A multi-laser additive manufacturing system and control method

Abstract

The present invention provides a multi-laser additive manufacturing system and control method, comprising: a blowing module, a suction module, a moving module, a circulating fan module, a control module and a data processing module, wherein the moving module is connected to the blowing module and the suction module; the circulating fan module is connected to the airflow for generating positive and negative pressures, and is in communication with the blowing module and the suction module; the circulating fan module and the control module are both electrically connected to the data processing module, and the data processing module is used for data processing, data partitioning of scan sections and overall control of the system. In addition to being able to achieve translation, the blowing gas and suction modules in the multi-laser additive manufacturing system of the above embodiment can also be raised and lowered, and different blowing and suction heights, flow rates and other parameters can be set according to different parts and processes to achieve the best smoke and dust treatment effect.

Description

Technical Field

[0001] The present invention relates to the field of additive manufacturing, and in particular to a multi-laser additive manufacturing system and a control method. Background Art

[0002] Rapid additive manufacturing (RAPM) is a rapid prototyping technology that uses digital models to directly drive the rapid creation of arbitrarily complex three-dimensional physical entities. RAPM, based on the principle of "layered manufacturing and layer-by-layer stacking," differs from traditional "subtractive" manufacturing methods and is a green, intelligent, "additive" approach to manufacturing.

[0003] Additive manufacturing integrates virtual design and digital manufacturing. Based on the three-dimensional model constructed on the computer, it uses software and numerical control systems to stack special metal materials, non-metallic materials or medical biomaterials layer by layer to create physical objects. It can manufacture products in a short time. Compared with traditional machining machines and mold manufacturing, it has many advantages such as low cost, short cycle, simple modification, and stable dimensions.

[0004] With the rapid development of metal additive manufacturing technology, the additive manufacturing solution of a single laser cannot meet the requirements of large-format and large-size part molding. Therefore, additive manufacturing with multiple lasers is the focus of future development. However, there are many difficulties in wind field design and smoke treatment for large-format additive manufacturing. If the wind speed is too high, the printing powder will be blown up, and if the wind speed is too low, the smoke cannot be sucked away in time. At the same time, when multiple lasers are printed, the smoke generated by the laser printing arranged parallel to the wind field will interfere with each other, which will lead to a decrease in the printing quality of the parts. In the actual printing process, due to the different shapes of the parts and the non-fixed placement of the parts, the current common solutions have different smoke absorption effects at different positions, resulting in a decrease in the overall quality of the parts. Summary of the Invention

[0005] The present invention aims to solve, at least to some extent, one of the technical problems in the related art. To this end, the present invention provides a multi-laser additive manufacturing system comprising:

[0006] A blowing module, the blowing module is used to blow out gas;

[0007] An air suction module, the air suction module is used to inhale gas;

[0008] a moving module, the moving module being connected to the blowing module and the suction module and being used to drive the blowing module and the suction module to move;

[0009] a circulation fan module, the circulation fan module being connected to the airflow for generating positive pressure and negative pressure, and being in communication with the blowing module and the suction module, so that the blowing module and the suction module respectively generate blowing effect and suction effect; and

[0010] A control module and a data processing module, wherein the circulating fan module and the control module are both electrically connected to the data processing module, and the data processing module is used for data processing, data partitioning of scan sections and overall control of the system; the control module controls the operation of the mobile module through the data processing module.

[0011] In addition to being able to move horizontally, the blowing module and suction module in the multi-laser additive manufacturing system of the above embodiment can also be raised and lowered. Different blowing and suction heights, flow rates and other parameters can be set according to different parts and processes to achieve the best smoke and dust treatment effect. Moreover, the system adopts a modular design and can be equipped with different numbers of blowing modules and suction modules according to different equipment, set different blowing pressures and blowing flows, and be compatible with different equipment to meet the needs of industrial applications.

[0012] Optionally, the blowing module includes an upper blowing module and a lower blowing module, the upper blowing module is located on the upper layer of the lower blowing module, the suction module and the lower blowing module are located on the same layer and are connected as a whole; the circulating fan module is connected to both the upper blowing module and the lower blowing module.

[0013] Optionally, multiple rows of first air blowing ports are provided on both sides of the upper blowing module, the first air blowing ports are circular, the apertures of the first air blowing ports in each row are different, and the first air blowing ports at the top are smaller than the first air blowing ports at the bottom.

[0014] Optionally, the lower blowing module is provided with multiple rows of second blowing ports on one side, the second blowing ports are circular, the apertures of the second blowing ports in each row are different, and the second blowing ports at the top are smaller than those at the bottom.

[0015] Optionally, a plurality of parallel guide plates for controlling the degree of opening and closing are provided on one side of the air suction module, and the guide plates are in a shutter structure.

[0016] Optionally, the mobile module includes a translation device and a lifting device;

[0017] The translation device is capable of driving at least one of the upper blowing module, the lower blowing module and the suction module to move in the horizontal direction;

[0018] The lifting device can drive the upper blowing module, the lower blowing module, the suction module and the translation device to rise and fall.

[0019] Optionally, the multi-laser additive manufacturing system further includes a filtering module, which is connected in series between the circulating fan module and the suction module to filter impurities in the smoke.

[0020] Optionally, the multi-laser additive manufacturing system further includes a pressure sensing module and a flow sensing module;

[0021] The pressure sensing module and the flow sensing module are both arranged at the air outlet of the circulation fan module. The pressure sensing module is used to detect the airflow pressure generated by the circulation fan module, and the flow sensing module is used to detect the airflow flow generated by the circulation fan module.

[0022] An embodiment of the present invention further provides a control method for a multi-laser additive manufacturing system, comprising the following steps:

[0023] S1. The system receives the part's current scanned cross-section data and uses a lifting device to raise the blowing and suction modules to a height above the powder spreading scraper, which then applies powder.

[0024] S2. The data processing module processes the data of the current scanned section of the part, partitions the scanned section into rectangles or squares, and obtains the partitioned scan data;

[0025] S3. Arrange the partitioned scan data in a checkerboard or matrix order, and divide it into the first scanning area, the second scanning area, the third scanning area, and the fourth scanning area; set the airflow pressure and airflow according to the size of the different scanning areas, the laser power, and the printing material, and control the opening and closing degree of the guide plate of the suction module;

[0026] S4. Move the blowing module and the suction module to corresponding positions through the moving module, exposing the first scanning area, and the laser scans the first scanning area; after the first scanning area is scanned, the blowing module and the suction module are moved to expose the second scanning area, and the laser scans the second scanning area, and so on, to complete the remaining rounds of scanning, and finally achieve scanning of the entire format.

[0027] Optionally, in S3 , the partitions of the scanning cross section and the size of the scanning area are set to different values ​​or the same value; the actual scanning order of the scanning area is freely set.

[0028] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0030] Figure 1 Schematic diagram of the structure of a multi-laser additive manufacturing system according to an embodiment of the present invention;

[0031] Figure 2 Schematic diagram of a blowing module and a suction module according to an embodiment of the present invention;

[0032] Figure 3 Schematic diagram of the partitioning of the scanning cross section of the multi-laser additive manufacturing system according to an embodiment of the present invention;

[0033] Figure 4 Schematic diagram of overall movement of modules of a multi-laser additive manufacturing system according to an embodiment of the present invention;

[0034] Figure 5 Schematic diagram of a two-partition scanning sequence of a multi-laser additive manufacturing system according to an embodiment of the present invention;

[0035] Figure 6 Schematic diagram of the free movement of modules in a multi-laser additive manufacturing system according to an embodiment of the present invention. DETAILED DESCRIPTION

[0036] The technical solutions of the present invention will be described in further detail below with reference to specific embodiments. It should be understood that the following embodiments are merely illustrative and explanations of the present invention and should not be construed as limiting the scope of protection of the present invention. All technologies implemented based on the above content of the present invention are encompassed within the scope of protection that the present invention is intended to protect.

[0037] See Figure 1 This embodiment provides a multi-laser additive manufacturing system that can be used for metal additive manufacturing using multiple lasers. Figure 1 In one embodiment, the multi-laser additive manufacturing system mainly includes: a blowing module, a suction module 3, a moving module, a circulating fan module 6, a control module 10 and a data processing module 11.

[0038] The blowing module is used to blow out gas, and the suction module 3 is used to suck in gas, thereby achieving the purpose of treating smoke and dust. The mobile module is connected to the blowing module and the suction module 3 to drive the blowing module and the suction module 3 to move. The circulating fan module 6 is used to generate positive and negative pressure airflow and is connected to the blowing module and the suction module 3, so that the blowing module and the suction module 3 produce blowing and suction effects respectively. The circulating fan module 6 and the control module 10 are both electrically connected to the data processing module 11. The data processing module 11 is used for data processing, data partitioning of scan sections, and overall system control. The control module 10 controls the operation of the mobile module through the data processing module 11.

[0039] The blowing and suction modules 3 in the multi-laser additive manufacturing system of the above embodiment can not only be moved horizontally but also raised and lowered. Different blowing and suction heights, flow rates, and other parameters can be set to suit different parts and processes to achieve optimal dust removal. Furthermore, the system adopts a modular design, allowing for different numbers of blowing and suction modules to be configured for different equipment, with varying blowing pressures and flow rates, making it compatible with diverse equipment and meeting the needs of industrial applications.

[0040] In some embodiments, the blowing module includes an upper blowing module 1 and a lower blowing module 2. The upper blowing module 1 is located above the lower blowing module 2. The suction module 3 and the lower blowing module 2 are located on the same layer and connected as a whole. The circulating fan module 6 is connected to both the upper blowing module 1 and the lower blowing module 2. Arranging the blowing modules in two layers can improve the blowing effect and thus improve the smoke and dust treatment effect.

[0041] For example, multiple rows of first air outlets 21 are provided on both sides of the upper air blowing module 1. The first air outlets 21 are circular, and the apertures of the first air outlets 21 in each row are different. The first air outlets 21 at the top are smaller than the first air outlets 21 at the bottom. For example, the diameter of the first air outlets 21 gradually increases from the top to the bottom.

[0042] Furthermore, multiple rows of second air blowing ports are provided on one side of the lower blowing module 2. The second air blowing ports are circular, and the apertures of the second air blowing ports in each row are different. The second air blowing ports at the top are smaller than those at the bottom.

[0043] The structures of the upper blowing module 1 and the lower blowing module 2 can be the same or different. The length direction of the upper blowing module 1 is perpendicular to the length direction of the lower blowing module 2, and the suction module 3 is parallel to the lower blowing module 2 and connected as one.

[0044] In some embodiments, a plurality of parallel guide plates 22 for controlling the degree of opening and closing are provided on one side of the air suction module 3 , and the guide plates 22 are in a louver structure.

[0045] In some embodiments, the mobile module includes a translation device 4 and a lifting device 5. The translation device 4 can drive at least one of the upper blowing module 1, lower blowing module 2, and suction module 3 to move horizontally; for example, the upper blowing module 1 can move in the X direction, and the lower blowing module 2 and lower suction module 3 can move in the Y direction. The upper blowing module 1, lower blowing module 2, and lower suction module 3 can move as a whole with their relative positions fixed, or each module can move freely. This allows for flexible adjustment of the blowing and suction effects for different printed parts, ensuring effective dust absorption and improving the overall print quality of the part.

[0046] Furthermore, the lifting device 5 can drive the upper blowing module 1, the lower blowing module 2, the suction module 3, and the translation device 4 to move up and down. For example, it can drive the upper blowing module 1 to move up or down, drive the lower blowing module 2 to move up or down, drive the suction module 3 to move up or down as a whole, and so on.

[0047] In some embodiments, the multi-laser additive manufacturing system further includes a filter module 7 , which is connected in series between the circulating fan module 6 and the suction module 3 to filter impurities in the smoke.

[0048] In some embodiments, the multi-laser additive manufacturing system also includes a pressure sensing module 8 and a flow sensing module 9; the pressure sensing module 8 and the flow sensing module 9 are both arranged at the air outlet of the circulating fan module 6, and the pressure sensing module 8 is used to detect the airflow pressure generated by the circulating fan module 6, and an alarm is prompted when the pressure is too high.

[0049] The flow sensor module 9 is used to detect the air flow generated by the circulation fan module 6, and control the fan speed of the circulation fan module 6 through the flow feedback value to ensure that the blowing air flow achieves dynamic balance and ensures the best smoke and dust removal effect.

[0050] In some embodiments, the control module 10 is used to control the motors of the moving module and the lifting device so that they perform corresponding driving operations.

[0051] This embodiment also provides a control method based on a multi-laser additive manufacturing system, which mainly includes the following steps:

[0052] S1. The system receives the current scanning cross-sectional data of the part, and lifts the blowing module and the suction module 3 to a height higher than the powder spreading scraper through the lifting device 5, and the powder spreading scraper starts spreading powder; specifically, the system receives the current scanning cross-sectional data of the part, and lifts the upper blowing module 1, the lower blowing module 2, and the suction module 3 to a height higher than the powder spreading scraper through the lifting device 5, and the powder spreading scraper starts spreading powder.

[0053] S2. The data processing module 11 processes the data of the current scan section of the part, partitions the scan section into rectangles or squares, and obtains the partitioned scan data, such as Figure 3 The outline and fill are partitioned accordingly, the size of the partition can be adjusted, and the location of the partition in each layer can also be different.

[0054] S3. Arrange the partitioned scan data in a checkerboard or matrix order, and divide them into the first round of scanning area 41, the second round of scanning area 42, the third round of scanning area 43, and the fourth round of scanning area 44. The same direction of the filled lines in the figure indicates the same round of scanning area, such as Figure 4According to the size of the scanning area, laser power, printing material, set the airflow pressure and airflow rate, and control the opening and closing degree of the guide plate 22 of the suction module 3 to ensure the best smoke dust effect;

[0055] S4. Move the blowing module and the suction module 3 to corresponding positions through the moving module, exposing the first scanning area 41, and the laser scans the first scanning area 41; after the first scanning area 41 is scanned, the blowing module and the suction module 3 are moved to expose the second scanning area 42, and the laser scans the second scanning area 42, and so on, to complete the remaining rounds of scanning, and finally achieve scanning of the entire format.

[0056] In some embodiments, in S3 , the partitions of the scanning cross section and the sizes of the scanning areas are set to different values ​​or the same value; the actual scanning order of the scanning areas is freely set.

[0057] Specifically, the divisions of the scanning cross-section and the size of the scanning area can be set to different values. That is, a scanning area can be composed of several divisions, allowing the scanning sections to be very small without increasing the number of blowing and suction modules. The actual scanning order of the scanning areas can be freely set. The order can be: first round scanning area 41, third round scanning area 43, second round scanning area 42, fourth round scanning area 44, or any other order.

[0058] Each blowing and suction module can be turned on and off freely. Due to the variety of shapes of parts actually printed, it is possible that there is no scan data for a certain position. In this case, the blowing and suction modules at that position can be turned off.

[0059] For special powder materials, you can use the solution of only opening the suction module and not opening the blowing module to ensure that no dust is generated. As a special case, you can omit the upper blowing module and only keep the lower blowing module and the lower suction module. In this case, you only need to divide the partition data into two scanning areas: the first round scanning area and the second round scanning area. Figure 5 .

[0060] In some embodiments, as Figure 6 As shown, all upper blowing modules, lower blowing modules, and suction modules can move as a whole with a fixed relative position as in step S4 of implementation example 1, and each module can also move freely to expose the first scanning area, the second scanning area, the third scanning area, and the fourth scanning area.

[0061] The control method in the above embodiment divides the dust removal area, making each dust removal area smaller, more effectively removing dust and splatter generated during printing, and improving print quality. By segmenting the multi-laser scanning cross-section in a checkerboard or determinant manner and classifying the segmented data into first-round scanning areas, second-round scanning areas, third-round scanning areas, and fourth-round scanning areas, the scanning strategy works in conjunction with the blowing and suction mechanisms, effectively accommodating multiple laser scanning conditions.

[0062] Furthermore, by dividing the entire format into multiple smoke and dust processing areas, the problem of smoke and dust not being able to be processed in time during large-format laser scanning, which leads to a decline in printing quality, can be avoided. At the same time, the mutual interference between the smoke and dust generated by different laser scans during multiple laser scans can be avoided.

[0063] Furthermore, the above control method can be compatible with multiple laser printing situations, thereby improving printing efficiency; regional scanning can also reduce the stress of printed parts, and there is no need for the suction module to quickly follow the laser scanning path.

[0064] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0065] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0066] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0067] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0068] In the present invention, the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples without contradiction.

[0069] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A multi-laser additive manufacturing system, characterized in that: include: A blowing module, the blowing module is used to blow out gas; An air suction module (3), the air suction module (3) being used to inhale gas; a moving module, the moving module being connected to the blowing module and the suction module (3) and being used for driving the blowing module and the suction module (3) to move; a circulating fan module (6), the circulating fan module (6) being used to generate positive pressure and negative pressure airflows, and being in communication with the blowing module and the suction module (3), so that the blowing module and the suction module (3) respectively generate blowing effects and suction effects; as well as A control module (10) and a data processing module (11), wherein the circulating fan module (6) and the control module (10) are both electrically connected to the data processing module (11), and the data processing module (11) is used for data processing, data partitioning of scan sections, and overall control of the system; the control module (10) controls the movement module to operate through the data processing module (11); The blowing module comprises an upper blowing module (1) and a lower blowing module (2), wherein the upper blowing module (1) is located on the upper layer of the lower blowing module (2), and the suction module (3) and the lower blowing module (2) are located on the same layer and connected as a whole; the circulating fan module (6) is connected to both the upper blowing module (1) and the lower blowing module (2), the length direction of the upper blowing module (1) and the length direction of the lower blowing module (2) are perpendicular to each other, and the suction module (3) is parallel to the lower blowing module (2).

2. The multi-laser additive manufacturing system according to claim 1, characterized in that: Multiple rows of first air blowing ports (21) are provided on both sides of the upper air blowing module (1); the first air blowing ports (21) are circular; the apertures of the first air blowing ports (21) in each row are different; the first air blowing ports (21) at the top are smaller than the first air blowing ports (21) at the bottom.

3. The multi-laser additive manufacturing system according to claim 1, wherein: The lower layer blowing module (2) is provided with multiple rows of second blowing ports on one side. The second blowing ports are circular, and the apertures of the second blowing ports in each row are different. The second blowing ports at the top are smaller than those at the bottom.

4. The multi-laser additive manufacturing system according to claim 1, wherein: A plurality of parallel guide plates (22) for controlling the degree of opening and closing are provided on one side of the air suction module (3), and the guide plates (22) are in the form of shutter structures.

5. The multi-laser additive manufacturing system according to claim 1, wherein: The mobile module comprises a translation device (4) and a lifting device (5); The translation device (4) is capable of driving at least one of the upper blowing module (1), the lower blowing module (2) and the suction module (3) to move in a horizontal direction; The lifting device (5) can drive the lifting and lowering of the upper blowing module (1), the lower blowing module (2), the suction module (3) and the translation device (4).

6. The multi-laser additive manufacturing system according to claim 1, characterized in that: It also includes a filter module (7), which is connected in series between the circulation fan module (6) and the suction module (3) and is used to filter impurities in the smoke.

7. The multi-laser additive manufacturing system according to claim 1, characterized in that: It also includes a pressure sensing module (8) and a flow sensing module (9); The pressure sensing module (8) and the flow sensing module (9) are both arranged at the air outlet of the circulating fan module (6); the pressure sensing module (8) is used to detect the airflow pressure generated by the circulating fan module (6); and the flow sensing module (9) is used to detect the airflow rate generated by the circulating fan module (6).

8. A control method for a multi-laser additive manufacturing system according to any one of claims 1 to 7, characterized in that: The following steps are involved: S1. The system receives the current scanned cross-section data of the part, and raises the blowing module and the suction module (3) to a height higher than the powder spreading scraper through the lifting device, and the powder spreading scraper spreads the powder; S2. The data processing module (11) processes the data of the current scan section of the part, partitions the scan section into rectangular or square sections, and obtains the partitioned scan data; S3. Arrange the partitioned scan data in a checkerboard or matrix order, and divide them into a first scanning area (41), a second scanning area (42), a third scanning area (43), and a fourth scanning area (44); set the airflow pressure and airflow rate according to the size of the different scanning areas, the laser power, and the printing material, and control the opening and closing degree of the guide plate (22) of the suction module (3); S4. The blowing module and the suction module (3) are moved to corresponding positions by the moving module to expose the first round of scanning area (41), and the laser scans the first round of scanning area (41); after the first round of scanning area (41) is scanned, the blowing module and the suction module (3) are moved to expose the second round of scanning area (42), and the laser scans the second round of scanning area (42), and so on, to complete the remaining rounds of scanning, and finally achieve scanning of the entire format.

9. The control method according to claim 8, characterized in that: In the above S3 , the partitions of the scanning cross section and the size of the scanning area are set to different values ​​or the same value; the actual scanning order of the scanning area is freely set.

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