General Manufacturing

Robotic Powder-Fed Cladding for Wind Power Steel Structures

HedraCAM Robot OLP offline programming applied to robotic powder-fed cladding on wind power steel structures, achieving surface hardening and defect repair with coating bond strength ≥300MPa and 2-3x extended service life.

Powder-Fed Cladding Wind Power Steel ABB Robot Surface Hardening Defect Repair

Path Planning

Spline trajectory continuous output, avoid start-stop fluctuations, uniform cladding

Efficiency Gain

Offline programming replaces manual teach, commissioning time reduced 60%

Quality Target

Coating bond strength ≥300MPa, hardness increased 2-3x

Robot Adapter

ABB robot post-processor accurate, no errors, no skipped points

Solution

Established complete robotic powder-fed cladding process for large steel structures
HedraCAM Robot OLP spline trajectory output avoids cladding droplets from start-stop
Smart point optimization: equidistant points, auto-delete, adjustable spacing for speed stability
Large workpiece split into multiple coordinated programs with auto-avoidance for safety
Standardized parameter library for Fe, Ni, Co based materials
Offline simulation verifies collision, singularities, posture limits in advance, 60% less commissioning
Edge optimization: reduced power and speed at edges to prevent burn-through, collapse, undercut
Layered cladding: thick coating in 3-20 layers with interpass deslagging and insulation

Project Results

Established 4 standard cladding processes: planar, arc, internal bore, defect repair
Dense coating with no visible porosity or cracks, bond strength ≥300MPa
Offline programming replaced manual teaching, path planning efficiency increased 50%+
First-pass yield improved, post-processing reduced, unit cost lowered 15%-25%
Component service life extended 2-3x after cladding hardening
Hardness increased 2-3x, maintenance cost significantly reduced

Robotic Powder-Fed Cladding for Wind Power Steel Structures

Solution

Project Results

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