A multi-robot electric arc additive manufacturing surface measurement and dynamic planning method

Abstract

The application discloses a kind of multi-robot electric arc additive manufacturing surface measurement and dynamic planning method, comprising: according to the three-dimensional model of the structure to be added material, partition planning is carried out, the three-dimensional modeling size of each layer of additive material and corresponding multi-robot additive manufacturing path and process parameters are obtained;Initialize parameter x=1;According to the path and process parameters of the x layer additive material, the x layer additive material is manufactured;The surface image of the x layer additive material is shot;According to the surface image of the x layer additive material, the three-dimensional reconstruction of the i layer additive material is carried out, and the actual three-dimensional size thereof is obtained;Determine whether x is equal to x top ;If equal, complete additive manufacturing;If not equal, compare the actual three-dimensional size of the x layer additive material with its three-dimensional modeling size, adjust the process parameters corresponding to the x+1 layer additive material according to the comparison result, and then continue to manufacture the next layer of additive material.The application can avoid the deviation from continuously accumulating during additive manufacturing, and reduce additive defects.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of additive manufacturing, and particularly relates to a multi-robot electric arc additive manufacturing surface measurement and dynamic planning method. BACKGROUND

[0002] In multi-robot collaborative electric arc additive manufacturing of large structural parts, the path and process parameters of the additive are often determined in advance by modeling software and then the additive manufacturing is performed. Due to the actual process parameter fluctuation, the surface undulation state of the front layer additive deposition layer, the molten pool fluidity and other factors, there is a certain deviation between the actual additive size of each layer and the data of the theoretical modeling software. If this deviation is not handled in time, the deviation will be continuously accumulated with the layer-by-layer additive, and finally leads to the interruption of the additive process, and even the generation of additive defects. SUMMARY

[0003] In order to solve the above problems existing in the prior art, the present application provides a multi-robot electric arc additive manufacturing surface measurement and dynamic planning method.

[0004] The technical problem to be solved by the present application is solved by the following technical scheme:

[0005] A multi-robot electric arc additive manufacturing surface measurement and dynamic planning method is applied to a multi-robot electric arc additive manufacturing system, the system comprising a plurality of industrial robots, and a line stripe laser sensor is installed at the end of each industrial robot, and the method comprises:

[0006] Step A, layering and zoning planning according to the three-dimensional model of the structure to be added, obtaining the three-dimensional modeling size of each layer of additive and the corresponding multi-robot additive manufacturing path and process parameters;

[0007] Step B, initializing the parameter x=1;

[0008] Step C, performing the xth layer of additive manufacturing according to the multi-robot additive manufacturing path and process parameters of the xth layer of additive;

[0009] Step D, using the line stripe laser sensor fixed at the front end of each industrial robot to respectively shoot the deposition layer surface image of the manufactured xth layer of additive;

[0010] Step E, three-dimensionally reconstructing the surface topography of the ith layer of additive according to the deposition layer surface images shot by the plurality of industrial robots, and obtaining the actual three-dimensional size of the ith layer of additive according to the three-dimensional reconstruction result;

[0011] Step F, judging whether x is equal to x top ; if x is equal to x top , the additive manufacturing is completed; if x is not equal to x top, execute step G; wherein x top is the total number of the additivities;

[0012] Step G, comparing the actual three-dimensional size of the xth layer of additivity with its three-dimensional modeling size, adjusting the process parameters corresponding to the x+1th layer of additivity according to the comparison result, and then letting x=x+1 and returning to step C.

[0013] In one embodiment,

[0014] The step B specifically comprises: initializing parameters x=1, y=1.

[0015] The step C specifically comprises: manufacturing the xth layer and yth sub-additivity according to the multi-robot additive manufacturing path and process parameters of the yth sub-additivity of the xth layer of additivity.

[0016] The step D specifically comprises: using a line-laser sensor fixed at the front end of each industrial robot to shoot a fusion layer surface image of the ith layer of additivity after manufacturing the xth layer and yth sub-additivity.

[0017] The step E specifically comprises: three-dimensionally reconstructing the ith layer of additivity according to the fusion layer surface images shot by the multiple industrial robots, and obtaining the actual height of the xth layer and yth sub-additivity according to the three-dimensional reconstruction result.

[0018] The method further comprises: step H, step I and step K.

[0019] Step H comprises: between step E and step F, judging whether y is equal to y max ; if y is equal to y max , continue to execute step F; if y is not equal to y max , execute step I; wherein y max is the total number of sub-additivities of the xth additivity.

[0020] Step I specifically comprises: judging whether x is equal to x top ; if x is equal to x top , let y=y+1 and return to step C; if x is not equal to x top , execute step K.

[0021] Step K comprises: comparing the actual height of the xth layer and yth sub-additivity with its modeling height, adjusting the process parameters corresponding to the x+1th layer and yth sub-additivity according to the comparison result; then let y=y+1 and return to step C.

[0022] Step G specifically comprises: comparing the actual height of the xth layer and yth sub-additivity with its modeling height, adjusting the process parameters corresponding to the x+1th layer and yth sub-additivity according to the comparison result; then let x=x+1, y=1 and return to step C.

[0023] In one embodiment,

[0024] The process parameters at least include: additive power supply current I(x, y) and the moving speed v(x, y) of the end of the manipulator of the industrial robot.

[0025] In one embodiment, the adjusting the process parameters corresponding to the x+1 layer and yth additive according to the comparison result comprises:

[0026] According to the difference e(x, y) between the actual height of the xth layer and yth additive and the modeling height thereof, ΔI(x, y)=α*e(x, y) and Δv(x, y)=β*e(x, y) are calculated; wherein, α and β are respectively preset process parameter adjustment coefficients; ΔI(x, y) is the additive power supply current adjustment amount, and Δv(x, y) is the end of the manipulator moving speed adjustment amount;

[0027] The additive power supply current corresponding to the x+1 layer and yth additive is adjusted by using ΔI(x, y), and the end of the manipulator moving speed corresponding to the x+1 layer and yth additive is adjusted by using Δv(x, y).

[0028] In one embodiment, the industrial robot is a six-axis robot.

[0029] In one embodiment, the process parameters acquired in the step A include: additive power supply current, additive power supply voltage and the end of the manipulator moving speed of the industrial robot.

[0030] In one embodiment, the line stripe laser sensor shoots the surface image of the fusion layer at a distance of 30mm from the center of the electric arc by emitting a red laser stripe with a wavelength of 650nm and a width of 5cm.

[0031] The multi-robot electric arc additive manufacturing surface measurement and dynamic planning method provided by the application shoots the surface image of each layer of additive manufactured by using the line stripe laser sensor fixed at the front end of each industrial robot, performs three-dimensional reconstruction on the ith layer of additive according to the surface images of the fusion layer shot by the plurality of industrial robots, obtains the actual three-dimensional size of the ith layer of additive according to the three-dimensional reconstruction result, compares the actual three-dimensional size of the upper layer of additive with the three-dimensional modeling size thereof, adjusts the three-dimensional modeling size of the next layer of additive and the corresponding process parameters, thereby avoiding the continuous accumulation of manufacturing deviation and reducing additive defects.

[0032] The application will be further described in detail below with reference to the drawings and the application. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1This is a schematic diagram of the structure of the multi-robot electric arc additive manufacturing system used in this embodiment of the invention;

[0034] Figure 2 This is a schematic diagram of an industrial computer controlling a line stripe laser sensor to take pictures in an embodiment of the present invention;

[0035] Figure 3 This is a schematic diagram illustrating how the surface measurement software in this embodiment of the invention calibrates and stitches images of the weld layer surface to achieve three-dimensional reconstruction of the weld layer surface morphology.

[0036] Figure 4 This is a flowchart of a multi-robot arc additive manufacturing surface measurement and dynamic planning method provided in an embodiment of the present invention;

[0037] Figure 5 This is a flowchart of another multi-robot arc additive manufacturing surface measurement and dynamic planning method provided in an embodiment of the present invention. Detailed Implementation

[0038] The present invention will be further described in detail below with reference to specific embodiments, but the implementation of the present invention is not limited thereto.

[0039] To promptly address deviations that arise during additive manufacturing and prevent their accumulation from disrupting the process, this invention provides a method for surface measurement and dynamic planning in multi-robot arc additive manufacturing, applicable to multi-robot arc additive manufacturing systems, such as... Figure 1 As shown, the system includes multiple industrial robots 1, preferably six-axis robots, whose robotic arms are more flexible and better suited for precision additive manufacturing. For example, ABB robots manufactured by ABB can be used, but the system is not limited to this.

[0040] like Figure 1 As shown, each industrial robot 1 is equipped with a line stripe laser sensor 5 at its end. The system also includes an additive power supply 2, a wire feeder 3, an arc welding torch 4, and an industrial computer 6. The wire feeder 3 provides the wire required for additive manufacturing and is connected to the industrial robot 1, the additive power supply 2, and the arc welding torch 4 via communication lines. The additive power supply 2 provides the electrical energy for additive manufacturing and is also connected to the industrial robot 1, the wire feeder 3, and the arc welding torch 4 via communication lines. The arc welding torch 4, used for arc ignition and wire melting, is installed at the end of the industrial robot 1 and is connected to the industrial robot 1, the additive power supply 2, and the wire feeder 3 via communication lines.

[0041] The industrial computer 6 is installed with additive modeling software and surface measurement software; the additive modeling software is used for three-dimensional modeling of the additive structure, so that the additive manufacturing layering and partitioning planning can be carried out based on the three-dimensional model, the three-dimensional modeling size of each layer of additive material and the corresponding multi-robot additive manufacturing path and process parameters are determined; the surface measurement software is used to control the line laser sensor to shoot the additive surface (as shown in Figure 2 In actual application, the additive modeling software can include IungoPNT software; IungoPNT is a 3D printing software independently developed by Inngoma Company, which can slice the large additive components layer by layer, so as to output the robot additive path and process parameters of each layer, so as to carry out 3D printing according to the additive path and process parameters. The process parameters mentioned here include additive height, density, etc. IungoPNT is mainly used for electric arc additive manufacturing technology, and has the advantages of stable, efficient and flexible printing forming. Therefore, using the IungoPNT to realize additive operation can make the quality of additive construction higher and more stable. The surface measurement software can include SmartRay Studio 4 software, which is a three-dimensional reconstruction software, which can reconstruct the actual three-dimensional size of the structure according to a large amount of two-dimensional image data of the structure. At the same time, SmartRay Studio 4 can also visualize, export and store the reconstruction results. Of course, the additive modeling software and the surface measurement software are not limited to the two listed above, and the embodiments of the present application do not limit them.

[0042] Based on the above multi-robot electric arc additive manufacturing system, as shown in Figure 1 The multi-robot electric arc additive manufacturing surface measurement and dynamic planning method provided by the embodiment of the present application comprises the following steps:

[0043] Step A, according to the three-dimensional model of the additive structure, the additive manufacturing layering and partitioning planning is carried out, and the three-dimensional modeling size of each layer of additive material and the corresponding multi-robot additive manufacturing path and process parameters are obtained.

[0044] In this step A, the three-dimensional model of the additive structure is mainly constructed in the additive modeling software, and the additive manufacturing layering and partitioning planning is carried out, so as to obtain the three-dimensional modeling size of each layer of additive material and the corresponding multi-robot additive manufacturing path and process parameters. Here, the process parameters can include: additive power current, additive power voltage and end-of-arm movement speed of industrial robot.

[0045] Step B, initialize parameter x = 1.

[0046] Here, the parameter x is used to track the number of additive layers.

[0047] Step C, the xth layer additive manufacturing is performed according to the multi-robot additive manufacturing path and process parameters of the xth layer additive.

[0048] In practical applications, the IungoPNT software can be used to control multiple industrial robots to perform additive manufacturing, but it is not limited thereto.

[0049] Step D, a line laser sensor fixed at the front end of each industrial robot is used to respectively shoot surface images of the manufactured xth layer additive.

[0050] Specifically, the line laser sensor sends a red laser stripe to the solidification area at the tail of the molten pool, and the red laser stripe is irradiated on the surface of the molten pool behind the molten pool to obtain an image of the surface of the molten pool after a single irradiation. Then, the industrial robot is moved to make the red laser stripe scan across the entire surface of the molten pool, and then all the surface images of the molten pool are sent to the industrial computer.

[0051] Step E, the surface topography of the ith layer additive is three-dimensionally reconstructed according to the surface images of the molten pool shot by the multiple industrial robots, and the actual three-dimensional size of the ith layer additive is obtained according to the three-dimensional reconstruction result.

[0052] Specifically, after the industrial computer receives all the surface images of the molten pool, the additive surface measurement software is run, and all the surface images are calibrated and spliced in the surface measurement software (as shown in Figure 3 ). The topography size of the entire surface of the molten pool of each layer is reconstructed, three-dimensional reconstruction and visual display are realized, and the three-dimensional reconstruction result is obtained.

[0053] Step F, whether x is equal to x top ; if x is equal to x top , the additive manufacturing is completed; if x is not equal to x top , step G is performed; wherein, x top is the total number of layers of the additive.

[0054] Step G, the actual three-dimensional size of the xth layer additive is compared with the three-dimensional modeling size thereof, the process parameters corresponding to the x+1th layer additive are adjusted according to the comparison result, then x is set to x+1, and the process returns to step C.

[0055] In practical applications, the actual height of the xth layer additive is mainly compared with the modeling height thereof. If the actual height is less than the modeling height, the actual height of the x+1th layer additive is increased by adjusting the process parameters corresponding to the x+1th layer additive. If the actual height is greater than the modeling height, the actual height of the x+1th layer additive is decreased by adjusting the process parameters corresponding to the x+1th layer additive.

[0056] The multi-robot electric arc additive manufacturing surface measurement and dynamic planning method provided by the embodiment of the present application uses a line stripe laser sensor fixed at the front end of each industrial robot to respectively shoot a fusion layer surface image of each layer of additive manufactured, performs three-dimensional reconstruction on the i-th layer of additive according to the fusion layer surface images shot by the multiple industrial robots, and obtains the actual three-dimensional size of the i-th layer of additive according to the three-dimensional reconstruction result. By comparing the actual three-dimensional size of the upper layer of additive with the three-dimensional modeling size thereof, the three-dimensional modeling size of the next layer of additive and the corresponding process parameters are adjusted, so that the manufacturing deviation is avoided from being accumulated continuously, and the additive defects are reduced.

[0057] In one embodiment, based on the method shown in the above formula (1), the embodiment of the present application further provides another multi-robot electric arc additive manufacturing surface measurement and dynamic planning method, which is shown in the above formula (2). Figure 4 Figure 5 Based on the method shown in the above formula (2), the embodiment of the present application further adds steps H, I and J, and further optimizes some steps in the method shown in the above formula (2). Figure 4 Figure 4

[0058] In the above formula (2), step B specifically includes: initializing parameters x = 1 and y = 1; here, the parameter y is used to track the number of sub-additive channels of the x-th layer of additive. Figure 5

[0059] Step C specifically includes: manufacturing the y-th sub-additive channel of the x-th layer of additive according to the multi-robot additive manufacturing path and the process parameters of the y-th sub-additive channel of the x-th layer of additive.

[0060] Step D specifically includes: using the line stripe laser sensor fixed at the front end of each industrial robot to shoot a fusion layer surface image of the i-th layer of additive after the x-th layer, y-th sub-additive channel of additive is manufactured.

[0061] Step E specifically includes: performing three-dimensional reconstruction on the i-th layer of additive according to the fusion layer surface images shot by the multiple industrial robots, and obtaining the actual height of the x-th layer, y-th sub-additive channel of additive according to the three-dimensional reconstruction result.

[0062] Step H specifically includes: between step E and step F, judging whether y is equal to y max ; if y is equal to y max , step F is continuously executed; if y is not equal to y max , step I is executed; wherein y max is the total number of sub-additive channels of the x-th layer of additive.

[0063] Step I specifically includes: judging whether x is equal to x top ; if x is equal to x top , y = y + 1 is set and step C is returned; if x is not equal to x top ​​​​, execute step J;

[0064] Step J specifically includes: comparing the actual height of the xth layer, yth sub-additive with its modeling height, adjusting the process parameters corresponding to the x+1th layer, yth sub-additive according to the comparison result; then let y=y+1 and return to step C;

[0065] Step G specifically includes: comparing the actual height of the xth layer, yth sub-additive with its modeling height, adjusting the process parameters corresponding to the x+1th layer, yth sub-additive according to the comparison result; then let x=x+1, y=1 and return to step C.

[0066] It can be understood that, Figure 5 The method shown can check the deviation between the actual size of the additive and the modeling size in time after each additive is completed, so as to adjust the process parameters of the next layer of additive in time, which can more accurately control the process of the additive process, thereby further reducing the additive defects and improving the additive quality.

[0067] In one embodiment, in Figure 5 In the method shown, the process parameters corresponding to the x+1th layer, yth sub-additive can be adjusted according to the comparison result in step G and step K, which can specifically include:

[0068] According to the difference e(x, y) between the actual height of the xth layer, yth sub-additive and its modeling height, ΔI(x, y)=α*e(x, y) and Δν(x, y)=β*e(x, y) are calculated; wherein, α and β are respectively preset process parameter adjustment coefficients; ΔI(x, y) is the additive power current adjustment amount, and Δν(x, y) is the end of the manipulator moving speed adjustment amount;

[0069] The additive power current corresponding to the x+1th layer, yth sub-additive is adjusted by using ΔI(x, y), and the end of the manipulator moving speed corresponding to the x+1th layer, yth sub-additive is adjusted by using Δν(x, y).

[0070] Therefore, by monitoring the height of each sub-additive in each layer in real time and adjusting the additive power current and the end of the manipulator moving speed of the next layer of additive in time, the additive process is accurately controlled, and the additive quality is improved.

[0071] It should be noted that the terms "first", "second", and so on are used herein to distinguish similar objects, and do not necessarily have to be used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances, so that the embodiments of the disclosure described herein can be implemented in an order other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all the embodiments consistent with the present disclosure. Rather, they are merely examples of devices and methods consistent with some aspects of the present disclosure.

[0072] In the description of the present specification, the description of the terms "one embodiment", "some embodiments", "an example", "a specific example", or "some examples" and the like means that the specific features or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features 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 the present specification.

[0073] Although the present application is described herein in conjunction with various embodiments, other variations of the disclosed embodiments can be understood and implemented by those skilled in the art with reference to the drawings and the disclosure. In the description of the present application, the word "comprising" does not exclude other components or steps, "one" or "an" does not exclude a plurality, and "plurality" means two or more, unless otherwise explicitly specified. In addition, some measures are described in different embodiments, but this does not mean that these measures cannot be combined to produce good results.

[0074] The above is a further detailed description of the present application in conjunction with specific preferred embodiments, and cannot be considered as limiting the specific implementation of the present application to these descriptions. For those skilled in the art to which the present application belongs, without departing from the concept of the present application, a number of simple deductions or replacements can be made, which should be considered as falling within the scope of protection of the present application.

Claims

1. A multi-robot electric arc additive manufacturing surface measurement and dynamic planning method, characterized in that, Applied to a multi-robot electric arc additive manufacturing system, the system comprises a plurality of industrial robots, each of which is provided with a line laser sensor at the end thereof, and further comprises an industrial computer; the industrial computer is provided with an additive modeling software and a surface measurement software; the method comprises: Step A, layering and partitioning planning according to the three-dimensional model of the additive structure to be added, obtaining the three-dimensional modeling size of each layer of additive and the corresponding multi-robot additive manufacturing path and process parameters; the process parameters at least include: additive power current I( x , y ) and the end of the mechanical hand of the industrial robot moving speed v( x , y ); Step B, initialize parameters x = 1, y = 1; Step C, according to the first x Layer additive, the first y Way additive, the first x Layer, the first y Way additive; Step D, a line laser sensor fixed at the front end of each industrial robot is used to detect the completion of the first layer of the manufacturing x layer, the first layer of the manufacturing y layer, the first layer of the manufacturing i layer, the first layer of the manufacturing Step E, according to the plurality of industrial robot shot fusion layer surface image to the first i layer additive three-dimensional reconstruction, and according to the three-dimensional reconstruction results obtained from the first x layer, the actual height of the first y sub additive Step F, determining x whether equal to x top ; if x equal to x top , then complete the additive manufacturing; if x not equal to x top , perform Step G; wherein, x top is the total number of layers of additive manufacturing; Step G, the first x Layer, First y The actual height of the Daozi additive manufacturing process is compared with its modeled height, and the height is adjusted accordingly. x+ 1st floor, No. y The corresponding process parameters for Daozi additive manufacturing; then let x = x+ 1. y= After step 1, return to step C; The method further comprises steps H, I and K. Step H comprises: between Step E and Step F, judging y whether equal to y max ; if equal to y , continuing to execute Step F; if not equal to y max , executing Step I; wherein, y y max , executing Step I; wherein, y max is the total number of sub-additive tracks of the first x additive.​ Step I specifically includes determining x whether or not x top ; if x is equal to x top , then setting y = y+ 1 and returning to Step C; if x is not equal to x top , then performing Step K; Step K includes: [The following is a list of steps, likely related to a specific step or process, and is not translated: "to x Layer, First y The actual height of the Daozi additive manufacturing process is compared with its modeled height, according to the first... x Layer, First y The difference e between the actual height of the Daozi additive manufacturing process and its modeled height. x , y ), calculate ΔI( x , y )=α*e( x , y ) and Δν( x , y )=β*e( x , y ); where α and β are preset process parameter adjustment coefficients; ΔI( x , y ) is the additive power supply current adjustment, Δν( x , y ) is the adjustment amount of the robot's end effector's moving speed; using ΔI( x , y Adjustment of the first x+ 1st floor, No. y The additive power supply current corresponding to the Daozi additive manufacturing process, and using Δν ( x , y Adjustment of the first x+ 1st floor, No. y The corresponding robotic end effector movement speed in Daozi additive manufacturing; then let y = y+ After step 1, return to step C.

2. The multi-robot electric arc additive manufacturing surface measurement and dynamic planning method of claim 1, wherein, The industrial robot is a six-axis robot.

3. The multi-robot electric arc additive manufacturing surface measurement and dynamic planning method of claim 1, wherein, The process parameters obtained in step A include an additive power supply current, an additive power supply voltage and a moving speed of the end of the manipulator of the industrial robot.

4. The multi-robot electric arc additive manufacturing surface measurement and dynamic planning method of claim 3, wherein, The line laser sensor shoots a surface image of the deposited layer by emitting a red laser stripe with a wavelength of 650 nm and a width of 5 cm at a distance of 30 mm from the center of the electric arc.

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