accumulating metal materials by using high-energy beams, has the advantages of high efficiency and high speed, and has wide application prospect in the aspects of quick manufacturing and repairing of large parts and large dies.

however, in the underwater metal additive manufacturing, on one hand, the problem of water cooling exists, namely, a melting channel manufactured by the additive manufacturing can be directly contacted with seawater to be rapidly cooled, which is an uncontrollable process, easily influences the printing quality, causes defects such as hole cracks and the like, and reduces the mechanical property; on the other hand, there is a problem that it is difficult to operate.

Disclosure of Invention

the invention aims to overcome the defects of the prior art and provides in-situ repair equipment for composite milling and material increase and decrease of a deepwater pipeline. The invention can realize the underwater rapid high-quality pipeline repair.

The purpose of the invention can be realized by the following technical scheme:

A deepwater pipeline composite milling material increase and decrease in-situ repair device comprises a repair cabin, an equipment cabin, a tool magazine, a local control system, a six-axis robot, a material increase repair system, a material decrease processing system and a monitoring system;

Both sides of the repair cabin are provided with a replaceable cabin door and a sealing cabin door which are used for loading the pipeline to be repaired into the repair cabin and ensuring the air tightness in the cabin; the top of the repair cabin is provided with a protective gas pipe interface used for providing high-pressure protective gas for the cabin to remove liquid in the cabin through a gas cylinder equipped on the water surface; the bottom of the repair cabin is provided with a movable cabin bottom and a sealing gasket, and the movable cabin bottom and the sealing gasket are used for sealing the repair cabin after liquid in the repair cabin is emptied;

an equipment cabin door and a sealing strip are arranged between the equipment cabin and the repair cabin and are used for keeping a closed state when the drainage work of the repair cabin is not finished; the top of the equipment cabin is provided with a comprehensive pipeline joint for leading in a power line, an air pipe and a communication line from the water surface;

The tool magazine, the six-axis robot, the material increase repair system, the material reduction processing system, the monitoring system and the control system are all arranged in the equipment cabin;

the additive repair system comprises a coaxial wire-feeding plasma welding gun, a coaxial wire-feeding laser cladding head, a wire feeder, a laser, a plasma welding machine and a laser water cooling machine;

The wire feeder is respectively connected with the coaxial wire feeding plasma welding gun and the coaxial wire feeding laser cladding head and is used for providing metal wires with different diameters for the coaxial wire feeding plasma welding gun and the coaxial wire feeding laser cladding head;

the coaxial wire feeding laser cladding head can convert high-energy laser into annular laser so as to realize coaxial wire feeding melting.

the material reducing processing system comprises a polishing disc, a three-dimensional scanner, an electric spindle and a milling cutter; the three-dimensional scanner is used for acquiring three-dimensional image data of a processing surface; the polishing disc is used for carrying out pretreatment work of derusting the processing plane and removing shellfish;

the monitoring system comprises a high-definition camera and a molten pool monitoring camera; the high-definition camera is used for acquiring a high-definition image of the whole equipment cabin; the molten pool monitoring camera is provided with a photodiode and is used for acquiring molten pool image data in the material increase process in real time;

The coaxial wire-feeding plasma welding gun, the coaxial wire-feeding laser cladding head, the polishing disc, the three-dimensional scanner and the milling cutter are all arranged in the cutter library;

the six-axis robot is provided with a welding module, and clamps and switches a coaxial wire feeding plasma welding gun, a coaxial wire feeding laser cladding head, a polishing disc, a three-dimensional scanner and a milling cutter through an electric spindle;

the tool magazine, the six-axis robot, the material increase repair system, the material reduction processing system and the monitoring system are all connected to the local control system through signal lines and are cooperatively controlled by the local control system.

furthermore, the local control system can introduce a signal line through the comprehensive pipeline joint, and transmits related data to the control system on the water surface, so that the water surface workers can observe and control the whole equipment conveniently.

The invention also aims to provide a deepwater pipeline composite milling material increase and decrease in-situ repair method, which comprises the following steps:

(1) hoisting the repair equipment to a specified working place to enable the repair cabin to cover the pipeline to be repaired;

(2) Closing the replaceable cabin door and the sealed cabin door, introducing argon into the repair cabin to empty water, closing the movable cabin bottom after the water is emptied, and opening the equipment cabin door;

(3) The six-axis robot clamps the three-dimensional scanner, scans the part to be repaired, acquires accurate image data and transmits the accurate image data to the control system;

(4) Comparing the acquired image data with a process database, and automatically adapting to make a repair scheme;

(5) The six-axis robot switches, clamps and clamps the polishing disc or the milling cutter to pre-treat the plane to be repaired, and removes the surface rust;

(6) the six-axis robot switches and clamps the coaxial wire-feeding plasma welding gun or the coaxial wire-feeding laser cladding head, and performs fused deposition on the area to be repaired until the deposition repair work is completed;

(7) The six-axis robot switches the clamping polishing disc or the milling cutter to carry out post-treatment on the deposition layer;

(8) the six-axis robot switches and clamps the coaxial wire feeding laser cladding head to clad the repaired surface with the corrosion-resistant material;

(9) The six-axis robot switches and clamps the three-dimensional scanner, three-dimensional scanning is carried out on the repaired area, high-definition three-dimensional image data are obtained and transmitted to the water surface, and a technician confirms whether the repairing is finished or not;

(10) and after the restoration is finished, restoring the equipment in the equipment cabin to the original position, closing the equipment cabin door, opening the movable cabin bottom, the sealing cabin door and the replaceable cabin door, and lifting the restoration equipment out of the water surface.

specifically, when the coaxial wire-feeding plasma welding gun is used for plasma fusion deposition repair, several times of preheating without wire feeding and with low current should be performed before the first layer is processed.

specifically, when plasma fused deposition repair is performed using dissimilar materials, laser fused deposition may be used to deposit a layer first from the first layer.

Specifically, the post-processing in the step (7) is as follows: when the surface is found to have overlarge undulation and poor quality in the deposition repairing process, the surface can be replaced by a polishing disc or a milling cutter to be leveled, and then the repairing is continued.

Compared with the prior art, the invention has the following beneficial effects:

1. the invention adopts an underwater high-pressure dry method to carry out underwater metal additive manufacturing, and the repaired part has the advantages of fewer holes, fewer cracks, high density, high strength and good mechanical property.

2. the invention adopts a material reduction manufacturing method combining plasma melting deposition and laser melting deposition, combines the advantages of high plasma melting deposition speed, high laser melting deposition precision and high bonding interface strength, and can meet the repair work under various conditions; in addition, the problem of interface combination of the first layer of plasma fusion deposition can be solved by adopting a laser pre-deposition mode, and the repair of dissimilar materials can be realized.

2. the forming quality monitoring system provided by the invention can monitor the repairing quality in real time, combine the material reducing method in time, level and repair the plane, and improve the repairing quality.

4. After the repair is finished, the laser melting deposition of the anti-corrosion layer can greatly improve the quality of the repaired part.

5. The invention adopts the replaceable cabin door in the repair cabin, can be adapted to the pipeline repair with different diameters, and can realize the repair of partial non-crown parts.

Drawings

FIG. 1 is a schematic structural diagram of a cabin body of the deepwater cylindrical pipeline high-pressure dry plasma-laser additive manufacturing composite milling material increase and decrease in-situ repair equipment.

FIG. 2 is a schematic sectional view of a cabin body of the deepwater cylindrical pipeline high-pressure dry plasma-laser additive manufacturing composite milling material increase and decrease in-situ repair equipment.

FIG. 3 is a schematic view of an equipment cabin structure in the deepwater cylindrical pipeline high-pressure dry plasma-laser additive manufacturing composite milling material increase and decrease in-situ repair device.

Detailed Description

The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited thereto.