In the heart of China’s Guilin University of Electronic Technology, a groundbreaking development is taking place that could revolutionize the energy sector’s approach to maintaining and repairing drilling equipment. Dr. J. Wang, a leading researcher from the School of Mechanical and Electrical Engineering, has spearheaded a project that leverages the precision of industrial robots and the power of laser cladding to repair high-value polycrystalline diamond compact (PDC) bits. These bits are crucial for drilling operations in the energy industry, and their repair has long been a challenging and costly endeavor.
The innovation lies in a dual-robot system that combines the capabilities of a KUKA-KR20 industrial robot equipped with a structural light 3D scanner and a KUKA-KR60 robot holding a laser head. The process begins with the KUKA-KR20 inspecting the damaged bit, capturing detailed point cloud data that is then converted into a stereolithography (STL) file format. This data is compared with a standard model to pinpoint the damaged region with remarkable accuracy. “The precision of this system is unparalleled,” says Dr. Wang. “It allows us to identify and repair even the most minute damages, ensuring the longevity and efficiency of the drilling bits.”
Once the damaged area is identified, the KUKA-KR60 robot takes over, using the laser head to perform the cladding repair. The real magic happens through a novel calibration method developed by Dr. Wang’s team, known as the three-point method for the dual-robot system. This method transforms the damaged region from the camera coordinate system to the cladding robot coordinate system, ensuring that the laser head can precisely target the damaged area. An upper computer program then plans the cladding path, sending the instructions to the KUKA-KR60 robot to complete the repair.
The implications for the energy sector are immense. PDC bits are essential for drilling operations, and their repair has traditionally been a time-consuming and expensive process. This dual-robot system offers a flexible and efficient solution, capable of repairing different types of parts with various blocky-surface damages. “This technology has the potential to significantly reduce downtime and maintenance costs for drilling operations,” Dr. Wang explains. “It’s a game-changer for the energy industry.”
The research, published in the journal Mechanical Sciences, which translates to Mechanical Science and Technology, demonstrates the system’s effectiveness through real-world experiments. The results are promising, showing that the dual-robot system can be widely applied to different types of part repair, making it a versatile tool for the energy sector.
As the energy industry continues to evolve, the need for innovative solutions to maintain and repair drilling equipment becomes ever more pressing. Dr. Wang’s work at Guilin University of Electronic Technology represents a significant step forward in this direction. By combining the precision of industrial robots with the power of laser cladding, this dual-robot system offers a glimpse into the future of maintenance and repair in the energy sector. The potential for reducing costs, increasing efficiency, and extending the lifespan of critical equipment is immense, and the energy industry is watching closely.
