Electric arc fuse wire additive manufacturing device capable of adjusting size of cladding layer in real time

Abstract

The invention belongs to the technical field of welding equipment, and particularly relates to an electric arc fuse wire additive manufacturing device capable of adjusting the size of a cladding layer in real time, the electric arc fuse wire additive manufacturing device comprises a welding gun and a deposition head installed at the gun head of the welding gun, and the deposition head is provided with a temperature distribution acquisition module, a morphology acquisition module and an execution mechanism; the temperature distribution acquisition module is used for detecting molten pool temperature distribution in real time, the morphology acquisition module is used for detecting the width and the layer height of a melting channel in real time, and the execution mechanism is used for adjusting the wire feeding speed of a fuse wire. According to the invention, the temperature distribution of a molten pool is monitored in real time through the temperature distribution acquisition module, the width and the layer height of a melting channel are detected in real time through the morphology acquisition module, and the control module generates a cladding quality evaluation coefficient according to acquired data and compares the cladding quality evaluation coefficient with a reference threshold value, so that the execution mechanism is accurately controlled to adjust the wire feeding speed. The mechanism can dynamically correct the size of the cladding layer in real time, the precision of the size of the cladding layer is greatly improved, and it is ensured that a final product meets the strict size standard.

Description

Technical Field

[0001] The invention relates to the technical field of welding equipment, and in particular to an arc fuse additive manufacturing device capable of adjusting the size of a cladding layer in real time. Background Art

[0002] In arc fuse additive manufacturing technology, precise control of the size of the cladding layer has always been a key problem in the industry. Traditional arc fuse additive manufacturing devices often lack real-time monitoring and adjustment mechanisms. During the manufacturing process, they are affected by a variety of factors, such as fluctuations in the molten pool temperature and unstable material wire feeding speed, which makes it difficult to accurately control the size of the cladding layer within the expected range. If the molten pool temperature is too high or too low, it will change the melting state of the material, thereby affecting the thickness and width of the cladding layer; uneven wire feeding speed will cause defects such as inconsistent thickness and uneven surface of the cladding layer.

[0003] These problems not only reduce the quality of additive manufacturing products, but also increase the cost and time of subsequent processing. At the same time, due to the lack of real-time monitoring and feedback control of the cladding process, it is difficult for operators to adjust process parameters in time according to actual conditions, resulting in low production efficiency and difficulty in meeting the needs of modern manufacturing for high-precision and high-efficiency production. Summary of the invention

[0004] Based on the technical problems existing in the prior art, the present invention proposes an arc fuse additive manufacturing device capable of adjusting the size of the cladding layer in real time.

[0005] The present invention proposes an arc fuse additive manufacturing device for adjusting the size of a cladding layer in real time, comprising a welding gun and a deposition head installed at the head of the welding gun, wherein the deposition head is provided with a temperature distribution acquisition module, a morphology acquisition module and an actuator; the temperature distribution acquisition module is used for real-time detection of the temperature distribution of a molten pool, the morphology acquisition module is used for real-time detection of the width and layer height of a melt path, and the actuator is used for adjusting the wire feeding speed of the fuse; during the additive manufacturing process, the control module receives the data collected by the temperature distribution acquisition module and the morphology acquisition module in real time, and performs a comprehensive analysis, and then generates a cladding quality assessment coefficient, compares the cladding quality assessment coefficient with a preset reference threshold of the cladding quality assessment coefficient, determines whether the size of the current cladding layer is within a reasonable range, and controls the working state of the actuator according to the comparison result; if the size of the current cladding layer is not within a reasonable range, the actuator will start to adjust the wire feeding speed of the fuse, thereby adjusting the size of the subsequent cladding layer.

[0006] Preferably, a mounting frame is fixed on the top of the deposition head, and the top end of the mounting frame is fixedly sleeved on the welding gun; in this way, the deposition head can be fixed to a suitable position away from the gun head through the mounting frame.

[0007] Preferably, the temperature distribution acquisition module is fixed to the side of the deposition head close to the welding gun through the first support rod, the morphology acquisition module is fixed to the side of the deposition head close to the welding gun through the second support rod, and the control module is fixed inside the deposition head; in this way, the temperature distribution acquisition module can be used to better detect the temperature distribution of the molten pool in real time, and the morphology acquisition module can be used to detect the melt track width and layer height in real time, thereby improving the accuracy of the detection results.

[0008] Preferably, the actuator includes a motor fixed to the inner wall of one side of the deposition head and a shaft column rotatably connected to the inner wall of one side of the deposition head, and gears and propulsion wheels are respectively installed on the output shaft and the shaft column of the motor, and the two gears are meshingly connected; the motor will start after receiving relevant instructions from the control module, and drive one of the propulsion wheels to rotate at a set speed, and then drive the two propulsion wheels to rotate synchronously through the meshing transmission of the two gears to feed the wire.

[0009] Preferably, a conical cylinder for the fuse to pass through is provided on one side of the deposition head close to the welding gun; the fuse is stabilized by the conical cylinder, thereby ensuring that the end of the fuse accurately enters the gun head position.

[0010] Preferably, the actuator is also used to preheat the fuse, and the actuator also includes a heating resistor, a temperature acquisition module, a heating control unit and an IGBT power module. An installation groove is opened in the conical cylinder, and the heating resistor and the temperature acquisition module are installed in the installation groove. The heating control unit and the IGBT power module and the control module are integrated together; the temperature acquisition module detects the preheating temperature of the heating resistor in real time. When the preheating temperature needs to be adjusted, the control module will send a corresponding signal to the heating control unit. After receiving the signal, the heating control unit sends a signal to the IGBT power module. After receiving the signal, the IGBT power module sends an instruction to the heating resistor, thereby adjusting the real-time heating power.

[0011] Preferably, the calculation formula of the cladding quality evaluation coefficient is:

[0012]

[0013] Where, T max : Maximum temperature of the molten pool; T set : process setting temperature; W: measured melt channel width; W tgt : Target melt channel width; H: Measured layer height; H tgt : target layer height; α, β, γ: weight coefficients.

[0014] Preferably, the control logic flow of the control module controlling the working state of the actuator according to the comparison result is as follows:

[0015] 1. Threshold determination:

[0016] When K ≤ 0.1, maintain the current wire feeding speed;

[0017] When 0.1 < K ≤ 0.3, enable proportional control;

[0018] When K > 0.3, enable fuzzy PID control;

[0019] II. Wire feeding speed adjustment equation:

[0020]

[0021] Constraint condition: V min ≤ V new ≤ V max ;

[0022] In the formula, V new : Adjusted wire feeding speed; V cur : Current wire feeding speed; K p : Proportional gain coefficient; K i : Integral time constant.

[0023] Preferably, the control logic process for preheating the fuse is as follows:

[0024] I. Adjust the target preheating temperature based on the thermodynamic state of the molten pool:

[0025] II. Achieve temperature closed-loop by regulating the heating resistance power through PWM.

[0026] Preferably, the calculation formula for the target preheating temperature is:

[0027]

[0028] In the formula, Molten pool set temperature; Q arc : Arc input heat flux; c p : Specific heat capacity of the material; ρ: Material density;

[0029] The regulation formula for the heating resistance power (P heat ) is:

[0030]

[0031] In the formula, P heat : Heating resistance power; T pre : Measured preheating temperature; K p , K i : PID parameters.

[0032] Compared with the prior art, the present invention provides an arc wire - feeding additive manufacturing device for real - time adjusting the size of the cladding layer, having the following beneficial effects:

[0033] 1. An arc fuse additive manufacturing device that adjusts the size of the cladding layer in real time. The temperature distribution acquisition module monitors the temperature distribution of the molten pool in real time, and the morphology acquisition module detects the width and layer height of the melt path in real time. The control module generates a cladding quality evaluation coefficient based on the acquired data and compares it with the reference threshold, and then accurately controls the actuator to adjust the wire feeding speed. This mechanism can dynamically correct the size of the cladding layer in real time, greatly improving the accuracy of the cladding layer size, ensuring that the final product meets strict size standards, and reducing the defective rate caused by size deviation.

[0034] 2. An arc fuse additive manufacturing device that adjusts the size of the cladding layer in real time. The conical cylinder set on one side of the deposition head stabilizes the fuse and guides the end of the fuse to accurately enter the gun head position, avoiding the fuse from deflecting or shaking during the feeding process, further improving the stability of the additive manufacturing process and the quality of the cladding layer.

[0035] 3. An arc fuse additive manufacturing device that adjusts the size of the cladding layer in real time. The actuator has the function of preheating the fuse. Through the coordinated work of the heating resistor, temperature acquisition module, heating control unit and IGBT power module, it can intelligently adjust the target preheating temperature according to the thermodynamic state of the molten pool, and achieve temperature closed-loop control by PWM control of the heating resistor power. This preheating mechanism optimizes the state of the fuse before it enters the molten pool, helps to improve the fusion effect of the fuse and the molten pool, improve the metallurgical quality of the cladding layer, and further enhance product performance.

[0036] 4. An arc fuse additive manufacturing device that adjusts the size of the cladding layer in real time, a calculation formula for the cladding quality assessment coefficient, and a control logic flow for the control module to control the working state of the actuator according to the comparison results, as well as a control logic flow for preheating the fuse. These advanced algorithms and control logic can flexibly adjust the wire feeding speed and fuse preheating temperature according to various parameter changes in the actual manufacturing process, realize intelligent and refined additive manufacturing process control, and significantly improve the quality and production efficiency of additive manufacturing products. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of an arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time proposed by the present invention;

[0038] Figure 2 This is a schematic diagram of the overall structure of an arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time proposed by the present invention;

[0039] Figure 3 For the present invention Figure 2 A schematic diagram of the enlarged structure at point A;

[0040] Figure 4A schematic diagram of the structure of a deposition head of an arc fuse additive manufacturing device for adjusting the size of a cladding layer in real time proposed by the present invention;

[0041] Figure 5 A schematic diagram of the internal structure of a deposition head of an arc fuse additive manufacturing device for adjusting the size of a cladding layer in real time proposed by the present invention;

[0042] Figure 6 For the present invention Figure 5 Schematic diagram of the enlarged structure at B.

[0043] In the figure: 1. welding gun; 2. IGBT power module; 3. deposition head; 4. conical cylinder; 5. temperature distribution acquisition module; 6. morphology acquisition module; 7. control module; 8. shaft column; 9. motor; 10. gear; 11. propulsion wheel; 12. mounting frame; 13. first support rod; 14. second support rod; 15. mounting slot; 16. heating resistor; 17. temperature acquisition module; 18. heating control unit. DETAILED DESCRIPTION

[0044] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0045] In the description of the present invention, it is necessary to understand that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0046] Reference Figure 1-Figure 6 , an arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time, comprising a welding gun 1 and a deposition head 3 installed at the head of the welding gun 1, and the deposition head 3 is provided with a temperature distribution acquisition module 5, a morphology acquisition module 6 and an actuator;

[0047] The temperature distribution acquisition module 5 is used to detect the temperature distribution of the molten pool in real time, the morphology acquisition module 6 is used to detect the width and layer height of the melt path in real time, and the actuator is used to adjust the wire feeding speed of the fuse;

[0048] When in use, during the additive manufacturing process, the control module 7 receives the data collected by the temperature distribution acquisition module 5 and the morphology acquisition module 6 in real time, and performs a comprehensive analysis, and then generates a cladding quality assessment coefficient, and compares the cladding quality assessment coefficient with a preset reference threshold of the cladding quality assessment coefficient to determine whether the size of the current cladding layer is within a reasonable range, and controls the working state of the actuator according to the comparison result. If the size of the current cladding layer is not within a reasonable range, the actuator will start to adjust the wire feeding speed of the fuse, thereby adjusting the size of the subsequent cladding layer.

[0049] Among them, a mounting frame 12 is fixed on the top of the deposition head 3, and the top end of the mounting frame 12 is fixedly sleeved on the welding gun 1;

[0050] When in use, the deposition head 3 can be fixed to a suitable position at a distance from the gun head through the mounting bracket 12 .

[0051] The temperature distribution acquisition module 5 is fixed to the side of the deposition head 3 close to the welding gun 1 through the first support rod 13, the morphology acquisition module 6 is fixed to the side of the deposition head 3 close to the welding gun 1 through the second support rod 14, and the control module 7 is fixed inside the deposition head 3;

[0052] When in use, the temperature distribution acquisition module 5 can better detect the temperature distribution of the molten pool in real time, and the shape acquisition module 6 can detect the width and layer height of the melt path in real time, thereby improving the accuracy of the detection results.

[0053] The actuator includes a motor 9 fixed to the inner wall of one side of the deposition head 3 and a shaft column 8 rotatably connected to the inner wall of one side of the deposition head 3. A gear 10 and a propulsion wheel 11 are respectively installed on the output shaft of the motor 9 and the shaft column 8. The two gears 10 are meshed and connected.

[0054] When in use, the motor 9 will start after receiving the relevant instructions from the control module 7, and drive one of the propulsion wheels 11 to rotate at a set speed, and then drive the two propulsion wheels 11 to rotate synchronously through the meshing transmission of the two gears 10 to feed the wire.

[0055] Among them, a conical cylinder 4 for the fuse to pass through is provided on one side of the deposition head 3 close to the welding gun 1;

[0056] When in use, the fuse is stabilized by the conical tube 4, thereby ensuring that the end of the fuse accurately enters the position of the gun head.

[0057] Furthermore, the actuator is also used to preheat the fuse, and the actuator also includes a heating resistor 16, a temperature acquisition module 17, a heating control unit 18 and an IGBT power module 2. A mounting groove 15 is provided in the conical cylinder 4, and the heating resistor 16 and the temperature acquisition module 17 are both installed in the mounting groove 15. The heating control unit 18 is integrated with the IGBT power module 2 and the control module 7;

[0058] When in use, the temperature acquisition module 17 detects the preheating temperature of the heating resistor 16 in real time. When the preheating temperature needs to be adjusted, the control module 7 will send a corresponding signal to the heating control unit 18. After receiving the signal, the heating control unit 18 will send a signal to the IGBT power module 2. After receiving the signal, the IGBT power module 2 will send an instruction to the heating resistor 16, thereby adjusting the real-time heating power.

[0059] Among them, the input end and output end of the temperature distribution acquisition module 5 are electrically connected to the output end and input end of the control module 7 respectively, the input end and output end of the morphology acquisition module 6 are electrically connected to the output end and input end of the control module 7 respectively, the input end and output end of the temperature acquisition module 17 are electrically connected to the output end and input end of the control module 7 respectively, the output end of the control module 7 is electrically connected to the input end of the motor 9 and the heating control unit 18 respectively, the output end of the heating control unit 18 is electrically connected to the input end of the IGBT power module 2, and the output end of the IGBT power module 2 is electrically connected to the input end of the heating resistor 16.

[0060] It should be noted that the temperature distribution acquisition module 5 can be a molten pool infrared thermal imaging module (sampling frequency ≥ 500 Hz, temperature measurement range 800-2500 ° C) or other equipment that can detect the temperature distribution of the molten pool in real time, the morphology acquisition module 6 can be a cladding layer morphology scanning module (using blue light laser triangulation, measurement accuracy ± 0.05 mm, scanning frequency ≥ 200 Hz) or other equipment that can detect the width and layer height of the melt in real time, the temperature acquisition module 17 can be a temperature sensor or other equipment that can detect the preheating temperature of the heating resistor 16 in real time, and the control module 7 is an embedded controller (such as Beckhoff CX2040 series) with an integrated data fusion algorithm. Therefore, the temperature distribution acquisition module 5, the morphology acquisition module 6, the temperature acquisition module 17 and the control module 7 are not specifically limited here and can be selected according to actual needs;

[0061] In another embodiment, through the cooperation between the temperature distribution acquisition module 5, the morphology acquisition module 6, the control module 7 and the actuator, the control logic of intelligently adjusting the wire feeding speed of the fuse is as follows:

[0062] 1. Threshold determination:

[0063] When K ≤ 0.1, maintain the current wire feeding speed;

[0064] When 0.1 < K ≤ 0.3, enable proportional control;

[0065] When K > 0.3, enable fuzzy PID control;

[0066] II. Wire feeding speed adjustment equation:

[0067]

[0068] Constraint condition: V min ≤ V new ≤ V max ;

[0069] In the formula, V new : Adjusted wire feeding speed (m / min); V cur : Current wire feeding speed (m / min); K p : Proportional gain coefficient; K i : Integral time constant.

[0070] In addition, a deposition efficiency factor can be introduced for real-time compensation:

[0071]

[0072] In the formula, η: Deposition efficiency (%); V depo : Deposition head moving speed (mm / s); d: Wire diameter (mm); Q deposit : Deposited metal amount (mm3 / s); Q wire : Wire feeding metal amount (mm3 / s); V wire : Wire feeding speed (mm / s).

[0073] Among them, the calculation formula for the cladding quality evaluation coefficient is:

[0074]

[0075] In the formula, T max : Maximum temperature of the molten pool (°C); T set : Process set temperature (°C); W: Measured width of the molten channel (mm); W tgt : Target width of the molten channel (mm); H: Measured layer height (mm); H tgt : Target layer height (mm); α, β, γ: Weight coefficients.

[0076] In another embodiment, through the cooperation between the temperature distribution acquisition module 5, the topography acquisition module 6, the temperature acquisition module 17, the control module 7 and the actuator, the control logic flow for intelligently preheating the fuse is as follows:

[0077] 1. Adjust the target preheating temperature based on the thermodynamic state of the molten pool:

[0078]

[0079] In the formula, Molten pool set temperature (℃); Q arc : Arc input heat flux (J / s); c p : material specific heat capacity (J / (kg·K)); ρ: material density (kg / m 3 );

[0080] 2. Use PWM to control the power of the heating resistor 16 to achieve a temperature closed loop:

[0081]

[0082] Where P heat : Heating resistor power (W); T pre : Measured preheating temperature (℃); K p , K i : PID parameters (need to be calibrated experimentally).

[0083] It should be understood that in the various embodiments of the present application, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0084] Those of ordinary skill in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this application.

[0085] In the several embodiments provided in the present application, it should be understood that the disclosed overall system, device and method can be implemented in other ways. For example, the device embodiments described above are only schematic. For example, the division of the units is only a logical function division. There may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another overall system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms.

[0086] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0087] In addition, each functional unit in each embodiment of the present application may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit.

[0088] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. An arc fuse additive manufacturing device capable of adjusting the size of a cladding layer in real time, comprising a welding gun (1) and a deposition head (3) mounted at the head of the welding gun (1), characterized in that: A temperature distribution acquisition module (5), a topography acquisition module (6) and an actuator are provided on the deposition head (3). The temperature distribution acquisition module (5) is used to detect the temperature distribution of the molten pool in real time, the topography acquisition module (6) is used to detect the width and layer height of the weld bead in real time, and the actuator is used to adjust the wire feeding speed of the welding wire. The control module (7) receives the data collected by the temperature distribution acquisition module (5) and the topography acquisition module (6), generates a cladding quality evaluation coefficient, compares it with a preset reference threshold, and controls the working state of the actuator according to the comparison result.

2. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 1, characterized in that: An installation frame (12) is fixed on the top of the deposition head (3), and the top end of the installation frame (12) is fixedly sleeved on the welding torch (1).

3. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 1, characterized in that: The temperature distribution acquisition module (5) is fixed on one side of the deposition head (3) close to the welding torch (1) through a first support rod (13), the topography acquisition module (6) is fixed on one side of the deposition head (3) close to the welding torch (1) through a second support rod (14), and the control module (7) is fixed inside the deposition head (3).

4. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 1, characterized in that: The actuator includes a motor (9) fixed on the inner wall of one side of the deposition head (3) and a shaft column (8) rotatably connected to the inner wall of one side of the deposition head (3). Gears (10) and a propulsion wheel (11) are respectively installed on the output shaft of the motor (9) and the shaft column (8), and the two gears (10) are meshed and connected.

5. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 1, characterized in that: A conical cylinder (4) for the welding wire to pass through is provided on one side of the deposition head (3) close to the welding torch (1).

6. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 5, characterized in that: The actuator is also used to preheat the welding wire. The actuator further includes a heating resistor (16), a temperature acquisition module (17), a heating control unit (18) and an IGBT power module (2). An installation groove (15) is formed in the conical cylinder (4), and the heating resistor (16) and the temperature acquisition module (17) are both installed in the installation groove (15). The heating control unit (18), the IGBT power module (2) and the control module (7) are integrated together.

7. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 1, characterized in that: The calculation formula of the cladding quality evaluation coefficient is as follows: Where, T max : Maximum temperature of the molten pool; T set : Process setting temperature; W: Measured weld bead width; W tgt : Target melt channel width; H: Measured layer height; H tgt : target layer height; α, β, γ: weight coefficients.

8. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 7, characterized in that: The control logic flow of the control module (7) for controlling the working state of the actuator according to the comparison result is as follows: I. Threshold judgment: When K ≤ 0.1, maintain the current wire feeding speed; When 0.1 < K ≤ 0.3, enable proportional control; When K > 0.3, enable fuzzy PID control; II. Wire feeding speed adjustment equation: Constraints: V min ≤V new ≤V max ; Where V new : Corrected wire feeding speed; V cur : Current wire feeding speed; K p : Proportional gain coefficient; K i : Integration time constant.

9. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 6, characterized in that: The control logic flow for preheating the welding wire is as follows: I. Adjust the target preheating temperature based on the thermodynamic state of the molten pool: II. Achieve temperature closed-loop by regulating the power of the heating resistor (16) through PWM.

10. The arc fuse additive manufacturing device for adjusting the size of the cladding layer in real time according to claim 9, characterized in that: The target preheating temperature The calculation formula is: In the formula, Molten pool set temperature; Q arc : arc input heat flux; c p : material specific heat capacity; ρ: Material density; Heating resistor (16) power (P heat ) is: Where P heat : Heating resistor power; T pre : Measured preheating temperature; K p , K i : PID parameters.

Images