CN110823758A - Observation device for powder density distribution and image processing and nozzle optimization method - Google Patents
Observation device for powder density distribution and image processing and nozzle optimization method Download PDFInfo
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- CN110823758A CN110823758A CN201911040199.XA CN201911040199A CN110823758A CN 110823758 A CN110823758 A CN 110823758A CN 201911040199 A CN201911040199 A CN 201911040199A CN 110823758 A CN110823758 A CN 110823758A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N9/00—Investigating density or specific gravity of materials; Analysing materials by determining density or specific gravity
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
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- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10004—Still image; Photographic image
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
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- G06T2207/00—Indexing scheme for image analysis or image enhancement
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30108—Industrial image inspection
- G06T2207/30136—Metal
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Abstract
An observation device for powder density distribution and an image processing and nozzle optimization method are disclosed, the device comprises a main body support, the main body support is composed of a bottom plate and a stand column arranged on the bottom plate, a powder collecting box is arranged on the bottom plate, a powder feeding nozzle is arranged above the powder collecting box, powder is formed into powder beams through the powder feeding nozzle and is sprayed downwards, a camera is arranged above the powder feeding nozzle, the camera is connected with the tail end of the powder feeding nozzle through a lens arranged downwards and a telescopic shield, and the lens, the telescopic shield and the powder feeding nozzle are arranged on the same axis; a linear light source is arranged below the powder feeding nozzle, and the light emitting direction of the linear light source is vertical to the spraying direction of the powder beams; the powder feeding nozzle is connected with the stand column through the adapter, the adapter can adjust the height of the powder feeding nozzle, the distance between the line light source and the powder feeding nozzle is equal to the working distance of the laser processing head, and the light emitting surface of the line light source is a working surface. The invention has flexible adjustment and can clearly reflect the powder distribution density on a specific cross section after image processing.
Description
Technical Field
The invention belongs to the field of additive manufacturing, and relates to an observation device for powder density distribution and an image processing and nozzle optimization method.
Background
In the metal additive manufacturing industry, the Laser Melting position (LMD) technology is more and more emphasized, the principle of the LMD technology is that a powder feeder sends metal powder to a nozzle part of a Laser processing head, the powder is converged on a working surface after passing through the nozzle, meanwhile, Laser is converged on the working surface through a collimating mirror and a focusing lens to form a molten pool, the metal powder is rapidly melted in the molten pool, and after the Laser processing head scans, the melted metal powder in the molten pool can be rapidly cooled to be solidified to finally form a metal layer with a certain thickness.
The matching condition of the powder density distribution and the laser power density distribution at the working surface has great influence on the forming quality and the powder utilization rate. In order to improve the powder delivery nozzle, increase the degree of powder matching and thus the quality of the shaping and the powder utilization, the powder density distribution at the working face must be measured. But there is currently no good solution to this problem.
Disclosure of Invention
The invention aims to provide an observation device for powder density distribution, an image processing method and a nozzle optimization method, aiming at the problem that the prior art cannot effectively acquire the powder density distribution at a working face in the metal additive manufacturing process.
In order to achieve the purpose, the invention adopts the technical scheme that:
an observation device for powder density distribution comprises a main body support, wherein the main body support consists of a bottom plate and a stand column arranged on the bottom plate, a powder collecting box is arranged on the bottom plate, a powder feeding nozzle is arranged above the powder collecting box, powder is formed into powder beams through the powder feeding nozzle and is sprayed downwards, and the powder collecting box is used for receiving the sprayed powder; a camera is arranged above the powder feeding nozzle, the camera is connected with the tail end of the powder feeding nozzle through a lens arranged downwards and a telescopic shield, the telescopic shield can prevent surrounding light rays from entering the lens, and the lens, the telescopic shield and the powder feeding nozzle are arranged on the same axis; the camera, the lens, the telescopic shield and the powder feeding nozzle are installed through an upright post, a linear light source is arranged on the upright post below the powder feeding nozzle, and the light emitting direction of the linear light source is perpendicular to the powder beam spraying direction; the powder feeding nozzle is connected with the stand column through the adapter, the adapter can adjust the height of the powder feeding nozzle, the distance between the line light source and the powder feeding nozzle is equal to the working distance of the laser processing head, and the light emitting surface of the line light source is a working surface.
Preferably, in an embodiment of the apparatus for observing powder density distribution according to the present invention, the retractable guard is retractable with movement of the position of the powder feeding nozzle, and the range of the retractable guard is larger than the range of the vertical movement of the adapter.
Preferably, in an embodiment of the observation apparatus for powder density distribution according to the present invention, the retractable shield is connected to the tail end of the powder feeding nozzle through an adapter, the upper end surface of the adapter is connected to the retractable shield, the lower end surface of the adapter is connected to the powder feeding nozzle, and a through hole through which the lens can observe is formed between the upper and lower end surfaces.
Preferably, in an embodiment of the observation apparatus for powder density distribution of the present invention, the camera, the adapter and the line light source are connected to an industrial personal computer; the industrial personal computer is used for controlling the adapter to move up and down, controlling the light source to emit required light, acquiring images collected by the camera, and storing and processing the images.
Preferably, in an embodiment of the observation apparatus for powder density distribution according to the present invention, the power of the light emitted from the line light source is not less than 1mW, the line width is not more than 5mm, and the wavelength band of the line light source should be included in the response wavelength band of the camera.
Preferably, in an embodiment of the observation apparatus for powder density distribution according to the present invention, the adapter has a repeated positioning accuracy of 0.5mm or less.
The invention also provides an image processing method of powder density distribution, based on the observation device of powder density distribution, firstly a plurality of photos are collected through a camera, RBG values of pixel points corresponding to the plurality of photos are superposed to obtain an average value, the average value is assigned to a new image, n pixel points of the new image are set, then the maximum value of R, the maximum value of G and the maximum value of B in all the pixel points are obtained and recorded as Rmax, Gmax and Bmax, a proportion coefficient α R is obtained and is 255/Rmax, α G is obtained and is recorded as 255/Gmax, α B is recorded as 255/Bmax, finally R of each pixel point of the new image is multiplied by α R, G of each pixel point of the new image is multiplied by α G, B of each pixel point of the new image is multiplied by α B, and finally a processed image is obtained.
The invention also provides an optimal design method of the powder feeding nozzle, according to the image processing method of the powder density distribution, the powder density distribution of other cross sections except the working surface of the laser processing head is obtained by adjusting the height of the powder feeding nozzle, and the design of the powder feeding nozzle is optimized by integrating the powder distribution conditions of the working surface of the laser processing head and other upper and lower positions.
Compared with the prior art, the observation device for powder density distribution has the following beneficial effects: the line light source emits light perpendicular to the spraying direction of the powder beams, the line light source illuminates the powder, a plane illuminated by the line light source is shot vertically downwards along the spraying direction from the upper side of the powder feeding nozzle through the camera, and the light emitting surface of the line light source is a working surface as the distance between the line light source and the powder feeding nozzle is equal to the working distance of the laser processing head, so that the powder density distribution of the working surface of the laser processing head can be obtained. The powder feeding nozzle is connected with the upright post through the adapter, the adapter can move up and down on the main body through any linear motion system, and the height of the powder feeding nozzle can be conveniently adjusted through the adapter. The camera lens links up the tail end of powder feeding nozzle through flexible guard shield, and flexible guard shield can reciprocate and prevent that light on every side from getting into the camera lens along with the adapter. The invention can accurately reflect the actual working condition of the nozzle when the laser processing head processes, has flexible adjustment and clear acquired image.
Compared with the prior art, the image processing method comprises the steps of firstly collecting a plurality of pictures by the camera, synthesizing the final image by the plurality of pictures, calculating the RBG value of each pixel point, calculating the average value of the RBG values, assigning the RBG value to a new image, calculating the ratio of the maximum RBG to 255 in the RBG of each point on the new image, and multiplying the RGB value of each pixel point by the ratio value, so that the image is brightened, the final picture is obtained, and the powder density distribution condition at the specific cross section is clearly reflected.
Compared with the prior art, in the method for optimally designing the powder feeding nozzle, after the shooting of the powder density distribution at the working face is finished, the powder density distribution at other cross sections is observed as required, so that the accuracy of the optimal design basis is improved.
Drawings
In order to more clearly illustrate the technical solution of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on the drawings without creative efforts.
FIG. 1 is a schematic view of the observation device of the present invention;
FIG. 2 is a diagram of the effect of the camera of the present invention in direct photographing: (a) the images taken at four different times are taken;
FIG. 3 is a powder density distribution diagram obtained after 20 pictures are taken at the focus of a powder beam and processed according to the present invention;
FIG. 4 is a powder density distribution diagram obtained by processing 20 pictures taken 2mm above the powder beam focus according to the present invention;
FIG. 5 is a powder density distribution diagram obtained by processing 20 pictures taken 4mm above the powder beam focus according to the present invention;
in the drawings: 1-a camera; 2-a lens; 3-a telescopic shield; 4-an adapter; 5-powder feeding nozzle; 6-powder bunching; 7-a line light source; 8-a powder collection box; 9-main body support; 10-industrial personal computer.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, also belong to the protection scope of the present invention.
Referring to fig. 1, the observation device for powder density distribution provided by the present invention includes a supporting device, in this embodiment, the supporting device adopts a main body bracket 9 composed of a bottom plate and a column installed on the bottom plate, a powder collecting box 8 is installed on the bottom plate, and a camera 1, a lens 2, a telescopic shield 3, an adapter 4, a powder feeding nozzle 5 and a line light source 7 are installed through the column.
The powder feeding nozzle 5 is arranged above the powder collecting box 8, powder is formed into a powder beam 6 through the powder feeding nozzle 5 and is sprayed downwards, and the powder collecting box 8 is used for collecting the sprayed powder. The camera 1 is arranged above the powder feeding nozzle 5, the camera 1 is connected with the tail end of the powder feeding nozzle 5 through the lens 2 which is arranged downwards through the telescopic shield 3, and the lens 2, the telescopic shield 3 and the powder feeding nozzle 5 are arranged on the same axis. A linear light source 7 is arranged on the upright post below the powder feeding nozzle 5, and the light emitting direction of the linear light source 7 is vertical to the spraying direction of the powder beam 6. The powder feeding nozzle 5 is connected with the stand column through the adapter 4, the adapter 4 can adjust the height of the powder feeding nozzle 5, the distance between the linear light source 7 and the powder feeding nozzle 5 is equal to the working distance of the laser processing head, and the light emitting surface of the linear light source 7 is a working surface.
The telescopic protective cover 3 is made of opaque material to prevent light from entering the lens from the periphery of the protective cover; the retractable shield 3 is retractable and the range of extension is larger than the range of vertical movement of the adapter 4. The telescopic shield 3 is connected with the tail end of the powder feeding nozzle 5 through the adapter 4, the connecting surface is tight, the disassembly and the assembly are convenient, the adapter 4 can be controlled by an industrial control machine, the upper end surface of the adapter 4 is connected with the telescopic shield 3, the lower end surface is connected with the powder feeding nozzle 5, and a through hole which can be observed by the lens 2 is processed between the upper end surface and the lower end surface.
The line light source 7 can be a visible light source or an invisible light source, the power is not less than 1mW, and the line width is not more than 5 mm. The wavelength band of the line light source 7 should be contained within the response wavelength band of the camera 1.
The camera 1 can be selected according to the line light source 7, and the matched line light source 7 can also be selected according to the camera 1.
When the observation device of the present invention is used, the linear light source 7 is first fixed at a certain height and the position is not changed. The line light source 7 and the camera 1 are turned on, and the observation state is entered. When the powder feeder is opened, the powder is ejected through the nozzle 5 to form a powder jet 6. At this time, the powder convergence at the cross section of the powder beam can be observed in the camera 1. The adapter 4 is moved up and down through the industrial personal computer 10 (the repeated positioning precision of the adapter 4 is less than or equal to 0.5mm), the nozzle 5 is driven to further drive the powder beam to carry out position adjustment, the distance between the line light source 7 and the powder feeding nozzle 5 is equal to the working distance of the laser processing head, and the observed cross section is a working surface.
The method comprises the steps of superposing RBG values of corresponding pixel points of a plurality of pictures to calculate an average value, assigning the average value to a new image, setting the number of the pixel points of the new image to be n, calculating the maximum value of R, the maximum value of G and the maximum value of B in all the pixel points to be Rmax, Gmax and Bmax, calculating a proportionality coefficient α R to be 255/Rmax, α G to be 255/Gmax and α B to be 255/Bmax, multiplying R of each pixel point of the new image by α R, multiplying G of each pixel point of the new image by α G, multiplying B of each pixel point of the new image by α B, and obtaining a finally processed picture which can clearly reflect the powder density distribution condition.
When the powder feeding nozzle is optimally designed, the powder density distribution at the working surface is observed and image-processed as required after shooting the powder density distribution at other cross sections is finished, so that the optimal design of the powder feeding nozzle is supported.
The powder spot of the device of the present invention is directly photographed by a camera, as shown in fig. 2(a) to 2 (d).
20 pictures are taken by the camera 1 at the focus of the powder beam, and the effect after image processing is shown in fig. 3.
In this embodiment, referring to fig. 4 to 5, the powder density distribution at 2mm above the focal point of the powder beam and the powder density distribution at 4mm above the focal point of the powder beam were obtained by collecting and processing by adjusting the height of the powder feeding nozzle 5 by the adapter 4.
The measurement results can clearly reflect the density distribution of the powder at different cross sections.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (8)
1. An observation device of powder density distribution is characterized in that: the powder spraying device comprises a main body support (9), wherein the main body support (9) consists of a bottom plate and a stand column installed on the bottom plate, a powder collecting box (8) is arranged on the bottom plate, a powder feeding nozzle (5) is arranged above the powder collecting box (8), powder is formed into powder beams (6) through the powder feeding nozzle (5) and is sprayed downwards, and the powder collecting box (8) is used for collecting the sprayed powder; a camera (1) is arranged above the powder feeding nozzle (5), the camera (1) is connected with the tail end of the powder feeding nozzle (5) through a lens (2) arranged downwards through a telescopic shield (3), the telescopic shield (3) can prevent surrounding light rays from entering the lens (2), and the lens (2), the telescopic shield (3) and the powder feeding nozzle (5) are arranged on the same axis; the camera (1), the lens (2), the telescopic shield (3) and the powder feeding nozzle (5) are installed through an upright post, a linear light source (7) is arranged on the upright post below the powder feeding nozzle (5), and the light emitting direction of the linear light source (7) is perpendicular to the spraying direction of the powder beam (6); the powder feeding nozzle (5) is connected with the upright post through the adapter (4), the adapter (4) can adjust the height of the powder feeding nozzle (5), the distance between the linear light source (7) and the powder feeding nozzle (5) is equal to the working distance of the laser processing head, and the light emitting surface of the linear light source (7) is a working surface.
2. Observation apparatus of powder density distribution according to claim 1, characterized in that: the telescopic shield (3) can be telescopic along with the movement of the position of the powder feeding nozzle (5), and the telescopic range is larger than the up-and-down movement range of the adapter (4).
3. Observation apparatus of powder density distribution according to claim 1 or 2, characterized in that: the telescopic shield (3) is connected with the tail end of the powder feeding nozzle (5) through the adapter (4), the upper end face of the adapter (4) is connected with the telescopic shield (3), the lower end face of the adapter is connected with the powder feeding nozzle (5), and a through hole which can be observed through the lens (2) is processed between the upper end face and the lower end face of the adapter.
4. Observation apparatus of powder density distribution according to claim 1, characterized in that: the camera (1), the adapter (4) and the line light source (7) are connected with an industrial personal computer (10); the industrial personal computer (10) controls the adapter (4) to move up and down, controls the line light source (7) to emit required light, acquires images collected by the camera (1), and stores and processes the images.
5. Observation apparatus of powder density distribution according to claim 1, characterized in that: the power of the light emitted by the line light source (7) is not less than 1mW, the line width is not more than 5mm, and the wave band of the line light source is contained in the response wave band of the camera (1).
6. Observation apparatus of powder density distribution according to claim 1, characterized in that: the repeated positioning precision of the adapter (4) is less than or equal to 0.5 mm.
7. An image processing method for powder density distribution is characterized in that a camera (1) is used for acquiring a plurality of pictures, RBG values of pixel points corresponding to the pictures are overlapped to obtain an average value, the average value is assigned to a new image, n pixel points of the new image are set, the maximum value of R, the maximum value of G and the maximum value of B in all the pixel points are obtained and recorded as Rmax, Gmax and Bmax, a proportion coefficient α R is obtained and is 255/Rmax, α G is 255/Gmax, α B is 255/Bmax, R of each pixel point of the new image is multiplied by α R, G of each pixel point of the new image is multiplied by α G, B of each pixel point of the new image is multiplied by α B, and a finally processed image is obtained.
8. An optimal design method of a powder feeding nozzle is characterized in that: the method for processing an image of a powder density distribution as defined in claim 6, wherein the height of the powder feeding nozzle (5) is adjusted to obtain the powder density distribution at a cross section other than the working surface of the laser processing head, and the design of the powder feeding nozzle is optimized by integrating the powder distribution at the working surface of the laser processing head and other positions up and down.
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| CN201911040199.XA CN110823758A (en) | 2019-10-29 | 2019-10-29 | Observation device for powder density distribution and image processing and nozzle optimization method |
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| CN201911040199.XA CN110823758A (en) | 2019-10-29 | 2019-10-29 | Observation device for powder density distribution and image processing and nozzle optimization method |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114486902A (en) * | 2021-12-03 | 2022-05-13 | 平方和(北京)科技有限公司 | Quality detection system and method |
| DE102021208745A1 (en) | 2021-08-11 | 2023-02-16 | Trumpf Laser- Und Systemtechnik Gmbh | Process and device for powder injection monitoring during laser cladding |
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