A multi-sensor fusion composite laser additive and subtractive hybrid manufacturing platform

Abstract

The application discloses a kind of composite material laser additive-subtractive composite manufacturing platforms of multi-sensor fusion, including mutually matched additive mechanical arm, subtractive mechanical arm and test platform;The end of additive mechanical arm is equipped with additive manufacturing laying head;The end of subtractive mechanical arm is equipped with multi-sensor fusion's laser subtractive manufacturing mechanism;Subtractive mechanical arm in working process, by first motor, second motor and third motor control rotation angle, so that laser emitted by laser reaches laser subtractive manufacturing mechanism after first reflector, second reflector and third reflector in turn.Using the application, it can realize the continuous fiber reinforced composite component manufacturing demand of high degree of freedom and high precision, for example, complex structure forming, mechanical property promotion, additive-subtractive integrated manufacturing and full laser processing etc..

Description

TECHNICAL FIELD

[0001] The present application relates to the field of carbon fiber composite materials, in particular to a multi-sensor fusion composite material laser additive and subtractive manufacturing platform. BACKGROUND

[0002] At present, continuous fiber reinforced composite components are mostly formed by molding and fiber winding, and then mechanical machining is used to remove burrs and drill holes for assembly and quality requirements.

[0003] A kind of additive and subtractive composite continuous fiber composite forming method and device for use disclosed in Chinese patent document with publication number CN114683534A uses additive and subtractive composite forming for continuous fiber composite materials, uses fused deposition for additive forming, and uses laser subtractive machining.

[0004] Chinese patent document with publication number CN103071928A discloses a method for machining small holes on carbon fiber composite materials using annular pulse laser, which uses annular pulse laser to irradiate the plate, and under the combined effect of thermal effect and shock wave force of annular pulse laser irradiation, the annular laser layer by layer cuts into the material, and finally cuts through the entire irradiation area of carbon fiber composite material to complete the machining of small holes.

[0005] However, the existing method has several challenges, for example, during the manufacturing process, inaccurate control of forming parameters will affect the interfacial bonding between fibers and matrix materials, and poor interfacial bonding will lead to a decrease in material performance; and fibers have high strength and high hardness, which can cause tool wear during subtractive process, affecting machining precision and forming efficiency. Moreover, the asynchronous process of additive manufacturing and subtractive manufacturing poses a challenge to the forming precision of composite components. SUMMARY

[0006] The present application provides a multi-sensor fusion composite material laser additive and subtractive manufacturing platform, which can realize the manufacturing requirements of high degree of freedom and high precision of continuous fiber reinforced composite components, such as complex structure forming, mechanical property improvement, integrated manufacturing of additive and subtractive, and full laser machining, etc.

[0007] A multi-sensor fusion composite material laser additive and subtractive manufacturing platform, comprising an additive mechanical arm, a subtractive mechanical arm and a test platform that cooperate with each other;

[0008] The end of the additive mechanical arm is provided with an additive manufacturing deposition head; the end of the subtractive mechanical arm is provided with a multi-sensor fusion laser subtractive manufacturing mechanism;

[0009] The subtractive mechanical arm comprises a mechanical arm base, a first connecting rod arm rotatably connected to the mechanical arm base, a second connecting rod arm rotatably connected to the first connecting rod arm, a third connecting rod arm rotatably connected to the second connecting rod arm, and a fourth connecting rod arm fixed to the end of the third connecting rod arm; the end of the fourth connecting rod arm is rotatably connected to a fifth connecting rod arm, the end of the fifth connecting rod arm is rotatably connected to a sixth connecting rod arm, and the end of the sixth connecting rod arm is connected to a laser subtractive manufacturing mechanism; the fourth connecting rod arm is provided with a fixed rod near the end thereof;

[0010] The second connecting rod arm is provided with a laser and a laser coupler on the side wall near one end of the first connecting rod arm, and is provided with a first reflector with a rotation angle controlled by a first motor on the side wall near one end of the third connecting rod arm; the side wall of the fixed rod is provided with a second reflector with a rotation angle controlled by a second motor; the laser subtractive manufacturing mechanism is provided with a reflector fixing plate with a rotation angle controlled by a third motor, and the outer end of the reflector fixing plate is provided with a third reflector;

[0011] During the working process of the subtractive mechanical arm, the rotation angles of the first motor, the second motor and the third motor are controlled to make the laser emitted by the laser emitter pass through the first reflector, the second reflector and the third reflector in turn and then reach the laser subtractive manufacturing mechanism.

[0012] Optionally, the laser emitter comprises a continuous laser emitter, a nanosecond pulse laser emitter, a picosecond pulse laser emitter and a femtosecond pulse laser emitter.

[0013] Further, if the third connecting rod arm rotates an angle θ1 around the second connecting rod arm, the first motor controls the first reflector to rotate an angle θ2 to offset the influence of θ1 during the transmission of the laser emitted by the laser emitter;

[0014] If the fifth connecting rod arm rotates an angle θ3 around the fourth connecting rod arm, the second motor controls the second reflector to rotate an angle θ4 to offset the influence of θ3;

[0015] If the sixth connecting rod arm rotates an angle θ5 around the fifth connecting rod arm, the third motor controls the reflector fixing plate to rotate an angle θ6 to offset the influence of θ5.

[0016] Further, the laser subtractive manufacturing mechanism comprises a connecting flange plate and a bearing seat; the upper end of the connecting flange plate is fixedly connected to the end of the sixth connecting rod arm, the lower end is fixed to the upper end of the bearing seat through a frame, a third motor with an output end downward is arranged in the frame; the output end of the third motor is connected to the upper end of a connecting shaft through a shaft coupling, the lower end of the connecting shaft is sequentially connected to a focusing mechanism, a protection mechanism and a laser light emitting head;

[0017] The side wall of the connecting shaft is provided with a light inlet hole, and a mirror fixing plate is arranged below the light inlet hole; the inside of the connecting shaft is provided with a fourth mirror at a position opposite to the light inlet hole; the laser reflected by the third mirror enters the inside of the connecting shaft from the light inlet hole, is reflected by the fourth mirror, and is then output after sequentially passing through a focusing mechanism, a protection mechanism and a laser light outlet head.

[0018] Further, the lower end of the bearing seat is provided with an ultrasonic probe and an infrared thermal imager.

[0019] Further, the setting angles of the third mirror and the fourth mirror are both 45°.

[0020] Further, the inside of the focusing mechanism is provided with a focusing optical element, and the inside of the protection mechanism is provided with an optical element protection mirror.

[0021] Further, the additive manufacturing laying head comprises a connecting plate, a material tray, a feeding mechanism, a shearing mechanism, a laser head, a gas cylinder and a guide plate fixed on the connecting plate; the upper end of the gas cylinder is fixedly connected with the connecting plate, and the lower end is fixedly connected with a compression roller; the upper end of the connecting plate is connected with the tail end of the additive mechanical arm through a flange connecting disc;

[0022] The composite material prepreg tape is wound on the material tray, and in the additive manufacturing process, the composite material prepreg tape is laid on the test platform after sequentially passing through the feeding mechanism, the shearing mechanism and the guide plate, and cooperates with the laser head and the compression roller.

[0023] Compared with the prior art, the present application has the following beneficial effects:

[0024] 1. The present application combines additive manufacturing and subtractive manufacturing with full laser processing, reduces tool wear and meets the forming requirements of complex structures with high degrees of freedom, and finally realizes efficient, low-cost and high-precision laser composite forming manufacturing.

[0025] 2. The present application fuses ultrasonic detection and infrared thermal imaging multi-sensor, senses fiber orientation and temperature distribution with high precision, and performs adaptive process parameter adjustment and intelligent path planning based on the detection results, greatly improving the forming efficiency and processing quality. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 It is a whole structure schematic view of a multi-sensor fusion composite material laser additive and subtractive composite manufacturing platform according to an embodiment of the present application.

[0027] Figure 2 It is a structure schematic view of an additive manufacturing laying head arranged on an additive mechanical arm in an embodiment of the present application.

[0028] Figure 3 It is a structure schematic view of a subtractive mechanical arm in an embodiment of the present application.

[0029] Figure 4 Variable laser light path schematic diagram in subtractive robot arm.

[0030] Figure 5 Laser subtractive manufacturing mechanism structure schematic diagram arranged on the subtractive robot arm in the embodiment of the application.

[0031] Figure 6 Sectional view of the laser subtractive manufacturing mechanism.

[0032] Figure 7 Ultrasonic detection principle schematic diagram of the fiber-reinforced composite material in the embodiment of the application.

[0033] Figure 8 Flow chart of the laser additive and subtractive composite in-situ manufacturing method of the continuous fiber-reinforced composite material in the embodiment of the application. DETAILED DESCRIPTION

[0034] The application will be further described in detail below with reference to the accompanying drawings and embodiments, and it should be pointed out that the following embodiments are intended to facilitate the understanding of the application and do not limit the application in any way.

[0035] As shown in Figure 1 , a composite laser additive and subtractive manufacturing platform based on multi-sensor fusion includes an additive robot arm 1, an additive manufacturing laying head 2, a subtractive robot arm 3, a subtractive manufacturing variable laser light path 4, a multi-sensor fusion laser subtractive manufacturing mechanism 5, and a test platform 6.

[0036] As shown in Figure 2 , the additive manufacturing laying head 2 mainly includes a tray 201, a shaft 202, a composite material prepreg 203, a flange connecting disc 204, a connecting plate 205, a feeding mechanism 206, a shearing mechanism 207, a laser head 208, a cylinder 209, a guide plate 210, and a compression roller 211.

[0037] The tray 201, the feeding mechanism 206, the shearing mechanism 207, the laser head 208, the cylinder 209, and the guide plate 210 are fixed on the connecting plate 205. The upper end of the cylinder 209 is fixedly connected with the connecting plate 205, and the lower end is fixedly connected with the compression roller 211. The compression roller 211 and the lower part of the cylinder 209 can move along the y direction. The upper end of the connecting plate 205 is connected with the end of the additive robot arm 1 through the flange connecting disc 204.

[0038] The tray 201 can rotate around the shaft 202, the shaft 202 is fixedly connected with the connecting plate 205, and the composite material prepreg 203 is wound on the tray 201. In the additive manufacturing process, the composite material prepreg 203 is laid on the test platform 6 in sequence after passing through the feeding mechanism 206, the shearing mechanism 207 and the guide plate 208, and is cooperated with the laser head 208 and the compression roller 211 to perform additive manufacturing.

[0039] As shown in Figure 3 and Figure 4 The subtractive mechanical arm 3 includes a mechanical arm base 415, a first connecting rod arm 416 rotatably connected on the mechanical arm base 415, a second connecting rod arm 417 rotatably connected on the first connecting rod arm 416, a third connecting rod arm 418 rotatably connected on the second connecting rod arm 417, and a fourth connecting rod arm 419 fixedly connected with the end of the third connecting rod arm 418; the end of the fourth connecting rod arm 419 is provided with a fifth connecting rod arm 421 rotatably connected, the end of the fifth connecting rod arm 421 is provided with a sixth connecting rod arm 422 rotatably connected, and the end of the sixth connecting rod arm 422 is connected with the laser subtractive manufacturing mechanism 5; the fourth connecting rod arm 419 is provided with a fixed rod 420 at a position close to the end.

[0040] The laser 401 and the laser coupler fixing plate 403 are arranged on the side wall of the second connecting rod arm 417 close to one end of the first connecting rod arm 416, the laser coupler fixing plate 403 is provided with a laser coupler 404, and a first reflector 406 controlled by a first motor 407 to rotate at an angle is arranged on the side wall close to one end of the third connecting rod arm 418; the side wall of the fixed rod 420 is provided with a second reflector 409 controlled by a second motor 410 to rotate at an angle; the laser subtractive manufacturing mechanism 5 is provided with a reflector fixing plate 413 controlled by a third motor 502 to rotate at an angle, and the outer end of the reflector fixing plate 413 is provided with a third reflector 414.

[0041] The main principle of the variable laser light path 4 of the subtractive manufacturing on the subtractive mechanical arm 3 includes:

[0042] Firstly, the laser 401 outputs a laser beam 402, the laser beam 402 outputs a laser beam 405 through the laser coupler 404, and then the laser beam 405 is converted into a laser beam 408 under the action of the first reflector 406. At this time, if the third connecting rod arm 418 rotates an angle θ1 around the second connecting rod arm 417, the first motor 407 controls the first reflector 406 to rotate an angle θ2 to offset the influence of θ1.

[0043] Then, the laser beam 408 is converted into a laser beam 411 under the action of the second reflector 409. At this time, if the fifth connecting rod arm 421 rotates an angle θ3 around the fourth connecting rod arm 419, the second motor 410 controls the second reflector 409 to rotate an angle θ4 to offset the influence of θ3.

[0044] Finally, the laser beam 411 is converted into the laser beam 412 under the action of the third mirror 414. At this time, if the sixth connecting arm 222 rotates an angle θ5 around the fifth connecting arm 421, the third motor 502 controls the mirror fixing plate 413 to rotate an angle θ6 to offset the influence of θ5.

[0045] As shown in Figure 5 and Figure 6 The laser subtractive manufacturing mechanism 5 includes a connecting flange plate 501 and a bearing seat 503, and the lower end of the bearing seat 503 is fixedly connected with a bearing cover 505. The upper end of the connecting flange plate 501 is fixedly connected with the end of the fourth connecting arm 422, and the lower end is fixed with the upper end of the bearing seat 503 through a frame, and the frame is internally provided with a third motor 502 with the output end downward. The output end of the third motor 502 is connected with the upper end of a connecting shaft 507 through a shaft coupling 511, and the lower end of the connecting shaft 507 is sequentially connected with a focusing mechanism 508, a protection mechanism 509 and a laser light output head 510. The inside of the focusing mechanism 508 is provided with a focusing optical element 516, and the inside of the protection mechanism 509 is provided with an optical element protection mirror 517. The lower end of the bearing seat 503 is provided with an ultrasonic probe 504, an ultrasonic probe 506 and an infrared thermal imager 519.

[0046] The bearing 512 and the bearing 513 are arranged between the connecting shaft 507 and the bearing seat 503. The outer ring of the bearing 512 and the bearing 513 is fixedly connected with the bearing seat 503, and the inner ring of the bearing 512 and the bearing 513 is fixedly connected with the connecting shaft 507.

[0047] The sidewall of the connecting shaft 507 is provided with a light inlet hole, and a mirror fixing plate 413 is arranged below the light inlet hole. The inside of the connecting shaft 507 is provided with a fourth mirror 514 at a position opposite to the light inlet hole. The laser reflected by the third mirror 414 enters the inside of the connecting shaft 507 through the light inlet hole, is reflected by the fourth mirror 514, and is sequentially outputted through the focusing mechanism 508, the protection mechanism 509 and the laser light output head 510.

[0048] The mechanism of the laser subtractive manufacturing mechanism with multi-sensor fusion is as follows: the laser beam 412 is reflected into the laser beam 515 by the fourth mirror 514. The laser beam 515 is converted into the laser beam 518 with smaller diameter under the focusing action of the focusing optical element 516. The laser beam 518 is outputted at the laser light output head 510 after passing through the optical element protection mirror 517. The ultrasonic probe 504, the ultrasonic probe 506 and the infrared thermal imager 519 detect the workpiece, and the detection results are used to guide the motion trajectory of the laser beam 518, so as to complete the subtractive manufacturing of the workpiece.

[0049] As shown in Figure 7As shown, the principle of multi-sensor fusion. The composite plate is composed of composite plates 101, 102, 103 and 104 with different fiber directions. The ultrasonic probe 504 emits ultrasonic waves to the composite plate, and then the ultrasonic probe 506 receives the propagation data of the ultrasonic waves, analyzes and processes, can detect the fiber direction of the composite plate, and can adjust the detection depth. The infrared thermal imager 519 can obtain the temperature field of the composite plate, and the ultrasonic detection result and the infrared thermal imaging result are fused, and the accurate composite plate depth and temperature information can be obtained.

[0050] In the embodiment of the application, the continuous fiber reinforced composite laser additive manufacturing method comprises the following steps: Figure 8 As shown, mainly includes: before the continuous fiber reinforced composite laser additive manufacturing, the additive manufacturing process parameters need to be determined, which is used to guide the subsequent formal processing. Turn on the laser additive and subtractive composite manufacturing equipment and install the clamping workpiece. Start laser-assisted additive manufacturing, measure and record laser power, roller pressure and feed speed and other process parameters, and evaluate the processing quality. Through the analysis of the relationship between process parameters and processing quality, the effect of optimizing process parameters is achieved, and finally the process parameters and processing quality are output.

[0051] The continuous fiber reinforced composite laser subtractive manufacturing method comprises the following steps: Figure 8 As shown, mainly includes: before the continuous fiber reinforced composite laser additive manufacturing, the additive manufacturing process parameters need to be determined, which is used to guide the subsequent formal processing. Turn on the laser additive and subtractive composite manufacturing equipment and install the clamping workpiece. Start laser-assisted additive manufacturing, measure and record laser power, roller pressure and feed speed and other process parameters, and evaluate the processing quality. Through the analysis of the relationship between process parameters and processing quality, the effect of optimizing process parameters is achieved, and finally the process parameters and processing quality are output.

[0052] The continuous fiber reinforced composite laser additive and subtractive composite in-situ manufacturing method comprises the following steps: Figure 8 As shown, mainly includes: turn on the laser additive and subtractive composite manufacturing equipment and install the clamping workpiece. Start laser-assisted manufacturing layer by layer, after the current layer is completed, use ultrasonic detection fiber orientation, use infrared thermal imager to measure temperature distribution, use multi-sensor fusion algorithm to fuse data measurement, which is used to guide the subsequent processing; then carry out adaptive process parameter adjustment and intelligent path planning, and then carry out laser subtractive processing of the layer. Judge whether all layers of processing are completed, if not, repeat the above steps until all layers of processing are completed, and finally output the processed workpiece

[0053] The above embodiments describe the technical solutions and advantages of the present application in detail. It should be understood that the above description is only a specific embodiment of the present application and is not intended to limit the present application. Any modification, supplement and equivalent replacement made within the principle range of the present application shall be included in the protection range of the present application.

Claims

1. A multi-sensor fusion composite laser additive and subtractive hybrid manufacturing platform, characterized in that, It comprises a mutually cooperating additive robot arm (1), a subtractive robot arm (3) and a test platform (6); The end of the additive robot arm (1) is provided with an additive manufacturing laying head (2); the end of the subtractive robot arm (3) is provided with a multi-sensor fusion laser subtractive manufacturing mechanism (5); The subtractive robot arm (3) comprises a robot arm base (415), a first connecting rod arm (416) rotatably connected to the robot arm base (415), a second connecting rod arm (417) rotatably connected to the first connecting rod arm (416), a third connecting rod arm (418) rotatably connected to the second connecting rod arm (417), and a fourth connecting rod arm (419) fixed to the end of the third connecting rod arm (418); the end of the fourth connecting rod arm (419) is provided with a fifth connecting rod arm (421) rotatably connected thereto, the end of the fifth connecting rod arm (421) is provided with a sixth connecting rod arm (422) rotatably connected thereto, and the end of the sixth connecting rod arm (422) is connected to the laser subtractive manufacturing mechanism (5); the fourth connecting rod arm (419) is provided with a fixed rod (420) at a position close to the end thereof; The second connecting rod arm (417) is provided with a laser (401) and a laser coupler (404) on the side wall close to one end of the first connecting rod arm (416), and is provided with a first reflector (406) controlled by a first motor (407) to rotate at an angle on the side wall close to one end of the third connecting rod arm (418); the side wall of the fixed rod (420) is provided with a second reflector (409) controlled by a second motor (410) to rotate at an angle; the laser subtractive manufacturing mechanism (5) is provided with a reflector fixing plate (413) controlled by a third motor (502) to rotate at an angle, and the outer end of the reflector fixing plate (413) is provided with a third reflector (414); During the operation of the subtractive robot arm (3), the first motor (407), the second motor (410) and the third motor (502) control the rotation angles to make the laser emitted by the laser (401) pass through the first reflector (406), the second reflector (409) and the third reflector (414) in sequence and then reach the laser subtractive manufacturing mechanism (5).

2. The multi-sensor fused composite laser additive-subtractive hybrid manufacturing platform of claim 1, wherein, The laser (401) comprises a continuous laser, a nanosecond pulse laser, a picosecond pulse laser and a femtosecond pulse laser.

3. The multi-sensor fused composite laser additive-subtractive hybrid manufacturing platform of claim 1, wherein, During the transmission of the laser emitted by the laser (401), if the third connecting rod arm (418) rotates around the second connecting rod arm (417) by an angle θ1, the first motor (407) controls the first reflector (406) to rotate by an angle θ2 to offset the influence caused by θ1; If the fifth connecting rod arm (421) rotates around the fourth connecting rod arm (419) by an angle θ3, the second motor (410) controls the second reflector (409) to rotate by an angle θ4 to offset the influence caused by θ3; If the sixth connecting rod arm (422) rotates around the fifth connecting rod arm (421) by an angle θ5, the third motor (502) controls the reflector fixing plate (413) to rotate by an angle θ6 to offset the influence caused by θ5.

4. The multi-sensor fused composite laser additive-subtractive hybrid manufacturing platform of claim 1, wherein, The laser subtractive manufacturing mechanism (5) comprises a connecting flange (501) and a bearing seat (503); the upper end of the connecting flange (501) is fixedly connected with the terminal end of the sixth connecting rod arm (422), and the lower end is fixedly connected with the upper end of the bearing seat (503) through a frame, and the frame is internally provided with a third motor (502) with an output end downward; the output end of the third motor (502) is connected with the upper end of a connecting shaft (507) through a shaft coupling (511), and the lower end of the connecting shaft (507) is sequentially connected with a focusing mechanism (508), a protection mechanism (509) and a laser light output head (510); The sidewall of the connecting shaft (507) is provided with a light inlet hole, and a mirror fixing plate (413) is arranged below the light inlet hole; the inside of the connecting shaft (507) is provided with a fourth mirror (514) at a position opposite to the light inlet hole; the laser reflected by the third mirror (414) enters the inside of the connecting shaft (507) from the light inlet hole, is reflected by the fourth mirror (514), and is sequentially output through the focusing mechanism (508), the protection mechanism (509) and the laser light output head (510).

5. The multi-sensor fused composite laser additive-subtractive hybrid manufacturing platform of claim 4, wherein, The lower end of the bearing seat (503) is provided with an ultrasonic probe and an infrared thermal imager.

6. The multi-sensor fused composite laser additive-subtractive hybrid manufacturing platform of claim 4, wherein, The setting angles of the third mirror (414) and the fourth mirror (514) are both 45°.

7. The multi-sensor fused composite laser additive-subtractive hybrid manufacturing platform of claim 4, wherein, The inside of the focusing mechanism (508) is provided with a focusing optical element (516), and the inside of the protection mechanism (509) is provided with an optical element protection mirror (517).

8. The multi-sensor fusion based hybrid laser additive and subtractive manufacturing platform in accordance with claim 1, wherein, The additive manufacturing laying head (2) comprises a connecting plate (205), a material tray (201), a feeding mechanism (206), a shearing mechanism (207), a laser head (208), a gas cylinder (209) and a guide plate (210) fixed on the connecting plate (205); the upper end of the gas cylinder (209) is fixedly connected with the connecting plate (205), and the lower end is fixedly connected with a compression roller (211); the upper end of the connecting plate (205) is connected with the terminal end of the additive mechanical arm (1) through a flange connecting disc (204); The material tray (201) is wound with a composite material prepreg (203), and in the additive manufacturing process, the composite material prepreg (203) is sequentially laid on the test platform (6) after passing through the feeding mechanism (206), the shearing mechanism (207) and the guide plate (210), and is matched with the laser head (208) and the compression roller (211).

Images