铸件毛坯自动修复机器人设计与实验研究

随着3D打印技术的发展,增材再制造技术也成为各类零件缺陷自动修复的手段之一。针对大型铸件缺陷的修复以人工堆焊为主,存在效率低、对工人伤害大、修复合格率低等缺点。为此,提出了利用3D打印再制造技术对缺陷进行自动修复的工艺方法,即利用视觉系统对工件自动扫描重构工件三维模型,并与标准CAD模型比对,确定缺陷的类型、分布及尺度特征,获取各损伤部位的3D点云数据,根据缺陷模型自动编程并生成机器人程序,驱动执行机构依次完成各缺陷自动焊接修复。实验结果表明:工件缺陷重构模型精度在±0.1 mm以内,扫描速度为1 000 mm/min,自动焊接修复工件无焊接缺陷,各项性能指标满足实际使用要求。

Design and Experimental Study of an Automatic Repair Robot for Casting Blank

With the development of 3D printing technology, additive remanufacturing technology has become one of the means of automatic repair for various defects.Artificial surfacing welding is the main method to repair large casting defects, which has the disadvantages of low efficiency, great injury to workers and low repair qualification rate.Therefore, a process method for automatic repair of defects was proposed by using 3D printing and remanufacturing technology. That was, the 3D model of the workpiece was scanned and reconstructed automatically by using the visual system. The type, distribution and scale characteristics of the defects were determined by comparing the model with the standard CAD model, and 3D point cloud data of each damaged part were obtained.The robot program was programmed and generated automatically according to the defect model, and the actuator was driven to complete the automatic welding repair of each defect successively.The experimental results show that the accuracy of the workpiece defect reconstruction model is within ±0.1 mm, the scanning speed is 1 000 mm/min, the workpiece is repaired by automatic welding without welding defects, and each performance index meets the actual application requirements