CN118218611A - Component forming quality monitoring for additive manufacturing - Google Patents
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Abstract
The present disclosure relates generally to a forming quality monitoring method for a component (202) for additive manufacturing, and further relates to providing at least one monitoring position for at least one layer of solid tissue of the component (202) formed during or after manufacturing, projecting measuring light on the at least one monitoring position with an optical measuring assembly (101) arranged above a building area of the manufactured component (202), acquiring three-dimensional information characterizing the at least one monitoring position according to feedback of the measuring light, determining that the forming quality of the at least one monitoring position does not conform to an expected forming quality of the component (202) according to an analysis result of the three-dimensional information, adjusting a manufacturing process of the component (202) to monitor the forming quality of the component (202) in real time, and finding and handling anomalies in the manufacturing process in time, thereby improving the forming quality of the component (202).
Description
Technical Field
The present disclosure relates to the field of additive manufacturing, and more particularly to a forming quality monitoring method for an additively manufactured component, a monitoring system, an additive manufacturing machine for manufacturing a component having the monitoring system, and a method for manufacturing a component in an additive manufacturing machine.
Background
In Additive Manufacturing (AM) processes, components may be affected by problems such as uneven material distribution, insufficient or excessive energy density, overheating or overcooling, and debris splattering, resulting in component geometries, dimensional accuracy, and material densities that do not meet design requirements.
In order to monitor the manufacturing process of the component, a method of photographing an image of the surface of the component by using a camera is currently mainly adopted to monitor the forming quality. However, this method is limited in that the photographed image reflects only the condition of the surface of the member, the multidimensional information cannot be directly obtained, and the image quality is unstable due to interference of factors such as uneven illumination and surface reflection.
Therefore, an efficient and real-time method for monitoring the forming quality of a component is urgently needed, and key parameters such as the form, the size, the material density and the like of the component can be detected in real time in the additive manufacturing process, and abnormal conditions in the manufacturing process can be found and processed in time, so that the forming quality of the component is improved.
Disclosure of Invention
Embodiments of the present disclosure aim to provide an efficient and real-time additive manufacturing component forming quality monitoring scheme to monitor the forming quality of a component in real time and to discover and handle anomalies in the manufacturing process in time, thereby improving the forming quality of the component.
In order to achieve the above purpose, the embodiments of the present disclosure adopt the following technical solutions:
In a first aspect, a method for monitoring the forming quality of a component for additive manufacturing is provided, having the steps of: scanning a current cross-sectional layer of the component layering data by using a forming energy beam to acquire a component profile of the current cross-sectional layer; determining at least one monitoring position of the component profile; projecting measurement light on the at least one monitoring location with an optical measurement assembly disposed over a build area where the component is manufactured, and obtaining three-dimensional information characterizing the at least one monitoring location based on feedback of the measurement light; determining whether the forming quality of the at least one monitoring position meets the expectations according to the analysis result of the three-dimensional information, and executing at least one of the following processing when the forming quality of the at least one monitoring position meets the expectations: a) Issuing an alarm; b) Recording abnormal conditions; c) The manufacturing process of the component is adjusted.
In a second aspect, there is provided a forming quality monitoring system for an additively manufactured component, comprising: an optical scanning system configured to scan a current cross-sectional layer of the component layering data with a shaped energy beam, acquire a component profile of the current cross-sectional layer to determine at least one monitoring location of the component profile; an optical measurement assembly disposed over a build area in which the component is fabricated and configured to project measurement light onto the at least one monitoring location and to obtain three-dimensional information characterizing the at least one monitoring location based on feedback of the measurement light; a control device configured to determine whether the forming quality of the at least one monitoring position meets expectations or not based on the analysis result of the three-dimensional information, and perform, when the determination is negative, at least one of the following processes: a) Issuing an alarm; b) Recording abnormal conditions; c) The manufacturing process of the component is adjusted.
In an alternative implementation of the first and/or second aspect, the at least one monitoring location comprises a part or all of the points and/or lines and/or faces that the at least one layer has.
In an optional embodiment of the first and/or second aspect, the forming mass comprises at least one of geometry, forming size and material density.
In an optional implementation manner of the first aspect and/or the second aspect, the determining whether the shaping quality of the at least one monitoring position meets an expectation according to the analysis result of the three-dimensional information includes: comparing the three-dimensional information with a library of information, wherein the library of information is pre-established and indicative of three-dimensional information of an intended manufacture, to determine whether the forming quality of the at least one monitored location meets an expectation.
In an optional implementation manner of the first aspect and/or the second aspect, the determining whether the shaping quality of the at least one monitoring position meets an expectation according to the analysis result of the three-dimensional information includes: and comparing and analyzing the obtained three-dimensional information representing the plurality of monitoring positions to determine whether the forming quality difference between the positions is in a preset interval, and if not, determining the forming quality of the monitoring positions beyond the preset interval as not meeting the expectations.
In an optional implementation of the first and/or second aspect, the optical measurement assembly is arranged on a mobile device, and the projecting of the measurement light comprises: controlling the optical measurement assembly to project the measurement light on the at least one monitoring position as the movement device moves over the build area.
In an alternative embodiment of the first and/or second aspect, the solid tissue of the component is formed via sintering/melting of a powder, the moving means being configured with a coating structure for performing a uniform coating of the powder before/after manufacturing the at least one layer of the component; one of the projection timings of the measurement light is in or after the manufacture of at least one layer of the member, and the coating structure is configured not to perform a coating operation.
In an optional implementation of the first and/or second aspect, the further projection occasion of the measuring light is before/after the completion of the manufacturing of the at least one layer of the component, and the coating structure is configured to perform in-coating or after finishing coating; the method further comprises the steps of: controlling the optical measurement assembly to project the measurement light on at least one powder layer formed during or after spreading coating as the moving device moves over the build area to measure three-dimensional information characterizing the at least one powder layer; determining whether the coating quality of the at least one powder layer meets the expectations according to the analysis result of the three-dimensional information, and executing at least one of the following processing when the determination is negative: i) issuing an alarm; ii) recording an abnormal situation; iii) adjusting the coating process.
In an optional implementation of the first and/or second aspect, the adjusting the manufacturing process of the component includes performing defect repair on the abnormal location and/or adjusting manufacturing parameters of the corresponding location in the next layer to perform defect compensation on the abnormal location.
In an optional implementation of the first and/or second aspect, the defect repair and/or defect compensation comprises: performing powder supplementing scanning on the abnormal concave and/or performing enhanced compensation scanning on the abnormal concave after coating of the next layer so as to form a tissue structure corresponding to the abnormal concave; and removing the abnormal bulge and/or carrying out weakening compensation scanning on the abnormal bulge after one layer of coating so as to repair the defect of the abnormal bulge.
In an optional implementation of the first and/or second aspect, the optical measurement assembly is configured to acquire the three-dimensional information using at least one structured light measurement system and/or a laser ranging sensor.
In a third aspect, there is provided an additive manufacturing machine having a system according to any of the second aspects and/or performing a method according to any of the first aspects.
In a fourth aspect, there is provided a method for manufacturing a component in an additive manufacturing machine, comprising: coating powder layer by layer above a substrate by using a coating device to form a powder layer; selectively sintering/fusing the coated powder layer using an energy beam generated by an optical scanning system; repeating the layer-by-layer coating and the selective sintering/melting until the component is made; wherein the additive manufacturing machine is configured to perform the method of any of the first aspects at least during the manufacture of the component.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, implementations, and features described above, further aspects, implementations, and features will become apparent by reference to the drawings and the following detailed description.
Drawings
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate one or more embodiments of the present disclosure and, together with the description, serve to explain the principles of the disclosure and to enable a person skilled in the pertinent art to make and use the disclosure.
FIG. 1 illustrates an application schematic of an exemplary monitoring system according to some embodiments of the present disclosure;
FIG. 2 illustrates an application schematic of an exemplary structured light measurement system according to some embodiments of the present disclosure;
FIG. 3A illustrates a schematic cross-sectional view of a component layer at an exemplary first measurement stage in accordance with some embodiments of the present disclosure;
FIG. 3B illustrates a schematic cross-sectional view of a component layer at an exemplary second measurement stage, according to some embodiments of the present disclosure;
FIG. 4 illustrates an application schematic of an exemplary optical measurement assembly according to some embodiments of the present disclosure;
FIG. 5 illustrates an application schematic of an exemplary coating apparatus according to some embodiments of the present disclosure;
FIG. 6 illustrates an exemplary cross-sectional layer abnormal pit repair and compensation schematic according to some embodiments of the present disclosure, wherein (a) illustrates a cross-sectional layer with abnormal pits, (b) illustrates a cross-sectional layer after abnormal pit repair, and (c) illustrates a cross-sectional layer after abnormal pit compensation;
FIG. 7 illustrates a schematic diagram of an exemplary powder dropping device according to some embodiments of the present disclosure;
FIG. 8 illustrates an exemplary bump repair and compensation schematic of a cross-sectional layer according to some embodiments of the present disclosure, wherein (a) illustrates a cross-sectional layer with an abnormal bump, (b) illustrates a cross-sectional layer after bump repair, and (c) illustrates a cross-sectional layer after bump compensation;
FIG. 9 illustrates a measurement light projection schematic during an exemplary coating process according to some embodiments of the present disclosure;
Fig. 10 illustrates a schematic of an exemplary additive manufacturing machine, according to some embodiments of the present disclosure.
Detailed Description
The following term explanations may aid in understanding the present disclosure:
Herein, "and/or" describes an association relationship of an association object, meaning that three relationships may exist. "at least one" or the like, means any combination of these items, including any combination of single item(s) or plural items(s), means one or more, and plural means two or more.
The subject matter of "monitoring method", "monitoring system", "additive manufacturing machine", "additive manufacturing method", etc. herein is interdependent and common. For example, the monitoring method requires support by a monitoring system and/or additive manufacturing machine to perform its functions, while the operation and output of the device is controlled and affected by the monitoring method and/or monitoring system. The detailed description herein for any subject matter may be covered by other subject matter.
An "energy beam" herein refers to a form of focusing energy in various forms into a beam for use in manufacturing components in an additive manufacturing process. Preferably a laser beam, but may also be in the form of an electron beam, ion beam, plasma beam, or the like. "measuring light" refers to a beam or ray of light used to make an optical measurement. For example in the form of a laser beam, structured light or the like, for projection onto a monitoring location of the component and for obtaining three-dimensional information about the location by interaction with the target surface.
The term "additive manufacturing" is a manufacturing way of building a three-dimensional object by stacking materials layer by layer, i.e. "layup manufacturing", "3D (three-dimensional) printing". It encompasses a variety of additive manufacturing categories that utilize energy beams to cure materials, such as the categories of selective laser sintering (SELECTIVE LASER SINTERING, SLS), selective laser melting (SELECTIVE LASER MELTING, SLM), electron beam melting (Electron Beam Melting, EBM), and photo-curing (Stereolithography, SLA), which are preferred for use in SLM additive manufacturing.
"Powder" refers to the raw materials used to make the component, and in physical structure primarily refers to powder particles, which may have different shapes, sizes, and particle sizes. The "powder" herein is preferably a metal material such as stainless steel, copper, titanium alloy, aluminum alloy, or the like. In addition, ceramic materials such as aluminum oxide (Al 2O3), silicon nitride (Si 3N4), etc., plastics such as Polyamide (PA), polycarbonate (PC), etc., and some composite materials may be used to construct 3D objects.
The term "coating" refers to a process of uniformly covering (laying) powder on the surface of a substrate or member (the upper layer). Coating is typically achieved by a coating structure, which is a means for uniformly covering the powder, such as a doctor blade (preferred) or a roll, for uniformly distributing the powder material over the surface of the manufacturing area. By a good coating process it is ensured that each layer of the component has a uniform powder distribution and thickness, thereby improving the forming accuracy of the component.
The terms "member" and "three-dimensional object" are interchangeable and each refer to a physical object having three dimensions.
The "forming quality" encompasses at least one of the geometry, forming size, and material density of the component. "geometry" refers to the profile and configuration of the component, including features in terms of curvature, angle, and angle. The "formed dimension" refers to the dimensional accuracy in terms of the actual as-built dimensions of the component, such as length, width, height, etc. And "material density" refers to the uniformity and compaction of the material within the component. For metal components, non-uniformity or too low a density of material may result in insufficient strength of the component.
"Three-dimensional information" refers to three-dimensional data of a component, including information about the shape, size, and material distribution of the component. Three-dimensional information obtained by optical measurement or the like may be used to evaluate the forming quality of the member. For example, by comparing the differences between the three-dimensional data of the actual component and the design model, it may be determined whether the geometry and dimensions of the component meet expectations. Meanwhile, the three-dimensional information can be used for detecting defects, cracks and other problems on the surface or in the component, so that whether the density of the material meets the requirement or not can be estimated.
Referring to fig. 1, a schematic application diagram of an exemplary monitoring system 100 according to some embodiments of the present disclosure is shown. According to some embodiments of the present disclosure, the monitoring system 100 includes an optical scanning system 105, an optical measurement assembly 101, and a control device 102. The building area of the component 202 on the substrate 201 is manufactured layer by a (shaped) energy beam L1 applied by the optical scanning system 105, and the optical measurement assembly 101 is arranged in the upper space of the substrate 201 (in particular above the component 202) to capture three-dimensional information of the surface of the component 202. The control device 102 is communicatively connected to the optical measurement assembly 101 for receiving and analyzing the three-dimensional information transmitted by the optical measurement assembly 101 to obtain the quality of the formation of the component 202. In addition, the control device 102 may also enable at least one of a) issuing an alarm b) recording an abnormal condition and c) adjusting control of the manufacturing process of the component 202 by communicating with other systems or components of the additive manufacturing machine when it is analyzed that the forming quality of the component 202 is not expected. Wherein the control device 102 may be configured as a computer control system of an additive manufacturing machine.
According to some embodiments of the present disclosure, the optical scanning system 105 is configured to scan a current cross-sectional layer of the component 202 layered data with the energy beam L1, acquire a component 202 profile of the current cross-sectional layer to determine at least one monitoring position of the component 202 profile. More specifically, during operation of the optical scanning system 105, a scan path/pattern is typically pre-set for determining the position of the current cross-sectional layer of the component 202, which may be pre-programmed, scanned over different portions of the component 202 in a sequence at each layer, or dynamically generated based on the design and geometry of the component 202. The optical scanning system 105 determines the position of the current cross-sectional layer according to the preset scanning path, and scans along the profile of the cross-sectional layer to obtain layered data of the layer, i.e. the data of the current cross-sectional layer. By scanning the current cross-sectional layer, the optical scanning system 105 can acquire profile data of the component 202 at that layer to determine at least one monitored location of the profile of the component 202 (e.g., a portion of the location on a critical portion or surface feature of the component 202, or all of the location of the profile) based on the profile data.
It should be appreciated that the member 202 is formed from a plurality of layers having solid tissue laminated together. Prior to manufacturing the component 202, an operator uses modeling software, such as Computer Aided Design (CAD) software, to create a model of the component 202 to be printed. Then, the model to be printed is subjected to layering processing, the model to be printed is divided into a plurality of planing sections, each planing section represents a layer to be printed, and corresponding layering data are generated. Layering data of a series of layers to be printed is generated by the layering process to describe the geometry and print path of each layer. The control device 102 may control the operation of the various components of the additive manufacturing machine based on these layered data, enabling selective sintering/melting layer by layer to build the completed component 202.
The optical measurement assembly 101 may be implemented alone or in combination, depending on the parameters, accuracy requirements, and application scenario to be monitored during additive manufacturing. The following is illustrated with only two specific examples of configurations of the optical measurement assembly 101.
Laser sensor
In one construction example, the optical measurement assembly 101 includes a plurality of laser sensors arranged in an array for measuring height information of a light source to a plurality of locations of a surface of the member 202 (layer). The laser sensors are arranged along the building area such that the measuring range covers the entire building area. For example, the measured ranges of adjacently disposed laser sensors meet to form a measurement range for the entire range of the build area, such that a comprehensive height information measurement is obtained for both the smaller and larger build surface area components 202. In addition, the number and arrangement of the laser sensors may be adjusted, for example, depending on the particular number or size of the components 202, to ensure that the laser sensors are able to accommodate different numbers or shapes of components 202.
Each laser sensor, after measuring the height information from the light source to a plurality of locations on the surface of the component 202 (layer), transmits it to the control device 102, so that the control device 102 combines the height information with the location of the light source to generate point cloud data representing three-dimensional information of each location on the surface of the component 202 (layer).
In particular, the control device 102 receives, in addition to the height information from each laser sensor, position data of the light source, that is, the position of the laser sensor itself, the light source is generated by the laser sensor and irradiates the surface of the member 202 (layer), and the height information of the surface of the member 202 (layer) is obtained by measuring the reflection of the light. The control means 102 combines the position data of the light source, for example comprising the coordinates of the laser sensor in space and its orientation information, with the altitude information, and by associating the position information of the light source with each altitude data, the control means 102 can determine the spatial position at which each measured position is located. In this way, the control device 102 generates point cloud data, each point representing one position of the surface of the member 202 (layer) and having its coordinates in three-dimensional space.
In this way, the control device 102 can calculate whether the height difference between the positions of the surface of the member 202 (layer) is within the preset section based on the acquired point cloud data. In addition, the control device 102 may also perform the following calculation using the point cloud data: the geometry of the component 202 (layer) is reconstructed by curve/curve fitting the point cloud data, including parameters in terms of curvature, angle, surface characteristics, etc. The dimensions of the member 202 (layer) in different directions, including parameters of length, width, etc., are determined by measuring and analyzing the point cloud data. By performing a volumetric calculation or density analysis on the point cloud data, the distribution and compaction of the material of the component 202 (layer) may be evaluated to determine whether the material density meets the requirements.
Structured light measuring system
Structured light measurement is based on the principle of optical triangulation, using projecting specific light structures (e.g. gratings, fringes, etc.) onto a target surface, and inferring the shape and profile of the target surface by observing the distortion or deformation of the light structures by the target surface.
Referring to fig. 2, a schematic application diagram of an exemplary structured light measurement system according to some embodiments of the present disclosure is shown. In one construction example, the optical measurement assembly 101 includes a structured light emitter 103 and an image capture 104. The structured light emitter 103 is configured to emit first structured light such that it forms a specific pattern on the surface of the member 202 (layer); the image capture device 104 (e.g., a camera) is configured to capture the second structured light reflected by the surface of the member 202 (layer) and to resolve the pattern to obtain three-dimensional information of the surface of the member 202 (layer).
Specifically, the structured light emitter 103 projects a pattern onto the surface of the member 202 (layer) by emitting a specific first structured light (e.g. a pattern of gratings or stripes). Then, the image capturer 104 captures and analyzes the second structured light (distorted or deformed pattern) reflected by the surface of the member 202 (layer), and by analyzing the deformation and displacement of the pattern on the surface of the member 202 (layer), the image capturer 104 can infer the shape and contour of the surface of the member 202 (layer). Thus, by a combination of structured light projection and capture, the optical measurement assembly 101 is able to accurately acquire three-dimensional information of the surface of the member 202 (layer).
When the structured light emitters 103 may be one or more, e.g. a plurality, these structured light emitters 103 may be arranged at different angles or positions to cover a range or specific area of the entire surface of the member 202 (layer) ensuring a sufficient projection of the entire surface. The image capturer 104 may also be one or more, such as a plurality, and the image capturers 104 may be mounted at different angles or positions to ensure full coverage and accurate capture of the surface of the component 202 (layer) to obtain accurate three-dimensional information.
After acquiring the three-dimensional information measured by the structured light measurement system, the control device 102 may perform the following operations: the obtained three-dimensional information is used to perform surface/curve fitting on the layer surface of the component 202 to reconstruct the layer geometry of the component 202, and the shape characteristics of the component 202, such as curvature and/or angle, are obtained through the fitted surface/curve parameters, so as to analyze whether the geometry of the component 202 meets the expectations. The dimensions of the component 202 in different directions can be measured using the obtained three-dimensional information, and the actual measured values can be compared with the design values to evaluate whether the formed dimensions of the component 202 meet the requirements. And analyzing the material density by using the obtained three-dimensional information, and evaluating the distribution condition and the compactness of the material of the component 202 by performing volume calculation or density analysis on the three-dimensional data of the surface of the layer of the component 202 so as to determine whether the material density meets the requirement. After analysis of the quality of the formation of the component 202, the control device 102 may compare with a pre-set standard or threshold. If the geometry, the forming size or the material density of the component 202 is found to be undesirable, the control device 102 will determine that the component 202 is abnormal and trigger corresponding treatment measures.
According to some embodiments of the present disclosure, optical measurement assembly 101 is configured to perform measurements at different stages in the manufacturing process of component 202 to obtain corresponding three-dimensional information. For example, the optical measurement component 101 may operate in the following two stages to obtain corresponding three-dimensional information.
First measuring stage
In a first measurement phase, the optical measurement assembly 101 is configured to project measurement light onto the surface of the component 202 after the fabrication of one of the layers has been completed (i.e. the surface of that layer) to obtain corresponding three-dimensional information.
Second measurement stage
In a second measurement phase, the optical measurement assembly 101 is configured to project measurement light onto the surface of the component 202 being manufactured on one of the layers to obtain corresponding three-dimensional information.
It will be appreciated that the second measurement phase differs from the first measurement phase mainly in measurement timing. In the second measurement phase, the optical measurement assembly 101 needs to measure the surface of the component 202 (the surface of the gradually formed layers) in real time in order to obtain corresponding three-dimensional information during the manufacturing process of each layer of the component 202, and such real-time monitoring can help the control device 102 to find and correct any anomalies in the manufacturing process in time to ensure that the forming quality of the component 202 meets expectations. Furthermore, during the second measurement phase, the optical measurement assembly 101 may need to perform measurements at a higher frequency to capture variations in the surface of the component 202 during the manufacturing process.
According to some embodiments of the present disclosure, the projected position of the measurement light may be selected for either the first measurement phase or the second measurement phase. For example, measuring light covering the (current) entire layer cross-section may be selected to obtain three-dimensional information characterizing the entire layer cross-section. This approach may provide a comprehensive measurement of the three-dimensional information of the entire layer cross-section, thereby obtaining detailed data about the overall morphology, size, and material density of the current layer of the component 202. Furthermore, it is also possible to choose to project measuring light towards specified monitoring positions provided over (current) the entire layer cross-section in order to obtain three-dimensional information characterizing these monitoring positions. Of course, measuring light projected over the (current) whole layer cross-section can also be understood as projected towards the specified monitoring location. The monitoring locations may be some or all of the points and/or lines and/or facets that the layer cross-section has. By taking measurements at specific monitoring locations, three-dimensional information about these locations can be acquired targeted to more finely monitor critical areas of the component 202.
Referring to fig. 3A, a schematic cross-sectional view of a component layer at an exemplary first measurement stage is shown, according to some embodiments of the present disclosure. The component 202 is formed in the build area of the substrate 201, and the N x th layer cross section of the component 202 is specifically shown in fig. 3A. The cross section is marked with various monitoring positions, including point-shaped A1 to A10, linear B1 to B10 and planar C1 to C10.
Specifically, the punctiform monitoring positions A1 to a10 represent discrete point positions on the N x th layer cross-section of the member 202. These points at different locations of the cross-section may be used to purposefully monitor localized features or critical areas of the surface of the component 202. For example, it may be selected to provide such monitoring points at edges, corners, or specific relief locations of the member 202 in order to more accurately detect the shape and size of the member 202. The linear monitor locations B1 through B10 represent linear regions formed in the N x th layer cross-section of the member 202. These linear regions may be used to monitor a particular portion of the surface of the member 202, such as along a certain edge or a particular geometry of the member 202. By taking measurements at these linear regions, local curvature, angle, or other geometric features of the component surface may be obtained. While the planar monitor locations C1 through C10 represent planar areas formed in the N x th layer cross-section of the component 202. These planar areas cover most (or even all) of the cross-section and can provide comprehensive monitoring of the entire cross-section. By taking measurements in these planar areas, global features of the surface of the component 202 may be obtained, thereby providing a more comprehensive understanding of the morphology of the component 202.
For these different forms of monitoring positions, different optical measurement schemes may be selected for measurement. For example, for point-like monitoring locations, measurements can be made using single-point laser sensors or structured light projection schemes; for linear or planar monitoring positions, a multi-point laser sensor or a multi-structure optical measurement system may be used to make full-scale measurements.
Referring to fig. 3B, a schematic cross-sectional view of a component layer at an exemplary second measurement stage is shown, according to some embodiments of the present disclosure. The N x layer cross-section (partial) formed during fabrication of the component 202 is shown in detail in fig. 3B. The cross section is marked with various different forms of monitoring positions, including point-shaped A1 to A3, linear B1 and B2 and planar C1 and C2. In the example of fig. 3B, the selection of the monitoring location is more focused on the real-time situation of the component layer cross section at the current point in time. The point-like, line-like and plane-like monitoring positions represent real-time positions on the current layer cross-section during the manufacturing process to monitor the morphology and size of the component surface in real time.
It should be appreciated that in either fig. 3A or 3B, the optical measurement assembly 101 may choose to project measurement light covering the (current) entire layer cross-section to obtain three-dimensional information characterizing the entire layer cross-section.
According to some embodiments of the present disclosure, the control device 102 may perform the intended analysis by analyzing whether the forming quality of the monitoring location meets the intended requirement in the following two ways.
First expectation analysis
Comparing the obtained three-dimensional information representing the forming quality of one or more monitoring positions with an information base to determine whether the forming quality of the monitoring positions meets the expectations.
Specifically, during the design phase of the component 202 or prior to fabrication, a library of information is pre-established containing three-dimensional information of the component 202 to be fabricated, such as may be generated by computer aided design software (CAD), and taking into account design requirements, geometry, dimensional accuracy, and the like. After the control device 102 receives the three-dimensional information of the monitoring position from the optical measurement component 101, the obtained three-dimensional information of the actual monitoring position is compared and analyzed with the expected three-dimensional information of the corresponding position in the information base, and by comparing the difference between the two three-dimensional information, the control device 102 can determine whether the forming quality of the monitoring position meets the expected or not. And if the comparison analysis result shows that the three-dimensional information of the actual monitoring position is consistent with the expected information in the information base or is within an acceptable range, the forming quality of the monitoring position is considered to be consistent with the expected. Conversely, if there is a significant discrepancy or an acceptable range is exceeded, the quality of the formation at the monitored location is deemed to be undesirable.
Second predictive analysis
And comparing and analyzing the obtained three-dimensional information representing the plurality of monitoring positions to determine whether the forming quality difference between the positions is within a preset interval, and if not, determining the forming quality of the monitoring positions beyond the preset interval as not meeting the expectations.
Specifically, the control device 102 performs a comparative analysis on the three-dimensional information of the plurality of monitoring positions to determine the forming quality difference between each other, which may be achieved by comparing parameters such as height, curvature, angle, length, width, etc. between the respective monitoring positions. The control device 102 sets a preset interval (which may be set according to design requirements or experience) in advance for tolerating forming quality differences between the individual monitoring positions. The control device 102 determines whether the forming quality difference between the monitoring positions is within a preset interval according to the comparison analysis result. If the forming quality of each position is within the preset interval, the forming quality of each position is considered to be in line with the expected forming quality; and if the forming quality exceeds the preset interval, determining the forming quality of the monitoring position exceeding the preset interval as not meeting the expectation. For example, the control device 102 may calculate whether the height difference between the positions of the surface of the member 202 (layer) is within the preset interval based on the obtained point cloud data, or may use the second expected analysis, and if the height difference is within the preset interval, the forming quality of the positions may be regarded as being expected; if the height difference exceeds the preset interval, the quality of the formation at these locations is considered to be unexpected.
Mobile device
Referring to fig. 4, a schematic application diagram of an exemplary optical measurement assembly according to some embodiments of the present disclosure is shown. According to some embodiments of the present disclosure, a moving device 203 is arranged in the upper space of the substrate 201 (in particular the member 202). The optical measurement assemblies 101a to 101e are arranged on the moving device 203 to project measurement light on the respective covered monitoring positions as the moving device 203 moves over the construction area. The movement means 203 can be moved in space in a predetermined path to ensure that the optical measuring assemblies 101a to 101e cover the whole construction area, as shown in fig. 4, the coverage of the optical measuring assemblies 101a to 101e corresponds to the areas d1 to d5, respectively, or at least the monitoring location of interest. By mounting a plurality of optical measurement assemblies 101a to 101e on the mobile device 203, measurements can be made at different locations simultaneously, thereby improving monitoring efficiency and achieving overall quality control.
According to some exemplary embodiments, the timing of movement of the mobile device 203 within the space is also divided into two. One in the first measurement phase disclosed above and the other in the second measurement phase disclosed above.
In a first measuring phase, i.e. after the manufacture of one of the layers of the component 202 has been completed with the energy beam, the displacement device 203 is displaced from the other area to above the build area. The movement of the movement device 203 at this stage aims to position the optical measurement assembly over the construction area for the measurement operation.
In a second measurement phase, i.e. in the ongoing manufacture of one of the layers of the component 202 with the energy beam, the moving means 203 are configured to follow the progress of the manufacture to move stepwise. This configuration is intended to ensure that the mobile device 203 does not interfere with the normal scanning of the energy beam and that real-time information of the layer being manufactured can be acquired in time. In particular, the moving device 203 is arranged on one side of the energy beam, entirely in the manufacturing area, to avoid interfering with the normal scanning of the energy beam. The movement means 203 will move stepwise with the movement of the energy beam to keep pace with the manufacturing process of the component 202. Thus, the optical measurement assembly can measure the surface of the current layer in real time in the manufacturing process of the component, and capture the change condition of key parameters such as the form, the size, the material density and the like of the component.
The movement of the mobile device 203 may be performed according to a preset path or may be adjusted according to real-time monitoring requirements. By positioning the mobile device 203 over the build area, the optical measurement assembly can accurately project measurement light onto the component surface to obtain three-dimensional information of the layer.
In practical applications, the length (fig. 4)/width of the mobile device 203 and the number of optical measurement components 101a to 101e can be adjusted according to specific measurement requirements. In particular, during the second measurement phase, in order to better accommodate the ongoing component manufacturing process and ensure that the optical measurement assembly does not interfere with the normal scanning of the energy beam, adjustments may be made, such as shortening the length of the mobile device 203 in the X-axis and/or the width of the Y-axis, to reduce the footprint of the mobile device 203 and thereby reduce interference with the component 202 manufacturing process. The number of optical measurement components is moderately reduced as needed. The layout of the optical measurement components is adjusted to maximize measurement efficiency for specific requirements in the fabrication of the component 202.
In addition, the specific form of the mobile device 203 is not limited, and an appropriate design may be selected according to actual requirements. For example, the rail system and the robot arm are both in the form of an optional moving device 203, which can perform the corresponding moving function.
Coating (powder spreading) device
Referring to fig. 5, a schematic application diagram of an exemplary coating apparatus 204 according to some embodiments of the present disclosure is shown. According to some embodiments of the present disclosure, the solid structure of the component 202 is formed via sintering/melting of the powder P. In this process, the powder P is gradually sintered/melted by the energy beam, forming a solid structure of the member 202. Thus, in the additive manufacturing process, powder P is also applied, i.e. after one layer of the component 202 is manufactured (or before the next layer is manufactured), the powder P deposited on the processing plane 205 is uniformly applied above the current layer of the component 202 as building material for the next layer structure by means of the application device 204. It is also understood that the layers of powder P deposited on the base plate 201 form a powder bed PB, and that the layer structure of the member 202 is manufactured on the powder bed PB.
In some embodiments, the coating device 204 is configured as part of the moving device 203, the moving device 203 being comprised of a moving mechanism 203a and the coating device 204. In a specific configuration example, the coating device 204 is composed of a mounting bracket 204a and a coating structure 204b (e.g., a doctor blade) configured below the mounting bracket 204 a. The coating device 204 is slidably mounted on the moving mechanism 203a to move in the X-axis direction (a function of lifting and lowering along the Z-axis may be added) by the driving of the moving mechanism 203 a. Each time one of the layers of the component 202 is manufactured, the coating device 204 will be driven by the moving mechanism 203a to coat a new layer of powder P over the current layer of the component 202.
The optical measuring assembly 101 is configured on the coating device 204 provided on the moving device 203, and further on the mounting bracket 204a provided on the coating device 204, so as to project measuring light onto the layer section of the member 202 on the coating device 204 to acquire corresponding three-dimensional information.
In the example of fig. 5, one of the projection opportunities of the measurement light is in or after the manufacture of at least one layer of the member 202, and the coating structure 204b is configured not to perform a coating operation.
It will be appreciated that to achieve projection of measurement light onto the layer cross section of the component 202 on the coating device 204 during the manufacturing of the component 202, the movement of the coating device 202 needs to be kept in a non-coated state, i.e. in a lay-down state, to ensure that the coating device 202 does not cover the surface of the component 202 with new powder P during the measurement.
To achieve this, the following measures can be applied in combination or individually:
1) During the movement of the coating device 204, no new powder P is deposited onto the working plane 205, thereby ensuring that the coating device 204 does not apply new powder P onto the surface of the component 202 while moving.
2) The coating device 204 is controlled by the moving mechanism 203a to be lifted up a distance so as to maintain a certain gap with the layer section of the member 202. In this way, even when the coating device 204 is moved, new powder P is not covered on the surface of the member 202.
3) The coating structure 204b may be designed to have a telescoping function, and when a measurement is desired, the distance from the surface of the member 202 may be adjusted by controlling the telescoping of the coating structure 204 b. In this way, during movement, the coating structure 204b may be retracted to avoid covering new powder P on the surface of the component 202.
In some embodiments, the mounting bracket 204a is a portion formed above the coating structure 204b and extending to at least one side in the coating direction (X-axis), and the mounting bracket 204a may be detachably coupled to the coating structure 204b or may be integrally formed. In this arrangement, the optical measurement assembly 101 is configured on the mounting bracket 204a of the coating apparatus 204 such that the optical measurement assembly 101 is maintained at a lateral distance from the coating structure 204b to ensure that the optical measurement assembly 101 is able to accurately measure three-dimensional information of the surface of the component 202.
It should be appreciated that the mounting bracket 204a may extend to one side, with the optical measurement assembly 101 disposed on one side (e.g., the left or right side) of the mounting bracket 204a, or may extend to both sides, respectively, to dispose the optical measurement assembly 101 on both the left and right sides of the mounting bracket 204a, respectively. The advantage of having optical measurement assembly 101 disposed on both sides is that whether coating apparatus 204 is moving from left to right or right to left, it is ensured that optical measurement assembly 101 can timely and fully acquire three-dimensional information of the surface of member 202. The optical measurement assembly 101 located to the left of the mounting bracket 204a can continuously monitor and measure the condition of the surface of the component 202 as the coating apparatus 204 moves from left to right. Meanwhile, the optical measurement assembly 101 positioned on the right side of the mounting bracket 204a can also timely acquire the information of the surface of the component 202, so that the omnibearing monitoring of the surface state of the component 202 is realized. Likewise, when the coating apparatus 204 is moved from right to left, the left and right optical measurement assemblies 101 can also complement each other, ensuring that three-dimensional information of the surface of the component 202 can be accurately obtained throughout the coating process.
Similarly, the timing at which the coating device 204 moves in space is also divided into two. One in the first measurement phase disclosed above and the other in the second measurement phase disclosed above. In the first measuring phase, i.e. after the manufacture of one of the layers of the component 202 has been completed with the energy beam L1, the coating device 204 is moved from the other area to above the build area, and after the movement has stopped (to the specified position) the optical measuring assembly 101 is started for measuring. In a second measurement phase, i.e. during the ongoing manufacture of one of the layers of the component 202 with the energy beam L1, the coating device 204 is configured to follow the progress of the manufacture to move stepwise, thereby bringing the optical measurement assembly 101 to move synchronously to project measurement light stepwise on the layer cross section of the component 202.
Handling when the forming quality is not in line with expectations
In some exemplary embodiments, upon determining that the forming quality of the component 202 is not expected, the control device 102 may apply the following measures, in combination or alone:
a) An alarm is raised to an operator or monitoring system that an abnormality exists in the quality of the formation of the member 202. Such an alert may be by sound (e.g., via an alarm), visual (e.g., via a display), or other suitable means.
B) The detailed information of the abnormal situation is recorded, including specific problems of the forming quality, the time and the position of occurrence of the abnormality, and the like. These records can be used for subsequent analysis and diagnosis, helping to determine the cause of the problem and taking corresponding improvements.
C) The control parameters during the manufacture of the component 202 are adjusted to correct for problems with the quality of the formation that are not expected.
According to some embodiments of the present disclosure, the manufacturing process of the adjustment member 202 referred to in c) comprises defect repair for an abnormal location and/or adjusting manufacturing parameters of a corresponding location in the next layer to perform defect compensation for the abnormal location.
Defect repair and compensation for abnormal dishing
Referring to fig. 6, a schematic diagram of abnormal pit repair and compensation of an exemplary cross-sectional layer according to some embodiments of the present disclosure is shown, wherein (a) shows a cross-sectional layer with abnormal pits, (b) shows a cross-sectional layer after abnormal pit repair, and (c) shows a cross-sectional layer after abnormal pit compensation.
In fig. 6 (a), the cross-sectional layer N x is formed with abnormal recesses e1-e4, in which the recesses of e1 and e4 are relatively deep and the recesses of e2 and e3 are relatively shallow. For e2 and e3 with shallower depressions, a defect repair strategy (for example, a height threshold value can be set, and a defect repair strategy without exceeding the threshold value is adopted) can be adopted, and powder filling scanning is carried out on the defect repair strategy; while for e2 and e3, which are deeper depressions, a defect compensation strategy (exceeding the height threshold) may be employed to enhance the compensation scan. In fig. 6 (b), a cross-sectional layer N x after the repair of the abnormal pit defect is shown. For e2 and e3 with shallower depressions, a defect repair strategy is adopted, the depressed areas are filled by powder filling scanning to keep the depressed areas consistent with surrounding structures, the surface of the repaired section layer N x looks flat, and the depressed parts are already replenished and restored to the expected height. In fig. 6 (c), the cross-sectional layer N x after the abnormal pit defect compensation is shown. For e1 and e4 with deeper depressions, a defect compensation strategy is adopted, and the structure of the depression area is filled by performing enhanced compensation scanning on the corresponding position of the section layer N x+1, so that the quality defect caused by the depressions is eliminated.
In some alternative embodiments, a defect repair strategy may be performed for all abnormal pits, or a defect compensation strategy may be performed for all abnormal pits.
The "powder replenishment scan" refers to filling a recessed region to be subjected to defect repair with a corresponding powder, then scanning the recessed region with an energy beam, and heating the powder in the recessed region to a sufficiently high temperature to sinter/melt the powder and fuse the powder with surrounding structures to form a corresponding tissue structure. Through the powder supplementing scanning, originally concave areas can be gradually filled up and connected with surrounding structures in a seamless mode, and a uniform surface is formed. In this way, the geometry and surface quality of the component is restored to meet the desired design requirements.
The "enhanced compensation scan" refers to a process of filling a recessed area to be defect-compensated, which is not processed in the current cross-section layer N x, but is coated with a new layer of powder over the cross-section layer N x by using a coating device. In the manufacture of the cross-sectional layer N x+1, the energy beam adopts a normal scanning strategy for other positions, and when reaching the corresponding position above the recessed region, the scanning depth is reduced (the light spot is positioned at a lower position of the Z axis), and the scanning depth is adjusted to be deeper than the surrounding region, so that the energy projected by the energy beam in the region is absorbed more, thereby forming more heat in the recessed region and promoting sintering/melting of the powder. In this way, in the next layer of the component (section layer N x), the recessed areas will gradually fill up and merge with the surrounding structure. The enhanced compensation scanning strategy can effectively compensate the defects of the concave area, so that the surface quality of the component is improved, and the whole geometric shape and the size of the component can be ensured to meet the design requirements.
In some embodiments, the recessed areas where defect repair is desired may be filled with the corresponding powder by feeding the powder up, for example, by controlling the flow of the powder by a powder dropping device located in the space above the component, to precisely deliver the powder to the recessed areas on the surface of the component.
Referring to fig. 7, a schematic structural diagram of an exemplary powder dropping device according to some embodiments of the present disclosure is shown. The blanking device is composed of a cartridge 208 and a driver 207, the bottom of the cartridge 208 is provided with a nozzle 209, and the driver 207 is used for driving the cartridge 208 to release a specified amount of powder from the nozzle 209 to the recessed area according to the instruction of the control device. In addition, the blanking device is further provided with a coating block 210, and the coating block 210 is driven to locally coat at a position corresponding to the concave area (by controlling the whole blanking device to descend and move) according to the instruction of the control device by virtue of a configured movement mechanism (with translation and lifting functions), so that the surface of the concave area after coating is kept at the same height with the adjacent area.
Illustratively, the driver 207 is configured to be composed of a screw 207b and a drive motor 207a for driving the screw 207b to rotate. One end of the screw 207b is connected to the driving motor 207a, and the other end of the screw 207b passes through the cylinder 208 and extends downward a distance, and the extending section of the screw 207b serves to convey and push powder, and the driving motor 207a can drive the screw 207b to rotate, so that the screw 207b drives the powder stored in the cylinder 208 to move downward in a rotating state and release the powder from the nozzle 209. And the coating block 210 is installed at one side of the cartridge 208 with its bottom lower than the nozzle 209 in the Z-axis direction so that accurate coating can be achieved.
Defect repair and compensation for abnormal bumps
Referring to fig. 8, a schematic diagram of abnormal bump repair and compensation of an exemplary cross-sectional layer according to some embodiments of the present disclosure is shown, wherein (a) shows a cross-sectional layer with abnormal bumps, (b) shows a cross-sectional layer after abnormal bump repair, and (c) shows a cross-sectional layer after abnormal bump compensation.
In fig. 8 (a), the cross-sectional layer N x is formed with abnormal protrusions e5-e8, in which the protrusions of e5 and e8 are relatively low and the protrusions of e6 and e7 are relatively high. For e6 and e7 with higher bulges, a defect repair strategy can be adopted (for example, a height threshold value can be set, and a defect repair strategy exceeding the threshold value is adopted), printing is stopped and the printing is removed; while for e5 and e8 with lower bumps, a defect compensation strategy (not exceeding the height threshold) may be employed to perform a fade compensation scan. In fig. 8 (b), a cross-sectional layer N x after the repair of the abnormal bump defect is shown. For higher protrusions e6 and e7, a defect repair strategy is used, the surface of the repaired cross-sectional layer N x looks flat, and the protrusions e6 and e7 have been removed and restored to the desired height. In fig. 8 (c), the cross-sectional layer N x after abnormal bump defect compensation is shown. For e5 and e8 with lower bumps, a defect compensation strategy is employed to repair defects of bumps e5 and e8 by performing a fade compensation scan at the corresponding location of cross-sectional layer N x+1.
In an exemplary embodiment, a specific implementation of bump culling may include the following strategies: during the manufacture of the component, the presence and position of the abnormal protrusions are detected by the optical measuring assembly, and the positions and features of the protrusions are recorded. Upon detection of an abnormal bulge (with a defect repair strategy), the control device issues a signal to instruct the additive manufacturing machine to stop printing the component. The process of bump removal may remove abnormal bumps, for example, using a laser cutting device. The laser cutting can accurately control the position and shape of the rejection to ensure the surface after the rejection to be flat. After the bumps are removed, the surface of the component may be further treated to ensure that the surface is smooth and even, including for example grinding or polishing, to remove any marks left after removal. In addition, residues left after the bulges are removed can be blown away through the blowing device, so that the cleaning of a working area is ensured. After the bump removal and the surface treatment are completed, the additive manufacturing process can be restored, and the next layer of the printing component is continued. Through the processing, the abnormal protrusions can be removed accurately, so that the forming quality of the surface of the component is ensured to meet the expectations.
The "weakening compensation scan" refers to a process of coating a new powder on the cross-sectional layer N x by using a coating device to cover the raised area to be defect-compensated, without processing the raised area in the current cross-sectional layer N x. In the manufacture of the cross-sectional layer N x+1, the energy beam adopts a normal scanning strategy for other positions, and when reaching the corresponding position above the raised area, the scanning depth is lifted (with the spot at a higher position on the Z-axis, with the spot above the raised position), and the scanning depth is adjusted to a higher degree than the surrounding area, i.e. the same amount of material is no longer added to the area. In this way, the component surface of the next layer will form a slightly lower height on the raised area than the surrounding area, thereby achieving compensation for the raised area. This way of adjusting the scanning depth ensures a smooth transition of the component surface of the next layer between the raised area and the surrounding area, so that the overall structure remains consistent.
In some embodiments, when the forming quality of the component is not as expected, in addition to repairing and/or compensating for abnormal depressions/protrusions, parameters such as power of the energy beam, scan speed, scan path, etc. may be adjusted to ensure that the sintering/melting process of the powder meets the expected quality requirements.
In one exemplary embodiment, for example, for situations where material density is not as expected, adjustments may be made by taking one or more of the following in combination: the power and scan speed of the energy beam are adjusted so that the material reaches the proper density during sintering/melting, and increasing the energy input promotes better melting and flow of the powder, thereby increasing the density. Attempts to replace powders with a more uniform particle distribution and proper particle size, the nature of the powder can directly affect the material density during sintering/melting. The scan path and layer thickness are optimized to ensure uniform powder distribution and good interlayer adhesion, and by adjusting the scan path and layer thickness, the solidity of the material inside the component can be improved. The heating and cooling rates are controlled to perform the heat treatment process at a suitable rate to avoid uneven or too low material density due to too fast or too slow heating and cooling.
Coating (powder spreading) quality monitoring
During additive manufacturing, the build-up powder coating quality is often affected by a variety of factors, such as debris splatter, uneven build-up, changes in the external environment, equipment wear, etc., which can result in anomalies in the build-up powder coating quality including, but not limited to, uneven layer thickness, the appearance of voids or cavities, and increased surface roughness, which can affect the final print quality of the component.
According to some embodiments of the present disclosure, the optical measurement assembly 101 also involves projecting measurement light at the surface of the powder P during the execution of the powder P coating or after the coating of a layer of powder P. In the additive manufacturing process, each time after one layer of the component 202 is manufactured (i.e., before the next layer is manufactured), the substrate 201 is driven by the lower lifting device 206 to descend by one layer thickness, and the powder P deposited on the processing plane 205 is uniformly coated above the current layer of the component 202 by the coating device 204 to form a new powder layer PL as a building material of the next layer structure.
Referring to fig. 9, a schematic diagram of measured light projection during an exemplary coating process according to some embodiments of the present disclosure is shown. The optical measuring assembly 101 is configured on the coating device 204 provided on the moving device 203, and further configured on the mounting bracket 204a provided on the coating device 204, so as to project measuring light onto the surface of the powder layer PL on the coating device 204 to acquire corresponding three-dimensional information. The optical measurement assembly 101 is capable of progressively projecting the generated measurement light onto the surface of the powder layer PL and capturing the light reflected by the surface as the layer coating (i.e., formation of the powder layer PL) proceeds to obtain three-dimensional information characterizing the powder layer PL and to communicate the three-dimensional information to the control device for its intended analysis.
"Progress of layer coating" refers to a real-time state in which the powder P is coated layer by layer in the build area to form the powder layer PL. When the additive manufacturing machine starts to operate, the coating device 204 starts to move on the processing plane 205 and covers the build area layer by layer of powder P deposited on the processing plane 205, the coating process of each layer being a stage, the start and end of the coating depending on the position of the coating device 204 in the build area, the coating device moving over the build area during the coating process, covering the entire area until the coating of the layer is completed. Of course this process may also need to be performed multiple times to ensure that the thickness and uniformity of each layer are as desired. Wait until the component 202 is fully built and all coating is complete.
In a specific configuration, it is conceivable to provide the optical measuring assembly 101 on both the left and right sides of the coating device 204, so that the coating device 204 can perform coating from left to right or from right to left, and the optical measuring assembly 101 can follow the movement of the coating device, thereby realizing omnibearing monitoring of the coating process.
In some embodiments, in the expected analysis of the three-dimensional information of the powder layer PL, for example, a comparison analysis may be performed on each position of the obtained three-dimensional information characterizing the powder layer PL to determine whether a coating quality difference (e.g., a height difference, a density difference) between the positions is within a preset interval, and if the quality difference between the positions is within the preset interval, the coating quality may be considered to be in line with the expected. Conversely, if there is a significant difference or outside of an acceptable range, the coating quality at these locations is determined to be unexpected.
In one implementation of the expected analysis example, for example, when the control device performs calculation of the height difference according to the three-dimensional information provided by the optical measurement assembly 101, for each position of the powder layer PL surface, the control device analyzes neighboring positions around it, calculates the height difference between the position and the surrounding position, and compares it with a preset interval (information base) to determine whether there is a quality problem. For example, each location may be considered as a data point. By calculating the height difference, the height difference between each location is obtained, which may be expressed as a positive value, a negative value or zero, indicating that the location is higher, lower or the same as the surrounding location, respectively. The preset interval defines an allowable range of height differences beyond which the print quality of the component 202 may be affected. If the height difference is within the preset interval, the coating quality is good, and the coating device 204 can continue to work normally. If the height difference exceeds a preset interval, a process is performed when the coating quality does not meet expectations.
Further, in one exemplary embodiment, the control device may also determine whether the height difference between the positions is within a preset section by analyzing the three-dimensional contour image by calculating to obtain the three-dimensional contour image characterizing the surface of the coated powder layer PL when calculating the height difference from the three-dimensional information. The three-dimensional contour image can clearly show the height change condition of the surface of the powder layer PL so as to intuitively understand the height difference between different positions, and the control device can rapidly and accurately judge whether the height difference between the positions is in a preset interval or not through analysis of the three-dimensional contour image.
Treatment when coating quality is not in line with expectations
In some exemplary embodiments, upon determining that the coating quality of the powder layer PL does not meet expectations, the control means may apply the following measures in combination or alone:
i) giving an alarm to an operator or a monitoring system to indicate that the coating quality of the powder layer PL is abnormal.
Ii) recording detailed information of abnormal conditions, including specific problems of coating quality, time and position of occurrence of the abnormality, and the like. These records can be used for subsequent analysis and diagnosis, helping to determine the cause of the problem and taking corresponding improvements.
Iii) adjusting the coating process to correct problems with coating quality that are not expected.
According to some embodiments of the present disclosure, when the control device confirms that the coating quality is not in line with the expectations (e.g., the height is abnormal), it is possible to determine a specific region and a position where the height is abnormal during the coating process, analyze the cause of the height abnormality, such as the coating speed being too fast or too slow, the coating pressure being insufficient or too large, the coating angle being incorrect, etc., and adjust the coating parameters accordingly according to the analysis result. For example, if a deviation in height is detected, it may be considered that it is necessary to reduce the coating speed or increase the coating pressure to increase the thickness of the coated powder layer PL; conversely, if the height difference is small, the coating speed may be increased or the coating pressure may be decreased to decrease the thickness of the powder layer PL. While adjusting the coating parameters, the surface height of the powder layer PL in the coating process is monitored in real time, and the coating parameters are continuously adjusted until the height difference enters a preset interval or is equal to a target value.
In some embodiments, the control device is further configured to control the coating device 204 to remove the coated powder layer PL and to recoat the powder layer PL according to the adjusted coating parameters.
In one exemplary implementation, the control device identifies problematic areas and locations in the coated powder layer PL, for example by analyzing altitude anomaly information and other monitoring data, and then issues instructions to control the coating device 204 to remove the entire coated powder layer PL. After the powder layer PL is emptied, the control device issues an instruction according to the adjusted coating parameters to control the coating device to recoat the build area, and the recoating process may include adjusting parameters such as a coating speed, a coating pressure, a coating angle, etc. to ensure that the recoated powder layer PL meets a preset quality standard.
In one possible example, the present disclosure may also locally supplement powder to the highly abnormal recessed region using the powder dropping device of fig. 7, and locally apply a small range of the powder-supplemented region using the application block 210 provided in the powder dropping device. In addition, in some embodiments, the control device may also generate a corresponding powder supplement amount according to the shape and the area of the concave region and in combination with the height information. In more detail, the control device may calculate the area of the depression area by processing the three-dimensional information to analyze the shape and size of the depression area. Thus, the control device can calculate the required powder supplementing amount according to the density of the powder and the height of the concave area. In general, the powder density is known, so the required make-up volume can be calculated from the area and height of the recessed area.
Monitoring method
All of the components and functions included in the monitoring system 100 are also encompassed by the monitoring method, which complement each other to collectively form the overall monitoring and control of the additive manufacturing process.
Additive manufacturing machine
Referring to fig. 10, a schematic diagram of an exemplary additive manufacturing machine 200 is shown, according to some embodiments of the present disclosure. The monitoring system 100 disclosed above is applied in the additive manufacturing machine 200, in other words all components and functions covered by the monitoring system 100 are also considered to be all of the additive manufacturing machine 200.
The additive manufacturing machine 200 is configured to include components such as an optical scanning system 218, a forming chamber 211, a build cylinder 212, a first powder cylinder 213, a second powder cylinder 214, a substrate 201, a coating apparatus 204, and a control apparatus 102.
The optical scanning system 218 mainly includes optical components such as an energy beam generator, a galvanometer system, and a focusing mirror. An energy beam generator (e.g., a laser) generates an energy beam L1 of high energy density to be incident on a galvanometer system composed of a set of mirrors capable of controlling the irradiation direction and path of the energy beam L1 and a motor for driving the mirrors to deflect, which can be rotated in different directions rapidly and accurately to control the irradiation position and angle of the energy beam L1; the focusing mirror focuses the energy beam L1 onto the surface of the powder P to achieve sintering/melting of the powder P.
The forming chamber 211 is the core area of the additive manufacturing machine 200 for housing the printing process and is typically formed of a series of sealed wall panels to prevent interference from the external environment with the printing process and to provide a controlled environment. The forming chamber 211 is typically filled with an inert gas such as Ar (argon) to reduce oxidation and adverse reactions of the mixed materials and to ensure the printing quality of the member 202.
The build cylinder 212 is a container in the forming chamber 211 for holding the component 202 formed during printing. During printing, the formed structure will gradually build up within the build cylinder 212, ultimately forming the completed component 202. The build cylinder 212 is typically made of a high temperature, corrosion resistant material to withstand the high temperatures and chemicals during printing. At the bottom of the construction cylinder 212 is arranged a lifting device 206, the lifting device 206 enabling the construction cylinder 212 to be moved up and down in a vertical direction. By adjusting the movement of the lifting device 206, the distance between the build cylinder 212 and the optical scanning system 218 can be controlled to accommodate different levels of printing operations. After each layer is printed, the lifting device 206 may move the build cylinder 212 a small distance down to lay a new layer of powder P on the powder bed PB.
The base plate 201 is a base assembly supporting the entire printing process, is detachably mounted in the build cylinder 212, and serves to carry the bottom surface of the member 202 and provide stable support. The base plate 201 can be moved up and down along the inner wall of the build cylinder 212 by the driving of the lifting device 206 to promote the layer-by-layer addition of the powder P to build the desired component 202 within the build cylinder 212.
The first and second powder cylinders 213 and 214 store therein powder P for 3D printing, are disposed on both sides of the construction cylinder 212, respectively, and the first and second elevating devices 216 and 217 (corresponding to the second powder cylinders 214) capable of being disposed therebelow are driven correspondingly to overflow a portion of the powder P to the processing plane 205, so that the coating device 204 (e.g., composed of the mounting bracket 204a and the coating structure 204 b) located on the processing plane 205 uniformly coats the powder P overflowed on the processing plane 205 on the substrate 201. The first powder cylinder 213 and the second powder cylinder 214 may be a remainder collecting container of each other, so that the unused powder P may be smoothly transferred from one powder cylinder to the other by the coating device 204 for subsequent reuse. In addition, in a specific construction, instead of arranging the first and second powder cylinders 213 and 214 on both sides of the construction cylinder 212, respectively, as shown in fig. 10, only one side of the powder cylinder, such as the first or second powder cylinder 213 or 214, may be left, and the supply and laying process of the powder P may be completed.
A controller 102 (e.g., a computer control system) is coupled to the various components of additive manufacturing machine 200 and is configured to control the precise execution of the entire 3D printing process.
In some embodiments, the optical measurement assembly is disposed within the forming chamber 211 of the additive manufacturing machine 200, preferably on the coating device 204, more preferably on the mounting bracket 204a of the coating device 204, to ensure that the optical measurement assembly is able to closely follow the movement of the coating device 204 and accurately acquire three-dimensional information of the surface of the component 202.
Additive manufacturing method
In accordance with some embodiments of the present disclosure, an "additive manufacturing method" may be understood as a method for manufacturing a component in an additive manufacturing machine, comprising the steps of: coating powder layer by layer above a substrate by using a coating device to form a powder layer; selectively sintering/fusing the coated powder layer using an energy beam generated by an optical scanning system; and repeating the layer-by-layer coating and the selective sintering/melting until the desired component is made.
Specifically, a uniform powder layer is formed by coating powder layer by layer on a substrate by a coating device. Next, the coated powder layer is selectively sintered/fused using an energy beam generated by an optical scanning system. The irradiation of the energy beam causes the powder particles to adhere to each other with the substrate or the previously sintered/fused formed structure forming part of the component.
When an energy beam is irradiated to a powder layer coated on a substrate, the temperature of the surface of powder particles is raised by the generated heat. Under the influence of heat, the powder particles start to sinter/melt, binding them with the adjacent particles and the substrate surface, and as the energy beam moves over the powder layer, the powder particles gradually solidify and form a layer of the component. This process is repeated, with the energy beam selectively sintering/melting the powder after each application of a layer of powder, until the component is manufactured. The component is built up gradually from the bottom up by a cyclic process of layer-by-layer coating and selective sintering/melting. This approach allows precise control of the geometry, material composition and internal structure of the component according to design requirements. Meanwhile, since it is manufactured layer by layer, it is possible to realize the manufacture of a member of a complicated shape and an internal structure without requiring a mold or tool required for the conventional manufacturing method.
According to some embodiments of the present disclosure, the additive manufacturing machine is configured to perform the monitoring method described previously in the manufacturing process of the component, i.e., all that is covered in the monitoring system 100 is implemented and performed in the additive manufacturing process. This includes real-time monitoring of the component with the optical measurement assembly and responding to any abnormal conditions detected by the control device. Thus, at each stage of the manufacture of the component, the monitoring system continuously monitors the quality and surface characteristics of the component, ensuring that the final manufactured component meets the expected requirements.
In the above-described method embodiments of the present disclosure, such as the monitoring method, the additive manufacturing method, may be implemented in whole or in part by software, hardware, firmware, or any other combination. When implemented in software, may be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, the processes or functions described in accordance with the method embodiments are produced in whole or in part. The computer may be a general purpose computer, a special purpose computer, a computer network, or other programmable apparatus. The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another computer-readable storage medium, for example, the computer instructions may be transmitted from one website, computer, server, or data center to another website, computer, server, or data center by a wired (e.g., coaxial cable, fiber optic, digital subscriber line (digital subscriber line, DSL)) or wireless (e.g., infrared, wireless, microwave, etc.). The computer readable storage medium may be any available medium that can be accessed by a computer or a data storage device such as a server, data center, etc. that contains an integration of one or more available media. The usable medium may be a magnetic medium (e.g., a floppy disk, a hard disk, a magnetic tape), an optical medium (e.g., a digital video disc (digital video disc, DVD)), or a semiconductor medium (e.g., a Solid State Drive (SSD)), or the like.
Those of ordinary skill in the art will appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, or combinations of computer software and electronic hardware. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the solution. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present disclosure.
The foregoing detailed description of the embodiments of the present disclosure has further described the objects, technical solutions and advantageous effects thereof, and it should be understood that the foregoing is merely a specific implementation of the embodiments of the present disclosure, and is not intended to limit the scope of the embodiments of the present disclosure, and any modifications, equivalent substitutions, improvements, etc. made on the basis of the technical solutions of the embodiments of the present disclosure should be included in the scope of the embodiments of the present disclosure.
Claims (18)
1. A method of monitoring the forming quality of a component for additive manufacturing, having the steps of:
scanning a current cross-sectional layer of the component layering data by using a forming energy beam to acquire a component profile of the current cross-sectional layer;
Determining at least one monitoring position of the component profile;
Projecting measurement light on the at least one monitoring location with an optical measurement assembly disposed over a build area where the component is manufactured, and obtaining three-dimensional information characterizing the at least one monitoring location based on feedback of the measurement light;
determining whether the forming quality of the at least one monitoring position meets the expectations according to the analysis result of the three-dimensional information, and executing at least one of the following processing when the forming quality of the at least one monitoring position meets the expectations:
a) Issuing an alarm; b) Recording abnormal conditions; c) The manufacturing process of the component is adjusted.
2. The method of claim 1, wherein the at least one monitoring location comprises a portion or all of a point and/or line and/or face the at least one layer has.
3. The method of claim 1, wherein the forming mass comprises at least one of geometry, forming size, and material density.
4. The method of claim 1, wherein the determining whether the forming quality of the at least one monitored location meets expectations based on the analysis of the three-dimensional information comprises:
Comparing the three-dimensional information with a library of information, wherein the library of information is pre-established and indicative of three-dimensional information of an intended manufacture, to determine whether the forming quality of the at least one monitored location meets an expectation.
5. The method of claim 1, wherein the determining whether the forming quality of the at least one monitored location meets expectations based on the analysis of the three-dimensional information comprises:
And comparing and analyzing the obtained three-dimensional information representing the plurality of monitoring positions to determine whether the forming quality difference between the positions is in a preset interval, and if not, determining the forming quality of the monitoring positions beyond the preset interval as not meeting the expectations.
6. The method of claim 1, wherein the optical measurement assembly is arranged on a mobile device, the projection of the measurement light comprising:
Controlling the optical measurement assembly to project the measurement light on the at least one monitoring position as the movement device moves over the build area.
7. The method of claim 6, wherein the solid tissue of the component is formed via sintering/melting of a powder, the moving device being configured with a coating structure for performing uniform coating of the powder before/after manufacturing the at least one layer of the component;
one of the projection timings of the measurement light is in or after the manufacture of at least one layer of the member, and the coating structure is configured not to perform a coating operation.
8. The method of claim 7, wherein another projection occasion of the measurement light is before/after completion of manufacturing at least one layer of the member, and the coating structure is configured to perform in-coating or after finishing coating;
The method further comprises the steps of:
Controlling the optical measurement assembly to project the measurement light on at least one powder layer formed during or after spreading coating as the moving device moves over the build area to measure three-dimensional information characterizing the at least one powder layer;
determining whether the coating quality of the at least one powder layer meets the expectations according to the analysis result of the three-dimensional information, and executing at least one of the following processing when the determination is negative:
I) issuing an alarm; ii) recording an abnormal situation; iii) adjusting the coating process.
9. The method of claim 1, wherein the adjusting the manufacturing process of the component includes defect repairing an abnormal location and/or adjusting manufacturing parameters of a corresponding location in a next layer to defect compensate the abnormal location.
10. The method of claim 1, wherein the defect repair and/or defect compensation comprises:
Performing powder supplementing scanning on the abnormal concave and/or performing enhanced compensation scanning on the abnormal concave after coating of the next layer so as to form a tissue structure corresponding to the abnormal concave;
and removing the abnormal bulge and/or carrying out weakening compensation scanning on the abnormal bulge after one layer of coating so as to repair the defect of the abnormal bulge.
11. The method of claim 1, wherein the optical measurement component is configured to acquire the three-dimensional information using at least one structured light measurement system and/or a laser ranging sensor.
12. A forming quality monitoring system for an additively manufactured component, comprising:
an optical scanning system configured to scan a current cross-sectional layer of the component layering data with a shaped energy beam, acquire a component profile of the current cross-sectional layer to determine at least one monitoring location of the component profile;
An optical measurement assembly disposed over a build area in which the component is fabricated and configured to project measurement light onto the at least one monitoring location and to obtain three-dimensional information characterizing the at least one monitoring location based on feedback of the measurement light;
A control device configured to determine whether the forming quality of the at least one monitoring position meets expectations or not based on the analysis result of the three-dimensional information, and perform, when the determination is negative, at least one of the following processes:
a) Issuing an alarm; b) Recording abnormal conditions; c) The manufacturing process of the component is adjusted.
13. The system of claim 12, wherein the optical measurement assembly is arranged on a mobile device to project the measurement light on the at least one monitoring location under the movement drive of the mobile device.
14. The system of claim 13, wherein the solid structure of the component is formed via sintering/melting of a powder,
The moving device has a coating structure for coating powder and is configured to drive the optical measurement assembly to project the measurement light onto the at least one monitoring position in a moving state when manufacturing of at least one layer of the member is performed or completed, and the coating structure does not perform coating of powder.
15. The system of claim 14, wherein the mobile device is further configured to perform coating of powder before/after completing manufacturing of at least one layer of the component;
The optical measurement assembly is further configured to project the measurement light on at least one powder layer formed during or after spreading the coating as the mobile device moves to measure three-dimensional information characterizing the at least one powder layer;
The control device is further configured to determine whether the coating quality of the at least one powder layer meets expectations according to the analysis result of the three-dimensional information of the at least one powder layer, and when the determination is negative, perform at least one of the following processes:
I) issuing an alarm; ii) recording an abnormal situation; iii) adjusting the coating process.
16. The system of claim 12, wherein the optical measurement component comprises at least one structured light measurement system and/or laser ranging sensor for acquiring the three-dimensional information.
17. An additive manufacturing machine having the system of any one of claims 12 to 16.
18. A method for manufacturing a component in an additive manufacturing machine, comprising:
coating powder layer by layer above a substrate by using a coating device to form a powder layer;
Selectively sintering/fusing the coated powder layer using an energy beam generated by an optical scanning system;
Repeating the layer-by-layer coating and the selective sintering/melting until the component is made;
wherein the additive manufacturing machine is configured to perform the method of any one of claims 1 to 11 at least during the manufacture of the component.
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