Automatic Pelton Bucket repair
Hydro 2024 reference case
Hydroelectric power is a flexible renewable energy source, crucial for slowing climate change. However, hydropower plants in sediment-heavy waters face challenges due to increased sediment from irregular rainfall caused by global warming [1]. Pelton turbines, in particular Pelton buckets, need frequent maintenance to remain efficient. In this case study we discuss the automatic repair of a Pelton bucket with MaxQ Repair.
How it worksMeet us at hydro
The Challenge
Welding is a widely used technique for the recovery of the profile of an eroded Pelton turbine bucket. However, manual welding is becoming increasingly expensive due to the shortage of manual welders, and repair with the use of robotic welding equipment is challenging due to the time-consuming tasks of generating tool paths by online programming or expensive CAD/CAM software.
The solution: Scan, plan, repair, repeat
MaxQ Repair utilizes a straightforward three-step process to repair metal parts. The Pelton bucket was scanned using the integrated 3D camera in the welding robot, capturing its dimensions. A comparison was made between the scan and the step file, generating tool paths automatically while considering torch tilting and collision checks. The repair job was then initiated with a press of a button, and real-time monitoring ensured quality control. This included geometry control with the 3D camera, interpass temperature control using a thermal camera, and anomaly detection with high-frequency current and voltage sensors. The process was automatically repeated for subsequent layers, ensuring efficient and reliable repairs.
For this case study we first 3D printed the complete Pelton bucket.
The result
- With MaxQ Repair we were able to repair the Pelton bucket fully automated within a few hours. The resulting image is the near net shape of the Pelton bucket, before grinding.
- Cost Savings: MaxQ Repair reduces costs by eliminating the need for time-consuming online programming or expensive CAD/CAM software tools.
- Enhanced Welding Quality: MaxQ Repair delivers consistent, high-quality welds, also on an uneven surface. This improves product durability and reduces defects.
How it works
About MaxQ Repair
MaxQ Repair is an all-in-one automated solution for the repair of metal parts, such as rails, rotors, and dies, that are subject to wear in service.
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