Intelligent real-time powder blending device and method for laser melting deposition

Abstract

The invention relates to an intelligent real-time powder blending device and method for laser melting deposition, and belongs to the technical field of laser surface engineering. The device integrates an advanced intelligent sensing technology and a dynamic control system, and is mainly composed of a sensing module, a control system, a mixing unit and a feeding system. The sensing module monitors the powder flow, the workpiece surface roughness and the temperature in real time. And the control system automatically adjusts the ratio of various powders according to sensing data. The mixing unit is provided with a comprehensive monitoring system, so that uniform mixing of different types of powder is ensured. And the feeding system ensures the powder conveying stability. According to the invention, accurate proportioning and instant automatic adjustment of various powder materials can be realized, so that individual requirements of different workpieces in the laser cladding process can be flexibly adapted and met. The method comprises the steps of data acquisition, parameter calculation, automatic allocation, continuous cladding, real-time adjustment and the like, and the cladding quality and efficiency are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of laser additive manufacturing technology, and in particular to a device and method for intelligent real-time powder mixing for laser melting deposition. The device and method achieve accurate proportioning and automatic adjustment of multiple powder materials through intelligent control systems and sensors, are suitable for the cladding requirements of different materials and workpieces, and optimize the cladding quality and efficiency. Background Art

[0002] Laser melting deposition is an important surface strengthening and repair technology. It uses a high-energy laser beam to melt metal powder materials and combine them with the substrate surface to form a cladding layer with high strength, wear resistance and corrosion resistance. This technology is widely used in high-end manufacturing industries such as aerospace and automobile manufacturing. However, the quality of the cladding layer depends to a large extent on the composition and ratio of the powder material. At present, in laser cladding, the preparation of powder materials usually relies on manual experience or preset formulas, leading to the following problems:

[0003] 1. Insufficient ratio accuracy: Due to the complexity of workpiece material, surface condition and cladding process, manual mixing is difficult to accurately match actual needs, which can easily lead to unstable performance of the cladding layer, thereby affecting the service life of the workpiece.

[0004] 2. Low degree of automation: Existing powder mixing methods are mostly manual operations, which cannot be dynamically adjusted according to the real-time status of the workpiece, resulting in low repair efficiency and inability to adapt to the needs of complex components or different material combinations.

[0005] 3. Low material utilization rate: Due to the low precision of powder mixing, the material utilization rate is low, and material waste or uneven distribution often occurs during the cladding process.

[0006] In response to the above problems, the present invention proposes a powder material mixing device based on intelligent sensing and control. The sensor monitors the state of the workpiece surface in real time, and the control system dynamically adjusts the powder ratio according to the data to ensure accurate mixing and uniform mixing of the powder, which significantly improves the quality and consistency of the cladding layer. Compared with traditional methods, the device has significantly improved the degree of automation and mixing accuracy, and can effectively solve the problems of inaccurate ratio, insufficient automation, and material waste in the prior art. Summary of the invention

[0007] In view of the problems of inaccurate powder mixing, low degree of automation, and inability to make real-time adjustments in the prior art, the present invention provides a device and method for intelligent real-time powder mixing for laser melting deposition. Through the coordinated work of a sensor module, a control system, a mixing unit, and a feeding system, accurate proportioning and automatic adjustment of powder materials are achieved, the cladding process is optimized, and the quality and efficiency of workpiece repair are improved.

[0008] In order to achieve the above object, the technical solution of the present invention is as follows:

[0009] A powder intelligent real-time mixing device for laser melting deposition, characterized in that it includes a sensor module, a control system, a mixing unit and a feeding system, wherein:

[0010] 1. Sensing module: including a flow sensor (5), a roughness sensor (13) and a temperature sensor (16), which are used to monitor the powder flow and the surface state of the workpiece in real time respectively;

[0011] 2. Control system: automatically controls the rotation of the ball valve (4) according to the sensor data to adjust the ratio of various powders. It can also be used to set and display the mixing parameters, and supports users to manually fine-tune the ratio;

[0012] 3. Mixing unit: comprising a mixing box (6), a stirrer (8), an X-ray generator (7) and a multifunctional X-ray detector (9), integrating X-ray transmission and X-ray fluorescence spectroscopy (XRF) technology to ensure uniform mixing of various powder materials and monitor powder composition in real time;

[0013] 4. Feeding system: ensure stable and continuous powder transportation, including multiple feeding pipelines and pneumatic conveying devices.

[0014] The intelligent real-time powder mixing device for laser melting deposition is characterized in that the sensor module can provide real-time feedback on powder flow and workpiece status, and transmit the data to the control system (1) for processing.

[0015] The intelligent real-time powder mixing device for laser melting deposition is characterized in that the control system includes a data processing unit for analyzing sensor data; and an algorithm module including a machine learning algorithm for optimizing powder ratio calculation.

[0016] The intelligent real-time powder mixing device for laser melting deposition is characterized in that the mixing unit is designed with multiple powder feed ports, which are respectively connected to different types of powder material bins; a comprehensive monitoring system is used to monitor the density distribution, uniformity and elemental composition of the powder in real time; and a multi-stage stirring device is used to ensure uniform mixing of the powder.

[0017] The intelligent real-time powder mixing device for laser melting deposition is characterized in that the feeding system includes: a quantitative feeding device for accurately controlling the powder conveying amount; and a constant pressure control technology for ensuring the stability of powder conveying.

[0018] The present invention also provides a method for intelligent real-time powder preparation for laser melting deposition, which is characterized by comprising the following steps:

[0019] 1. Data collection: obtain real-time workpiece surface information and various powder flow data through the sensor module, and perform preliminary processing on the data;

[0020] 2. Parameter calculation: The control system calculates the optimal powder ratio based on real-time data and preset targets, and optimizes it in combination with machine learning algorithms;

[0021] 3. Automatic mixing: By adjusting the operating status of the mixing unit, the powder ratio is adjusted to achieve precise mixing;

[0022] 4. Continuous cladding: The prepared powder material is fed into the laser cladding equipment through the feeding system for cladding operation;

[0023] 5. Feedback adjustment: According to the real-time monitoring data during the cladding process, the powder ratio is automatically adjusted to adapt to the changes in the workpiece state.

[0024] The beneficial effects of the present invention include:

[0025] 1. Through the cooperation of intelligent sensing and control systems, human errors are reduced, the accuracy and consistency of the powder material mixing process are ensured, and the quality and uniformity of the cladding layer are improved;

[0026] 2. The dynamic adjustment function enables the device to quickly adapt to the needs of different workpieces and is suitable for repairing a variety of material combinations and complex workpieces;

[0027] 3. The present invention greatly improves the automation level of the laser cladding process, reduces manual operations, improves process efficiency, and can perform repairs without affecting production progress. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the overall structure of an intelligent real-time powder mixing device for laser melting deposition provided by the present invention;

[0029] Figure 2 The overall structure diagram of the mixing unit;

[0030] Figure 3 Cross-sectional structural diagram of the mixing unit;

[0031] Figure 4 Flow chart of the intelligent real-time deployment method of the present invention;

[0032] Explanation of numbers in the figure: 1. Control system; 2. Gravity sensor; 3. Feeding barrel; 4. Ball valve; 5. Flow sensor; 6. Mixing box; 7. X-ray generator; 8. Agitator; 9. Multifunctional X-ray detector; 10. Visualization screen; 11. Laser head; 12. Laser beam; 13. Roughness sensor; 14. Powder feeding pipe; 15. Workbench; 16. Temperature sensor; 17. Protective gas cylinder; 18. Laser generator. DETAILED DESCRIPTION

[0033] In order to make the objectives, technical solutions and advantages of the present invention more clear, the specific implementation modes of the present invention are further described in detail below with reference to the accompanying drawings.

[0034] Embodiment 1: Structural design of intelligent real-time allocation device.

[0035] The present invention provides a powder intelligent real-time mixing device for laser melting deposition, which includes the following main components: a sensor module, a control system, a mixing unit and a feeding system. The device realizes dynamic mixing and automatic adjustment of multiple powder materials through intelligent sensing and control technology.

[0036] 1. Sensing module: The sensing module contains multiple sensors for real-time monitoring of the surface status of the workpiece, including temperature sensors, surface roughness sensors and powder flow sensors. The temperature sensor uses a high-temperature thermocouple with a measurement range of 0°C to 1600°C and an accuracy of ±2°C. It is installed around the laser nozzle and keeps a distance of 10mm±2mm from the workpiece surface to monitor the surface temperature of the workpiece in order to adjust the cladding parameters of the powder material; the roughness sensor uses the principle of laser triangulation measurement with a measurement range of 0-500μm and a resolution of 0.1μm. It is installed near the laser nozzle and keeps a distance of 5mm±1mm from the workpiece surface to measure the roughness changes on the workpiece surface to ensure the uniformity of the cladding layer; the powder flow sensor uses a Coriolis mass flowmeter with a measurement range of 0-5kg / h and an accuracy of ±0.5%. It is installed on each powder supply pipeline to monitor the flow of various powder materials entering the mixing unit for precise control.

[0037] 2. Control system: The control system integrates a data processing unit and an algorithm module. The system uses a built-in control algorithm to calculate the optimal powder ratio based on the real-time data collected by the sensor module. The data processing unit uses FPGA to achieve high-speed data acquisition and preprocessing, with a sampling frequency of up to 10kHz. Through a comprehensive analysis of temperature, surface state and powder flow, the working state of the mixing unit is adjusted to achieve automatic powder mixing. The control system can also preset different ratio parameters according to different workpieces and cladding processes, and automatically adjust according to real-time data during the cladding process, with a response time of <100ms.

[0038] 3. Mixing unit: The mixing unit includes multiple powder feed ports, each of which is connected to different types of powder material bins.

[0039] a) Mixing box: Made of 316L stainless steel, with an effective volume of 10L, the inner wall is specially polished, and the surface roughness Ra is less than 0.4μm.

[0040] b) Stirring device: It adopts double helical blade design, the blade material is wear-resistant tungsten steel alloy, and the speed can be adjusted steplessly within the range of 100-2000rpm. The agitator shaft adopts magnetic sealing technology to ensure no dust leakage.

[0041] c) Comprehensive monitoring system: An X-ray generator (7) and a multifunctional X-ray detector (9) are installed on the side of the mixing box (6). The system integrates X-ray transmission and X-ray fluorescence spectroscopy (XRF) technology to achieve multi-dimensional real-time monitoring of powder:

[0042] X-ray transmission: X-rays emitted by the X-ray source pass through the mixed powder and are received by the multifunctional detector. By analyzing the attenuation of the X-rays, the density distribution and mixing uniformity of the powder can be monitored in real time. X-ray fluorescence spectrum: The same multifunctional detector can also capture the characteristic fluorescent X-rays generated by the powder after being excited by X-rays. By analyzing the energy and intensity of these fluorescent X-rays, the type and content of each element in the powder can be determined, thereby realizing real-time analysis of the composition. Visualization screen (10): Connected to the integrated monitoring system, it displays the state of powder mixing in real time, including density distribution diagram, uniformity analysis results and element composition analysis chart. The operator can observe the mixing process intuitively through the screen and promptly discover and solve potential problems.

[0043] The mixing unit ensures uniform mixing of powders through a multi-stage stirring device, and can adjust the proportion of each powder in a short time according to the instructions of the control system to meet different cladding requirements. A fine adjustment system is set in the stirring device to ensure that the mixed powder material has good uniformity, thereby improving the quality of the cladding layer.

[0044] 4. Feeding system: The feeding system includes a quantitative feeding device and a powder conveying pipeline. The quantitative feeding device accurately conveys the powder material prepared by the mixing unit to the laser nozzle. The feeding system adopts constant pressure control technology to ensure the flow stability of the powder material during the conveying process and avoid blockage or unevenness.

[0045] a) Quantitative feeding device: It uses a double screw feeder and a high-precision weighing sensor to achieve a feeding accuracy of ±0.1%. The maximum feeding rate is 5kg / h and the minimum can be controlled to 0.1g / min.

[0046] b) Powder conveying pipeline: It adopts 316L stainless steel pipe with polished inner wall, inner diameter 6mm, and the maximum conveying distance can reach 10m. The pipeline adopts modular quick connection design, which is easy to clean and replace.

[0047] Example 2: Powder material preparation method for laser melting deposition.

[0048] The intelligent real-time allocation device of the present invention specifically comprises the following steps in actual operation:

[0049] 1. Data collection: Before the cladding operation, the sensor module scans the workpiece surface to obtain information such as surface temperature and roughness. At the same time, the powder flow sensor monitors the current flow of various powder materials and transmits the data to the control system.

[0050] 2. Parameter calculation: The control system uses the algorithm to calculate the optimal powder ratio suitable for the current workpiece repair needs based on the collected data and the preset process parameters. This process is carried out in real time and can dynamically adjust the ratio when the process conditions change.

[0051] 3. Automatic mixing: The mixing unit adjusts the feed amount of various powders according to the instructions of the control system, and achieves accurate mixing of powders through the stirring device. After mixing, the powder material is tested to ensure that its ratio is accurate and the uniformity meets the requirements.

[0052] 4. Powder feeding: The prepared powder material is transported to the laser cladding equipment at a constant speed through the feeding system to participate in the cladding process. The feeding system monitors the flow rate and flow of the powder in real time during the transportation process to avoid material waste or insufficient feeding.

[0053] 5. Cladding completed: After laser cladding is completed, the sensor module detects the surface status of the workpiece again to ensure that the uniformity and performance of the cladding layer meet the requirements. If the cladding area needs to be adjusted, the control system can automatically adjust the powder ratio and perform secondary cladding repair.

[0054] Through the above specific implementation, the device and method of the present invention can realize the intelligent preparation of powder materials and efficient laser cladding repair process. This method can adapt to a variety of different workpieces and material combinations, ensuring the quality and production efficiency of the cladding layer.

[0055] The above description is only a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several improvements without departing from the principle of the present invention, and these improvements should also be regarded as within the protection scope of the present invention.

Claims

1. An intelligent real-time powder mixing device for laser melting deposition, characterized in that: It includes a sensor module, a control system, a mixing unit and a feeding system, wherein: Sensing module: the sensing module comprises a flow sensor (5), a roughness sensor (13) and a temperature sensor (16), which are respectively used to monitor the powder flow and the surface state of the workpiece in real time; Control system: automatically controls the rotation of the ball valve (4) according to the sensor data to adjust the proportion of various powders. It can be used to set and display the mixing parameters and support the user to manually fine-tune the proportion; Mixing unit: comprising a mixing box (6), a stirrer (8), an X-ray generator (7) and a multifunctional X-ray detector (9), integrating X-ray transmission and X-ray fluorescence spectroscopy (XRF) technology to ensure uniform mixing of various powder materials and monitor powder composition in real time; Feeding system: To ensure stable and continuous powder transportation, the feeding system includes multiple feeding pipelines and pneumatic conveying devices.

2. A method for intelligent real-time powder preparation for laser melting deposition, characterized in that: The following steps are involved: Data collection: obtain real-time workpiece surface information and various powder flow data through the sensor module, and perform preliminary processing on the data; Parameter calculation: The control system calculates the optimal powder ratio based on real-time data and preset targets, and optimizes it with machine learning algorithms; Automatic mixing: By regulating the operating status of the mixing unit, the powder ratio is adjusted to achieve precise mixing; Continuous cladding: The prepared powder material is fed into the laser cladding equipment through the feeding system for cladding operation; Feedback adjustment: According to the real-time monitoring data during the cladding process, the powder ratio is automatically adjusted to adapt to the changes in the workpiece state. The method according to claim 2, wherein The data collection steps include real-time monitoring of the workpiece surface temperature and roughness to evaluate surface adaptability; obtaining various powder flow data to record the flow characteristics and deposition of different powders during the cladding process; and collecting environmental condition data such as temperature through sensors to conduct a comprehensive analysis of factors affecting cladding quality. The method according to claim 2, wherein The parameter calculation step uses an optimization algorithm to calculate the best ratio scheme based on real-time monitoring data and cladding targets, taking into account the compatibility and performance of different powders; Generate a dynamic ratio chart to help users understand the current ratio and future adjustment trends in a visual way. The method according to claim 2, wherein The automatic mixing steps include adjusting the speed and mixing mode of the mixing unit to ensure that various powders are fully mixed within the specified time; adjusting the working state of the feeding system according to real-time flow data to achieve accurate delivery of various powders; A feedback mechanism is set up to monitor the mixing uniformity in real time using X-ray transmission technology, and the data is collected by a multifunctional X-ray detector. A high-resolution visual screen (10) is used to display the powder mixing status and component analysis results in real time. If a deviation in mixing uniformity is detected, the control system will automatically adjust the mixing parameters, including the speed, mixing method and mixing time, to ensure that the preset uniformity standard is achieved. The method according to claim 2, wherein The feedback adjustment steps include regularly generating adjustment reports based on real-time data during the cladding process to analyze the impact of the ratio on the cladding effect; providing users with the option of manual intervention, allowing users to make personalized adjustments based on the report to meet the needs of special workpieces; using data analysis tools to monitor and evaluate the performance of the mixing system and make optimization suggestions to further improve mixing efficiency and cladding quality.

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