EQUIPAMENTOS E SISTEMA PARA MANUFATURA ADITIVA COM ARAME E ARCO APRESENTANDO AUTOMATIZAÇÃO DO CONTROLE DE PARÂMETROS E DA DETECÇÃO / DIAGNÓSTICO / CORREÇÃO DE FALHASNO PROCESSO DURANTE DEPOSIÇÃO DE CONSUMÎVEL
Patent Information
- Application Number
- BR102020023966
- Authority / Receiving Office
- BR · BR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2020-11-24
- Publication Date
- 2026-08-04
- Estimated Expiration
- 2040-11-24
Smart Images
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Abstract
Description
Equipment and system for additive manufacturing with wire and arc featuring automated control of PARAMETERS FOR DETECTION / DIAGNOSIS / CORRECTION OF PROCESS FAULTS DURING CONSUMABLE DEPOSITION Field of invention
[001] This patent application relates to a system and method for additive manufacturing of metal parts using wire and arc welding. The proposed manufacturing method starts from the CAD design of the metal part to be manufactured, a design that is modified to take into account the limitations of the near net-shape additive manufacturing process. The wire and arc additive manufacturing method uses robotic welding to deposit layers that, when superimposed, produce a component. The proposed sensor assembly allows for the detection and diagnosis of defects in the different layers, also performing automatic correction of defects in subsequent layers. In this way, the products obtained have mechanical properties and integrity that can meet various requirements in the manufacture of parts for various industries, such as oil and gas, with short development times and high production process efficiency. Fundamentals of the invention
[002] The development, manufacturing, and assembly of industrial metal equipment can have varying levels of complexity and involve numerous components that can be produced by processes such as forging, casting, machining, rolling, stamping, and combinations thereof. These processes are known as the conventional production route and often have a slow production cycle, which directly affects the equipment delivery date. Furthermore, the conventional route presents greater material waste since a significant portion of the material applied to the component tends to be removed by a final machining step to achieve the desired shape and finish. Obviously, this material waste translates into... Petition 870260061140, dated 06 / 22 / 2026, page 6 / 25 2 / 17 directly results in higher energy consumption and increased CO2 emissions for the manufacturing and transportation of parts.
[003] In addition to the conventional route, processes based on the progressive addition of material in a localized and controlled manner, usually encompassed by the term additive manufacturing, have gained great prominence in the last decade due to their numerous advantages. Although the technological concepts associated with additive manufacturing (AM) are not so recent, its development for metallic components at an industrial level is still innovative. Additive manufacturing (AM) of metallic components has emerged as one of the technologies to be fully developed for the 4.0 industrial revolution. Additive manufacturing is a process in which the component is manufactured layer by layer and the geometry of the manufactured part is very close to the geometry of the final component. For this reason, manufacturing time, raw material usage, and energy consumption are drastically reduced.
[004] Currently, there are different types of processes that can be applied to additive manufacturing of metal components, such as direct arc deposition, direct laser beam deposition, selective laser beam melting, direct electron beam deposition, among others.
[005] Each process has advantages and disadvantages, differing, broadly speaking, in the deposition rate and thickness of the deposited layer, with arc-based processes having a higher deposition rate (productivity) and a coarser deposited layer when compared to laser and electron beam-based methods. Despite academic and industrial development, in general, there is still much uncertainty regarding the quality, reproducibility, and integrity of parts manufactured by these processes, mainly because there is still no complete understanding of the dependence of quality and integrity on the various manufacturing parameters, nor of the specific criteria for manufacturing stability.
[006] Thus, there is a great dependence on the operator's prior experience (in the process and material) for defining the manufacturing procedure and batch deposition tests for fine-tuning the process parameters. Petition 870260061140, dated 06 / 22 / 2026, page 7 / 25 3 / 17 for each type of part, also typically requiring inspection and human intervention during the manufacturing process itself.
[007] Effectively, it is a trial-and-error development that still makes little use of the ability to record and modify manufacturing process parameters in each layer and section of the part, and for these reasons the operation tends to be tied to parameters and databases provided by a limited number of manufacturers.
[008] From the perspective of AAM or Arc Welding Additive Manufacturing, the metallic consumable in wire form is melted using an electric arc as an energy source and deposited layer upon layer along a specific path to form the desired part. Despite inheriting know-how and tooling (machinery, equipment, devices, sensors, software, tools and components in general) from automated welding, there are very few commercial solutions dedicated to AAM worldwide. Even existing solutions implement few aspects of sensing, feedback control and pre-processing software beyond the usual automated arc welding systems. It should be noted that in arc welding, the concern with the shape and deposition strategy of the weld bead / layer is less, since there is basically a mold (the bevel) as a boundary condition and the deposited volume is much smaller.Furthermore, in joint welding, it is common to have a much more favorable heat flow condition than in the case of MAAA. Effectively, MAAA systems in operation at the industrial level are simple and of low maturity, requiring a great deal of human intervention / expertise from the operator and batches of trial and error for the optimized configuration of manufacturing parameters.
[009] Within this context, the objective of this invention is to provide an intelligence system, through experimental data and computer simulations of the physical phenomena of deposition and movement of a given robotic manipulator and positioning table, capable of planning a MAAA deposition process (trajectory and deposition parameters), Petition 870260061140, dated 06 / 22 / 2026, page 8 / 25 4 / 17 characterize the properties and defects of deposits / parts produced under various conditions, control the process to ensure the correct deposition of a layer, and replan the next layer in order to compensate for errors in previous layers. Background of the invention
[010] Referring to the state of the art related to patent registrations, documents US20150331402A1, US9815135 and WO2017 / 085469 A1 related to the control and monitoring of printing and material deposition processes can be cited.
[011] The first registration US20150331402A1 (Intelligent 3D printing through optimization of 3D printing parameters) presents, in a very generic way, any 3D printing system aggregating numerical simulation and databases to allow the optimization of printing parameters as a function of the type of printing. It also includes in the description the use of sensors to control key variables and the possibility of changing printing parameters during the printing process.
[012] Despite the effort in the description to maintain the relationship of the system view independent of the printing apparatus, in all examples and greater detail of the system, the focus on additive manufacturing methods in polymers, especially the FDM and SLA techniques, is clearly seen. Additive manufacturing processes in polymers are quite different from those used in metals, and this registration does not align with the proposal, which deals with a wire and electric arc method, lacking a monitoring system for the key variables, current and voltage, as well as feed rate. These variables are the basis for defining the wire and electric arc process and are not covered in the patent text, as they are irrelevant in plastic processes.
[013] The patent does not detail the sensor logistics or more sophisticated sensor fusion concepts (use of complementary, redundant, and cooperative sensors) to detect conditions where a single sensor alone is not sufficient. Petition 870260061140, dated 06 / 22 / 2026, page 9 / 25 5 / 17 capable of reliably presenting the desired variable, it is clear from the patent that the failure analysis system fundamentally depends on user analysis after printing, with no real-time detection of printing failures by the sensor system and aggregated software itself, which would reduce the dependence on subsequent user analysis, as proposed in this invention.
[014] The second patent application, number US9815135 (Systems and Methods providing location feedback for additive manufacturing), claims a system and method for height correction during robotic welding in an additive manufacturing process. One or two welding output currents and wire feed speeds are shown during the process when creating a layer. A plurality of instantaneous workpiece end-to-end distances (CTWD) is determined based on at least one or both welding output currents and wire feed speeds. An average CTWD is determined based on the plurality of instantaneous CTWDs. A correction factor is generated, based on the minimum of the average CTWD, which is used to compensate for any error in the height of the current weld layer.
[015] This patent focuses on controlling only the layer height indirectly using welding parameters, there is no control over other geometric aspects, such as height, it does not have an intelligent system and cannot be used in other electric arc and wire feed processes, such as GMAW-CMT and PAW.
[016] Finally, the third patent application, WO 2017 / 085469 A1 (Machine control for additive manufacturing process and apparatus), deals with a generic way of controlling apparatus for additive manufacturing, consisting of a plurality of unspecified subsystems and a control system that can be any control system. Despite the attempt to generalize the application to any additive manufacturing process, all further description in the document refers to laser processes, with MAAA only mentioned in the background of the invention. With respect to sensing, a set of general sensors is proposed for monitoring Petition 870260061140, dated 06 / 22 / 2026, page 10 / 25 6 / 17 broad aspects of an additive manufacturing process, lacking monitoring of wire feed speed and electrical parameters, analysis of different data to infer, for example, the cooling rate, and the use of such data to perform closed-loop control, i.e., to implement corrections during the deposition of a layer. In this sense, the control system proposed by this third record is actually the planning of the construction of a part, defining tasks to be performed at specific times by the different subsystems existing in some generic additive manufacturing apparatus, without any type of automatic intervention in the process resulting from the data obtained by the sensors, thus characterizing an open-loop system. Brief description of the invention
[017] The present innovation presents different technological aspects (knowledge, methodologies, techniques, instructions, models, simulations, algorithms, components, prototype effector system) of MAAA processes for manufacturing metal parts used in industrial equipment, focusing on the development of knowledge and means to guarantee a high level of quality of the manufactured parts.
[018] MAAA was selected because it is more suitable for manufacturing larger volume parts with less stringent dimensional accuracy requirements, as well as avoiding problems related to handling powdered material (which is more expensive and complex from an operational and safety standpoint) and inheriting some of the well-developed know-how (equipment, filler material, and production experience) from the application of wire and electric arc in conventional welding. The MAAA processes addressed are GMAW (“Gas Metal Arc Welding”), specifically the controlled short-circuit metal transfer mode, and PTAW (“Plasma Transfer Arc Welding”). The MAAA system described in this invention can be integrated into different continuous wire feed electric arc welding processes, including, but not limited to, GMAW (“Gas Metal Arc Welding”), including controlled short-circuit metal transfer modes, FCAW (“Fluxed Cored Arc Welding”), PAW (“Plasma Arc Welding”) and Petition 870260061140, dated 06 / 22 / 2026, page 11 / 25 7 / 17 GTAW (“Gas-Shielded Tungsten Arc Welding”). In a more detailed description of the invention, the GMAW and PTAW processes will be specifically indicated, to make the description more concise and because they accurately represent the key parameters of other applicable processes.
[019] Regarding the MAAA system itself (machinery, equipment, devices, sensors, software, tools and components in general), the commercially available options truly dedicated to MAAA are sparse, not being fully capable of taking advantage of the specific characteristics and automation of MAAA manufacturing, nor of addressing the practical problems of implementing this manufacturing technique in an industrial setting.
[020] Thus, the proposed invention aims to increase know-how dedicated to deposition planning (manufacturing procedure pre-processing software, for optimization and definition of initial trajectory and basic reference of deposition parameters), to sensing (position, temperatures and electrical parameters), to fault diagnosis (lack of fusion, overlap failure between passes, pores, widening of the weld pool) and to feedback control (of trajectory and deposition parameters during the layer under construction and between layers, in the form of deposition replanning) of the MAAA process. Therefore, the process requires less operator intervention and experience for correct operation and offers reproducibility, since there is deposition planning intelligence, a fault monitoring and diagnosis system and feedback control strategies for correcting defects during the process.Furthermore, the use of automatic process control methods leads to a lower incidence of defects, scrap parts, and the need for rework in machining / deposition.
[021] A MAAA system incorporates the risks inherent in robotic systems and welding systems and must meet the safety requirements of both. Therefore, the proposed invention seeks to enable remote operation of the process through communication interfaces with the cell equipment. Petition 870260061140, dated 06 / 22 / 2026, page 12 / 25 8 / 17 of MAAA allowing the process to be started, stopped and monitored through the field network.
[022] The maturity status of MAAA systems motivates the present innovation, of a system, method and equipment for MAAA manufacturing comparable to the best available technologies for automated deposition, with advanced and customized components and software for MA application, which allows studying the parameters, potential and challenges of this technique.
[023] The innovation is summarized in an integrated intelligence system for MAAA based on sensors, actuators, couplers, interfaces and algorithms capable of monitoring and controlling in real time the key variables and conditions of the process, ensuring a higher level of quality and repeatability while minimizing process failures and the need for human intervention. Description of the drawings
[024] The following description seeks to highlight the proposal at the principle level, without being limited to the drawings or components mentioned, using the following illustrations listed below as a reference: Figure 1, flowchart representing the system architecture for additive manufacturing with wire and arc; Figure 2, partial flowchart of the system architecture for additive manufacturing with wire and arc, emphasizing the sensors used. Brief description of the invention
[025] The present invention discloses a wire and arc remote operated additive manufacturing system composed of a robotic cell, with safety system, deposition station, positioning table and control computer.
[026] The wire and arc additive manufacturing monitoring system employs sensors, communication interfaces with a control computer, and graphical user interfaces. Examples of sensors include... Petition 870260061140, dated 06 / 22 / 2026, page 13 / 25 9 / 17 employees, including but not limited to, pyrometers, digital cameras, thermal cameras, 2D profilometers, and thermal profilometers.
[027] It also discloses a method for detecting and diagnosing online faults in the wire and arc additive manufacturing process from measurements of the monitoring system.
[028] Finally, the manufacturing method proposed in the present invention defines a technology for automatic fault correction in the wire and arc additive manufacturing process. Detailed description of the invention
[029] This invention is specified to have advanced and customized deposition functions for specific application in MAAA, including a robotic cell with deposition sources geared towards the GMAW and PTAW processes (the former being the most widespread industrial process in automated welding and the latter having greater potential for deposition quality), pre-processing software for manufacturing parameters, deposition process sensors, actuators, and safety and control peripherals. The invention takes into account all the hardware, interfaces, databases, technical process knowledge, and software necessary for instrumentation, operation, and automation of the MAAA process.
[030] The main focus is on monitoring and acting upon thermal distribution, cooling rate, deposited bead geometry, and stability in metal transfer. In this sense, the main sensors indicated are pyrometers, process cameras, thermographic cameras, 2D laser scanners, laser interferometers, and sound sensors. To correct these process variables (thermal and dimensional of the bead, in addition to precise control of trajectory, speed, and deposition parameters), the development of accelerated cooling devices (based on convection and / or conduction) for thermal actuation and a double wire feeder with a special controller to allow dynamic feeding and supply of wire heated by electrical resistance is indicated. These two characteristics allow Petition 870260061140, dated 06 / 22 / 2026, page 14 / 25 10 / 17 Expand control over the weld pool shape and increase productivity. Multiple wire feed also has significant potential in controlling the size and temperature of the weld pool, as well as allowing adjustment of the chemical composition in each section of the part, thus enabling optimization of part performance.
[031] Indeed, the proposed system aims to address some of the main challenges of MAAA, such as defining construction strategy, process stability and reproducibility, ensuring the integrity (absence of critical discontinuities) of the deposited part, reducing geometric distortions, residual stress formation, and anisotropy and heterogeneity of the deposited material properties. The main defects in the manufactured part, for which automatic detection during layer deposition is desirable, are lack of fusion, excessive fusion, flow, distortion, craters, undercuts, pores, misalignment, excessive roughness, among others. The proposed system will use direct measurements and inferences from the signals obtained by the sensors to allow contactless and real-time layer-by-layer inspection.In order to avoid these defects, a feedback control routine is proposed that integrates sensors and actuators, and considers the later addition of some level of intelligence to the model.
[032] An example of the complexity of the interaction between manufacturing parameters and metallurgy is the variation in layer thickness, or simply its division and sequencing into sections, which has a large impact on heat flow and mechanical constraints, reflecting, in turn, on the microstructure and the stresses generated, and can lead a part to failure, even when using appropriate electrical parameters (i.e., exhibiting stable metal transfer).
[033] To take full advantage of MAAA capabilities and ensure a high degree of quality by minimizing trial and error, an intelligent system embedded in the MAAA machine system is essential. This system is basically composed of sensors that allow reading indicators in real time and Petition 870260061140, dated 06 / 22 / 2026, page 15 / 25 11 / 17 key process variables (aggregated with raw data processing), with automatic processing capabilities for parameter correction models using algorithms and mechanical and / or electronic devices capable of acting on these key variables, adjusting the process in real time and / or identifying defects and flaws in the part being built.
[034] The actual architecture for the invention described, as seen in figure 1, is defined by the MAAA Cell (Additive Manufacturing with Wire and Arc) (1) composed of a deposition system (1.1) linked to an end effector (1.2), which is capable of embedding the tools / sensors (2), and a robotic manipulator (1.3) equipped with a robotic cell controller (1.4) and a positioning table (1.5), connected to the MAAA cell (1) is a control computer (3) where software for the following systems are embedded: planning (3.1), control (3.2), diagnosis (3.3) and monitoring (3.4).
[035] Detailing the deposition system (1.1), this system is responsible for generating the electric arc, feeding at least one metallic consumable and shielding gas for the deposition of the material onto a substrate in the formation of the part to be produced by additive manufacturing with electric arc. This system can use different technologies for wire and arc deposition and can switch between such technologies as needed, with the choice of the best process determined by the characteristics of the part to be produced. Such technologies include, but are not limited to, the CMT (GMAW) process and the plasma process (PTAW). This system may include, according to the wire and electric arc deposition technologies used, one or more of the following equipment: deposition source, torch, wire feeder, cooling unit, shielding gas and plasma gas.The deposition system receives commands (open or close the electric arc, turn the gas supply on and off) and a set of parameters (voltage and / or electric current, wire feed speed, gas flow rate) from the robotic cell controller (1.4) via field network.
[036] The robotic manipulator (1.3) moves the end effector (1.2) which is mechanically coupled at its last joint (flange). Together with the table Petition 870260061140, dated 06 / 22 / 2026, page 16 / 25 12 / 17 positioning table (1.5) and coordinated by the robotic cell controller (1.4), the set of joints of the robot and the positioning table (1.5) move in order to generate the desired trajectory for the end effector (1.2). This trajectory defines the geometry formed by the deposited material and consequently the geometry of the part to be manufactured by additive manufacturing. The robotic manipulator (1.3) communicates via field network with the robotic cell controller (1.4) sending information about its state (position and speed of its motors) and receiving commands (position and speed for its motors) on how to move.
[037] Referring to the robotic cell controller (1.4), its function is to receive information from the other subsystems, process and manage such information in order to coordinate the operation of the robotic cell for the production of the part by additive manufacturing. The controller communicates via field network with the equipment - robotic manipulator (1.3), positioning table (1.5) and deposition sources (deposition system) - and computational subsystems - planning system (3.1), control system (3.2), diagnostic system (3.3) and monitoring system (3.4).
[038] The positioning table (1.5) is responsible for supporting the part being manufactured. It has two degrees of freedom and its movement is controlled by the robotic cell controller (1.4). The positioning table communicates via field network with the robotic cell controller, sending information about its state (position and speed of its motors) and receiving commands (position and speed for its motors) on how to move.
[039] Regarding the sensors (2) represented in the flowchart of figure 2 — (pyrometers (2.1), thermographic camera (2.2), profilometer (2.3), process camera (2.4), microphone (2.5), NIR process camera (2.6), collision sensor (2.7), electrical parameter sensor (2.8), sensor for measuring wire feed speed (2.9), sensor for measuring wire feed speed and sensor for measuring gas flow (2.10)), these are responsible for reading, in real time, the variables and indicators of the process. Each sensor has its own communication interface with the monitoring system of Petition 870260061140, dated 06 / 22 / 2026, page 17 / 25 13 / 17 Control computer. The following sections detail the different sensors and their intended function within the system:
[040] Pyrometers (2.1) - These are devices for non-contact temperature measurement. Pyrometers (2.1) are used in front of and behind the torch. The front pyrometer(s) provide(s) the interpass temperature, which can reflect the geometry of the pass being executed, hence the importance of knowing it. The rear pyrometer(s) provide(s) data on the temperature of the newly deposited pass. Both sensors are capable of informing the system of situations of heat accumulation.
[041] Thermal imaging camera (2.2) - This equipment captures images in the infrared field, which allows the use of this image for temperature measurement. Its application in the prototype will be to monitor the weld pool and its surroundings.
[042] Profilometer (2.3) - Laser sensor that measures the cross-sectional dimensions of the bead and / or layer. The function of this equipment in the system is to read the geometry of the deposit for comparison with the planned reference model.
[043] Process camera (2.4) - This equipment is a camera developed for use in welding processes. Its function is to allow the user / operator to view the metal transfer region, filtering the light intensity of the electric arc.
[044] Microphone (2.5) - This sensor forms part of the recording system along with the process camera described in the previous paragraph. Its purpose is to record sounds generated by the deposition process, which can serve as an indication of the stability of the metal deposition.
[045] NIR Process Camera (2.6) - This equipment captures images in the near-infrared spectrum (near infrared - NIR). Its usefulness is in determining the boundaries of sections at different temperatures. In the MAAA system, it can be used, for example, to monitor the geometry (height and / or width) of the newly deposited bead. Petition 870260061140, dated 06 / 22 / 2026, p. 18 / 25 14 / 17
[046] Collision sensor (2.7) - This is a support fixed to the robot's wrist. The deposition torch holder is attached to it while it functions as a collision sensor. The function of this sensor is protection and safety during operation.
[047] Electrical parameter sensor (2.8) - These are sensors that measure the current and voltage of the electric arc in a synchronized manner. The functionality of these parameters is associated with the stability of the process and the possible detection of any faults during the deposition process.
[048] Sensor for measuring wire feed speed (2.9) - This sensor is coupled to the wire being fed into the process and measures the speed at which it moves through the sensor. Its functionality, in the MAAA system, is associated with monitoring the deposition rate, the speed at which wire is consumed by the process.
[049] Sensor for measuring gas flow (2.10) - This sensor is coupled to the gas line that feeds the deposition process and monitors the flow of this gas, which passes through the sensor. Its functionality is associated with the stability of the deposition and the quality of the deposited metal.
[050] Detailing the control computer (3) further, the planning system (3.1) is responsible for planning the production process, trajectory, and deposition parameters of the part by MAAA. It uses a CAD model to intelligently slice and partition, assign construction strategy and sequence, and finally generate the toolpath. In addition, the module is capable of generating trajectories that coordinate movements of the robotic arm along with the positioning table. The automatic calculation of process parameters is performed from an experimental database built taking into account different geometries and materials. The system automatically loads parameters according to the torch's position in space and is capable of automatically generating geometric compensations for density variations and compensations to avoid structural deformations of the part under manufacture. Finally, the planning system generates a program in Petition 870260061140, dated 06 / 22 / 2026, page 19 / 25 15 / 17 The robot's language that makes up the manufacturing cell sends this program via field network to the robotic cell controller.
[051] The control system (3.2) is designed to compensate for unforeseen deviations and disturbances during process planning, with the aim of ensuring that no defects occur during deposition. This system receives process variable information from the monitoring system and, through different simplified models (based on differential equations or neural networks), a database and the reference given by the planning system, is able to calculate and define trajectory corrections and deposition parameters during the process. These corrections are sent to the robotic cell controller via the field network. The control system also acts in the replanning of the deposition at each layer, comparing the newly constructed layer with what was expected by the planning system and establishing a new planning objective for the next layer.
[052] The next item, called the diagnostic system (3.3), has the function of evaluating process data and providing information on the normality of the process, relaying the need for parameter correction to the control system, when applicable, and recording the position of the deposition section that presented this instability divergence. This record can guide a subsequent (offline) inspection to verify if the control system was able to completely overcome the instability without generating defects. During deposition, the diagnostic system receives data from the monitoring system and determines if the process is occurring normally, based on a database of experimental data and pre-established limits for specific variables, issuing alarms to the operator and the control system in case of deviation of variables outside the expected operating range.This system also analyzes the received data to identify defects in the part under construction, using image processing and pattern recognition algorithms, and correlating different process parameters with databases and computational models. The diagnostic system has the ability to pause. Petition 870260061140, dated 06 / 22 / 2026, page 20 / 25 16 / 17 automatically interrupts the process if a large deviation occurs in any critical variable or if it identifies any fault / defect that cannot be corrected and renders the part under construction unusable.
[053] Finally, the monitoring system (3.4) is a set of software running on the control computer of the MAAA cell. It is responsible for establishing a communication interface with the different sensors present in the cell, processing the received data, performing simple calculations of variables and indicators derived from the measurements obtained, presenting the process data from the sensors in a graphical interface and storing them.
[054] Instrumentation will allow detailed monitoring of key variables in the quality of parts manufactured by AAW, such as bead and part geometry, temperature distribution and cooling rate of the deposited bead, energy and stability of the electric arc, weld pool size and presence of defects (internal and surface discontinuities in the material). Access to this information will also allow real-time control of the process.
[055] The objective of this system is to imbue a new level of intelligence into MAAA processes, allowing for a more meaningful record of the production process during manufacturing, layer by layer (aiding in the understanding of the relationship between manufacturing parameters and deposit characteristics, increasing the reproducibility of parts and locating indicators of failures / defects) and automatically adjusting parameters (increasing the quality and reliability of the deposited part and bead). The system is capable of correlating the main principles and measurable physical variables of metal deposition through carefully selected and installed sensors (detection, positioning and integration capabilities), as well as defining strategies and interfaces for adapting and correcting controllable process parameters (e.g.: adjust trajectory and torch distance from workpiece based on layer height measurement, modify feed rate or arc power based on heat build-up or cooling rate, etc.). To achieve this, the system includes a series of databases, algorithms, and capable process models. Petition 870260061140, dated 06 / 22 / 2026, page 21 / 25 17 / 17 of interpreting the readings and executing active, closed-loop process control behind the controllable manufacturing variables, these extended through the use of special actuators (physical components). In this development, a series of practical experiments on a prototype system were performed, allowing for reliability in the system's response.
[056] It is worth noting that the inventive activity described should be understood as a representative and not limiting object, and may undergo variations and modifications in its form of realization, provided that these modifications do not depart from the essence of the project.
Claims
1. SYSTEM FOR ADDITIVE MANUFACTURING with wire and arc featuring automation of parameter control and fault detection / diagnosis / correction in the process during consumable deposition, CHARACTERIZED by an architecture defined by the MAAA Cell (Additive Manufacturing with Wire and Arc) (1) composed of a deposition system (1.1) linked to an end effector (1.2), which is capable of embedding the tools / sensors (2), and a robotic manipulator (1.3) equipped with a robotic cell controller (1.4) and a positioning table (1.5), with a control computer (3) connected to the MAAA cell (1) where the planning (3.1), control (3.2), diagnostic (3.3) and monitoring (3.4) system software is embedded; also composed of sensors (2): pyrometers (2.1), thermal imaging camera (2.2), profilometer (2.3), process camera (2.4), microphone (2.5), NIR process camera (2.6), collision sensor (2.7), electrical parameters sensor (2.8), sensor for measuring wire feed speed (2.9) and sensor for measuring gas flow rate (2.10), which read, in real time, the variables and indicators of the process, each sensor having its own communication interface with the monitoring system (3.4) of the control computer (3).
2. ADDITIVE MANUFACTURING SYSTEM, according to claim 1, CHARACTERIZED by the deposition system (1.1) receiving commands (opening or closing the electric arc, switching the gas supply on and off) and a set of parameters (voltage and / or electric current, wire feed speed, gas flow rate) from the robotic cell controller (1.4) via field network; placing the robotic manipulator (1.3), together with the positioning table (1.5) and coordinated by the robotic cell controller (1.4), generates the desired trajectory to the end effector (1.2) to define the geometry of the part to be manufactured by additive manufacturing, the robotic manipulator (1.3) communicating via field network with the robotic cell controller (1.4) to send information about its state (position and speed of its motors) and receive commands (position and speed for its motors) on how to move; placing the robotic cell controller (1.4) coordinate the operation of the robotic cell for the production of the part by additive manufacturing, with the controller (1.4) communicating via field network with the robotic manipulator (1.3), positioning table (1.5), deposition sources (deposition system), planning system (3.1), control system (3.2) and monitoring system (3.4); because the positioning table (1.5) has two degrees of freedom and the movement is controlled by the robotic cell controller (1.4), with the positioning table (1.5) communicating via field network with the controller (1.4) sending information about its state (position and speed of its motors) and receiving commands (position and speed for its motors) on how to move.
3. ADDITIVE MANUFACTURING SYSTEM, according to claim 1, CHARACTERIZED by the front pyrometers (2.1) providing the interpass temperature that reflects the geometry of the pass being executed and the rear pyrometers providing data on the temperature of the newly deposited pass; the thermographic camera (2.2) capturing images in the infrared field and monitoring the weld pool and its surroundings for use of the images in temperature measurement; the profilometer (2.3) measuring the cross-sectional dimensions of the weld bead, performing a reading of the deposit geometry for comparison with the planned reference model; the process camera (2.4) allowing the user / operator to visualize the metal transfer region, filtering the light intensity of the electric arc; the microphone (2.5) recording sounds generated by the deposition process; the NIR process camera (2.6) determine the boundaries of sections at different temperatures by monitoring the geometry (height and / or width) of the newly deposited bead; the collision sensor (2.7) support the deposition torch while functioning as a collision sensor; the electrical parameters sensor (2.8) measure the current and voltage of the electric arc in a synchronized manner, detecting any faults during the deposition process; the wire feed speed sensor (2.9) measure the speed at which the wire moves through the sensor, monitoring the deposition rate and wire consumption rate; and the gas flow sensor (2.10) monitor the flow rate of the gas that feeds the deposition process and passes through the sensor.
4. SYSTEM FOR ADDITIVE MANUFACTURING with wire and arc, according to claim 1, CHARACTERIZED by the planning system (3.1) planning the production process, trajectory and part deposition parameters by AAM using a CAD model to intelligently slice, partition, assign construction strategy and sequence and, finally, generate the toolpath, Petition 870260061140, dated 06 / 22 / 2026, page 24 / 25 3 / 4 generating, including, trajectories that coordinate movements of the robotic arm together with the positioning table.
5. ADDITIVE MANUFACTURING SYSTEM, according to claim 1, CHARACTERIZED by the control system (3.2) receiving information from the monitoring system and defining trajectory and deposition parameter corrections during the process, sending the corrections to the robotic cell controller via field network, the control system also acting in the replanning of the deposition for each layer by comparing the newly constructed layer with what was expected by the planning system itself and establishing a new plan for the next layer.
6. ADDITIVE MANUFACTURING SYSTEM, according to claim 1, CHARACTERIZED by the diagnostic system (3.3) receiving data from the monitoring system and determining whether the process is occurring normally, issuing alarms to the operator in case of variable deviations or automatic process stoppage, also analyzing the received data to identify defects in the part under construction, through image processing and pattern recognition algorithms and the correlation of different process parameters with databases and computational models.
7. ADDITIVE MANUFACTURING SYSTEM, according to claim 1, CHARACTERIZED by the monitoring system (3.4) establishing a communication interface with the sensors present in the cell, processing the received data, performing simple calculations of variables and indicators derived from the measurements obtained, presenting the process data, originating from the sensors, in a graphical interface, and storing the process data.