Large-format Laser Scanning System for Additive Manufacturing of Large Aerospace Metal Parts

Abstract

The present invention provides a large-format laser scanning system for additive manufacturing of large aerospace metal parts, comprising: a scheme automatic generation module, configured to automatically plan a laser scanning path based on the three-dimensional model of the additive device to be manufactured, and generate a scanning movement scheme for the workbench and the laser during the large-format scanning of the additive; a scanning beam analysis module, configured to analyze the laser beam according to the printed material data during the process of controlling the laser to perform laser printing based on the scanning movement scheme, and obtain a beam analysis result; and a laser scanning optimization module, configured to control a liquid lens to perform real-time coaxial focusing based on the beam analysis result. The present invention ensures that the maximum scanning range corresponding to the laser scanning of the additive to be manufactured can be completely printed, avoids the occurrence of poor splicing, and controls the liquid lens to perform real-time coaxial focusing, which is beneficial to improving the accuracy of laser alignment during the printing process, and provides a guarantee for generating high-quality large aerospace metal parts by additive manufacturing.

Description

Technical Field

[0001] The present invention relates to the technical field of large-format laser scanning, and particularly to a large-format laser scanning system for additive manufacturing of large aerospace metal parts. Background Art

[0002] Metal additive manufacturing (AM) encompasses manufacturing techniques that involve adding materials to produce layers of metal components. The important features of this technology lie in its commercialization and performance advantages, which have enabled its rapid development and wide application in the aerospace industry. Different from traditional subtractive manufacturing techniques, additive manufacturing uses multi-layer manufacturing to generate the final pattern on ordinary raw materials (usually powder or wire melted by a heat source or curing agent) with a digital heat source trajectory. The advantages of manufacturing using AM are shortening the production cycle, reducing related costs, enhancing the ability to design and manufacture complex geometries; enabling lightweighting; integrating multiple components to improve performance; and providing optimization of solution and technical risk management within a certain cost and time range. Using the design flexibility of metal AM, the material layout can be optimized, the mass can be reduced, the mechanical and other properties of the components can be maintained, and components can be combined to reduce risks and costs and reduce the potential failure risk of cross joints. However, since the maximum scanning range of the existing metal additive manufacturing format is 400 mm - 450 mm, for larger additive devices, splicing manufacturing is still required, and splicing manufacturing will affect the accuracy of the device to a certain extent. At the same time, due to the movement of the laser during the additive process and the absorption and reflection characteristics of the metal powder on the laser, it is easy to cause small errors in laser printing. Therefore, the present invention proposes a large-format laser scanning system for additive manufacturing of large aerospace metal parts. Summary of the Invention

[0003] The present invention provides a large-format laser scanning system for additive manufacturing of large aerospace metal parts to solve the above problems.

[0004] The present invention provides a large-format laser scanning system for additive manufacturing of large aerospace metal parts, comprising:

[0005] A scheme automatic generation module, configured to automatically plan a laser scanning path based on a three-dimensional model of an additive device to be manufactured, and generate a scanning movement scheme for the workbench and the laser during the large-format additive scanning;

[0006] A scanning beam analysis module, configured to analyze a laser beam according to the printed material data during the process of controlling the laser to perform laser printing based on the scanning movement scheme, and obtain a beam analysis result;

[0007] A laser scanning optimization module for controlling a liquid lens to perform real-time coaxial focusing based on the beam analysis result.

[0008] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the scheme automatic generation module includes:

[0009] A connection scheme determination unit for determining the scanning movement scheme of the laser during the printing layer connection process according to the scanning movement scheme of the workbench during the printing layer connection process and the laser position change trajectory within the effective manufacturing scanning range;

[0010] A first scheme generation unit for generating the scanning movement scheme of the laser corresponding to the printing process of the additive device to be manufactured based on the scanning movement scheme of the laser during the printing layer connection process and the laser position change trajectory of the single printing circle corresponding to the same data printing layer;

[0011] A second scheme generation unit for stipulating that the workbench and the laser are horizontally perpendicular in the same data printing layer, and generating the scanning movement scheme of the workbench corresponding to the printing process of the additive device to be manufactured in combination with the scanning movement scheme of the workbench during the printing layer connection process.

[0012] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the connection scheme determination unit includes:

[0013] A model layering sub-unit for classifying the additive device to be manufactured into multiple layers with the same data based on the model annotation dimensions corresponding to the 3D model, and obtaining the printing patterns corresponding to each layer with the same data of the additive device to be manufactured and their corresponding pattern size data;

[0014] A position determination sub-unit for respectively extracting the line features of the printing patterns corresponding to different layers with the same data, and generating the laser position change trajectory of the single printing circle in the layer with the same data based on the default printing starting position, the line features, and the pattern size data;

[0015] A scheme determination sub-unit for respectively comparing the line features and pattern size data of the layer with the same data printing layer and its adjacent layer with the same data printing layer to obtain the layer pattern correlation;

[0016] Based on the layer pattern correlation, determine the change in the layer superposition angle for printing adjacent layers with the same data, and according to the change in the layer superposition angle, combined with the projection position of the printing layer on the workbench, determine the scanning movement scheme of the workbench during the printing layer connection process.

[0017] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the scheme automatic generation module further includes:

[0018] A scanning range determination unit, configured to obtain a three-dimensional model of the additive device to be manufactured, determine the maximum scanning area of the additive device to be manufactured based on the top view perspective of the three-dimensional model, and determine the effective manufacturing scanning range corresponding to the additive device to be manufactured according to the maximum scanning area.

[0019] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the scanning beam analysis module includes:

[0020] A central axis determination module, configured to determine the device central axis of the additive device to be manufactured based on the three-dimensional model of the additive device to be manufactured, and establish an arbitrary model coordinate system on the horizontal plane based on the central axis;

[0021] A detection and analysis unit, configured to determine the target central coordinates of the same-layer center point corresponding to the current printing single loop based on the model coordinate system;

[0022] When the current printing single loop is not a layer connection loop, generate a first vector based on the current printing position and the target center point, and synchronously generate a second vector in the three-dimensional model, and determine whether the first vector and the second vector are exactly the same. If they are the same, it is determined that the printing position of the current printing laser beam is normal;

[0023] Otherwise, it is determined that there is a deviation in the printing position of the current printing laser beam;

[0024] When the current printing single loop is a layer connection loop, obtain the standard position coordinates of the adjacent printing points of the current printing position on the non-homogeneous data layer, generate a third vector based on the target central coordinates and the standard position coordinates, and synchronously obtain the beam vector corresponding to the actual printing position from the output point of the laser beam to the current printing position,

[0025] And determine whether the third vector and the beam vector are perpendicular. If they are perpendicular, it is determined that the printing position of the current printing laser beam is normal;

[0026] Otherwise, it is determined that there is a deviation in the printing position of the current printing laser beam;

[0027] A printing error analysis unit, configured to determine the laser alignment angle deviation value when it is determined that there is a deviation in the printing position of the current printing laser beam, and generate a beam analysis result based on the laser alignment angle deviation value, and send it to the laser scanning optimization module.

[0028] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the printing error analysis unit includes:

[0029] An error analysis subunit, configured to determine a laser alignment position deviation value based on a first vector and a second vector when the current single printed layer is not a layer connection layer, obtain a normal vector of the layer plane where the current printing position is located, and determine a laser alignment angle deviation value based on the cosine theorem, in combination with the normal vector modulus and the laser alignment position deviation value;

[0030] When the current single printed layer is a layer connection layer, determine a laser alignment angle deviation value based on a third vector and a beam vector;

[0031] An information sending subunit, configured to generate a beam analysis result based on the laser alignment angle deviation value and send it to the laser scanning optimization module.

[0032] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, it further includes:

[0033] An automatic quality inspection module, configured to compare the laser alignment angle deviation value with a preset maximum allowable deviation value. When the laser alignment angle deviation value is greater than or equal to the preset maximum allowable deviation value, mark the maximum deviation as 1; otherwise, mark it as 0;

[0034] Obtain the marked digital situation of the current additive device to be manufactured in real time. When the marked quantity of the maximum deviation is greater than a preset value, determine that the current additive device to be manufactured is a defective device and abort the printing of the current additive device to be manufactured.

[0035] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the laser scanning optimization module includes:

[0036] An information analysis unit, configured to analyze the beam analysis result to determine the laser alignment angle deviation value;

[0037] A focusing instruction generation unit, configured to determine a focusing error between the lens and the laser beam based on the laser alignment angle deviation value, and generate a focusing control instruction according to the focusing error;

[0038] A focusing control unit, configured to control the coaxial focusing of the liquid lens and the laser beam based on the focusing control instruction.

[0039] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, the laser scanning optimization module further includes:

[0040] A variable spot automatic switching unit, configured to obtain various historical printing data based on big data and obtain similar printing historical data according to the current printed metal material;

[0041] Based on the model annotation dimensions corresponding to the three-dimensional model, determine the line parameters corresponding to the next printing layer. Based on the line parameters, screen the same type of printing historical data to obtain the same type of line spot parameters;

[0042] Based on the same type of line spot parameters, determine the target spot parameters corresponding to the next printing layer;

[0043] Generate a spot switching instruction according to the target spot parameters and send it to the laser controller;

[0044] After receiving the spot switching instruction, the laser controller controls the laser emitter to switch the spot size at the critical point of the current printing layer.

[0045] Preferably, in a large-format laser scanning system for additive manufacturing of large aerospace metal parts, it further includes:

[0046] A fault continuation module, which is used to generate a storage node in the pre-stored whole part printing data of the current additive device to be manufactured based on the printed data of the current additive device to be manufactured when the laser scanning is abnormally interrupted, and send it to a preset database;

[0047] After the laser scanning of the current additive device to be manufactured is restarted, control the laser printing device to perform virtual printing based on the pre-stored whole part printing data, and when the virtual printing reaches the storage node, control the laser printing device to start normal printing.

[0048] Compared with the prior art, the present invention has at least the following beneficial effects:

[0049] Through the scheme automatic generation module of the present invention, the laser scanning path is automatically planned based on the three-dimensional model of the additive device to be manufactured, and the scanning movement schemes of the workbench and the laser during the large-format additive scanning are generated, and the scanning scheme of the additive device to be manufactured is automatically generated, ensuring that the additive to be manufactured can be completely printed in one time within the maximum scanning range corresponding to the laser scanning, and avoiding the occurrence of poor splicing; then, during the process of controlling the laser to perform laser printing based on the scanning movement scheme by the scanning beam analysis module, the laser beam is analyzed according to the printed material data to obtain the beam analysis result, realizing the real-time monitoring and analysis of the printing laser beam, which is beneficial to timely discovering printing errors and reducing the defective rate of products; finally, based on the beam analysis result, the laser scanning optimization module controls the liquid lens to perform real-time coaxial focusing, which is beneficial to improving the accuracy of laser alignment during printing, providing a guarantee for generating high-quality large aerospace metal parts by additive manufacturing.

[0050] Other features and advantages of the present invention will be set forth in the following description, and in part will be obvious from the description, or may be learned by practice of the present invention. The objectives and other advantages of the present invention may be realized and attained by the structure particularly pointed out in the specification.

[0051] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Description of the Drawings

[0052] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention, but do not constitute a limitation to the present invention. In the drawings:

[0053] Figure 1 It is a schematic diagram of a large-format laser scanning system for additive manufacturing of large aerospace metal parts according to the present invention;

[0054] Figure 2 It is a schematic diagram of an automatic generation module for the large-format laser scanning system solution for additive manufacturing of large aerospace metal parts according to the present invention;

[0055] Figure 3 It is a schematic diagram of a scanning beam analysis module of a large-format laser scanning system for additive manufacturing of large aerospace metal parts according to the present invention;

[0056] Figure 4 It is a schematic diagram of a laser scanning optimization module of a large-format laser scanning system for additive manufacturing of large aerospace metal parts according to the present invention. Detailed Embodiments

[0057] The following describes the preferred embodiments of the present invention with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only for the purpose of illustrating and explaining the present invention, and are not used to limit the present invention.

[0058] Embodiment 1:

[0059] The present invention provides a large-format laser scanning system for additive manufacturing of large aerospace metal parts, as Figure 1 shown, including:

[0060] An automatic generation module for the solution, which is used to automatically plan the laser scanning path based on the three-dimensional model of the additive device to be manufactured, and generate the scanning movement solutions of the workbench and the laser during the large-format additive scanning;

[0061] A scanning beam analysis module, which is used to analyze the laser beam according to the printed material data during the process of controlling the laser to perform laser printing based on the scanning movement solution, and obtain the beam analysis result;

[0062] A laser scanning optimization module for controlling a liquid lens to perform real-time coaxial focusing based on the beam analysis result.

[0063] In this embodiment, the laser used in the laser scanning system can be switched between a 500w single-mode Gaussian laser and a 3000w multi-mode laser, and the corresponding focused spot sizes are 60um - 120um and 200 - 300um respectively.

[0064] The maximum scanning range can reach 710mm * 710mm, the printing speed is 3.5m / s, and the focal length is 801mm.

[0065] The maximum number of coaxial focusings of the liquid lens can reach 500 times.

[0066] Advantages of the above technical solution: Through the solution automatic generation module of the present invention, based on the three-dimensional model of the additive device to be manufactured, the laser scanning path is automatically planned, and the scanning movement scheme of the workbench and the laser during the large-format additive scanning is generated, and the scanning scheme of the additive device to be manufactured is automatically generated, ensuring that the additive to be manufactured can be completely printed in one pass within the maximum scanning range corresponding to the laser scanning, avoiding the occurrence of poor splicing; then, during the process of controlling the laser to perform laser printing based on the scanning movement scheme by the scanning beam analysis module, the laser beam is analyzed according to the printed material data to obtain the beam analysis result, realizing the real-time monitoring and analysis of the printing laser beam, which is beneficial to timely detecting printing errors and reducing the defective rate of products; finally, through the laser scanning optimization module based on the beam analysis result, the liquid lens is controlled to perform real-time coaxial focusing, which is beneficial to improving the accuracy of laser alignment during the printing process and providing guarantee for generating high-quality large-scale aerospace metal additive parts.

[0067] Embodiment 2:

[0068] Based on Embodiment 1, the solution automatic generation module, as Figure 2 shown, includes:

[0069] A connection scheme determination unit for determining the scanning movement scheme of the laser during the printing layer connection process according to the scanning movement scheme of the workbench during the printing layer connection process and the laser position change trajectory within the effective manufacturing scanning range;

[0070] A first scheme generation unit for generating the scanning movement scheme of the laser corresponding to the printing process of the additive device to be manufactured based on the scanning movement scheme of the laser during the printing layer connection process and the laser position change trajectory of the single printing circle corresponding to the same data printing circle;

[0071] A second solution generation unit is configured to stipulate that the workbench and the laser are horizontally perpendicular in the same data printing layer, and generate a scanning movement solution for the workbench corresponding to the printing process of the additive device to be manufactured in combination with the scanning movement solution of the workbench during the connection process of the printing layers.

[0072] Among them, the connection solution determination unit includes:

[0073] A model layering sub-unit is configured to classify the additive device to be manufactured into layers based on the model annotation dimensions corresponding to the three-dimensional model, obtain multiple same-data layers, and obtain the printing patterns corresponding to each same-data layer of the additive device to be manufactured and the corresponding pattern dimension data;

[0074] A position determination sub-unit is configured to respectively extract the line features of the printing patterns corresponding to different same-data printing layers, and generate a laser position change trajectory for a single printing circle in the same-data printing layer based on the default printing start position, the line features, and in combination with the pattern dimension data;

[0075] A solution determination sub-unit is configured to respectively compare the line features and pattern dimension data of the same-data printing layer and its corresponding adjacent same-data printing layer to obtain the layer pattern correlation;

[0076] Based on the layer pattern correlation, determine the change in the layer superposition angle for printing adjacent same-data printing layers, and according to the change in the layer superposition angle, in combination with the projection position of the printing layer on the workbench, determine the scanning movement solution of the workbench during the connection process of the printing layers.

[0077] In this embodiment, the laser position change trajectory refers to the position change trajectory of the laser emitted by the laser relative to the horizontal plane.

[0078] Advantages of the above technical solution: Through the model layering subunit, position determination subunit, and solution determination subunit of the connection solution determination unit, the present invention first classifies the layers of the additive device to be manufactured, obtains multiple same-data layers, and obtains the printing patterns and their corresponding pattern size data corresponding to each same-data layer of the additive device to be manufactured. Then, it extracts the line features of the printing patterns corresponding to different same-data printing layers respectively. Based on the default printing start position and the line features, combined with the pattern size data, it generates the laser position change trajectory of a single printing circle in the same-data printing layer. Then, it compares the line features and pattern size data of the same-data printing layer with its corresponding adjacent same-data printing layer respectively to obtain the layer pattern correlation. Based on the layer pattern correlation, it determines the change in the layer superposition angle for printing adjacent same-data printing layers, and according to the change in the layer superposition angle, combined with the projection position of the printing layer on the workbench, it determines the scanning movement solution of the workbench during the connection process of the printing layers. According to the scanning movement solution of the workbench during the connection process of the printing layers and the laser position change trajectory within the effective manufacturing scanning range, it determines the scanning movement solution of the laser during the connection process of the printing layers. Finally, it generates the scanning movement solutions of the laser and the workbench respectively for the integration of the connection process and the non-connection process of the printing layers, and correlates and plans the movement of the workbench and the laser, which can meet the manufacturing of additive devices with various complex shapes, ensure that the additive to be manufactured can be completely printed in one time within the maximum scanning range corresponding to the laser scanning, and avoid the occurrence of poor splicing situations.

[0079] Embodiment 3:

[0080] Based on Embodiment 2, the solution automatic generation module, as Figure 2 shown, further includes:

[0081] A scanning range determination unit, configured to obtain the three-dimensional model of the additive device to be manufactured, determine the maximum scanning area of the additive device to be manufactured based on the top view perspective of the three-dimensional model, and determine the effective manufacturing scanning range corresponding to the additive device to be manufactured according to the maximum scanning area.

[0082] In this embodiment, the effective manufacturing scanning range refers to the projected area of the additive device to be manufactured on the workbench, and this range is smaller than the maximum scanning range of the scanning system.

[0083] Advantages of the above technical solution: The present invention obtains the three-dimensional model of the additive device to be manufactured, determines the maximum scanning area of the additive device to be manufactured based on the top view perspective of the three-dimensional model, and determines the effective manufacturing scanning range corresponding to the additive device to be manufactured according to the maximum scanning area, realizing the preliminary judgment of the laser scanning area and providing a basis for the determination of the scanning solution.

[0084] Embodiment 4:

[0085] Based on Embodiment 2, the scanning beam analysis module, as Figure 3 shown, includes:

[0086] A central axis determination module, configured to determine the device central axis of the additive device to be manufactured based on the three-dimensional model of the additive device to be manufactured, and establish an arbitrary model coordinate system on the horizontal plane based on the central axis;

[0087] A detection and analysis unit, configured to determine the target central coordinates of the center point of the same layer corresponding to the current single printing circle based on the model coordinate system;

[0088] When the current single printing circle is not a layer connection circle, generate a first vector based on the current printing position and the target center point, and synchronously generate a second vector in the three-dimensional model, and determine whether the first vector and the second vector are exactly the same. If they are the same, it is determined that the printing position of the current printing laser beam is normal;

[0089] Otherwise, it is determined that there is a deviation in the printing position of the current printing laser beam;

[0090] When the current single printing circle is a layer connection circle, obtain the standard position coordinates of the adjacent printing points of the current printing position on the non-same data layer, generate a third vector based on the target central coordinates and the standard position coordinates, and synchronously obtain the beam vector corresponding to the actual printing position from the output point of the laser beam to the current printing position,

[0091] and determine whether the third vector and the beam vector are perpendicular. If they are perpendicular, it is determined that the printing position of the current printing laser beam is normal;

[0092] Otherwise, it is determined that there is a deviation in the printing position of the current printing laser beam;

[0093] A printing error analysis unit, configured to determine the laser alignment angle deviation value when it is determined that there is a deviation in the printing position of the current printing laser beam, and generate a beam analysis result based on the laser alignment angle deviation value, and send it to the laser scanning optimization module.

[0094] In this embodiment, the arbitrary model coordinate system is a high-precision coordinate system, and the minimum scale can reach 1 um. The directions of the two coordinate axes on the horizontal plane are parallel to the edge of the workbench.

[0095] In this embodiment, a single printing circle refers to the lines on the same layer during the laser printing process, and the same data layer refers to a layer formed by multiple or single printing circles with the same line features and pattern size data.

[0096] In this embodiment, the first vector refers to the direction vector from the actual current printing position to the target center point; the second vector refers to the direction vector from the position corresponding to the current printing position in the three-dimensional model to the corresponding center point of the same layer. Among them, the center of the same layer refers to the point on the central axis that is on the same horizontal plane as the current printing single circle.

[0097] In this embodiment, the standard position coordinate refers to the coordinate system established in the three-dimensional model that is consistent with any model coordinate system, and the standard coordinates of the adjacent printing points of the current printing position on the non-data circle layer (referring to the previous printing single circle corresponding to the current printing single circle) in this coordinate system.

[0098] In this embodiment, the third vector refers to the direction vector formed by the coordinate point corresponding to the target center coordinate and the coordinate point of the standard position coordinate.

[0099] In this embodiment, the beam vector refers to the output direction vector of the laser beam.

[0100] The beneficial effects of the above technical solutions: First, the present invention determines the device central axis of the additive device to be manufactured based on the three-dimensional model of the additive device to be manufactured through the central axis determination module, and establishes an arbitrary model coordinate system on the horizontal plane based on the central axis. Then, the detection and analysis unit determines the coordinates of different reference points according to the different properties of the printing single circle, and then generates a direction vector. Based on the direction and modulus of the direction vector, the quality of the laser beam is detected to determine whether there is a deviation in the printing position of the current printing laser beam. When it is determined that there is a deviation in the printing position of the current printing laser beam, the printing error analysis unit determines the laser alignment angle deviation value and generates a beam analysis result based on the laser alignment angle deviation value, and sends it to the laser scanning optimization module, realizing real-time monitoring and analysis of the printing laser beam, which is beneficial to timely discovering printing errors and reducing the defective rate of products.

[0101] Embodiment 5:

[0102] On the basis of Embodiment 4, the printing error analysis unit includes:

[0103] An error analysis subunit, configured to, when the current printing single circle is not a circle connection circle, determine the laser alignment position deviation value based on the first vector and the second vector, obtain the normal vector of the circle plane where the current printing position is located, and determine the laser alignment angle deviation value based on the cosine theorem, in combination with the normal vector modulus and the laser alignment position deviation value;

[0104] When the current printing single circle is a circle connection circle, determine the laser alignment angle deviation value based on the third vector and the beam vector;

[0105] An information sending subunit, configured to generate a beam analysis result based on the laser alignment angle deviation value and send it to the laser scanning optimization module.

[0106] Advantages of the above technical solution: By using the first vector and the second vector or the third vector and the beam vector, the present invention determines the angular deviation of laser alignment, providing a basis for the coaxial focusing of the lens.

[0107] Embodiment 6:

[0108] Based on Embodiment 5, a large-format laser scanning system for additive manufacturing of large aerospace metal parts further includes:

[0109] An automatic quality inspection module for comparing the laser alignment angle deviation value with a preset maximum allowable deviation value. When the laser alignment angle deviation value is greater than or equal to the preset maximum allowable deviation value, the maximum deviation is marked as 1; otherwise, it is marked as 0.

[0110] Obtain the marked digital situation of the current additive device to be manufactured in real time. When the marked quantity of the maximum deviation is greater than a preset value, it is determined that the current additive device to be manufactured is a defective device, and the printing of the current additive device to be manufactured is aborted.

[0111] Advantages of the above technical solution: The present invention compares the laser alignment angle deviation value with a preset maximum allowable deviation value. When the laser alignment angle deviation value is greater than or equal to the preset maximum allowable deviation value, the maximum deviation is marked as 1; otherwise, it is marked as 0, realizing the automatic detection of the local printing effect during the additive manufacturing process, and obtaining the marked digital situation of the current additive device to be manufactured in real time. When the marked quantity of the maximum deviation is greater than a preset value, it is determined that the current additive device to be manufactured is a defective device, and the printing of the current additive device to be manufactured is aborted. By transitioning from the local printing effect to the overall quality inspection of the additive device, aborting the manufacturing of unqualified products in a timely manner can effectively reduce the probability of finished product residuals, improve the product precision, and also reduce the waste of raw materials to a certain extent.

[0112] Embodiment 7:

[0113] Based on Embodiment 1, a laser scanning optimization module, as Figure 4 shown, includes:

[0114] An information analysis unit for analyzing the beam analysis result to determine the laser alignment angle deviation value;

[0115] A focusing instruction generation unit for determining the focusing error between the lens and the laser beam based on the laser alignment angle deviation value, and generating a focusing control instruction according to the focusing error;

[0116] A focusing control unit for controlling the coaxial focusing of the liquid lens and the laser beam based on the focusing control instruction.

[0117] Beneficial effects of the above technical solution: Based on the beam analysis results, the laser scanning optimization module of the present invention controls the liquid lens for real-time coaxial focusing, which is beneficial to improving the accuracy of laser alignment during the printing process and provides guarantee for generating high-quality large-scale aerospace metal parts by additive manufacturing.

[0118] Example 8:

[0119] Based on Example 1, the laser scanning optimization module, as Figure 4 shown, further includes:

[0120] A variable spot automatic switching unit, which is used to obtain various historical printing data based on big data and obtain similar printing historical data according to the current printing metal material;

[0121] Based on the model annotation dimensions corresponding to the 3D model, determine the line parameters corresponding to the next printing layer. Based on the line parameters, screen the similar printing historical data to obtain the similar line spot parameters;

[0122] Based on the similar line spot parameters, determine the target spot parameters corresponding to the next printing layer;

[0123] Generate a spot switching instruction according to the target spot parameters and send it to the laser controller;

[0124] After receiving the spot switching instruction, the laser controller controls the laser emitter to switch the spot size at the critical point of the completion of the current printing layer.

[0125] In this embodiment, the similar line spot parameters refer to the spot parameters corresponding to the historical printing lines with the same form as the line parameters corresponding to the next printing layer.

[0126] In this embodiment, the completion of the critical point refers to the time point when the current printing layer is completed and the next printing layer is about to start printing.

[0127] Beneficial effects of the above technical solution: The present invention determines the applicable spot machine and the corresponding spot parameters for the next printing layer through various historical printing data, and controls the laser emitter to switch the spot size at the critical point of the completion of the current printing layer, realizing the adaptive switching of the spot during the additive manufacturing process, which is beneficial to improving the precision of the additive device.

[0128] Example 9:

[0129] Based on Example 1, a large-format laser scanning system for additive manufacturing of large-scale aerospace metal parts further includes:

[0130] A fault persistence module, which is used to generate a storage node in the pre-stored whole-piece printing data of the currently to-be-manufactured additive device based on the printed data of the currently to-be-manufactured additive device when the laser scanning is abnormally interrupted, and send the storage node to a preset database;

[0131] After the laser scanning of the currently to-be-manufactured additive device is restarted, control the laser printing device to perform virtual printing based on the pre-stored whole-piece printing data, and when the virtual printing reaches the storage node, control the laser printing device to start normal printing.

[0132] In this embodiment, the abnormal interruption refers to the interruption of laser scanning caused by equipment failure or power outage.

[0133] Beneficial effects of the above technical solution: When the laser scanning is abnormally interrupted, the present invention generates a storage node according to the printed data of the to-be-manufactured additive device, which provides a basis for continuous printing after fault repair. After the laser scanning of the currently to-be-manufactured additive device is restarted, control the laser printing device to perform virtual printing based on the pre-stored whole-piece printing data, and when the virtual printing reaches the storage node, control the laser printing device to start normal printing, realizing continuous printing after the fault of the additive device. While reducing the probability of defective products caused by faults, it can also effectively avoid the problems of material waste and product qualification caused by repeated printing.

[0134] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention also intends to include these changes and modifications.

Claims

1. A large-format laser scanning system for additive manufacturing of large aerospace metal parts, characterized in that: include: The automatic scheme generation module is used to automatically plan the laser scanning path based on the 3D model of the additive device to be manufactured, and generate the scanning movement scheme of the workbench and the laser during the additive large-format scanning process; A scanning beam analysis module is used to analyze the laser beam according to the printed material data to obtain a beam analysis result during the process of controlling the laser to perform laser printing based on the scanning movement scheme; Laser scanning optimization module, used to control the liquid lens to perform real-time coaxial focusing based on the beam analysis results; Among them, the automatic solution generation module includes: A connection scheme determination unit, used to determine the scanning movement scheme of the laser in the process of connecting the printing circles according to the scanning movement scheme of the workbench in the process of connecting the printing circles and the laser position change trajectory within the effective manufacturing scanning range; The first scheme generating unit is used to generate a scanning movement scheme of the laser corresponding to the printing process of the additive device to be manufactured based on the scanning movement scheme of the laser in the process of connecting the printing circles and the laser position change trajectory of the printing single circle corresponding to the data printing circle; The second scheme generating unit is used to stipulate that the workbench and the laser in the same data printing circle layer are kept horizontal and vertical, and generate a scanning movement scheme of the workbench corresponding to the printing process of the additive device to be manufactured in combination with the scanning movement scheme of the workbench during the connection of the printing circle layer; Among them, the laser scanning optimization module includes: The variable spot automatic switching unit is used to obtain a variety of historical printing data based on big data, obtain similar printing history data according to the current printing metal material, and adjust the target spot parameters corresponding to the next printing circle.

2. A large-format laser scanning system for additive manufacturing of large aerospace metal parts according to claim 1, characterized in that: The unit for determining the connection plan includes: The model stratification subunit is used to classify the additive device to be manufactured into circles based on the model annotation size corresponding to the three-dimensional model, obtain multiple circles with the same data, and obtain the printing pattern corresponding to each circle with the same data of the additive device to be manufactured and its corresponding pattern size data; The position determination subunit is used to extract line features of the printing patterns corresponding to different printing circles with the same data, and generate the laser position change trajectory of the printing single circle in the printing circle with the same data based on the default printing start position and line features and the pattern size data; The scheme determination subunit is used to compare the line features and pattern size data of the same data printing circle layer with its corresponding adjacent same data printing circle layer, so as to obtain the correlation of the circle layer patterns; Based on the correlation of circle patterns, the change in the circle superposition angle of adjacent circles with the same data is determined, and according to the change in the circle superposition angle and the projection position of the printed circle on the workbench, the scanning movement plan of the workbench during the connection of the printed circles is determined.

3. A large-format laser scanning system for additive manufacturing of large aerospace metal parts according to claim 1, characterized in that: The automatic scheme generation module also includes: The scanning range determination unit is used to obtain a three-dimensional model of the additive device to be manufactured, determine the maximum scanning format of the additive device to be manufactured based on the top-down perspective of the three-dimensional model, and determine the effective manufacturing scanning range corresponding to the additive device to be manufactured according to the maximum scanning format.

4. A large-format laser scanning system for additive manufacturing of large aerospace metal parts according to claim 2, characterized in that: Scanning beam analysis module, including: A central axis determination module, for determining a device central axis of the additive device to be manufactured based on the three-dimensional model of the additive device to be manufactured, and establishing an arbitrary model coordinate system on a horizontal plane based on the central axis; A detection and analysis unit, used to determine the target center coordinates of the center point of the same layer corresponding to the current printing single circle based on the model coordinate system; When a single-circle non-circle layer connection circle is currently printed, a first vector is generated based on the current printing position and the target center point, and a second vector is synchronously generated in the three-dimensional model to determine whether the first vector and the second vector are completely consistent. If they are consistent, it is determined that the current printing laser beam printing position is normal; Otherwise, it is determined that there is a deviation in the current printing laser beam printing position; When the current printing single circle is a circle connecting the circles, the standard position coordinates of the adjacent printing points of the current printing position on the non-same data circle layer are obtained, and the third vector is generated based on the target center coordinates and the standard position coordinates, and the beam vector corresponding to the actual printing position corresponding to the laser beam from the output point to the current printing position is synchronously obtained. and judging whether the third vector and the light beam vector are perpendicular to each other, if so, judging that the current printing laser beam printing position is normal; Otherwise, it is determined that there is a deviation in the current printing laser beam printing position; The printing error analysis unit is used to determine the laser alignment angle deviation value when determining that the current printing laser beam printing position is deviated, and generate a beam analysis result based on the laser alignment angle deviation value and send it to the laser scanning optimization module.

5. A large-format laser scanning system for additive manufacturing of large-scale aerospace metal parts according to claim 4, characterized in that: Printing error analysis unit, comprising: The error analysis subunit is used to determine the laser alignment position deviation value based on the first vector and the second vector when currently printing a single-circle non-circle connection circle, and obtain the normal vector of the circle plane where the current printing position is located, and determine the laser alignment angle deviation value based on the cosine theorem, combined with the normal vector modulus and the laser alignment position deviation value; When the currently printed single circle is a circle connecting the circles, the laser alignment angle deviation value is determined based on the third vector and the beam vector; The information sending subunit is used to generate a beam analysis result based on the laser alignment angle deviation value and send it to the laser scanning optimization module.

6. A large-format laser scanning system for additive manufacturing of large-scale aerospace metal parts according to claim 5, characterized in that: Also includes: An automatic quality inspection module, used to compare the laser alignment angle deviation value with a preset maximum allowable deviation value, and when the laser alignment angle deviation value is greater than or equal to the preset maximum allowable deviation value, the maximum deviation is marked as 1, otherwise, it is marked as 0; The marking digital situation of the current additive device to be manufactured is obtained in real time. When the maximum deviation marking amount is greater than a preset value, the current additive device to be manufactured is determined to be a defective device, and the printing of the current additive device to be manufactured is terminated.

7. A large-format laser scanning system for additive manufacturing of large-scale aerospace metal parts according to claim 1, characterized in that: Laser scanning optimization module, including: An information analysis unit, used to analyze the beam analysis results and determine the laser alignment angle deviation value; A focus instruction generating unit, used to determine a focus error between the lens and the laser beam based on the laser reference angle deviation value, and to generate a focus control instruction according to the focus error; The focus control unit is used to control the coaxial focusing of the liquid lens and the laser beam based on the focus control instruction.

8. The large-format laser scanning system for additive manufacturing of large-scale aerospace metal parts according to claim 1, characterized in that: Also includes: A fault persistence module, for generating a storage node in the pre-stored whole-piece printing data of the current additive device to be manufactured and sending it to a preset database based on the printed data of the current additive device to be manufactured when the laser scanning is abnormally interrupted; After the laser scanning of the current additive device to be manufactured is restarted, the laser printing device is controlled to perform virtual printing based on the pre-stored whole-piece printing data, and when the virtual printing reaches the storage node, the laser printing device is controlled to start normal printing.

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