CN109900707B - Powder paving quality detection method and device and readable storage medium - Google Patents
Powder paving quality detection method and device and readable storage medium Download PDFInfo
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Abstract
A powder paving quality detection method, equipment and readable storage medium, arrange the pixel in the image of the current layer according to array type; processing pixel points line by line and/or line by line from one side of a current layer image in sequence according to a preset direction to obtain one or two intermediate images, wherein the intermediate images comprise all normal pixels and abnormal pixels; corroding the intermediate image to remove noise and a normal sintering edge of the workpiece to be printed to obtain a result image; counting the area of at least one region formed by abnormal pixels in the result image, and selecting the area value of the region with the largest area as a result value; the powder paving quality is judged according to the result value, so that the technical problem that in the prior art, the change increment of each layer is small, the accumulated large quality problem cannot be detected by adopting the previous method, and the misjudgment of powder quality detection is caused is solved, and therefore the detection is more accurate and the detection method is simpler.
Description
Technical Field
The application relates to the technical field of additive manufacturing, in particular to a powder paving quality detection method and device and a readable storage medium.
Background
The additive manufacturing technology is an advanced manufacturing technology with the distinct characteristics of digital manufacturing, high flexibility and adaptability, direct CAD model driving, high speed, rich and various material types and the like, and has a very wide application range because the additive manufacturing technology is not limited by the complexity of the shape of a part and does not need any tool die. Selective Laser Sintering (SLS) and Selective Laser Melting (SLM) are the most rapidly developing additive manufacturing techniques in recent years.
In the additive manufacturing technology, after a workpiece is printed, powder laying actions are generally required to be repeated thousands of times, and some accidents occasionally occur in the middle of a printing device, so that problems such as powder laying loss, powder collapse, sintered workpiece warping, support collapse and the like are caused. It may also be a problem with the product design itself, such as warping of the workpiece due to defective support design. These problems may cause sintering failure of the entire workpiece if not processed, if they occur once in several thousand sintering passes.
Although the prior art proposes some powder quality detection methods in order to solve the above drawbacks caused by powder spreading quality, the method generally compares the current layer image with the previous layer image or the stored image, and although the method can detect the powder spreading quality of the powder, the method has a problem that the accumulated powder spreading quality problem is large because the change increment of each layer is small, and if the previous powder quality detection method is adopted, the powder spreading quality problem may not be detected, so that misjudgment of powder quality detection is caused, that is, the accuracy of detection is affected.
Disclosure of Invention
Aiming at the technical problems in the prior art, the invention provides a powder paving quality detection method, equipment and a readable storage medium, wherein the detection is more accurate and simpler.
In order to achieve the purpose, the application provides a powder laying quality detection method, which comprises the following steps:
when a powder paving quality detection instruction is received, acquiring a current layer image of a working area through an optical camera;
arranging pixels in the current layer image according to an array;
processing pixel points line by line and/or line by line from one side of a current layer image in sequence according to a preset direction to obtain one or two intermediate images, wherein the intermediate images comprise all normal pixels and abnormal pixels, and all the normal pixels and the abnormal pixels are displayed after binarization processing;
corroding the intermediate image to remove noise and a normal sintering edge of the workpiece to be printed to obtain a result image;
counting the area of at least one region formed by abnormal pixels in the result image, and selecting the area value of the region with the largest area as a result value;
and judging the powder paving quality according to the result value.
As a further preferred embodiment of the present invention, the pixel points are processed in the following manner:
starting from the first pixel point of each row or each column, acquiring N pixel points in the row or the column and storing the N pixel points in the row or the column into a storage unit;
comparing each pixel point with the average value of all pixel points stored in the storage unit from the (N + 1) th pixel point;
when the difference between a certain pixel point and the average value of all pixel points stored in the storage unit exceeds the allowable range, the pixel point is marked as an abnormal pixel, otherwise, the pixel point is marked as a normal pixel, the normal pixel is stored in the storage unit and is used as the last pixel point stored in the storage unit, and the first pixel point stored in the storage unit is removed.
As a further preferable scheme of the present invention, when two result images are obtained by processing pixel points row by row and column by column in turn in a preset direction from one side of a current layer image, the present invention further includes the following method;
and performing expansion processing on the two result images respectively, and performing synthesis processing on the two result images after the expansion processing to obtain a new image as a result image, wherein the synthesis processing is to remove the non-overlapped abnormal pixels.
As a further preferable scheme of the present invention, judging the powder laying quality according to the result value specifically includes:
when the result value is smaller than or equal to a first preset value, judging that the powder paving is normal;
when the result value is larger than the first preset value and smaller than the second preset value, judging that the powder paving quality is poor;
and when the result value is greater than or equal to the second preset value, judging that the powder spreading is abnormal.
As a further preferable aspect of the present invention, the method further comprises:
when the powder spreading is abnormal, the powder spreading is reminded to spread again.
As a further preferable scheme of the invention, when the powder paving abnormality is judged and the powder paving abnormality continuously reaches the set times, the sintering of the workpiece is stopped, and the alarm is started.
As a further preferable aspect of the present invention, the preset direction is from top to bottom, from bottom to top, from left to right, or from right to left.
In a further preferred embodiment of the present invention, N is 10 to 20.
The invention also provides a powder paving quality detection device which comprises a memory, a processor and a computer program which is stored on the memory and can run on the processor, and is characterized in that the processor executes the computer program to realize the steps of the powder paving quality detection method.
The invention also provides a readable storage medium, which stores a computer program, and the stored computer program is executed by a processor to realize the steps of the powder laying quality detection method.
The powder paving quality detection method, the powder paving quality detection equipment and the readable storage medium are characterized in that pixels in a current layer image are arranged in an array manner; processing pixel points line by line and/or line by line from one side of a current layer image in sequence according to a preset direction to obtain one or two intermediate images, wherein the intermediate images comprise all normal pixels and abnormal pixels, and all the normal pixels and the abnormal pixels are displayed after binarization processing; corroding the intermediate image to remove noise and a normal sintering edge of the workpiece to be printed to obtain a result image; counting the area of at least one region formed by abnormal pixels in the result image, and selecting the area value of the region with the largest area as a result value; the powder paving quality is judged according to the result value, so that the invention solves the technical problems that in the prior art, the change increment of each layer is small, the accumulated large quality problem cannot be detected by adopting the previous powder quality detection method, and the misjudgment of the powder quality detection is caused, therefore, the detection of the invention is more accurate, and the detection method is simpler, and on the other hand, the invention only needs to process the current layer image without storing a large amount of other layer images, thereby greatly saving the storage space of equipment.
Drawings
Fig. 1 is a flowchart of a method for detecting powder laying quality according to an embodiment of the present invention;
fig. 2 is a flowchart of a method for detecting the quality of the spread powder in another embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present application more apparent, the present application is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.
As shown in fig. 1, the powder laying quality detection method provided by the present application includes the following steps:
in specific implementation, a powder paving detection instruction is generally sent when powder paving of a front layer is finished, but as a preferable scheme of the invention, the powder paving detection instruction can be sent when the powder paving is not finished completely, namely when the powder paving device paves powder from one side to the other side of a working area and paves the powder to the other side of the working area, and specifically the powder paving detection instruction can be sent to an upper computer by a PLC (programmable logic controller), so that the time that the powder paving device continues to move forwards from the other side of the working area to a powder feeding cylinder and returns to the other side of the working area can be saved, and further the working efficiency is further improved. In addition, it should be noted that the sending time of the dusting detection command is determined according to design requirements, for example, the dusting detection command may be sent by each layer, or may be sent by several layers, or may be sent only when detection is required, which is not limited herein.
The specific arrangement positions of the optical cameras are not limited in the invention, and one or more optical cameras can be adopted according to actual needs, for example, when the working area is large and one optical camera cannot shoot images of all the working areas, a plurality of optical cameras can be selected.
the preset direction is from top to bottom, from bottom to top, from left to right or from right to left. Specifically, an intermediate image may be finally obtained after the pixel points are sequentially processed from left to right column by column from one side of the current layer image, or an intermediate image may be finally obtained after the pixel points are sequentially processed from top to bottom row by row from one side of the current layer image, and other specific implementation manners are not described herein.
In step 13, the pixel points may be processed in the following manner:
step 131, starting from the first pixel point of each row or each column, acquiring N pixel points in the row or the column and storing the N pixel points in the row or the column into a storage unit; the N can be set reasonably according to design requirements, preferably, the N can be 10-20, and other specific values can be selected.
Step 132, starting from the (N + 1) th pixel point, comparing each pixel point with the average value of all pixel points stored in the storage unit;
step 133, when the difference between a certain pixel point and the average value of all pixel points stored in the storage unit exceeds the allowable range, marking the pixel point as an abnormal pixel, otherwise, marking the pixel point as a normal pixel, storing the normal pixel in the storage unit, and using the normal pixel as the last pixel point stored in the storage unit, and removing the first pixel point stored in the storage unit, so that the storage unit can be updated for the data stored in the data storage unit, and the detection accuracy is further improved.
The allowable range in step 133 can be specifically set by the designer according to the illumination condition of the device, for example, it can be ± 5%, for example, when the average value is 100, and when the value of a certain pixel point is 96 or 102, the pixel point is labeled as a normal pixel because the difference between the pixel point and the average value is ± 5%, that is, within the allowable range.
specifically, the parameters used in the etching process in step 14 may be set according to the sintering material, the equipment hardware, and the workpiece shape, and for example, odd rectangles such as 3 × 3, 5 × 5, or 7 × 7 may be used for etching. Since the specific manner of the etching process is known in the art, it is not described in detail in the present invention.
and step 16, judging the powder paving quality according to the result value.
In step 16, the step of judging the powder paving quality according to the result value specifically includes:
when the result value is smaller than or equal to a first preset value, judging that the powder paving is normal;
when the result value is larger than the first preset value and smaller than the second preset value, judging that the powder paving quality is poor;
and when the result value is greater than or equal to the second preset value, judging that the powder spreading is abnormal.
It can be understood that the first preset value and the second preset value are set by a designer according to specific situations, and it is required to satisfy that the first preset value is smaller than the second preset value. Of course, the above is only one embodiment for judging the powder paving quality, and in a specific implementation, only two results, namely normal powder paving or abnormal powder paving, can be obtained, and are not specifically described herein.
As a preferred aspect of the present invention, the method further comprises: when the powder spreading is abnormal, the powder spreading is reminded to spread again.
As a further preferable scheme of the invention, in order to save time and improve working efficiency, when the powder paving abnormality is judged and reaches a set number of times continuously, workpiece sintering is stopped, and an alarm is started to remind that the equipment has a fault and needs manual maintenance.
As shown in fig. 2, the present invention further provides a method flow chart of a powder laying quality detection method in another embodiment, as shown in fig. 2, the embodiment includes the following steps:
in step 23, specifically, the pixel points may be sequentially processed from left to right column by column from one side of the current layer image to obtain an intermediate image, and the pixel points may be sequentially processed from top to bottom row by row from one side of the current layer image to obtain another intermediate image; or processing the pixel points line by line from top to bottom in sequence from one side of the current layer image to finally obtain an intermediate image, and processing the pixel points line by line from left to right in sequence from one side of the current layer image to finally obtain another intermediate image; it should be noted here that two intermediate images may also be obtained from different sides of the current layer image.
24, respectively carrying out corrosion treatment on the two intermediate images to remove noise and the normal sintering edge of the workpiece to be printed to obtain two final images;
and step 25, performing expansion processing on the two final images respectively, and performing synthesis processing on the two final images after the expansion processing to obtain a new image as a result image, wherein the synthesis processing is to remove non-overlapped abnormal pixels.
In this step 25, the dilation is a dual operation of erosion, which is used to connect very small-pitch points, lines, or small regions into a larger region, resulting in a larger total area than the original area, and this is not described in detail in the present invention because it belongs to the prior art in the field of image processing. In addition, in step 25, a new image is obtained by combining the two images, mainly to avoid the inaccuracy of the result of the abnormal pixel and the normal pixel obtained by processing due to the error caused by the lamp irradiation of the optical system, so that the error can be further reduced by removing the non-overlapped abnormal pixel.
and 27, judging the powder paving quality according to the result value.
This embodiment is substantially the same as the previous embodiment, except that step 25 is added, and step 23 is different from step 13 of the previous embodiment, which further improves the accuracy of detection compared to the previous embodiment.
The invention also provides a powder paving quality detection device which comprises a memory, a processor and a computer program which is stored on the memory and can run on the processor, and is characterized in that the processor executes the computer program to realize the steps of the powder paving quality detection method according to any one of the embodiments.
The invention also provides a readable storage medium, which stores a computer program, and the stored computer program is executed by a processor to realize the steps of the powder paving quality detection method according to any one of the above embodiments.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present application, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the concept of the present application, which falls within the scope of protection of the present application. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (9)
1. A powder paving quality detection method is characterized by comprising the following steps:
when a powder paving quality detection instruction is received, acquiring a current layer image of a working area through an optical camera;
arranging pixels in the current layer image according to an array;
processing pixel points line by line and/or line by line from one side of a current layer image in sequence according to a preset direction to obtain one or two intermediate images, wherein the intermediate images comprise all normal pixels and abnormal pixels, and all the normal pixels and the abnormal pixels are displayed after binarization processing;
corroding the intermediate image to remove noise and a normal sintering edge of the workpiece to be printed to obtain a result image;
counting the area of at least one region formed by abnormal pixels in the result image, and selecting the area value of the region with the largest area as a result value;
judging the powder paving quality according to the result value; wherein, the following method is adopted to process the pixel points:
starting from the first pixel point of each row or each column, acquiring N pixel points in the row or the column and storing the N pixel points in the row or the column into a storage unit;
comparing each pixel point with the average value of all pixel points stored in the storage unit from the (N + 1) th pixel point;
when the difference between a certain pixel point and the average value of all pixel points stored in the storage unit exceeds the allowable range, the pixel point is marked as an abnormal pixel, otherwise, the pixel point is marked as a normal pixel, the normal pixel is stored in the storage unit and is used as the last pixel point stored in the storage unit, and the first pixel point stored in the storage unit is removed.
2. The dusting quality detection method of claim 1, wherein when two result images are obtained by processing pixel points row by row and column by column in a preset direction sequentially from one side of a current layer image, the method further comprises the following steps;
and performing expansion processing on the two result images respectively, and performing synthesis processing on the two result images after the expansion processing to obtain a new image as a result image, wherein the synthesis processing is to remove the non-overlapped abnormal pixels.
3. The breading quality detection method according to claim 1 or 2, characterized in that judging the breading quality according to the result value specifically comprises:
when the result value is smaller than or equal to a first preset value, judging that the powder paving is normal;
when the result value is larger than the first preset value and smaller than the second preset value, judging that the powder paving quality is poor;
and when the result value is greater than or equal to the second preset value, judging that the powder spreading is abnormal.
4. The dusting quality detection method of claim 3, wherein the method further comprises:
when the powder spreading is abnormal, the powder spreading is reminded to spread again.
5. The powder paving quality detection method according to claim 4, wherein when the powder paving is judged to be abnormal and the powder paving abnormality is continuously reached to a set number of times, the sintering of the workpiece is stopped, and an alarm is started.
6. The dusting quality detection method of claim 5, wherein the predetermined direction is from top to bottom, bottom to top, left to right, or right to left.
7. The dusting quality detection method of claim 6, wherein N is 10-20.
8. A dusting quality detection apparatus comprising a memory, a processor and a computer program stored on the memory and executable on the processor, characterized in that the processor implements the steps of the dusting quality detection method according to any of claims 1 to 7 when executing the computer program.
9. A readable storage medium storing a computer program, wherein the stored computer program, when executed by a processor, performs the steps of the dusting quality detection method according to any one of claims 1 to 7.
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| CN111289517B (en) * | 2020-03-27 | 2022-10-04 | 安泰科技股份有限公司 | Tool and method for measuring spreadability of powder for additive manufacturing |
| CN116871537B (en) * | 2023-09-08 | 2024-02-20 | 易加三维增材技术(杭州)有限公司 | Powder paving quality detection method and device, electronic equipment and 3D printer |
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