(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)

(19) World Intellectual Property

Organization
International Bureau
(10) International Publication Number
(43) International Publication Date WO 2014/025244 Al
13 February 2014 (13.02.2014) PO PCT

(51) International Patent Classification: HN, HR, HU, ID, IL, IN, IS, JP, KE, KG, KN, KP, KR,
B23P 6/00 (2006.01) C23C 24/08 (2006.01) KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME,
B23K 26/342 (2006.01) B23K 26/70 (2006.01) MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ,
B23K 37/04 (2006.01) OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SC,
SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN,
(21) International Application Number: TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW.
PCT/LV20 13/000006
(84) Designated States (unless otherwise indicated, for every
(22) International Filing Date: kind of regional protection available): ARIPO (BW, GH,
18 July 2013 (18.07.2013)
GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ,
(25) Filing Language: English UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ,
TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK,
(26) Publication Language: English EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, ΓΓ , LT, LU, LV,
(30) Priority Data: MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM,
P-12-130 7 August 2012 (07.08.2012) LV TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW,
KM, ML, MR, NE, SN, TD, TG).
(72) Inventor; and
(71) Applicant : TORIMS, Toms [LV/LV]; Aleksandra Caka Declarations under Rule 4.17 :
Str., 49-44, LV-101 1 Riga (LV). — of inventorship (Rule 4. 1 7(iv))
(81) Designated States (unless otherwise indicated, for every Published:
kind of national protection available): AE, AG, AL, AM,
— with international search report (Art. 21(3))
AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY,
BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM,
DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT,

= (54) Title: APPARATUS AND METHOD FOR REPAIR AND RENOVATION OF CRANKSHAFT JOURNAL SURFACES IN-
;= SITU BY MEANS OF LASER CLADDING

FIG. 4
(57) Abstract: The invention refers to manufacturing engineering, in particular to shipbuilding and ship repair. Said invention ap -
plies to internal combustion engines, such as marine diesel engines. The invention relates to an apparatus in above described fields
for repair and renovation of the crankshaft journal (bearing) surfaces, by means of laser build-up (cladding). Invented apparatus and
¾ method is designed to perform journals build-up (cladding) operations directly in the engine housing, without removing the crank -
shaft from the engine.
 APPARATUS AND METHOD FOR REPAIR AND RENOVATION OF
CRANKSHAFT JOURNAL SURFACES IN-SITU BY MEANS OF LASER
CLADDING
Field of the invention

The field of invention refers to manufacturing engineering, in particular to shipbuilding

and ship repair. Said invention applies to internal combustion engines, such as marine
diesel engines.

The invention relates to an apparatus in above described fields for repair and renovation
of the crankshaft journal (bearing) surfaces, by means of laser build-up (cladding).
Invented apparatus and method is designed to perform crankpin journals surfaces build
up (cladding) operations directly in the engine housing, without removing the crankshaft
from the engine.

Background of the invention

Heavy working conditions and intensive wear of the marine diesel engine crankshaft
main and crankpin journals surfaces, accompanied with eventual lubrication failures are
causing various damages of the journal surfaces. Common faults in the surface of the
journals are: ridges, cuts, grooves, tearings, marks and formation of built-up edge. Wear
is causing also loss of required geometrical clearances of the crankshaft journals, such
as roundness and alignment to the centre.

The above mentioned damages are also affecting mechanical properties of journal
surfaces. This results in reduced hardness and stiffness or in contrary excessive surface
hardening. Therefore regular repairs of marine diesel engine crankshaft main and
crankpin journals surfaces are needed in order to perform partial or complete renovation
of the worn-out crankshaft journals. These repairs are done in the workshop, by
removing crankshaft from engine and subsequently performing journal grinding on
stationary machines. Crankshaft usually is fixed in the centres and rotated around its
central axe.
Where it is necessary also various types of build-up operations are carried out in the
specialized on-shore workshops. Subsequently crankshaft journal is machined to the
required dimensions as per manufacturers' specifications.

Crankshaft journals can be renovated using various technologies, e.g.: conventional

TIG/MIG/MAG build-up welding, plasma coating - welding and spraying. These
surface refurbishing techniques are approved by certain Ship Classification Societies,
yet are limited to use only within workshop (onshore) environments, are time
consuming and can be performed only by highly sophisticated machinery. Other
manual operations (e.g. metal-plastics, grinding and lapping) can be applied for
emergency repairs and only as a temporary solution.

None of these technologies can be used on board the ship to fully build-up crankshaft
crankpin journal surfaces. However, frequently crankshaft crankpin repairs have to be
done directly on board of the vessel or even at sea and not in the comfortable conditions
of on-shore facilities.

Prior efforts have been made to tackle a problem of in situ repair of crankshaft journals.
In article "Torims T., Gerins E., Ratkus A . Shipboard Crankshaft Bearing In-Situ
Repairs Utilizing Laser Build-Up Welding // Annals of DAAAM & Proceedings 2011,
Austria, Vienna, 23.-26. November, 2011. - pp 597-598" is outlined an idea of laser
build-up welding application to the marine engine crankshafts, however, without
proposing particular technical solutions.

In article "H. Koehler, K . Partes, T. Seefeld, F. Vollertsen. Laser reconditioning of

crankshafts: From lab to application. Physics Procedia, Volume 5, Part A, 2010, pp.
387-397. " is described a technique of laser build up on crankshaft. Described technique
is limited to the workshop conditions and is not in-situ technological solution.

In article "I. A . Vishnevetskaya, V. A . Denisov and A . V. Solovyov. Tribotechnical

efficiency of journal-bearing connection of crankshaft renewed by laser built-up
welding. Proc. SPIE 2713, 301, 1996, pp 301-305" is addressed material properties
issues and do not give any technical solutions or applications of the laser build-up
technology itself.
In-situ crankshaft journal grinder is described in document US No. 2,937,479. Given
apparatus refers to an "on-site" journal correctors or reconditioning devices. Document
GB No. 869,240 describes a crankshaft grinder relevant to above mentioned document
US No. 2,937,479. Said apparatuses are limited to the grinding only. Similar technology
is described in documents US No. 3,054,233 and US No. 3,103,088. Mentioned
crankshaft grinders are similar to the previous patents, but now are applicable also to the
crankshafts having no filets. In document SU131 191 1 is described a device for grinding
connecting-rod journal of crankshaft inside engine. All above documents describe
apparatuses for in-situ grinding of crankshaft journals.

There is also a document CN No. 101922006 describing process for repairing

crankshaft of internal combustion engine by laser cladding or build-up laser technology.
Said process refers to a repair of crankshafts which are taken out from the engine and
does not proposes a technique for laser cladding of a crankshaft in situ.

After analysing said apparatuses and methods it was discovered that it is impossible to
implement laser technologies. There is a need for a totally new approach to implement
laser built up technologies in in-situ crankshaft journal repair apparatuses.

Objective and summary of the invention

The aim of invention is to design an apparatus and method for renovation and repair of
crankshaft journal surfaces in-situ by means of laser build-up (cladding).

The essence of the invention is an apparatus for repair and renovation of crankshaft
journal surfaces. The apparatus comprising two guide-ways and two opposite-guide-
ways for positioning said apparatus on crankshafts fillets and two frame parts where
each frame part is fixed to respectively guide-way.

Additionally apparatus comprises at least two upper rods by means of which both frame
parts are in fixed connection to each other, wherein the upper rods are position in the
upper part of the frame part, and at least two lower rods by means of which both frame
parts are in fixed connection to each other, wherein the lower rods are position in the
lower part of the frame part. Apparatus further comprises two carriages which are
installed on the upper rods and lower rods so that both carriages can be slidably moved
along said rods. A laser nozzle is installed operatively between both carriages.
Apparatus comprises two control motors, wherein a first control motor is installed in the
first carriage and operatively connected to the laser nozzle to control its pivoting angle,
and a second control motor is installed in the second carriage and operatively connected
to the one of the two lower rods by means of a gearing transmission to control a
longitudinal position of the laser nozzle.

The gearing transmission of the apparatus comprises a spur gear connected to the
second control motor and a toothed rack, which is made directly onto the lower rod.

The first control motor is connected to the laser nozzle through a bush.

To ensure positioning and controlled rotation of the apparatuses around the crankshaft
journal, it comprises two above described guide-ways and two opposite-guide-ways.
Two supporting plates are permanently fixed on the opposite-guide-ways. Further, these
supporting plates are connected to each other by at least two opposite-rods by means of
which both opposite-guide-ways are in fixed connection to each other.

When installed on the crankshaft journal, guide-ways and opposite-guide- ways are
connected and fixed to each other by means of four adjustable arms. Adjustable arms
are connected with guide-ways and opposite-guide-ways by eight guidance-screws.

While crankshaft is being rotated around its main axe, the laser head top-down position
is ensured by eight expandable-shrinkable elements (e.g. pneumatic cylinders). These
eight expandable-shrinkable elements are connected with the guide-ways and opposite-
guide-ways by the aforementioned eight guidance-screws. Expandable-shrinkable
elements can freely rotate around these eight guidance-screws.

Further, said expandable-shrinkable elements are connected to the housing of the engine
by means of four side-plates. These four side plates in turn are positioned and fixed on
the engine housing opening hatches bolts. Additionally expandable-shrinkable elements
are connected to the said side-plates by eight guidance-bolts. These expandable-
shrinkable elements can freely rotate around these eight guidance-bolts.

The invention also describes a method for repair and renovation of crankshaft journal
surfaces using above-mentioned apparatus.

The method includes the steps of:

a) positioning of said apparatus above a damaged (renewable) surface of the journal by
means of said guide-ways and opposite-guide-ways;
b) applying a cladding powder onto the damaged surface of the journal;
c) positioning of a laser nozzle above the damaged surface of the journal by means of
two control motors;
d) irradiation of the cladding powder by a laser beam emitted from the laser nozzle;
e) repeatedly performing steps b) through d) until the damaged surface of the journal is
cladded.

In step c) a pivoting motion of the laser nozzle is performed by means of the first
control motor and a longitudinal positioning of the laser nozzle is performed by means
of the second control motor and its gearing transmission.

In accordance with the apparatus and method of this invention, the crankshaft does not
need to be removed from the engine or motor block in order to repair or renovate the
crankshaft journal surfaces.
Brief description of drawings

The invention will be better understood in connection with the accompanying drawings,
in which:

FIG. 1 is an isometric view of an apparatus positioned on internal fillets of a crankshaft;

FIG. 2 is an fragmentary view of a crankshaft showing crankshaft external fillets on
which said apparatus is positioned by means of guide ways 2;
FIG. 3 is the orthogonal projection of an apparatus positioned on a crankshaft;
FIG. 4 is an isometric view of apparatus for in-situ laser build-up (cladding) positioned
on a crankshaft;
FIG. 5 is a cross-sectional view of an apparatus positioned on a crankshaft - upper part;
FIG. 6 is a cross-sectional view of an apparatus positioned on a crankshaft; and
FIG. 7 a cross-sectional view of an apparatus positioned on a crankshaft - lower part

Detailed description of the invention

This invention is an apparatus and method for in-situ laser build-up (cladding) of the
crankshaft crankpin journals.

Invention is achieved by placing laser build-up (cladding) nozzle positioning and

guidance apparatus directly on the crankshaft journal fillets. These fillets as a rule are
not damaged or worn-out and thus holding the original manufacturers dimensions of the
crankshaft. Therefore the internal fillets (FIG. 1) or external fillets (FIG. 2) can be used
as a reference surface where position the laser cladding nozzle guidance platform,
especially guide-ways 2 of the apparatus.

The apparatus (FIG. 3 - FIG. 7) is mounted on the crankshaft crankpin 1 journal fillets
by means of two sliding guide-ways 2 and two opposite-guide-ways 14. Guide-ways 2
are provided with two frames 4, which are each fixed with two screws (are not showed
in the figures). Frames 4 are connected and fixed by means of rods 5 and 6 . On the rods
5 and 6 are mounted carriages 7A and 7B allowing longitudinal movement of the
carriages 7A and 7B.
Opposite-guide-ways 14 are provided with two supporting plates 15, which are each
fixed with two screws (are not showed in the figures). Supporting plates 15 are
connected and fixed by means of two opposite-rods 16.

Guide-ways 2 and opposite-guide-ways 14 are placed on the crankshaft journal 1 fillets,

and fixed to each other by means of four adjustable arms 17. Angle of the adjustable
arms 17 is fixed by the four screws 18. Adjustable arms 17 are connected to the guide-
ways 2 and opposite-guide-ways 14 by eight guidance-screws 19.

Crankshaft 1 is being rotated around its main axe, the laser nozzle 10 top-down position
is ensured by eight expandable-shrinkable elements 20 (e.g. pneumatic cylinders).
These expandable-shrinkable elements 20 are connected with the guide-ways 2 and
opposite-guide-ways 14 by the eight guidance-screws 19. Expandable-shrinkable
elements 20 are rotating around these eight guidance-screws 19.

Expandable-shrinkable elements 20 are connected to the engine housing 21 with four

side-plates 22. These side plates 22 are positioned and fixed on the engine housing 21
service hatches openings bolts 23. Expandable-shrinkable elements 20 are connected to
the side-plates 22 by eight guidance-bolts 24. The expandable-shrinkable elements 20
freely rotate around guidance-bolts 24.

Longitudinal feed of the laser nozzle 10 towards crankshaft bearing surface 1 thereto
achieved by means of transmission between spur gear 11 and feeding rod - toothed rack
66. Spur gear 11 is fixed on the shaft of a second control motor 8B. Positioning angle or
pivoting angle X of the laser nozzle 10 towards the crankpin 1 surface is ensured by a
first control motor 8A. Laser nozzle 10 and the first control motor 8A is connected
through a bush 9 . Laser nozzle 10 is fixed rotatably in carriage 7A by means of a pin 12.
Control motors 8A and 8B are secured to the carriages 7A and 7B by means of four
fixation screws 13.

During build-up (cladding) operation crankshaft itself is rotated in the engine by built-in
means, conventionally by service-electrical motor. This motion is aligned with
controlled movements of the control motors 8A and 8B.
The laser build-up (cladding) process includes a step of applying cladding powder or
any other cladding material to the damaged surface of the journal. In the same time the
cladding powder is irradiated by the high-energy laser beam. Thus a metallurgical
bound between crankpin surface and substrate material is achieved by melting both
cladding material and substrate. As a result worn-out or damaged surface is restored to
its original configuration or to any other desired shape allowing for subsequent
mechanical machining.

The following parameters (feeding elements) are synchronised and numerically

controlled:
1. Positioning of the second control motor 8B - guiding laser nozzle radial feed;
2. Positioning of the second control motor 8A - guiding laser nozzle angle;
3. Crankshaft rotation frequency ;
4. Laser power;
5. Feeding of welding powder.

Laser power lines are flexible as well as cladding powder supply pipes are flexible.
They are deployed through piston liner from the top of the engine.

The present invention has been shown and described herein in what is considered to be
the most practical and preferred embodiment. It is recognized, however, that departures
may be made therefrom within the scope of the invention.

List of reference numerals:

1 - a crankshaft;
2 - a guide-way;
4 - a frame part;
5 - an upper rod;
6 - a lower rod;
7A - a first carriage;
7B - a second carriage;
8A - a first control motor;
8B - a second control motor;
9 - a bush;
10 - a laser nozzle;
11 - a spur gear;
12 - a pin;
13 - a fixation screw;
14 - an opposite-guide-way;
15 a supporting plate;
16 - an opposite-rod;
17 - an adjustable arm;
18 - a screw;
19 - a guidance-screw;
20 - an expandable-shrinkable element;
2 1 - an engine housing;
22 - a side plate;
23 - a bolt;
24 - a guidance-bolt;
66 - a toothed rack;
X - a pivoting angle.
 CLAIMS

Apparatus for repair and renovation of crankshaft journal surfaces, wherein said
apparatus comprising:

- two guide- ways (2) and two opposite-guide- ways ( 1 ) for positioning said
apparatus on crankshafts (1) fillets;
- two frame parts (4) where each frame part (4) is fixed to respectively
guide-way (2);
- at least two upper rods (5) by means of which both frame parts (4) are in
fixed connection to each other, wherein the upper rods (5) are position in the
upper part of the frame part (4);
- at least two lower rods (6) by means of which both frame parts (4) are in
fixed connection to each other, wherein the lower rods (6) are position in the
lower part of the frame part (4);
- two carriages (7A; 7B) which are installed on the upper rods (5) and the
lower rods (6) so that the carriages (7A; 7B) can be slidably moved along
said rods (5, 6);
- a laser nozzle (10) installed on the carriages (7A; 7B);
- two control motors (8A; 8B), wherein a first control motor (8A) is
installed in the first carriage (7 A) and operatively connected to the laser
nozzle (10) to control its pivoting angle (X), and a second control motor
(8B) is installed in the second carriage (7B) and operatively connected to the
one of the two lower rods (6) by means of a gearing transmission to control
a longitudinal position of the laser nozzle (10);
two supporting plates (15) where each supporting plate (15) is fixed to
respectively opposite-guide-way (14);
- at least two opposite-rods (16) by means of which both supporting plates
(15) are in fixed connection to each other, wherein the opposite-rods (16)
are position in the opposite-guide-ways (14);
- four adjustable arms (17) by means of which guide- ways (2) and opposite-
guide-ways (14) are fixed slidably on the crankshaft journal fillets (1);
 - at least four screws (18) by means of which angle and position of the
adjustable arms (17) is fixed;
- at least eight guidance-screws (19) by means of which adjustable arms
(17) are connected to the guide- ways (2) and opposite-guide- ways (14); and
by means of which also eight expandable-shrinkable elements (20) are
rotatably connected to the guide-ways (2) and opposite-guide-ways (14);
- at least eight expandable-shrinkable elements (20) by means of which laser
nozzle (10) top-down centre position is ensured towards crankshaft fillet
(i);
- at least four side plates (22), fixed on the engine housing (21) service
hatches bolts (23), by means of which expandable-shrinkable elements (20)
are connected to the engine housing (21);
- at least eight guidance-bolts (24) fixed to the side plates (22) allowing
rotatable connection of the expandable-shrinkable elements (20).

Apparatus according to Claim 1, characterized in that the gearing transmission

comprises a spur gear ( 1 1) connected to the second control motor (8B) and a
toothed rack (66), which is made directly onto the lower rod (6).

Apparatus according to Claim 1, characterized in that the first control motor

(8A) is connected to the laser nozzle (10) through a bush (9).

Method for repair and renovation of crankshaft journal surfaces using apparatus
according to one or more of Claims 1-3, wherein said method includes the steps
of:

a) positioning of said apparatus above a damaged surface of the journal by

means of said guide- ways (2), opposite-guide-ways (14) and expandable-
shrinkable elements (20);
b) rotation of the crankshaft (1) in the engine housing using service motor;
c) applying a cladding powder onto the damaged surface of the journal;
d) positioning of a laser nozzle (10) above the damaged surface of the
journal by means of two control motors (8A; 8B);
 e) irradiation of the cladding powder by a laser beam emitted from the laser
nozzle (10);
f) repeatedly performing steps b) through e) until the damaged surface of the
journal is cladded.

5. Method according to Claim 4, wherein in step c) a pivoting motion of the laser

nozzle (10) is performed by means of the first control motor (8A) and a
longitudinal positioning of the laser nozzle (10) is performed by means of the
second control motor (8B) and its gearing transmission.

6. Method according to Claim 4, wherein top-down positioning of the laser nozzle

(10) inside the engine housing is ensured by means of guide-ways (2), opposite-
guide-ways (14) and expandable-shrinkable elements (20), ensuring constant
cantering of the laser nozzle (10) towards upper centre of rotating crankshaft
journal (1).
A. CLASSIFICATION OF SUBJECT MATTER
B23P 6/00 (2006. 01)
B23K 26/342 (2014. 01)
B23K 37/04 (2006. 01)
C23C 24/08 (2006.01)
B23K 26/70 (2014. 01)
According to International Patent Classification (IPC) or to both national classification and IPC
B. FIELDS SEARCHED
Minimum documentation searched (classification system followed by classification symbols)

B23P 6/00-6/04, B23 26/00-26/70, 37/00, 37/02, 37/04, C23C 24/00-24/1 0

Documentation searched other than minimum documentation to the extent that such documents are included in the fields searched

Electronic data base consulted during the international search (name of data base and, where practicable, search terms used)

PatSearch (RUPTO internal), USPTO, PAJ, Esp@cenet, information Retrieval System of FIPS

DOCUMENTS CONSIDERED TO BE RELEVANT

Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No.

A SU 13 19 11 A l (MURMANSKOE MORSKOE PAROKHODSTVO) 23.05. 1987 1-3

A C 10 1922006 A (GANSU JINGCHENG PHOTOELECTRIC TECHNOLOGY 4-6

CO., LTD) 22. 12.20 10

A RU 2 107598 C I (GLAZKOV VLADIMIR SERGEEVICH et al.) 27.03. 1998 1-6

A JP H02 11863 A (SUZUKI MOTOR CO LTD) 24.04. 990 1-6

A EP 0456847 A (BERNEX GMBH) 2 1. 11. 199 1 1-6

□ Further documents are listed in the continuation of Box C . [ See patent family annex.

* Special categories of cited documents: "T" later document published after the international filing date o r priority

date and not in conflict with the application but cited to understand
"A" document defining the general state of the art which is not considered the principle or theory underlying the invention
to be of particular relevance "X" document of particular relevance; the claimed invention cannot be
"E" earlier document but published on o r after the international filing date considered novel or cannot be considered to involve an inventive
"L" document which may throw doubts on priority claim(s) or which is step when the document is taken alone
cited to establish the publication date of another citation or other "Y" document of particular relevance; the claimed invention cannot be
special reason (as specified) considered to involve an inventive step when the document is
"0" document referring to an oral disclosure, use, exhibition or other combined with one or more other such documents, such combination
means being obvious to a person skilled in the art
"P" document published prior to the international filing date but later than "&" document member of the same patent family
the priority date claimed

Date of the actual completion of the international search Date of mailing of the international search report

09 October 20 13 (09. 10.20 13) 07 November 2 0 13 (07. 11.201 3)

Name and mailing address of the ISA/ FIPS Authorized officer

Russia, 123995, Moscow, G-59, GSP-5.
Bcrezhkovskaya nab., 30-1 L . Nazarova

Facsimile No. +7 (499) 243-33-37 Telephone No. (499) 240-25-9 1

Form PCT/ISA/2 10 (second sheet) (July 2009)