Intelligent composite material additive manufacturing wire monitoring device
By detecting the motion parameters of the motor and extrusion structure of the 3D printer nozzle and calculating the real-time wire margin, the problems of unstable wire supply and low monitoring accuracy in the prior art are solved, and more efficient wire management and stability of the printing process are achieved.
Patent Information
- Application Number
- CN202510496758.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-21
- Publication Date
- 2025-06-13
AI Technical Summary
In the existing 3D printing technology, unstable supply of wire materials leads to printing interruption, and the existing monitoring technology has low accuracy, making it difficult to accurately judge the remaining wire materials.
By detecting the motion parameters of the motor and extrusion structure of the 3D printer nozzle, the real-time wire margin is calculated to improve the accuracy of wire monitoring.
Higher precision wire monitoring is achieved, reducing printing interruptions and cost increase due to insufficient or waste of wire materials, and improving the efficiency of wire material management.
Smart Images
Figure CN120134618A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of composite additive manufacturing, and in particular to an intelligent composite material additive manufacturing wire material monitoring device. Background Art
[0002] 3D additive printing technology manufactures objects by stacking materials layer by layer. This manufacturing method has brought about major innovations and changes in the manufacturing industry. It makes it easier to manufacture complex structures and reduces the dependence on special tools. 3D printing technology has a wide range of applications in many fields, including medicine, aerospace, automobiles, and construction. In the medical field, 3D printing can be used to manufacture surgical guides, implants, etc.; in the aerospace field, 3D printing can be used to manufacture parts for complex structures; in the automotive field, 3D printing can be used for rapid prototyping and parts replacement; in the construction field, 3D printing can be used to manufacture complex building structures, etc. In standard FDM 3D printing technology, the extrusion and deposition of filaments are achieved through precise control of mechanical devices (such as screws or pistons) and stepper motors.
[0003] Filament is a key material in the 3D printing process, and its quality and supply stability directly affect the accuracy and quality of the printed parts. By monitoring the status of the filament, potential problems such as filament breakage, exhaustion or poor supply can be discovered and solved in a timely manner, thereby ensuring the smooth progress of the printing process and the quality of the printed parts. During the 3D printing process, if there is a problem with the filament supply, such as blockage, breakage or exhaustion, it will cause printing interruption, which will not only waste time and materials, but may also damage the printer. Through filament monitoring, you can understand the remaining amount and supply status of the filament in real time, and take timely measures to avoid printing interruptions.
[0004] In the existing 3D printing filament monitoring technology, the parameters of the rotation of the material tray driven by the filament are generally monitored to determine the amount of filament used and then the surplus and abnormal conditions of the filament. However, this kind of 3D printing filament generally has a certain toughness. During the rotation of the material tray, the part of the filament wrapped on the material tray is easy to lift away from the material tray. When this part of the filament is used, the material tray and the filament will not move synchronously, resulting in the actual surplus being less than the monitored surplus. When this difference accumulates too much, it will cause the 3D printer to stop printing due to the exhaustion of filament, affecting the printing efficiency.
[0005] Therefore, the present invention proposes an intelligent composite material additive manufacturing wire material monitoring device to solve the above problems. Summary of the invention
[0006] To solve the above problems, the present invention provides an intelligent monitoring device for the wire material in the additive manufacturing of composite materials. By detecting the motion parameters of the motor and the extrusion structure inside the nozzle of the 3D printer, the corresponding real-time remaining wire material can be calculated to improve the accuracy of wire material monitoring.
[0007] To achieve the above object, the technical solution of the present invention is as follows: An intelligent monitoring device for the wire material in the additive manufacturing of composite materials, comprising:
[0008] A data acquisition module, configured to obtain the motion parameters of the driving motor at the nozzle of the 3D printer and output the rotation number signal of its motor;
[0009] A remaining amount judgment module, configured to obtain the wire material diameter or the nozzle diameter of the 3D printer, defined as the first judgment data, and then obtain the pushing stroke of the extrusion mechanism inside the nozzle when the driving motor at the nozzle of the 3D printer rotates one circle, defined as the second judgment data; Based on the first judgment data and the second judgment data, calculate the wire material usage amount when the driving motor at the nozzle of the 3D printer rotates one circle, defined as the unit amount;
[0010] When performing 3D printing, calculate the actual wire material usage amount by calculating the real-time rotation number of the driving motor at the nozzle of the 3D printer obtained by the data acquisition module and the unit amount, and then calculate it with the pre-obtained total wire material amount to obtain the real-time remaining wire material amount;
[0011] The remaining amount judgment module is further configured to establish a thermal expansion compensation model for the wire material, input the physical property data of the wire material into the thermal expansion compensation model to obtain the ratio value of the volume of the wire material after being heated and melted to its solid state, and output the compensation data of the unit amount based on this ratio value and the second judgment data;
[0012] An alarm module, configured to output an alarm signal for wire material exhaustion based on the real-time remaining wire material amount.
[0013] Further, in the alarm module, when the real-time remaining wire material amount is less than the preset safety remaining amount threshold, an alarm signal for wire material exhaustion is output.
[0014] Further, the alarm signal includes sound and light signals.
[0015] Further, it further includes an image acquisition module. The image acquisition module is configured to obtain the image of the unused wire material in the 3D printing area and analyze its continuity. When the wire material breaks, a break signal is output.
[0016] Further, the alarm module outputs a corresponding alarm signal based on the break signal.
[0017] Further, it further includes an estimation module. The estimation module is configured to obtain the three-dimensional data information of the 3D printing target and calculate the theoretical wire material usage amount and the remaining estimated wire material usage amount based on this information.
[0018] Further, in the alarm module, when the remaining estimated filament usage is greater than the real-time filament remaining amount, an alarm signal will be output.
[0019] Further, it further includes an optimization module, which is used to calculate the difference between the filament usage when the printing target is completed and the theoretical filament usage, and dynamically adjust the estimation model based on this difference.
[0020] Further, the optimization module is also used to analyze abnormal situations during the printing process, including filament jamming and filament breakage, and record the driving motor rotation parameters and filament state data at the nozzle of the 3D printer when these abnormal situations occur. Based on these data, the printing strategy is further optimized, including adjusting the printing speed and increasing the preheating time.
[0021] Further, it further includes a user interaction module, which is used to display the real-time filament remaining amount, the estimated printing completion time, and the printing progress, and provide a user setting interface, allowing the user to customize the alarm threshold and adjust the printing parameters.
[0022] Adopting the above solution has the following beneficial effects:
[0023] 1. Compared with the prior art, the intelligent 3D printer filament monitoring device of the present invention can accurately calculate the actual filament usage in real time by precisely collecting the motion parameters of the internal motor and extrusion structure of the 3D printer nozzle, so as to obtain a more accurate real-time filament remaining amount. This high-precision monitoring method greatly improves the efficiency of filament management and reduces printing interruptions and cost increases caused by insufficient or wasted filaments.
[0024] 2. In this solution, the optimized alarm module is reasonably designed and can emit sound and light alarm signals in time when the filament remaining amount is lower than the preset safety threshold or the filament breaks, reminding the user to handle it in time and effectively avoiding printing failures caused by filament problems. At the same time, the alarm module can also issue a warning according to the comparison between the remaining estimated filament usage and the real-time filament remaining amount, further enhancing the user experience.
[0025] 3. This solution also introduces an optimization module, which can not only dynamically adjust the estimation model according to the difference between the filament usage when the printing target is completed and the theoretical filament usage to improve the accuracy of estimation, but also analyze abnormal situations during the printing process, such as filament jamming and filament breakage, and record relevant data for further optimizing the printing strategy. This intelligent optimization method helps to improve the printing quality and efficiency and reduce resource waste. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Figure 1 It is a schematic flow chart of an embodiment of the intelligent 3D printer filament monitoring device of the present invention. Detailed Implementation Modes
[0027] The present invention will be further clarified below in conjunction with the accompanying drawings and specific implementation modes. It should be understood that the following specific implementation modes are only used to illustrate the present invention and not to limit the scope of the present invention. It should be noted that the terms "front", "rear", "left", "right", "up" and "down" used in the following description refer to the directions in the accompanying drawings, and the terms "inner" and "outer" respectively refer to the directions towards or away from the geometric center of a specific component.
[0028] Embodiment 1:
[0029] As shown in the attached Figure 1 figure: An intelligent composite material additive manufacturing wire monitoring device includes: a data acquisition module for obtaining the motion parameters of the driving motor at the nozzle of a 3D printer and outputting the rotation signal of its motor;
[0030] A remaining amount judgment module for obtaining the wire diameter or the nozzle diameter of the 3D printer, defined as the first judgment data, and then obtaining the pushing stroke of the extrusion mechanism inside the nozzle when the driving motor at the nozzle of the 3D printer rotates one circle, defined as the second judgment data; Based on the first judgment data and the second judgment data, calculate the wire usage amount when the driving motor at the nozzle of the 3D printer rotates one circle, defined as the unit amount;
[0031] When performing 3D printing, calculate the actual wire usage amount by calculating the real-time rotation number of the driving motor at the nozzle of the 3D printer obtained by the data acquisition module and the unit amount, and then calculate it with the total wire amount obtained in advance to obtain the real-time wire remaining amount.
[0032] The remaining amount judgment module is also used to establish a thermal expansion compensation model for the wire, input the physical property data of the wire into the thermal expansion compensation model, obtain the ratio value of the volume of the wire after being heated and melted to its solid state, and output the compensation data of the unit amount based on this ratio value and the second judgment data.
[0033] Specifically, for example, the wire diameter is 0.4 mm and the nozzle diameter is 0.4 mm (these parameters may be different in actual applications, and are only examples here), but generally the wire diameter and the nozzle diameter are matched, and it is known that when the motor rotates one circle, the extrusion mechanism pushes the wire forward a certain distance (such as 5 mm). Based on this information, the remaining amount judgment module can calculate the length of the wire used for each rotation of the motor. Considering the errors in the heating, melting and extrusion processes of the wire in the nozzle, corresponding mathematical models or experimental data can be applied for calibration to make the monitoring data more accurate. The calibration algorithm in it establishes a compression rate database of different materials through experimental data and uses polynomial regression to fit the unit amount correction coefficient. The mathematical model of the thermal expansion compensation model of the wire is as follows:
[0034] V 实际 = V 理想 × (1 + k·ΔT)
[0035] where k is the expansion coefficient of the wire material, and ΔT is the temperature difference between the nozzle and the environment.
[0036] During the 3D printing process, the data acquisition module continuously outputs the real-time number of rotations of the motor. The remaining amount judgment module then multiplies these rotations by the unit amount to obtain the actual usage amount of the wire material. Then, it subtracts this actual usage amount from the total amount of wire material obtained in advance to obtain the real-time wire material remaining amount.
[0037] An alarm module, which is used to output an alarm signal for wire material exhaustion based on the real-time wire material remaining amount. In the alarm module, when the real-time wire material remaining amount is less than the preset safety remaining amount threshold, an alarm signal for wire material exhaustion is output. The alarm signal includes sound and light signals.
[0038] Specifically, for example, when a user is performing a 3D printing task, the preset safety remaining amount threshold is 1 meter. As the printing progresses, the real-time wire material remaining amount gradually decreases. When the remaining amount judgment module calculates that the real-time wire material remaining amount is lower than 1 meter, the alarm module is immediately activated, emitting a clear sound warning and a prominent light reminder to ensure that the user can promptly discover and handle the problem of insufficient wire material.
[0039] Thus, it is possible to improve the accuracy of wire material monitoring to solve the problem of low accuracy of remaining amount monitoring caused by the non-synchronous movement of the wire material on the tray when the wire material on the tray warps.
[0040] Embodiment 2:
[0041] The difference from Embodiment 1 is that, as Figure 1 shown, it further includes an image acquisition module. The image acquisition module is used to acquire the image of the unused wire material in the 3D printing area and analyze its continuity. When the wire material breaks, it outputs a break signal. It further includes an estimation module. The estimation module is used to acquire the three-dimensional data information of the 3D printing target and, based on this information, calculate the theoretical wire material usage amount and the remaining estimated wire material usage amount. In the alarm module, when the remaining estimated wire material usage amount is greater than the real-time wire material remaining amount, an alarm signal will be output. This real-time monitoring helps to promptly discover the breakage of the wire material. Once a breakage is detected, the system will immediately output a break signal, thus allowing the operator to respond quickly and avoid printing interruption or failure caused by wire material breakage.
[0042] For example, during the printing process, the image acquisition module suddenly captured an image of a broken wire and immediately output a break signal. At the same time, the estimation module calculated that the remaining estimated wire usage was much greater than the real-time wire surplus based on the current printing progress and the remaining model data. Therefore, the alarm module also issued an alarm signal. After receiving the alarm, the user immediately paused the printing task and checked the status of the wire. Sure enough, it was found that the wire had broken at a certain point, resulting in insufficient wire supply during the printing process. The user quickly replaced the new wire and restarted the printing task. Since the wire breakage problem was discovered and handled in a timely manner, the printing task was successfully completed.
[0043] This means that the device can issue an early warning before the filament is about to run out, giving the operator enough time to replenish the filament and thus avoid printing interruptions due to material shortages.
[0044] Embodiment 3:
[0045] The difference from Example 2 is that Figure 1 As shown, it also includes an optimization module, which is used to calculate the difference between the amount of wire used when the printing target is completed and the theoretical amount of wire used, and dynamically adjust the estimation model based on the difference. The optimization module is also used to analyze abnormal conditions during the printing process, including wire jamming and wire breakage, and record the rotation parameters of the drive motor and the wire status data at the nozzle of the 3D printer when these abnormal conditions occur. Based on these data, the printing strategy is further optimized, including adjusting the printing speed and increasing the preheating time. For the judgment of wire jamming, the peak value of the drive motor current is detected and compared with the preset safety peak value. When it is greater than the safety peak value, it is judged as wire jamming, and an abnormal log containing timestamps and position coordinates is generated for subsequent users to view. It also includes a user interaction module, which is used to display the real-time wire balance, the estimated printing completion time and the printing progress, and provides a user setting interface to allow users to customize the alarm threshold and adjust the printing parameters.
[0046] For example, during the printing process, the optimization module found that the actual amount of filament used was much greater than the theoretical amount of filament used. After analysis, it was found that the problem was caused by the blockage of the nozzle. At the same time, the user interface on the user interaction module also displays information such as the real-time filament remaining and the estimated printing completion time.
[0047] After receiving the alarm, the user viewed the detailed printing status and abnormal situation records through the user interface. According to the suggestions of the optimization module, the user adjusted the printing speed, increased the preheating time, and cleaned the nozzle. After these adjustments, the printing process became more stable, and the actual filament usage gradually approached the theoretical filament usage.
[0048] Finally, the printing task is successfully completed. The user views the final printing result and the filament usage report through the user interface. The report details information such as abnormal situations during the printing process, adjustment measures, and the final filament usage. Based on this information, the user further optimizes the printing strategy and prepares for future printing tasks.
[0049] The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.
Claims
1. An intelligent composite material additive manufacturing wire material monitoring device, characterized in that: include: The data acquisition module is used to obtain the motion parameters of the driving motor at the nozzle of the 3D printer and output the rotation number signal of the motor; The remaining amount judgment module is used to obtain the diameter of the wire or the diameter of the nozzle of the 3D printer, which is defined as the first judgment data, and then obtain the pushing stroke of the extrusion mechanism inside the nozzle when the driving motor at the nozzle of the 3D printer rotates one circle, which is defined as the second judgment data; based on the first judgment data and the second judgment data, the amount of wire used when the driving motor at the nozzle of the 3D printer rotates one circle is calculated, which is defined as the unit amount; When 3D printing is performed, the real-time rotation number of the driving motor at the nozzle of the 3D printer obtained by the data acquisition module is calculated with the unit amount to obtain the actual usage of the filament, and then the real-time filament surplus is obtained by calculating with the total amount of filament obtained in advance; The surplus judgment module is also used to establish a thermal expansion compensation model for the wire material, input the physical property data of the wire material into the thermal expansion compensation model, obtain the ratio value of the volume of the wire material after being heated and melted to its solid state, and output the compensation data of the unit amount based on the ratio value and the second judgment data; The alarm module is used to output an alarm signal of wire depletion based on the real-time wire remaining amount.
2. The intelligent composite material additive manufacturing wire material monitoring device according to claim 1, characterized in that: In the alarm module, when the real-time wire remaining amount is less than the preset safety margin threshold, an alarm signal indicating wire depletion is output.
3. The intelligent composite material additive manufacturing wire material monitoring device according to claim 2, characterized in that: Alarm signals include sound and light signals.
4. The intelligent composite material additive manufacturing wire material monitoring device according to claim 1, characterized in that: The system also includes an image acquisition module, which is used to obtain an image of unused wire in the 3D printing area and analyze its continuity. When the wire is broken, a break signal is output.
5. The intelligent composite material additive manufacturing wire material monitoring device according to claim 1, characterized in that : The alarm module outputs the corresponding alarm signal based on the fracture signal.
6. The intelligent 3D printer filament monitoring device according to claim 1, characterized in that: It also includes an estimation module, which is used to obtain three-dimensional data information of the 3D printing target, and based on the information, calculate the theoretical wire usage and the remaining estimated wire usage.
7. The intelligent 3D printer filament monitoring device according to claim 1, characterized in that: In the alarm module, when the remaining estimated wire usage is greater than the real-time wire surplus, an alarm signal will be output.
8. The intelligent 3D printer filament monitoring device according to claim 1, characterized in that: The system also includes an optimization module, which is used to calculate the difference between the amount of wire used when the printing target is completed and the theoretical amount of wire used, and dynamically adjust the estimation model based on the difference.
9. The intelligent 3D printer filament monitoring device according to claim 8, characterized in that: The optimization module is also used to analyze abnormal conditions during the printing process, including wire jams and wire breaks, and to record the rotation parameters of the drive motor and wire status data at the 3D printer nozzle when these abnormal conditions occur. Based on these data, the printing strategy is further optimized, including adjusting the printing speed and increasing the preheating time.
10. The intelligent 3D printer filament monitoring device according to claim 1, characterized in that: It also includes a user interaction module, which is used to display the real-time filament remaining amount, estimated printing completion time and printing progress, and provides a user setting interface to allow the user to customize the alarm threshold and adjust the printing parameters.