An additive manufacturing scraper life testing device, system and method

Abstract

This invention provides an additive manufacturing scraper life testing device, system, and method. The device includes a base plate, a first lifting track structure, a second lifting track structure, a drive system, a connecting plate, a clamping mechanism, a nozzle, a substrate, a pressure sensor, a lifting structure, a camera bracket, and a camera. The first and second lifting track structures are mounted on opposite sides of the base plate, capable of vertical lifting and lowering, and equipped with horizontally movable components. One end of the connecting plate is connected to the movable component of the first lifting track structure, and the other end is connected to the movable component of the second lifting track structure. The drive system is connected to both the first and second lifting track structures. The top of the clamping mechanism is fixed to the lower surface of the connecting plate, and the scraper to be tested is fixed below the clamping mechanism. The lifting structure is located on one side of the base plate. The top of the substrate has a protrusion and is mounted on the lifting structure. The pressure sensor is positioned between the substrate and the lifting structure. This invention offers higher testing accuracy.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, and in particular to an additive manufacturing scraper life detection device, system and method. Background Technology

[0002] In modern manufacturing, improving production efficiency and product quality are crucial goals. Additive Manufacturing Technologies (AM), also known as 3D printing (3DP), is a technology that manufactures solid parts by adding materials layer by layer based on three-dimensional CAD data. As an innovative manufacturing method, AM is widely used in the manufacture of various complex parts. The squeegee, a key component in powder placement, directly affects printing accuracy and finished product quality due to its wear. Real-time monitoring of squeegee wear is essential to ensure efficient equipment operation and extend squeegee lifespan. However, current technologies lack devices for monitoring the lifespan of 3D printing squeegees.

[0003] Patent application No. 201010167331.6 discloses an accelerated wear life testing machine for the surface coating of remanufactured parts and its testing method. The testing machine includes a friction drive component, a degree-of-freedom loading component, and a signal testing and acquisition component, which detects the life of the surface coating of the parts through friction. However, this testing machine is not suitable for the life testing of scrapers. Firstly, scrapers do not suffer from simple frictional wear; they experience contact wear with particles during the laying process. Therefore, directly using this testing machine for scraper life testing would yield inaccurate results. Secondly, scrapers need to handle large amounts of powder and maintain a high frequency of material laying during laying, which this testing machine cannot adapt to. Summary of the Invention

[0004] To address the problems existing in the prior art, the purpose of this invention is to provide an additive manufacturing scraper life detection device, system, and method with higher detection accuracy.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solution:

[0006] A device for detecting the lifespan of an additive manufacturing scraper includes a base plate, a first lifting track structure, a second lifting track structure, a drive system, a connecting plate, a clamping mechanism, a nozzle, a substrate, a pressure sensor, a lifting structure, a camera bracket, and a camera. The first and second lifting track structures are mounted on opposite sides of the base plate. Both structures are vertically movable and have horizontally movable components. One end of the connecting plate is connected to the movable component of the first lifting track structure, and the other end is connected to the movable component of the second lifting track structure. The drive system is connected to the movable components of both structures to drive their movement. The top of the clamping mechanism is fixed to the lower surface of the connecting plate, and the scraper to be tested is fixed below it. The nozzle is connected to the lower surface of the connecting plate and faces the scraper to be tested. The lifting structure is located on one side of the base plate. The top of the substrate has a protrusion and is mounted on the lifting structure. The pressure sensor is located between the substrate and the lifting structure. The camera bracket is placed on the other side of the base plate, and the camera is mounted on the camera bracket.

[0007] Furthermore, the first lifting track structure includes a lifting platform, a connecting member, a track base, a track, and a slider. The lifting platform is placed on one side of the base plate, the connecting member is placed on the lifting platform, the track base is fixed on the connecting member, the track is located within the track base, and the slider, as a moving component, can move horizontally along the track.

[0008] Furthermore, the second lifting track structure is identical to the second lifting track structure.

[0009] Furthermore, the drive system includes a motor, a coupling, and a rotating shaft. The motor is connected to the rotating shaft via the coupling, and the rotating shaft is connected to couplings built into the two side rails. The torque is transmitted to the slider through the internal couplings to drive the slider to move on the rails.

[0010] Furthermore, the clamping mechanism includes an upper top plate, a first clamping plate, and a second clamping plate. The first clamping plate and the second clamping plate are vertically connected to the upper top plate, and the scraper to be tested is fixed between the first clamping plate and the second clamping plate by a fixing mechanism.

[0011] Furthermore, the nozzle is connected to an air jet device.

[0012] Furthermore, the lifting structure includes an electric cylinder, a motor, and a support plate. The electric cylinder is mounted on the base plate, the support plate is disposed on the top of the electric cylinder, and the motor is electrically connected to the electric cylinder to drive the electric cylinder to move up and down.

[0013] Furthermore, the base plate is also provided with a first partition and a second partition placed vertically side by side at intervals. The first partition and the second partition divide the base plate into an experimental area, a cleaning area and a camera area. The lifting structure is set in the experimental area and the camera bracket is set in the camera area.

[0014] A system for detecting the lifespan of an additive manufacturing scraper includes:

[0015] The aforementioned device for testing the lifespan of additive manufacturing scrapers;

[0016] The first lifting control device is used to control the lifting of the first lifting track structure and the second lifting track structure, so that the scraper to be tested rises to a preset height.

[0017] The second lifting control device is used to control the lifting structure, so that the scraper under test presses against the substrate during the experiment.

[0018] A drive control device is used to control the drive system so that the scraper under test moves to the top of the substrate during the experiment and moves back and forth on the substrate to complete the powder spreading experiment on the substrate, moves to the cleaning area when cleaning is required, and moves to the front of the camera when shooting is required.

[0019] The jet control device is used to control the opening and closing of the nozzle, thereby enabling the cleaning of powder from the scraper blade.

[0020] The lifespan detection device is used to predict the lifespan of the scraper under test based on images taken by a camera after a period of testing and pressure data collected by a pressure sensor, using a lifespan prediction model. The lifespan prediction model is a machine learning model trained using several scraper images, pressure data, and corresponding lifespans as samples.

[0021] A method for detecting the lifespan of an additive manufacturing scraper, the method being based on the aforementioned device for detecting the lifespan of an additive manufacturing scraper, the method comprising:

[0022] S1. Place the powder to be laid on the laying substrate;

[0023] S2. Control the lifting of the first lifting track structure and the second lifting track structure so that the scraper to be tested rises to the preset height;

[0024] S3. Control the drive system so that the scraper to be tested moves directly above the substrate.

[0025] S4. Control the lifting structure to lift so that the scraper to be tested presses against the substrate.

[0026] S5. Control drive system, which makes the scraper under test reciprocate on the substrate to complete the powder spreading experiment on the substrate;

[0027] S6. Control the drive system to move the scraper under test to the cleaning area and open the nozzle switch to clean the powder on the scraper under test;

[0028] S7. Control the drive system to move the scraper under test in front of the camera and use the camera to capture an image of the scraper under test;

[0029] S8. Based on the images of the scraper under test taken by the camera after a period of time and the pressure data collected by the pressure sensor, the lifespan of the scraper under test is predicted using a lifespan prediction model. The lifespan prediction model is a machine learning model trained using several scraper images, pressure data and corresponding lifespans as samples.

[0030] Compared with the prior art, the beneficial effects of this invention are:

[0031] 1. The scraper life detection device of the present invention, through the combination of pressure sensor and camera, can monitor the wear of scraper in multiple powder laying experiments in real time, providing accurate wear data. The high-resolution images captured by the camera can record the wear degree of the scraper in detail, ensuring the accuracy of wear analysis. Combined with the data collected by pressure sensor, it can be used to comprehensively evaluate the stress state and wear of the scraper, greatly improving the detection accuracy.

[0032] 2. The scraper life detection device of the present invention is designed with an automated slide rail system, which allows the scraper to move automatically between the test area, the cleaning area and the camera area, reducing manual intervention, improving detection efficiency and increasing detection accuracy.

[0033] 3. The scraper life testing device of this invention employs an electric cylinder to precisely control the gap between the scraper and the substrate, ensuring consistency of experimental conditions for each test. Furthermore, after each test, the scraper moves to a cleaning area, where a nozzle removes residual powder using airflow, ensuring the scraper remains clean in subsequent tests. This cleaning process significantly improves the repeatability of experimental results and ensures the reliability of wear data.

[0034] 4. The scraper life detection system and method of the present invention analyzes wear data and mechanical data using machine learning algorithms, and can automatically analyze the data and provide life prediction results. Unlike traditional detection methods, the present invention can provide early warning of scraper wear, preventing the scraper from continuing to operate after reaching its service limit, reducing production problems caused by excessive scraper wear, and improving the initiative of equipment maintenance.

[0035] 5. This invention is applicable to different types of 3D printing equipment and can detect the lifespan of the scraper under various working conditions. By adjusting the electric cylinder and different types of substrates, the device can adapt to different printing materials and process conditions, and has broad application prospects. Attached Figure Description

[0036] Figure 1 This is a front structural schematic diagram of the additive manufacturing scraper life detection device provided in an embodiment of the present invention;

[0037] Figure 2 This is a schematic diagram of the right side structure of the additive manufacturing scraper life detection device provided in an embodiment of the present invention;

[0038] Figure 3 This is a top view schematic diagram of the additive manufacturing scraper life detection device provided in an embodiment of the present invention;

[0039] Figure 4 This is a structural diagram of the clamping mechanism provided in an embodiment of the present invention;

[0040] Figure 5 This is a structural diagram of the lifting structure provided in an embodiment of the present invention;

[0041] Figure 6 This is a structural diagram of the substrate provided in an embodiment of the present invention;

[0042] Figure 7 This is a connection diagram of the additive manufacturing scraper life detection method provided in an embodiment of the present invention;

[0043] Figure 8 This is a schematic diagram of the nozzle in use in an embodiment of the present invention. Detailed Implementation

[0044] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0045] This invention provides a device for detecting the lifespan of additive manufacturing scrapers, such as... Figure 1 , 2 As shown in Figures 1 and 3, the system includes a base plate 1, a first lifting track structure 2, a second lifting track structure 3, a drive system 4, a connecting plate 5, a clamping mechanism 6, a nozzle 7, a laying substrate 8, a pressure sensor 9, a lifting structure 10, a camera bracket 11, a camera 12, a first partition 14, and a second partition 15.

[0046] like Figure 1As shown, the first lifting track structure 2 and the second lifting track structure 3 are installed on both sides of the base plate 1. Both structures can be raised and lowered vertically and are equipped with movable components that can move horizontally. Specifically, the first lifting track structure includes a lifting platform 201, a connecting piece 202, a track base 203, a track 204, and a slider 205. The lifting platform 201 is placed on one side of the base plate 1. The connecting piece 202, specifically an I-shaped connecting piece, is placed on the lifting platform 201. The track base 203 is fixed to the connecting piece 202, and the track 204 is located within the track base 203. The slider 205, as a movable component, can move horizontally along the track 204. The second lifting track structure 3 has the same structure as the first lifting track structure 2. One end of the connecting plate 5 is connected to the slider of the first lifting track structure 2, and the other end is connected to the slider of the second lifting track structure 3. The drive system 4 is connected to the sliders of both the first and second lifting track structures for movement. The clamping mechanism 6 is fixed at the top to the lower surface of the connecting plate 5, and the scraper 13 to be tested is fixed below the clamping mechanism 6. The nozzle 7 is connected to the lower surface of the connecting plate 5 and faces the scraper 13 to be tested. The nozzle 7 is connected to the air jet device to realize air jet and clean the powder. The lifting structure 10 is set on one side of the base plate 1, the laying substrate 8 is set on the lifting structure 10, the pressure sensor 9 is set between the laying substrate 8 and the lifting structure 10, the camera bracket 11 is placed on the other side of the base plate 1, and the camera 12 is placed on the camera bracket 11. The camera 12 is specifically a CCD camera.

[0047] like Figure 2 and Figure 3 As shown, the base plate is provided with a first partition 14 and a second partition 15 placed vertically side by side at intervals. The first partition 14 and the second partition 15 divide the base plate into an experimental area, a cleaning area and a camera area. The lifting structure 10 is set in the experimental area and the camera bracket 11 is set in the camera area.

[0048] The drive system 4 includes a motor 401, a coupling 402, and a rotating shaft 403. The motor 401 is connected to the rotating shaft 403 through the coupling 402. The rotating shaft 403 is connected to the couplings built into the two side rails 204. The torque is transmitted to the slider 205 through the internal couplings to drive the slider 205 to move on the rails 204.

[0049] like Figure 4 As shown, the clamping mechanism 6 includes an upper top plate 601, a first clamping plate 602 and a second clamping plate 603. The first clamping plate 602 and the second clamping plate 603 are vertically connected to the upper top plate 601. The scraper to be tested 13 is fixed between the first clamping plate 602 and the second clamping plate 603 by a fixing mechanism.

[0050] like Figure 5As shown, the lifting structure 10 includes an electric cylinder 101, a motor 102, and a support plate 103. The electric cylinder 101 is mounted on the base plate 1, and the support plate 103 is located on the top of the electric cylinder 101. The motor 102 is electrically connected to the electric cylinder 101 and is used to drive the electric cylinder 101 to move up and down.

[0051] like Figure 6 As shown, the top of the substrate 8 has a protrusion to better simulate the pressure in actual applications. Since the wear of the scraper is mainly caused by the jamming process between the particles and the scraper, the force acting on the substrate 8 experiences a momentary increase during jamming. The narrower the width of the protrusion, the less jamming occurs in that area, and the more pronounced the rise and fall (peaks and troughs) of the stress curve received by the sensor. Without the protrusion, the areas where jamming occurs across the entire plane increase, and the pressure trend received by the pressure sensor is less obvious. Furthermore, in actual 3D printing, the powder layer is not completely flat; uneven accumulation or localized protrusions may exist. By setting a protrusion on the experimental substrate, these working conditions can be simulated, allowing for testing the scraper's performance and wear rate when facing these uneven surfaces.

[0052] This invention also provides a system for detecting the lifespan of additive manufacturing scrapers, comprising:

[0053] The aforementioned device for detecting the lifespan of additive manufacturing scrapers;

[0054] The first lifting control device is used to control the lifting of the first lifting track structure and the second lifting track structure, so that the scraper 13 to be tested rises to a preset height.

[0055] The second lifting control device is used to control the lifting structure 10, so that the scraper 13 under test presses against the protrusion on the substrate 8 during the experiment.

[0056] A drive control device is used to control the drive system 4, so that the scraper 13 to be tested moves to the top of the substrate 8 during the experiment and moves back and forth on the substrate 8 to complete the powder spreading experiment on the substrate 8, moves to the cleaning area when cleaning is required, and moves to the front of the camera 12 when shooting is required.

[0057] A jet control device is used to control the opening and closing of nozzle 7, thereby enabling the cleaning of powder from the scraper 13 to be tested when necessary.

[0058] The lifespan detection device is used to predict the lifespan of the scraper 13 under test based on the images of the scraper 13 under test taken by the camera 12 after a period of experimentation and the pressure data collected by the pressure sensor 9, using a lifespan prediction model. The lifespan prediction model is a machine learning model trained using several scraper images, pressure data and corresponding lifespans as samples.

[0059] This invention also provides a method for detecting the lifespan of additive manufacturing scrapers, the method being based on the aforementioned device for detecting the lifespan of additive manufacturing scrapers, such as... Figure 7 As shown, the method includes:

[0060] S1. Place the powder to be laid on the laying substrate 8;

[0061] S2. Control the lifting of the first lifting track structure and the second lifting track structure so that the scraper 13 to be tested rises to the preset height;

[0062] S3, control drive system 4, so that the scraper 13 to be tested moves directly above the substrate 8;

[0063] S4. Control the lifting structure 10 to lift so that the scraper 13 to be tested presses against the substrate 8.

[0064] S5, control drive system 4, so that the scraper 13 under test moves back and forth on the substrate 8 to complete the powder spreading experiment on the substrate 8;

[0065] S6. Control the drive system 4 to move the scraper 13 to the cleaning area and turn on the nozzle 7 switch to clean the powder on the scraper 13, such as... Figure 8 As shown;

[0066] S7, control drive system 4, so that the scraper 13 under test moves in front of camera 12 and the camera 12 takes an image of the scraper 13 under test;

[0067] S8. Based on the images of the scraper 13 under test captured by the camera 12 after a period of experimentation and the pressure data collected by the pressure sensor 9, the lifespan of the scraper 13 under test is predicted using a lifespan prediction model. The lifespan prediction model is a machine learning model trained using several scraper images, pressure data and corresponding lifespans as samples.

[0068] Through the above-described operational steps, the 3D printing scraper life rapid detection device of the present invention exhibits several significant technical advantages. First, the device utilizes a pressure sensor and camera system to achieve high-precision monitoring of the scraper's wear state. The pressure sensor captures real-time changes in the force applied to the scraper during operation, while the camera provides high-resolution image recording, ensuring that every detail of the wear process is accurately recorded. Second, the device is highly automated. A sliding rail system allows the scraper to move automatically between the experimental area, cleaning area, and camera area, reducing manual intervention and improving experimental efficiency. After each experiment, the nozzle automatically cleans residual powder from the scraper surface using airflow, ensuring consistent experimental conditions. Furthermore, the present invention incorporates machine learning algorithms, enabling accurate prediction of the scraper's remaining lifespan through analysis of sensor data and wear images. When the scraper wear exceeds a set particle diameter, the system issues an alarm, preventing production problems caused by excessive scraper use. Precise control of the electric cylinder ensures that the gap between the scraper and the substrate remains constant in each experiment, greatly improving the repeatability of experimental data. Meanwhile, this device is highly adaptable, suitable not only for different types of 3D printing equipment but also for various materials and process conditions, providing stable wear monitoring and lifespan prediction functions. This design greatly improves equipment utilization, avoids downtime losses due to sudden scraper failure, and helps operators better plan maintenance, reducing maintenance costs. In summary, the device of this invention improves production efficiency and extends equipment lifespan through precise detection and intelligent operation, and has broad application prospects, especially suitable for manufacturing environments requiring efficient lifespan monitoring.

Claims

1. A device for detecting the lifespan of an additive manufacturing scraper, characterized in that: The system includes a base plate (1), a first lifting track structure (2), a second lifting track structure (3), a drive system (4), a connecting plate (5), a clamping mechanism (6), a nozzle (7), a substrate (8), a pressure sensor (9), a lifting structure (10), a camera bracket (11), and a camera (12). The first lifting track structure (2) and the second lifting track structure (3) are mounted on both sides of the base plate (1). Both structures are vertically movable and have horizontally movable components. One end of the connecting plate (5) is connected to the movable component of the first lifting track structure (2), and the other end is connected to the movable component of the second lifting track structure (3). The drive system (4) is connected to the first lifting track structure (1) and the second lifting track structure (3). The moving parts of the lowering track structure (2) and the second lifting track structure (3) are used to drive the moving parts to move. The top of the clamping mechanism (6) is fixed to the lower surface of the connecting plate (5). The scraper to be tested (13) is fixed below the clamping mechanism (6). The nozzle (7) is connected to the lower surface of the connecting plate (5) and faces the scraper to be tested (13). The lifting structure (10) is set on one side of the base plate (1). The top of the laying substrate (8) is provided with a protrusion and is set on the lifting structure (10). The pressure sensor (9) is set between the laying substrate (8) and the lifting structure (10). The camera bracket (11) is placed on the other side of the base plate (1). The camera (12) is placed on the camera bracket (11). The first lifting track structure includes a lifting platform (201), a connector (202), a track corner (203), a track (204), and a slider (205). The lifting platform (201) is placed on one side of the base plate (1), the connector (202) is placed on the lifting platform (201), the track corner (203) is fixed on the connector (202), the track (204) is located inside the track corner (203), and the slider (205) is a moving component that can move horizontally along the track (204). The second lifting track structure (3) is the same as the first lifting track structure (2).

2. The device for detecting the lifespan of additive manufacturing scrapers according to claim 1, characterized in that: The drive system (4) includes a motor (401), a coupling (402), and a rotating shaft (403). The motor (401) is connected to the rotating shaft (403) through the coupling (402). The rotating shaft (403) is connected to a coupling built into the track (204). The torque is transmitted to the slider (205) through the built-in coupling to drive the slider (205) to move on the track (204).

3. The device for detecting the lifespan of additive manufacturing scrapers according to claim 1, characterized in that: The clamping mechanism (6) includes an upper top plate (601), a first clamping plate (602) and a second clamping plate (603). The first clamping plate (602) and the second clamping plate (603) are vertically connected to the upper top plate (601). The scraper to be tested (13) is fixed between the first clamping plate (602) and the second clamping plate (603) by a fixing mechanism.

4. The device for detecting the lifespan of additive manufacturing scrapers according to claim 1, characterized in that: The nozzle (7) is connected to the jetting device.

5. The device for detecting the life of additive manufacturing scrapers according to claim 1, characterized in that: The lifting structure (10) includes an electric cylinder (101), a motor (102), and a support plate (103). The electric cylinder (101) is mounted on the base plate (1), and the support plate (103) is located on top of the electric cylinder (101). The motor (102) is electrically connected to the electric cylinder (101) and is used to drive the electric cylinder (101) to move up and down.

6. The device for detecting the life of additive manufacturing scrapers according to claim 1, characterized in that: The base plate is also provided with a first partition (14) and a second partition (15) placed vertically side by side at intervals. The first partition (14) and the second partition (15) divide the base plate into an experimental area, a cleaning area and a camera area. The lifting structure (10) is set in the experimental area and the camera bracket (11) is set in the camera area.

7. A detection system for the life of an additive manufacturing scraper, characterized in that, include: The device for detecting the life of additive manufacturing scrapers according to any one of claims 1-6; The first lifting control device is used to control the lifting of the first lifting track structure and the second lifting track structure, so that the scraper (13) to be tested rises to a preset height; The second lifting control device is used to control the lifting structure (10) so that the scraper (13) to be tested presses against the substrate (8) during the experiment. A drive control device is used to control the drive system (4) so ​​that the scraper (13) to be tested moves to the top of the substrate (8) during the experiment and moves back and forth on the substrate (8) to complete the powder spreading experiment on the substrate (8), and moves to the cleaning area when cleaning is required, and moves to the front of the camera (12) when shooting is required. A jet control device is used to control the opening and closing of the nozzle (7) so as to clean the powder on the scraper (13) to be tested when needed; The lifespan detection device is used to predict the lifespan of the scraper (13) under test based on the images of the scraper (13) under test taken by the camera (12) after a period of experimentation and the pressure data collected by the pressure sensor (9), using a lifespan prediction model. The lifespan prediction model is a machine learning model trained using several scraper images, pressure data and corresponding lifespans as samples.

8. A method for testing the lifespan of an additive manufacturing scraper, characterized in that, The method is based on the additive manufacturing scraper life detection device according to any one of claims 1-6, and the method includes: S1. Place the powder to be laid on the laying substrate (8); S2. Control the lifting of the first lifting track structure and the second lifting track structure so that the scraper (13) to be tested rises to the preset height; S3. Control the drive system (4) to move the scraper (13) to be tested directly above the substrate (8); S4. Control the lifting structure (10) to lift so that the scraper (13) to be tested presses against the substrate (8); S5. Control drive system (4) to make the scraper (13) under test move back and forth on the substrate (8) to complete the powder spreading experiment on the substrate (8); S6. Control the drive system (4) to move the scraper (13) to be tested to the cleaning area and turn on the nozzle (7) switch to clean the powder on the scraper (13); S7. Control the drive system (4) to move the scraper (13) under test to the front of the camera (12) and use the camera (12) to take an image of the scraper (13) under test; S8. Based on the images of the scraper (13) under test taken by the camera (12) after a period of time and the pressure data collected by the pressure sensor (9), the lifespan of the scraper (13) under test is predicted using a lifespan prediction model. The lifespan prediction model is a machine learning model trained using several scraper images, pressure data and corresponding lifespans as samples.

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