A method and apparatus for additive manufacturing of composite materials based on dimensional error compensation

Abstract

The application provides a composite material additive manufacturing method and device based on size error compensation, which comprises the following steps: according to the material performance of the prepared component and the local thermodynamic performance and mechanical performance of the component, the quantity, type and combination mode of the material required by each strip of the layered structure are selected; all strips of a single layered structure are laid simultaneously or one by one in each round to form the single layered structure; each strip is a single type of material or is composed of multiple single type of material layers, and an adaptive laying method is executed according to the data of multiple sensors in the laying process and the detection mechanism after laying; the above steps are repeated, and the strips are laid layer by layer according to the layer sequence of the layered structure until the component is formed. The method of the application combines the additive manufacturing methods of the fiber composite material in multiple ways, combines multiple materials and then lays them, and ensures that the distribution of the fibers and the infiltration effect of the matrix reach the ideal state.

Description

Technical Field

[0001] The present invention belongs to the field of continuous fiber composite materials, and specifically relates to a composite material additive manufacturing method and equipment based on dimensional error compensation, which is suitable for the preparation of various composite materials, such as composite metal materials and continuous fiber composite materials. Background Art

[0002] Continuous fiber composites, composed of continuous fibers and a matrix material (resin), offer excellent properties such as high strength, high modulus, lightweight, corrosion resistance, and wear resistance. They are widely used in a wide range of fields, including aerospace, deep-sea shipping, automotive, and electronics. Common continuous fiber composite molding methods include traditional hand placement, liquid molding, filament winding, and automated placement.

[0003] Among them, the manual laying method is a molding method in which the reinforcing fiber material and resin are laid on the mold manually or with the assistance of machinery, and the resin is cured to form a composite material. It has the advantages of low production cost, no restrictions on product size and shape, and a wide range of applications. However, its production efficiency is low, the labor intensity is high, and the product quality is easily affected by manual operation skills.

[0004] Liquid molding refers to a molding method in which liquid resin is injected into a closed mold cavity lined with a fiber preform, or a resin film pre-placed in the mold cavity is heated and melted. The liquid resin completes the impregnation of the fiber resin while flowing to fill the mold cavity, and becomes a composite product after curing and demolding. It has the advantages of high product strength and performance reliability, high production efficiency, and good environmental performance, and is widely used. However, the size and shape accuracy of the parts are limited by mold manufacturing technology, and its application is limited in the manufacture of large-size composite structural parts.

[0005] The winding molding method is to lay preheated resin-impregnated continuous fibers on a core mold along a certain path through a multi-axis winding mechanism, and then obtain products with equal strength characteristics through hot pressing, curing, and demolding. It has the advantages of high specific strength of the parts, low manufacturing cost, high manufacturing quality and repeatability. However, it is not suitable for the manufacture of parts with concave curves, and it is difficult to prepare complex-shaped structural parts.

[0006] The automatic placement molding method uses a five-axis motion device or a robotic arm to lay the continuous fiber prepreg tape material onto the mold along a certain path and heat and consolidate it in situ. It has the advantages of high placement efficiency and is suitable for rapid manufacturing of large parts, but it has difficulties in preparing the thermal expansion coefficient of the component or controlling the local thermal / mechanical properties of the component.

[0007] In addition, the above-mentioned traditional molding methods all require mold and autoclave solidification / melting molding and heat treatment processes, resulting in the size of the prepared components being limited by the structural design of the high-pressure autoclave or autoclave, and there are problems of high process cost and long time consumption.

[0008] At present, the additive manufacturing technology of continuous fiber composite materials is in the development stage. The basic forming principle is based on the principle of layered forming and layer-by-layer accumulation of additive manufacturing. The continuous fiber reinforcement and the matrix are laid according to the pre-designed structure to achieve rapid and controllable forming of complex composite components: not only have the characteristics of high strength, high stiffness, and light weight, but also can realize the regulation of the overall performance of the component by controlling the distribution direction and density of the fiber reinforcement. Current research directions in additive manufacturing of continuous fiber-reinforced composites include, but are not limited to: laser-assisted heating-based additive methods, including automated placement, layered solid manufacturing, and fused deposition modeling, which achieve the production of components with excellent mechanical properties through rapid and precise temperature control of raw fibers or prepreg tapes; pressure-injected Z-pin-like interlayer reinforcement additive methods (publication number: CN118046575A), which construct Z-pin-like structures with continuous fiber cross-laminates and continuous longitudinal reinforcement. Pressure-injected thermosetting resins suppress associated porosity defects and improve overall component performance; and ultrasonic micro-rolling additive methods (publication number: CN114290668A), which utilize ultrasonic high-frequency impact and rolling devices to flatten and compact the printed material, reducing internal defects and improving build density and interlaminar mechanical properties. These continuous fiber composite additive manufacturing methods lack a means to define the thickness, length, layup angle, dimensional accuracy, and material type of the layup layers.

[0009] The patent document (publication number: CN114013069A) proposes a composite process for automated placement and fused deposition modeling of fiber-reinforced thermoplastic materials. This patent belongs to laser-assisted heating and embodies a combined additive manufacturing of automated placement molding and fused deposition modeling. By combining automated fiber placement (AFP) and fused deposition modeling (FDM) technologies, it achieves efficient molding of high-strength complex structural parts. Among them, the main load-bearing structure is formed by automated fiber placement (AFP), and the functional structure is formed by fused deposition modeling (FDM) to avoid the problems of continuous fiber breakage and interlayer damage caused by bolt holes, etc. First, the main load-bearing structure is path-planned and laid and cured using continuous unidirectional fiber-reinforced thermoplastic material prepreg tape. Then, the functional assembly structure (at least one of the reinforcement, clips, corner braces and ribs) is sliced ​​and deposited using short fiber reinforcement material. This avoids fiber damage caused by traditional connection methods and significantly improves the overall mechanical properties of the component. It has significant mechanical performance improvement and manufacturing efficiency advantages. In this method, the placement of fiber thermoplastic materials and the melt deposition of composite materials are performed sequentially and in separate steps. The melt deposition of a partial structure is performed after the automated placement solidifies. Automated placement and melt deposition are used to manufacture different component structures and cannot be performed simultaneously. This is because the manufacture of different component structures is time-sequential. Therefore, it is only suitable for the manufacture of functional assembly structures on component surfaces.

[0010] The patent document (publication number: CN 116787802 A) proposes an automatic placement device for thermoplastic composite materials and a method for improving the speed, efficiency, and molding quality of prepreg tape placement. This method involves automated placement and molding of continuous fiber composite additive manufacturing. By integrating a translation stage, lifting device, rotary table, pressure device, placement head, laser, and placement platform, it achieves precisely controlled placement of composite prepreg tape. The device heats the prepreg tape at two key locations using a laser, and uses a charge-coupled device and infrared thermometer to precisely adjust the heating temperature, ensuring stable temperature control during the placement process. This method is only applicable to thermoplastic continuous fiber composite materials and lacks support for the manufacture of continuous fiber components requiring multiple types and sizes. Therefore, it is not suitable for the manufacture of continuous fiber components requiring multiple types and sizes, and cannot achieve the manufacture of such components. It is only applicable to thermoplastic composite materials.

[0011] The patent document (publication number: CN115534257A) proposes a multi-component composite additive manufacturing apparatus and method for forming fiber sandwich materials. This novel extrusion-based 3D printing additive manufacturing method involves laying down a first layer of thermoplastic material into a predetermined shape. A second layer of thermoplastic material containing fiber material is then laid down on top of the first layer, or the second layer is laid down alone without fiber material. This process is repeated until the desired number of layers is reached. The fiber material can be continuous or discontinuous, and each layer is laid down as multiple adjacent strips to form a continuous layer surface. Before laying, the fibers can be selectively cut or separated into predetermined lengths and cut in multiple lengths based on fiber length distribution. Between each pair of layers, the second layer is laid immediately adjacent to the first and can be laid at an angle to meet the component's desired mechanical and thermodynamic properties. Furthermore, an automated placement mechanism controls the placement of the fiber layers, allowing for variable fiber length, distribution, and laydown angle between layers. However, this method requires laying the thermoplastic layer before laying the fiber material layer, which makes it impossible to achieve customized simultaneous laying of multiple material combinations and lacks the means to control the build dimensional accuracy. Summary of the Invention

[0012] The purpose of the present invention is to provide a composite material additive manufacturing method and equipment based on dimensional error compensation, so as to measure and predict the thickness, length, laying angle, dimensional accuracy and material type of the laid layer material during the composite material manufacturing process, and realize the control problem of simultaneous combination and laying of multiple materials.

[0013] In order to achieve the above-mentioned object, the present invention provides a composite material additive manufacturing method based on dimensional error compensation, comprising:

[0014] S0: Select the quantity, type and combination of materials required for the strips of each layered structure based on the material properties of the prepared component and the local thermodynamic and mechanical properties of the component;

[0015] S1: laying all strips of a single layered structure simultaneously or individually in each round to form a single layered structure; at least one layered structure uses multiple strips at the same height and adjacent to each other; each strip is formed by laminating and / or adjacently laminating multiple materials of a single type and has a strip shape;

[0016] S2: Repeat step S1 so that the strips are laid layer by layer in the order of the layers of the layered structure until a component with a continuous layer structure is formed; in step S1, an adaptive laying method is performed based on data from various sensors during the laying process and detection mechanisms after the laying process; the adaptive laying method includes:

[0017] A1: Obtain pressure, thickness, and infrared thermal imaging data, and perform data preprocessing on these data;

[0018] A2: Construct the corresponding graph structure based on the pressure, thickness, and infrared thermal imaging data;

[0019] A3: For each graph structure, perform graph feature extraction to obtain an initialized graph feature matrix;

[0020] A4: Use the initialized graph feature matrix and graph feature learning model to obtain the graph embedding vector;

[0021] A5: Using the modal fusion module, the weighted image embedding vectors of pressure, thickness, and infrared thermal images are concatenated and weighted summed to obtain a fused feature vector. This fused feature vector is then fed into the fully connected layer and the Softmax function to obtain the probability distribution of each category.

[0022] A6: During the execution of steps A1 to A5, the probability distribution of each category is obtained as experience, and the strategy corresponding to the probability distribution of each category is reinforced by sampling the experience.

[0023] Step A6 includes:

[0024] A61: Multiple executors simultaneously adjust parameters according to the strategies corresponding to the probability distributions of each category in step A5, obtain the probability distributions of each category before and after the parameter adjustment as experience and store them in the playback buffer;

[0025] A62: Learner samples experience from the replay buffer: The learner samples training batches from the replay buffer and updates the weights of the policy network and the evaluation network; and the learner uses a deep reinforcement learning algorithm to optimize the policy network so that it can maximize the expected cumulative reward;

[0026] A63: The learner sends the updated weights of the policy network to the executor's copy of the policy network, enabling the executor to interact with the environment using the latest policy.

[0027] A64: Repeat steps A61-A63 until the executor's copy of the policy network converges.

[0028] At least one layered structure adopts a plurality of strips at the same height and adjacent to each other, and the remaining single layered structures adopt a single strip or a plurality of strips at the same height and adjacent to each other.

[0029] When the strip is made of multiple layers of a single type of material, laying the strip includes:

[0030] S11: Laying the primary layer material according to a predetermined design as a base to be laid;

[0031] S12: Laying the secondary layer material on top of the entire substrate to be laid according to a predetermined design, and laminating the layers to obtain a new substrate to be laid;

[0032] S13: Repeat step S12 until a predetermined number of layers are laid;

[0033] S14: Laying the primary layer material on top of the substrate to be laid according to the pre-designed method, and laminating the materials to form a strip.

[0034] The single type of material includes thermoplastic material, thermosetting material, fiber component, elastomer, fluoroplastic, fiber or metal foil; the stacking and compounding method includes one or more of melt co-extrusion, thermal pressing / welding, photocuring, and direct energy deposition.

[0035] In the step S2, during the process of laying the strips layer by layer, other component parts other than the strips are inserted / embedded to combine and obtain a composite component; in the step S2, before laying each strip of the layered structure, the top of the laid layered structure is preheated by using laser, infrared heating, hot air, electromagnetic induction or electric heating pipe, or the top of the laid layered structure is surface activated by using plasma irradiation, deep ultraviolet irradiation, or electron beam irradiation; in the step S2, after laying the strips, a pressing force is applied to the upper surface of the top layer of the laid strips; in the step S2, the strip laying operation is coupled with an additive manufacturing method of fused deposition technology, digital light processing, photo-stereolithography, direct energy deposition, or coupled with a subtractive manufacturing method of multi-axis milling, multi-axis grinding, laser cutting, water jet cutting, plasma cutting and ultrasonic cutting to adjust the laid strips.

[0036] On the other hand, the present invention provides a composite material additive manufacturing device based on dimensional error compensation, which is used to execute the composite material additive manufacturing method based on dimensional error compensation described by Agan, including a substrate, and an additive manufacturing device that moves relative to the substrate, the additive manufacturing device including a stacking unit, each stacking unit is configured to: when in use, lay a single or multiple materials on the top surface of the substrate or the layered structure to be laid to combine to form strips.

[0037] The stacking unit is used to lay only a single strip at the same time or to lay multiple strips at the same time, and the strips are composed of a single material or a combination of multiple materials; the stacking unit includes at least one stacking composite unit, and the types of stacking composite units of the stacking unit include one or more combinations of melt extrusion mechanism, direct energy deposition mechanism, automatic laying mechanism, photocuring mechanism, and inkjet mechanism.

[0038] The additive manufacturing device also includes a pre-processing unit, a pressure applying unit and a post-processing unit; the pre-processing unit includes a heating device and / or an activation device; the pressure applying unit is used to apply a pressing force after laying the strip; the post-processing unit includes a detection mechanism, a post-processing additive mechanism and a post-processing subtractive mechanism.

[0039] The composite material additive manufacturing equipment also includes a temperature and humidity control device, which is installed on the outside of the additive manufacturing device; and / or the composite material additive manufacturing equipment also includes a displacement device for realizing relative movement of the substrate and the additive manufacturing device in multiple directions, and the displacement device includes a gantry system, an industrial robot system or a robot-gantry composite collaborative system.

[0040] The composite material additive manufacturing method based on dimensional error compensation of the present application effectively combines various fiber composite material additive manufacturing methods, combines various materials and then lays them, so as to achieve the definition, prediction and adaptive adjustment of the material thickness, length, laying angle, dimensional accuracy and material type of each laying layer in the component molding and composite material manufacturing process by adopting different types of material laying devices, and controlling the laying temperature and applying pressure, so as to ensure that the distribution of fibers and the infiltration effect of the matrix reach an ideal state.

[0041] In the additive manufacturing process of continuous fiber composite materials, the quantity, type and combination order of materials are selected from a variety of materials and then laid. This is conducive to controlling the material properties of the prepared components and regulating the local thermodynamic properties and mechanical properties of the prepared components; according to the dimensional error of the strip thickness or the spacing between adjacent strips of the required prepared components, their size is adaptively adjusted to keep it consistent with the setting, which is conducive to controlling and reducing the porosity of the prepared components and controlling the strength and durability of the components. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1A-1E Schematic diagram of a single strip and structure of a component obtained by the composite material additive manufacturing method based on dimensional error compensation of the present invention, wherein Figure 1A-1C Shows a single strip of different materials combined, Figure 1D-1E Partial components of different strip compositions are shown.

[0043] Figure 2 This is a schematic diagram of the composite material additive manufacturing method based on dimensional error compensation of the present invention when a layered structure reinforcement strategy is adopted.

[0044] Figure 3 It is a schematic diagram of feeding and laying a single continuous fiber composite material of the composite material additive manufacturing equipment of the present invention.

[0045] Figure 4is a schematic diagram of the principle of laying of the melt extrusion mechanism of the composite material additive manufacturing equipment of the present application, wherein Figure 4 the left side shows a single screw extrusion mechanism, Figure 4 the middle shows a twin screw extrusion mechanism, Figure 4 the right side shows a screw-plunger composite mechanism.

[0046] Figure 5 is a schematic diagram of the principle of laying of the direct energy deposition mechanism of the composite material additive manufacturing equipment of the present application.

[0047] Figure 6 is a schematic diagram of the principle of laying of the light curing mechanism of the composite material additive manufacturing equipment of the present application.

[0048] Figures 7A-7C is a schematic diagram of the principle of laying of the post-processing mechanism of the composite material additive manufacturing equipment of the present application, wherein it includes a detection mechanism, a post-processing additive mechanism, and a post-processing subtractive mechanism.

[0049] Figure 8 is a schematic diagram of the overall structure of the composite material additive manufacturing equipment according to an embodiment of the present application, wherein the layering unit includes a melt extrusion mechanism, a direct energy deposition mechanism, and an automatic laying mechanism.

[0050] Figure 9 is a schematic diagram of the overall structure of the composite material additive manufacturing equipment according to an embodiment of the present application, wherein the layering unit includes a melt extrusion mechanism and an automatic laying mechanism.

[0051] Figure 10 is a schematic diagram of the overall structure of the composite material additive manufacturing equipment according to an embodiment of the present application, wherein the layering unit includes a melt extrusion mechanism and an automatic laying mechanism.

[0052] Figure 11 is a schematic diagram of the overall structure of the composite material additive manufacturing equipment according to an embodiment of the present application, wherein the layering unit includes two automatic laying mechanisms.

[0053] Figure 12 is a schematic diagram of the overall structure of the composite material additive manufacturing equipment according to an embodiment of the present application, wherein the layering unit includes a direct energy deposition mechanism and an automatic laying mechanism.

[0054] Figure 13 is a schematic diagram of the overall structure of the composite material additive manufacturing equipment according to an embodiment of the present application, wherein the layering unit includes a direct energy deposition mechanism and an automatic laying mechanism.

[0055] Figure 143 is a schematic diagram of the overall structure of a composite material additive manufacturing device according to an embodiment of the present invention, wherein the lamination unit includes a melt extrusion mechanism and two automatic placement mechanisms.

[0056] Figure 15 3 is a schematic diagram of the overall structure of a composite material additive manufacturing device according to an embodiment of the present invention, wherein the stacking unit includes a direct energy deposition mechanism and two automatic placement mechanisms.

[0057] Figure 16 It is a schematic diagram of the principle of the composite material additive manufacturing equipment of the present invention in executing the adaptive laying method.

[0058] Figure 17 It is a schematic diagram of the overall structure of the composite material additive manufacturing equipment of the present invention when a gantry system is adopted.

[0059] Figure 18 It is a schematic diagram of the overall structure of the composite material additive manufacturing equipment of the present invention when an industrial robot system is adopted.

[0060] Reference numerals:

[0061] 1 is a first material; 2 is a second material; 3 is a third material; 10 is a substrate; 20 is a pre-treatment unit; 30 is a layering unit; 40 is a pressure application unit; 50 is a detection mechanism; 60 is a post-treatment additive mechanism; 70 is a post-treatment subtractive mechanism; 31 is a melt extrusion mechanism; 32 is a direct energy deposition mechanism; 33 is an automatic deposition mechanism; 331 is a supply reel mechanism; 332 is a magnetic powder brake; 333 is a tension controller; 334 is a driving mechanism; 335 is a cutter; 336 is a heater; 337 is a pressure application roller; 338 is a thin pneumatic cylinder; 339 is a rubber pad; 3341 is a driving mechanism driving roller; 3342 is a driving mechanism driven roller; 311 is a servo motor; 312 is a speed reducer; 313 is a single screw extrusion mechanism housing; 314 is a first extrusion nozzle; 315 is a twin screw; 316 is a single screw extrusion mechanism; 317 is a plunger extrusion mechanism; 318 is a second extrusion nozzle; 41 is a laser source; 42 is a laser beam; 43 is a carrier gas; 44 is a powder feeding mechanism; 45 is a deposition head / nozzle; 46 is a molten pool; 51 is a fiber material; 52 is a light curing nozzle; 53 is a delivery pipe; 54 is a excitation light providing mechanism; 6-1 is a layering laying device, 6-2 is a first line laser sensor, 6-3 is a previous layer laying strip, 6-4 is a strip being laid, 6-5 is a micro melt deposition mechanism, 6-6 is an ultrasonic cutter; 6-7 is a second line laser sensor, 6-8 is a first thermal infrared scanner, 6-9 is a laying strip being laid in the same layer structure, 6-10 is a previous laying strip in the same layer structure, 6-11 is a first micro melt extrusion mechanism, 6-12 is a micro laser cutting device; 6-13 is a laying strip in the layer structure, 6-14 is a laser scanning imaging vision system, 6-15 is a second thermal infrared scanner, 6-16 is a second micro melt extrusion mechanism, 6-17 is a small CNC milling mechanism, 6-18 is a micro laser cutting machine; 71 is a robot track; 72 is a robot base; 73 is a robot main body; 74 is a robot end platform; 75 is a mold platform; 76 is a gantry system beam; 77 is a rotating platform; 78 is a lifting platform; 79 is a gantry beam platform. DETAILED DESCRIPTION

[0062] The application will be further described below in conjunction with specific embodiments. It should be understood that the following embodiments are only used to illustrate the application and not to limit the scope of the application.

[0063] The application proposes a composite material additive manufacturing method based on size error compensation, which is a new composite forming process based on continuous fiber reinforced material laying and additive forming. The self-defined preparation of complex structure continuous fiber composite components is realized by layering forming and layer-by-layer laying.

[0064] The composite material additive manufacturing method based on dimensional error compensation of the present invention comprises the following steps:

[0065] Step S0: selecting the quantity, type and combination of materials required for the strips of each layered structure according to the material properties of the prepared component and the local thermodynamic properties and mechanical properties of the component;

[0066] Step S1: laying all strips of a single layered structure simultaneously or individually in each round to form a single layered structure;

[0067] At least one single layered structure comprises multiple strips at the same height and adjacent to each other; each strip is made of a single type of material, or is a composite of multiple materials of a single type. Adjacent to each other means that all portions of the strip that are not at the edge of the layered structure are adjacent to at least one other strip.

[0068] In the present invention, at least one layered structure uses a plurality of adjacent strips, so that the manufacturing method of the component is more flexible and faster than the prior art, and can be laid simultaneously on the same layered structure.

[0069] When the strip is made of multiple layers of a single type of material, laying the strip includes:

[0070] Step S11: Laying the primary layer material according to a predetermined design as a substrate to be laid;

[0071] Step S12: Laying the secondary layer material on top of the entire substrate to be laid according to a predetermined design, and laminating and compounding the layers to obtain a new substrate to be laid;

[0072] Step S13: Repeat step S12 until a predetermined number of layers are laid;

[0073] Step S14: Laying the primary layer material on top of the substrate to be laid according to the pre-designed method, and laminating and compounding the materials to form a strip.

[0074] like Figure 1A-1C The specific structure of the strip is shown. Figure 1A A single strip is shown, where the primary layer of the strip is a fused flat cylindrical tape, and the secondary layers are pre-impregnated fiber tapes and powder fused tapes laid alternately. Figure 1B A single strip is shown, with three different colors and shapes representing three materials. A fused flat cylinder is one of the materials that make up the strip, with a combination of powder fused tape and pre-impregnated fiber tape alternately laid with fused flat cylinder tape. Figure 1CThe three structures are shown with materials laid alternately as primary layers, and only as primary layers. In other words, a strip is defined as a strip of composite material used to form a layered structure. Each strip is composed of multiple layers of a single material, laminated and / or abutting each other, and has a pre-designed strip-like shape. The structure within the strip is pre-designed based on the material's properties, and the materials in a single strip are a limited number.

[0075] The one or more materials of the primary layer (and the optional secondary layer materials) together form a same strip, for example, the primary layer and the optional secondary layer can be considered to together form a strip.

[0076] like Figure 1A-1C As shown, according to the local mechanical and thermodynamic properties of the prefabricated components, the material types and laying combinations of the laying strips can be selectively combined, and the combination methods include but are not limited to Figure 1A-1C types and quantities.

[0077] like Figure 1A As shown, first, the melt extrusion mechanism is turned on to lay the molten granular or filamentary composite material onto the substrate or the previous layered structure to form a flat cylindrical belt as the primary layer of the strip, and the direct energy deposition mechanism and the automatic placement mechanism are turned on intermittently and alternately with each other to lay the powdered material in the form of rectangular pore belts and the thermoplastic pre-impregnated fiber belt in the form of rectangular woven belts intermittently on the upper surface of the primary layer to form a secondary layer, and by applying a pressing force to the upper surface of the secondary layer, a laid strip is formed by bonding.

[0078] like Figure 1B As shown, the melt extrusion mechanism is turned on to lay the molten granular or filamentous composite material with a thickness of H on the substrate or the previous layered structure to form a flat cylindrical belt; the melt extrusion mechanism is turned off, and the direct energy deposition mechanism and the automatic placement mechanism are turned on. Immediately after the flat cylindrical belt, the direct energy deposition mechanism first lays the powdered material on the substrate or the previous layered structure to form a rectangular pore belt as the primary layer, and then the automatic placement mechanism lays the thermoplastic pre-impregnated fiber belt with a thickness of h3 on the upper surface of the primary layer to form a rectangular woven belt as the secondary layer. By applying a pressing force to the upper surface of the material, it is bonded to form a laid strip.

[0079] like Figure 1CAs shown, the three mechanisms in the stacking unit are turned on in sequence. First, the melt extrusion mechanism is turned on to lay the molten granular or filamentous composite material with a thickness of H on the substrate or the previous layer structure to form a flat cylindrical belt. Then the direct energy deposition mechanism is turned on. Following the flat cylindrical belt, the powdered material is laid with a thickness of H on the substrate or the previous layer structure to form a rectangular pore belt. Then the automatic laying mechanism is turned on. Following the rectangular pore belt, the thermoplastic pre-impregnated fiber belt is laid with a thickness of H on the substrate or the previous layer structure to form a rectangular woven belt. By applying a pressing force to the upper surface of the material, it is bonded to form a laid strip.

[0080] Through the above Figure 1A-1C Different strips can be laid in a combination of ways. Also, according to the local mechanical and thermodynamic properties of the prefabricated components, the same layered structure can have and not only have the following strip arrangements: Figure 1D As shown, through Figure 1A 、 Figure 1B 、 Figure 1C The three strips shown are laid out in sequence to complete the preparation of a layered structure of the component. Figure 1E As shown, through Figure 1A 、 Figure 1B The two strips shown are laid out in sequence to complete the preparation of a layered structure of the component. Figure 1D Shows one of the strip laying combinations for constructing the same layered structure. Figure 1E Another combination of strip laying in the same layered structure of a component is shown. In addition, the thickness of different strips in the same layered structure must be the same. The width of the strip refers to the width of the strip after a single laying of the component is completed. The width of the strip is the left-right length of the strip, the horizontal dimension; the thickness is the vertical dimension of the strip. Multiple adjacent strips refer to multiple strips at the same height, and each strip is adjacent to at least one other strip at the same height. Wherein, H is the total thickness of a single strip, h1 is the thickness of the first material, h2 is the thickness of the second material, and h3 is the thickness of the third material.

[0081] Step S2: Repeat step S1 so that the strips are laid layer by layer in the order of layers of the layered structure until a component of a continuous layer structure is formed.

[0082] The resulting component is the composite material of the present invention. Thus, the strips of primary layer material and secondary layer material are formed into a single layered structure in the form of multiple adjacent strips and laid down to form part of a continuous layer structure, wherein each strip abuts its adjacent strips.

[0083] Therefore, the width of the strips formed by the primary and secondary layers of material does not affect the width of the component. The cross-sectional dimensions of a component are determined by the length, width, and placement trajectory of all strips in the layered structure corresponding to that cross-section, not solely by the strip width. The impact of component forming factors such as the thickness of the layered structure, strip width, and placement method (including one or more of the relative angle, strip distribution, and strip length) on the component's strength, stiffness, and thermodynamic properties is determined through finite element analysis and stress / thermodynamic modeling and optimization. The relative angle refers to the angle between corresponding strips in two adjacent layered structures.

[0084] Furthermore, layer-by-layer laying according to the layer sequence of a layered structure refers to laying multiple layered structures layer by layer, accumulating layer by layer until the component is formed. Layer-by-layer laying can be a discontinuous process, meaning that the primary and secondary layer materials of a strip can be laid either "step by step" or "sequentially." Step-by-step laying means that a single composite material in a strip is laid first, followed by the next composite material, until a strip is formed; sequential laying means that multiple single materials are laid simultaneously into a strip in a pre-set order according to pre-designed material properties. This layer-by-layer laying process is a highly controllable and adaptive process. Therefore, the height of the component is determined by the number of layered structures. The thickness of the layered structure formed by the primary and secondary layer materials will affect the thickness of the component, but it is not the determining factor.

[0085] In step S1 , the strip is a single type of material, or a plurality of materials formed by sequentially laying a primary layer material and a secondary layer material.

[0086] When the strip is a single type of material, the single type of material may include films or strips of thermoplastic materials (such as polyphenylene sulfide PPS, polyetherimide PEI, polyetheretherketone PEEK, high-temperature resistant nylon PPA, thermoplastic polyimide TPI, etc. and their composites) or thermosetting materials (such as epoxy resin EP, polyimide PI, polybenzimidazole PBI, etc. and their composites), and may also include continuous or discontinuous fiber components (the fiber components are short fibers, long fibers or continuous fibers), and may also include elastomers (such as rubber, thermoplastic polyurethane elastomer TPU, thermoplastic elastomer TPE, etc. and their composites), fluoroplastics (such as polytetrafluoroethylene PTFE, ethylene-tetrafluoroethylene copolymer ETFE, etc. and their composites), fibers (such as aramid, glass fiber, polyester, metal fiber, mineral fiber, etc. and their composite forms) or metal foil strips (such as copper, aluminum, tungsten, molybdenum, tantalum, niobium, titanium, steel and stainless steel, etc. and their composite forms), etc.

[0087] When the strip is composed of multiple laminated materials of a single type (i.e., a strip of multiple materials), the strip material can be a composite of two or more of the aforementioned single materials laminated in a predetermined manner. The lamination method can be a sequential lamination method of one or more of melt coextrusion, thermal compression / welding, photocuring, and direct energy deposition (DED). The ratio of the multiple materials during the lamination process can be varied according to design requirements. When the strip comprises continuous fibers, tapes, films, or metal foils, the strip can be selectively cut into multiple predetermined lengths during the lamination process according to design requirements.

[0088] Preferably, the bottommost strip is laid on a base plate of the composite material additive manufacturing apparatus and comprises a tape of thermoplastic or thermosetting material to serve as a support structure.

[0089] In step S2, during the strip laying process, the strips are selectively cut into a plurality of predetermined lengths according to a laying trajectory. By varying the material combination within the strips, the strip length, or controlling the strip laying trajectory, precise control of the local mechanical or thermodynamic properties of each layered structure is achieved. The laying trajectory refers to the strip laying path designed based on the shape of the prefabricated component. The resulting adjoining combination of strips forms the cross-sectional shape of the component.

[0090] When the component has a fiber distribution profile, the fiber distribution profile can be designed and laid according to the setting of predetermined mechanical and thermodynamic properties of the component.

[0091] In step S2, during the process of laying the strips layer by layer, other component parts (metal reinforcements, ribs or other material components, reinforcement materials) other than the strips are inserted / embedded to combine and obtain a composite component.

[0092] like Figure 2As shown, for the manufacturing requirement of local reinforcement of the special area of the prefabricated component, the application proposes a layered structure reinforcement strategy based on a laminated unit. During the process of strip-by-strip laying, the strategy adds reinforcement material according to the additional requirements for the specific area to achieve the effect of local reinforcement. The specific implementation method is as follows: first, according to the preset path, the molten material is uniformly laid on the surface of the substrate or the previous layer of the layered structure with a specific thickness to form a flat cylindrical strip primary layer. Then, lay the thermoplastic composite fiber strip on the primary layer to form a woven fiber strip secondary layer. Use the pressure roller to apply appropriate pressure to ensure that the two layers of material are tightly bonded to form a laid strip. When the strip is laid to the special area, turn on the direct energy deposition mechanism to accurately add reinforcement material between the flat cylindrical strip primary layer and the thermoplastic woven fiber strip secondary layer, and lay it into a porous strip material layer as the first secondary layer. By controlling the power and extrusion amount of the molten extrusion mechanism, and adjusting the height and pressure of the pressure roller, the thickness error of the laid strip in the special area is controlled within the preset range. After completing the reinforcement laying of the special area, return to the initial laying parameters and process. During the entire laying process, the line laser sensor in the post-processing subtractive mechanism monitors the thickness of the laid strip in real time to ensure that it always remains within the preset error range.

[0093] In the step S2, before laying each strip of the layered structure, the top of the laid layered structure is preheated using laser, infrared heating, hot air, electromagnetic induction or electric heating tube, or the top of the laid layered structure is surface activated using plasma irradiation, deep ultraviolet irradiation, electron beam irradiation, so that the preheating / surface activation treatment can improve the bonding / welding between any two adjacent layers, and ensure good bonding / welding strength between adjacent layers (and previous layers) during the forming process of large-size components, so that the components are better consolidated.

[0094] In the step S2, after laying the strip, a pressing force is applied to the top surface of the laid strip, so as to press / push the laid strip into the top surface of the adjacent layer strip that has been preheated / surface activated, thereby preventing the generation of voids and improving the interlayer bonding / welding strength.

[0095] In this embodiment, the pressing force is applied by a pressing device, wherein the pressing device is installed behind the laminating unit, and the pressing force is applied immediately after the strip is laid, so that the pressing force is applied immediately after the strip is laid. In this embodiment, the pressing device can be a compacting roller / wheel with heating or cooling capabilities, or a rolling device with ultrasonic high-frequency impact, so as to have the ability to adjust the bonding / welding strength between adjacent layers. In addition, the pressing force applied by the pressing device can be adjusted by adjusting the height of the roller, and has the characteristic of variable pressing force, so as to prevent interlayer gaps and accurately define the height of the strip layer while ensuring the stability of the total mass between adjacent layers.

[0096] In step S2, the strip laying operation can be coupled with existing additive manufacturing methods such as fused deposition modeling (FDM), digital light processing (DLP), stereolithography (SLA), and direct energy deposition (DED), and can also be coupled with existing subtractive manufacturing methods such as multi-axis milling, multi-axis grinding, laser cutting, water jet cutting, plasma cutting, and ultrasonic cutting to adjust the laid strips. The coupling with the strip laying operation means that according to the pre-design of the component, one or more additive / subtractive manufacturing methods are used synchronously or asynchronously to adjust the laid strips during the strip laying process, thereby achieving the adjustment of the hierarchical structure of the laid strips, the shape of the local area of ​​the component, or the entire component; the strip adjustment includes the addition of at least one heterogeneous material structure of reinforcing ribs, inserts, clips, gussets, and ribs, and also includes the adjustment of the structural shape, surface finish, and hole structure of the component.

[0097] On the other hand, Figure 8 As shown, the present invention provides a composite material additive manufacturing device, which is used to perform the composite material additive manufacturing method based on dimensional error compensation described above. The composite material additive manufacturing device includes a substrate 10, and an additive manufacturing device that moves relative to the substrate 10, and the additive manufacturing device includes a pre-processing unit 20, a stacking unit 30, a pressure applying unit 40 and a post-processing unit. The stacking unit 30 is used for laying the strips; the pre-processing unit 20 is used for preheating and / or activation before laying, which usually adopts a heating device and / or an activation device; the pressure applying unit 40 is used to apply a pressing force after laying the strips. The post-processing unit includes a detection mechanism 50, a post-processing additive mechanism 60 and a post-processing subtractive mechanism 70; the detection mechanism 50 is used to detect defects and dimensional errors during the laying process; the post-processing additive mechanism 60 and the post-processing subtractive mechanism 70 are used to repair defects or dimensional errors during the laying process.

[0098] Each laminating unit 30 is configured to lay a single or multiple materials on the top surface of the substrate 10 or the layered structure to be laid to form a single strip. The laminating unit can also be configured to selectively cut or separate the fiber material in the strip when in use.

[0099] The laying direction of the strips can be consistent with or inconsistent with the laying direction of the strips on the top of the layered structure to be laid; and in the same layered structure, the plurality of strips are adjacent to each other to jointly form a layered structure.

[0100] As shown in Figure 8 , the layering unit 30 comprises at least one melt extrusion mechanism 31, at least one direct energy deposition mechanism 32, and at least one automatic laying mechanism 33. The layering unit 30 is used to realize the laying of a single strip; the melt extrusion mechanism 31 is used to lay granular or filamentous composite materials in a structure of a flat cylinder; the direct energy deposition mechanism 32 is used to lay powdered materials in a structure of a porous strip; and the automatic laying mechanism 33 is used to lay thermoplastic pre-impregnated fiber strips in a structure of a woven strip, which includes a strip-shaped pre-impregnated strip, a strip-shaped film strip, or a strip-shaped metal foil, etc. The automatic laying mechanism comprises a plurality of feeding devices, in which different thicknesses of strip-shaped materials of the same material are placed (the thicknesses can be represented by 0.5h3, h3, 1.5h3, 2h3, etc., and in specific embodiments, h3 is a fixed value once the material is selected).

[0101] In this embodiment, as shown in Figure 8 , the layering unit 30 is used to lay only a single strip at the same time, which is composed of a single material or a combination of multiple materials. However, in other embodiments, the combination of the plurality of layering units 30 is used to simultaneously lay multiple strips, thereby simultaneously combining to form multiple adjacent strips; in addition, the downstream of the plurality of layering units 30 is provided with the same segmented pressure application unit 40 to apply a pressing force to the simultaneously laid multiple adjacent strips. In this way, the simultaneous laying of the multiple adjacent strips is realized.

[0102] The laying process is as follows: 1) pre-treatment stage: start the pre-treatment unit, and preheat or surface activation treat the upper surface of the preform substrate or the upper surface of the previous layered structure according to the preset laying track, to prepare for material laying. 2) material laying: a. first start the melt extrusion mechanism 31, and lay granular or filamentous composite materials on the substrate or the previous layered structure in a certain shape (such as Figure 8 a flat cylindrical strip shape) as a primary layer at a certain speed according to the preset strip width w. b. immediately after, the direct energy deposition mechanism 32 lays powdered materials on the upper surface of the primary layer to form a secondary layer (the secondary layer is Figure 8 a hollow porous strip). c. the automatic laying mechanism 33 then lays a thermoplastic pre-impregnated fiber strip as another secondary layer on the laid first material 1 and second material 2 (this layer is Figure 8The laying strip of the layered structure is formed by combining three different forms of hierarchical materials. The width of the strip is determined by the nozzle of the deposition mechanism and the width of the automatic laying thermoplastic pre-impregnated fiber belt. 3) Pressure application: the upper surface of the strip is subjected to pressure by the pressure application unit 40, which ensures better adhesion between the primary layer and the secondary layer, between the secondary layer and the secondary layer, and between the strip and the previous layer of the layered structure. The size of the pressure is adjusted by controlling the height of the pressure roller. 4) Strip thickness control: the thickness of the laid strip is monitored in real time by the post-processing detection mechanism line laser sensor, and when the thickness error occurs, the height of the pressure application roller of the pressure application unit 40 is adjusted, and then the size of the applied pressure is controlled; the power of the direct energy deposition mechanism or the melting extrusion mechanism is adjusted, and then the material laying amount is controlled, both of which control the thickness of the laid strip. 5) Lamination control: after a strip in the layered structure is laid, the lamination unit returns to the starting position of the adjacent strip, and the robot or gantry system of the lamination unit moves the laying head to the left or right side of the strip movement direction by a distance of w+L (L is the spacing of the adjacent strips), and repeats steps 1) to 3), until the layered structure laying of the entire prefabricated component is completed. The spacing between adjacent strips is monitored in real time by other line laser sensors and thermal infrared sensors in the detection mechanism, and when the spacing error occurs, the displacement amount at the end of the robot or gantry system is controlled, and then the spacing between adjacent strips is controlled. 6) Real-time monitoring and repair: during the strip laying process, the post-processing unit monitors the errors or defects of the strip in real time, locates and quantifies the detected defects and errors, and repairs the defects such as pits and the gaps between adjacent strips during the laying process by the post-processing additive mechanism (micro melting extrusion mechanism or inkjet mechanism); the protrusions or excess parts appearing during the laying process are trimmed by the post-processing subtractive mechanism. 7) Angle adjustment and repetition: after the laying of a certain layered structure is completed, the relative laying angle of the laying strip is adjusted by the rotating device connected to the lamination unit, and then steps 1) to 6) are repeated until the entire component is prepared.

[0103] Depending on the local mechanical and thermal properties of the preform, the material types and the layer thicknesses of the deposited strips can be selectively combined in a manner that is not limited to the following types and quantities. 1) All three deposition mechanisms in the layering unit are simultaneously activated, wherein the hot thermoplastic pre-impregnated fiber strips in the automated deposition mechanism 33 have a thickness of h3, and the strips are deposited in the manner described above, first the molten granular or filamentous composite material is deposited by the molten extrusion mechanism 31 onto the substrate or the previous layered structure to form a flat cylindrical strip as a primary layer, then the powdered material is deposited by the direct energy deposition mechanism 32 into a rectangular porous strip structure as a first secondary layer, and then the hot thermoplastic pre-impregnated fiber strips are deposited by the automated deposition mechanism 33 into a rectangular woven strip structure as a second secondary layer, and the pressure exertion unit 40 exerts a compacting force on the upper surface of the hot thermoplastic pre-impregnated fiber strips to form a deposited strip. 2) All three deposition mechanisms in the layering unit are simultaneously activated, wherein the hot thermoplastic pre-impregnated fiber strips in the automated deposition mechanism 33 have a thickness of 0.5h3, and the strips are deposited in the manner described above, first the molten granular or filamentous composite material is deposited by the molten extrusion mechanism 31 onto the substrate or the previous layered structure to form a flat cylindrical strip as a primary layer, then the powdered material is deposited by the direct energy deposition mechanism 32 into a rectangular porous strip structure as a first secondary layer, and then the hot thermoplastic pre-impregnated fiber strips are deposited by the automated deposition mechanism 33 into a rectangular woven strip structure as a second secondary layer, and the height of the pressure exertion rollers of the pressure exertion unit 40 is appropriately increased to reduce the compacting force exerted on the upper surface of the hot thermoplastic pre-impregnated fiber strips, so that the three types of materials form another deposited strip. 3) All three deposition mechanisms in the layering unit are simultaneously activated, wherein the hot thermoplastic pre-impregnated fiber strips in the automated deposition mechanism 33 have a thickness of 0.5h3, and the strips are deposited in the manner described above, first the molten granular or filamentous composite material is deposited by the molten extrusion mechanism 31 onto the substrate or the previous layered structure to form a flat cylindrical strip as a primary layer, then the powdered material is deposited by the direct energy deposition mechanism 32 into a rectangular porous strip structure as a first secondary layer, and then the hot thermoplastic pre-impregnated fiber strips are deposited by the automated deposition mechanism 33 into a rectangular woven strip structure as a second secondary layer, and the height of the pressure exertion rollers of the pressure exertion unit 40 is continuously increased to further reduce the compacting force exerted on the upper surface of the hot thermoplastic pre-impregnated fiber strips, so that the three types of materials form another deposited strip.4) In the lamination unit, only the melt extrusion mechanism 31 and the automatic placement mechanism 33 are activated. The automatic placement mechanism 33 uses a thermoplastic pre-impregnated fiber tape with a thickness of 1.5h3. According to the above-mentioned placement method, the molten granular or filamentary composite material is first laid onto the substrate or the previous layer structure to form a flat cylindrical tape as the primary layer. Then, the automatic placement mechanism 33 lays the thermoplastic pre-impregnated fiber tape into a rectangular woven tape structure with a thickness of 1.5h3 as the secondary layer. The height of the pressure-applying roller of the pressure-applying unit 40 is appropriately lowered, and the compressive force applied to the upper surface of the thermoplastic pre-impregnated fiber tape is increased, so that the two structures of materials form a laid strip. At the same time, during the laying process of the strip, the thickness of the laid strip is monitored in real time by a line laser sensor. By controlling the laying amount of the direct energy deposition mechanism 32 and the melt extrusion mechanism 31, the thickness error of the laid strip is kept within a certain range, and the thickness of different strips of the same layered structure must be the same.

[0104] The composite additive manufacturing equipment may also include a temperature and humidity control device. This device, mounted externally to the additive manufacturing apparatus, comprises a modular frame, thermal insulation panels, an air circulation mechanism, and a temperature and humidity control mechanism. The modular frame is a square lattice structure surrounded by thermal insulation panels to form an insulated cavity. The exterior of the cavity is connected to the air circulation mechanism and the temperature and humidity control mechanism to maintain ambient temperature and humidity during component placement and molding.

[0105] In other embodiments, the type, number, and location of the laminated composite units within a single lamination unit 30 can be varied as needed. Specifically, the lamination unit 30 can be configured to determine the type and combination of strip materials based on the local mechanical and thermodynamic performance requirements of the layered structure of the molded component, using systematic finite element analysis and stress / thermal modeling analysis. Furthermore, the type, number, and location of the laminated composite units can be determined based on the type and combination of the strip materials, thereby achieving a combination of multiple materials within a single strip layup.

[0106] The lamination unit 30 includes at least one lamination and compounding unit. The lamination and compounding units of the lamination unit 30 may include one or more combinations of a melt extrusion mechanism 31 (which melts and extrudes thermoplastic materials), a direct energy deposition mechanism 32 (i.e., a DED mechanism, which heats, melts, and lays down materials such as powders), an automated placement mechanism 33 (for laying down tape-shaped composite materials such as fiber prepregs), a photocuring mechanism (which in-situ cures photocurable resins), and an inkjet mechanism (which converts liquid resins into a liquid). In other words, the lamination unit 30 includes at least one of the melt extrusion mechanism 31, the direct energy deposition mechanism 32, the automated placement mechanism 33, the photocuring mechanism, and the inkjet mechanism.

[0107] like Figure 3As shown, the automatic placement mechanism 33 includes a supply reel mechanism 331 around which a strip of composite material is wound, a tension controller 333, a drive mechanism 334, a cutter 335, a heater 336, and a pressure-applying roller 337, arranged downstream of the supply reel mechanism 331. The drive mechanism 334 is used to rotate the supply reel mechanism 331 to pull out the composite material strip. The drive mechanism 334 includes a driving roller 3341 and a driven roller 3342 for clamping the composite material strip. The heater 336 is used to preheat the composite material strip before laying. The cutter 335 is used to selectively cut or separate the composite material strip to form multiple composite material strips of predetermined lengths. Thus, the composite material strip is pulled out of the supply reel mechanism 331 by the drive mechanism 334, transported to the cutter 335, and then passed through the heater 336 before being laid out.

[0108] Furthermore, the supply reel mechanism 331 is equipped with a magnetic powder brake 332, which applies a certain amount of preload. Rubber pressure blocks 339 are installed upstream and downstream of the cutter 335 to prevent the composite material strip from slipping during cutting, ensuring cutting quality and overall tension. In this embodiment, the supply reel mechanism 331 serves as a composite material strip unwinding wheel. The pressure-applying roller 337 is connected to a thin cylinder 338 for driving.

[0109] It should be noted that the automatic laying mechanism 33 is only used for conveying and laying a certain type of strip composite material. This strip composite material is only a part of the laid strip. The feeding unit mechanism, direct energy deposition mechanism, melt extrusion mechanism, etc. together constitute the stacking unit 30.

[0110] The melt extrusion mechanism 31 is used for melt extrusion of thermoplastic material, and has an extrusion nozzle for laying thermoplastic material. Figure 4 The single screw extruder shown on the left side of Figure 4 The twin-screw extruder or multi-screw extruder (including planetary screw, Buchanan extruder, etc.) shown in the middle of the figure can also be a single-plunger or double-plunger mechanism, or as shown in the figure Figure 4 The screw-plunger composite structure shown on the right.

[0111] like Figure 4 As shown on the left side of the figure, the single screw extruder mechanism includes a single screw extruder mechanism housing 313, a first extrusion nozzle 314 provided at the bottom of the single screw extruder mechanism housing 313, a single screw provided inside the single screw extruder mechanism housing 313, and a servo motor 311 and a reducer 312 connected to the single screw. The servo motor 311 and the reducer 312 are used to drive the rotation of the single screw, thereby controlling the switch and extrusion amount of the melt extruder mechanism 31. Figure 4 As shown in the middle part of , the structure of the twin-screw extrusion mechanism is basically the same as that of the single-screw extrusion mechanism, with the only difference being that the single screw is replaced by a twin screw 315.

[0112] like Figure 4 As shown on the right side of , the screw-plunger composite structure includes a single-screw extrusion mechanism 316 and a plunger extrusion mechanism 317 connected to the outlet at the bottom of the single-screw extrusion mechanism 316 through a hollow tube, and a second extrusion nozzle 318 is provided at the bottom of the plunger extrusion mechanism 317.

[0113] The extrusion nozzle's outlet shape can be a slit, oblate, or circular, and the internal flow channel structure of the melt extrusion mechanism 31 can be a fishtail or clothes-hanger structure. Through simulation and optimization of the screw or plunger structure, the nozzle outlet shape, and the flow channel structure, as well as intelligent control of the melt extrusion mechanism 31, the size and flow rate of the extruded strip can be precisely controlled.

[0114] like Figure 5 As shown, the direct energy deposition mechanism 32 includes a powder storage mechanism, a powder feeding mechanism 44 and a motor connected to the powder storage mechanism, a deposition head / nozzle 45 connected to the bottom of the powder feeding mechanism 44, a carrier gas 43 passing into the powder feeding mechanism 44, and an energy generator for focusing an energy beam at the bottom of the deposition head / nozzle 45. The powder storage mechanism is used to store bulk materials such as metals, the powder feeding mechanism 44 and the motor are used to transport the powder material to the deposition head / nozzle 45, the energy generator is used to emit a focused energy beam to generate a molten pool 46 on the upper surface of a substrate or a formed body, and the deposition head / nozzle 45 is used to transport the powder material to the generated molten pool 46 via the carrier gas 43.

[0115] The energy beams provided by the energy generator mainly include laser beams, electron beams and ion arc beams. Figure 5 As shown, the energy beam provided by the energy generator is a laser beam 42 , so the energy generator includes a laser source 41 .

[0116] like Figure 6 As shown, the light-curing mechanism includes a material storage tank, a light-curing nozzle 52 connected to the material storage tank via a delivery tube 53, a delivery pump provided on the delivery tube 53, and an excitation light providing mechanism 54 for providing excitation light to the extrusion outlet of the light-curing nozzle 52. Thus, the material storage tank is used to store resin, and the delivery tube 53 and the delivery pump are used to pump the resin to the light-curing nozzle 52.

[0117] In this embodiment, the photocuring nozzle 52 is a composite nozzle, including a fiber material inlet, a resin impregnation area connected to the delivery pipe 53, and an extrusion port. The fiber material inlet area is used for inputting the fiber material 51, the resin impregnation area is used for impregnation and compounding of the resin material and the fiber material, and the extrusion port is used for outputting the impregnated fiber and resin material.

[0118] The excitation light providing mechanism 54 is used for projecting multi-band excitation light such as UV and NIR, including DLP, halogen lamp, ultraviolet mercury lamp, semiconductor laser and gas / solid laser, etc. The excitation light is used to cure the resin.

[0119] In addition, a static mixer can be provided in the storage tank, and the static mixer is used to uniformly mix single-component or multi-component resins.

[0120] The inkjet mechanism includes a liquid storage tank, a nozzle connected to the tank via a delivery tube, and an excitation light supply mechanism for supplying excitation light to the nozzle outlet. The tank mechanism stores liquid; the nozzle, which can be either a piezoelectric or thermal spray nozzle, sprays materials such as resin liquid onto a substrate or a previous layer of components. The excitation light supply mechanism projects multi-band excitation light, such as UV and NIR, and can use a UV mercury lamp, a halogen lamp, or a laser, to solidify the sprayed liquid.

[0121] It should be noted that the difference between the inkjet mechanism and the light-curing mechanism lies in the different laying materials. The light-curing mechanism can only be used for laying photosensitive resin, while the inkjet mechanism can be used to spray a variety of liquid materials.

[0122] See also Figure 8 In this embodiment, the pressure-applying unit 40 is located downstream of the automatic placement mechanism 33, the direct energy deposition mechanism 32, and the melt extrusion mechanism 31. It is used to apply pressure immediately after the strip is laid. The pressure-applying unit 40 comprises a roller mechanism, a wheel mechanism, or a rolling mechanism with ultrasonic high-frequency impact, thereby applying a compressive force to the top surface of the top layer of the laid strip, thereby adjusting the bond / weld strength between adjacent layers. The roller mechanism can be a cylindrical roller or a segmented roller composed of stacked discs of different diameters. The wheel mechanism can be a roller with a silicone or rubber-coated structure or a wheel-driven double-steel belt pressure roller mechanism. Optionally, the roller or wheel mechanism includes a heating mechanism (thermal oil, electromagnetic heating, water heating) or a cooling mechanism (water cooling, oil cooling). The cooling mechanism of the roller or wheel mechanism primarily prevents the thermoplastic material from adhering to the roller / wheel surface, while the heating roller / wheel mechanism primarily improves cooling time. The above-mentioned ultrasonic high-frequency impact rolling mechanism includes an ultrasonic generator, an ultrasonic impact head connected to the ultrasonic generator, a fixing seat, and a special-shaped roller / wheel or a flat roller / wheel installed on the fixing seat.

[0123] The pressure applying unit 40 may further include an electric actuator or a pneumatic actuator (such as a cylinder) for controlling the height of a roller mechanism, a wheel mechanism or a crushing mechanism with ultrasonic high-frequency impact, and a force sensor for collecting a pressing force signal.

[0124] The composite additive manufacturing equipment also includes a displacement device for achieving relative movement of the substrate 10 and the additive manufacturing device in multiple directions. The displacement device includes a gantry system, an industrial robot system, or a robot-gantry composite collaborative system. When in use, the gantry system, the industrial robot system, or the robot-gantry composite collaborative system follows: moving according to a predetermined program to form the contour of a multi-layer, multi-material composite component, and a continuous or discontinuous predetermined fiber distribution pattern. Specifically, the substrate 10 and the additive manufacturing device are respectively fixed to two platforms that can move relative to each other in the gantry system, the industrial robot system, or the robot-gantry composite collaborative system to achieve relative movement of the substrate 10 and the additive manufacturing device.

[0125] When the composite material additive manufacturing equipment adopts an industrial robot system, the industrial robot can be in the form of an articulated robot, a parallel robot and a linear slide robot. In one embodiment, Figure 18 As shown, the industrial robot includes a robot track 71, a robot base 72 that slides on the robot track, a robot body 73 mounted on the robot base 72, a rotating platform, and a robot end platform 74. In addition to the industrial robot, the industrial robot system also includes a fixed mold platform 75. The substrate 10 is mounted on the fixed mold platform 75, while the additive manufacturing device is mounted on the robot end platform 74 of the movable robot gripper.

[0126] When the composite material additive manufacturing equipment adopts a gantry system, the gantry system can be a crane-type five-axis gantry system or the like. In one embodiment, Figure 17 As shown, the gantry system includes a fixed gantry system beam 76, a rotating platform 77 mounted on the gantry system beam 76, and a lifting platform 78. Therefore, the substrate can be mounted on the lifting platform 78 of the gantry system and move up and down with the lifting platform, while the additive manufacturing device is mounted on the fixed gantry system beam 76 through the rotating platform 77 and the gantry beam platform 79.

[0127] When the composite material additive manufacturing equipment adopts a robot-gantry composite collaborative system, the robot-gantry composite collaborative system includes a gantry system, one or more industrial robots and a lifting platform installed on the crossbeam of the gantry system, the substrate 10 is installed on the lifting platform, and the additive manufacturing device is installed on the robot end platform of the industrial robot, so that the substrate 10 and the additive manufacturing device can move relative to each other.

[0128] In addition, the robot-gantry composite collaborative system can also be a variety of combined applications of the above-mentioned gantry system and industrial robots.

[0129] The pre-treatment unit 20 includes a heating device and / or an activation device. The heating device is used to preheat the top of the laid layered structure using methods such as laser, infrared heating, hot air, electromagnetic induction, or electric heating pipes. The activation device is used to activate the top surface of the laid layered structure using equipment such as plasma irradiation, deep ultraviolet irradiation, or electron beam irradiation, thereby improving the bonding / weldability between adjacent layers. The heating temperature of the heating device is controlled by its power and can be detected by a temperature sensor.

[0130] The post-processing unit includes a detection mechanism 50, a post-processing additive mechanism 60, and a post-processing subtractive mechanism 70. The detection mechanism 50 is used to monitor in real time the structural and dimensional errors and defects (including slits, pits, holes, etc. that appear during the laying process) in the laid strips. It can include one or more combinations of visual detection mechanisms (including area cameras, line scan cameras, multispectral cameras, grating cameras, etc.), laser scanning mechanisms (including point laser scanners, line laser sensors, and laser vision systems, etc.), thermal imaging detection mechanisms, ultrasonic detection mechanisms, etc.

[0131] The post-processing additive mechanism 60 and the post-processing subtractive mechanism 70 are used to repair defects or dimensional errors during the laying process. The post-processing subtractive mechanism 70 is used to cut, grind, drill, and other operations on the laid strips, errors and defects in the layered structure, and / or excess post-processing additive material according to the pre-designed strip shape, in conjunction with real-time defect detection during the printing process. The post-processing subtractive mechanism 70 includes a multi-axis grinding mechanism, a laser cutting mechanism, an ultrasonic cutting mechanism, or a water jet cutting mechanism, and is used to perform subtractive processing on the layered structure of the laid component. The multi-axis grinding mechanism includes a dual-arm five-axis head, a right-angle / 45° oscillating milling head, a CNC flat turntable, a turning and milling oscillating head, and other forms. The laser cutting mechanism can use ultraviolet, infrared, or green lasers, as well as nanosecond, picosecond, or femtosecond lasers. The ultrasonic cutting mechanism can select the appropriate blade type, width, and material based on a variety of materials, including fiber fabrics, films, rubber, and carbon fiber. The water jet cutting mechanism can use pure water jet cutting or abrasive water jet cutting.

[0132] The post-processing additive mechanism 60 is used to add filler material to defects such as slits, pits, and holes monitored in real time during the placement process, based on the pre-designed strip shape; to fill thickness errors (areas where the strip thickness falls below a preset value); and / or to fill the gaps between adjacent strips (areas where the gaps between adjacent strips exceed a preset value), thereby reducing porosity during component formation. The post-processing additive mechanism 60 includes a post-processing extruder and / or a post-processing inkjet mechanism. The post-processing extruder can be a micro FDM / FFF (fused deposition modeling) extruder, a dual- or multi-head extruder, or other specialized material extruders (including ceramics, light- or heat-curable resins, and their composites). The post-processing inkjet mechanism includes a micro piezoelectric inkjet mechanism or a micro inkjet mechanism.

[0133] like Figure 16 As shown, the composite material additive manufacturing equipment is also configured to perform an adaptive laying method based on data from multiple sensors and detection mechanisms 50 of the additive manufacturing device, thereby detecting and compensating for strip thickness errors of a single strip or gap errors between adjacent strips in a layered structure of a component.

[0134] like Figure 16 As shown, the adaptive paving method specifically includes:

[0135] Step A1: Obtaining data of pressure, thickness, and infrared thermal imaging images, and performing data preprocessing on these data;

[0136] In this embodiment, the data of pressure, thickness and infrared thermal imaging images are obtained from a variety of sensors during the laying process and the detection mechanism 50 after laying, including: 1) pressure signal: the pressure information applied to the upper surface of the strip when laying is collected in real time by the pressure sensor, in the form of X P 2) Thickness signal: The thickness information of the strip laid by the first line laser sensor 6-2 is collected in real time and expressed as X H 3) Infrared thermal imaging signal: The infrared thermal imaging sensor (thermal infrared camera) collects the infrared thermal imaging visual signals of adjacent laying strips and the areas between them in real time when laying strips. F Indicates (used to extract the characteristic parameter F of the infrared thermal imaging image. The obtained characteristic parameter F of the infrared thermal imaging image is used to determine the gap between adjacent strips and compare it with the preset gap to calculate the gap error).

[0137] Therefore, the collected data set is represented as {X i k |1≤i≤L},X i k ∈R dk×nk , where dk dimension representing unimodal characteristics, n k L represents the length of a single signal, X i k X represents the data value of the i-th data segment in the k-th modal signal, X k X represents the k-th dimensional signal and can be pressure information X P , thickness information X H , infrared thermal imaging visual signal X F These different modal signals.

[0138] Therefore, data preprocessing is performed, specifically including: using a VAE (Variational Autoencoder) module to preprocess the extracted data, including denoising, filtering, threshold segmentation, etc., so that the obtained data information is clean and effective, and normalization processing is performed.

[0139] Step A2: constructing a corresponding graph structure according to the data of pressure, thickness, and infrared thermal imaging graph;

[0140] In this embodiment, the graph structure includes a node matrix of thickness, pressure, and infrared thermal imaging, and a graph adjacency matrix of thickness value, pressure value, and infrared thermal imaging graph.

[0141] Among them, the graph structure of pressure or thickness specifically includes: cutting the pressure or thickness information sample into equal-length data segments using a fixed time length cutting method, regarding each data segment as a node of the graph structure, splicing each data segment node into a node vector, and splicing all data segment node vectors along the longitudinal axis to form a node matrix A i of the graph structure. i The generated node matrix A P of the pressure can be a pressure node matrix A H and the thickness node matrix A i .

[0142] In this embodiment, the collected data set is represented as {X k |1≤i≤L}, L represents the length of a single signal, which is cut into multiple equal-length data segments. X i k X represents the data value of the i-th data segment in the k-th modal signal, i.e., it represents a single signal data, and a data segment is composed of multiple signal data. Each signal data can be a pressure and thickness signal feature such as mean, variance, peak, time difference, phase difference, frequency, zero-crossing rate, etc.

[0143] Subsequently, according to the formula of the graph adjacency matrix X i , the graph adjacency matrix X i; Graph adjacency matrix X i Including the pressure graph adjacency matrix X P and thickness graph adjacency matrix X H Graph adjacency matrix X i The element X in i (j, k) represents the connection state between the jth node and the kth node. Therefore, the element corresponding to the connection between the jth node and the kth node is set in the jth row and kth column of the adjacency matrix. When |j−k|=1, it means that the jth node and the kth node are adjacent. At this time, the graph adjacency matrix X i The element corresponding to the connection between the two nodes in is set to 1, indicating that the adjacent nodes are connected. For other cases, the graph adjacency matrix X corresponding to the connection between the jth node and the kth node is i The elements in are set to 0. This graph structure naturally reflects the time series of pressure or thickness signals and can capture the changes of pressure signals over different time periods.

[0144] Constructing the graph structure of infrared thermal imaging images specifically includes: treating each frame of the image as a node of the graph structure, and arranging each node of the image according to its actual spatial distribution to form the final node matrix A i ;Generated image node matrix A i Including infrared thermal imaging node matrix A F ;

[0145] Then, the connection is defined according to the known spatial distribution coordinates of the node matrix, the spatial distance between all node pairs is calculated, and a distance threshold d0 is set. If the distance d(i, j) between two nodes i and j is less than or equal to this threshold d0, then the adjacency matrix X i The positions of row i, column j and row j, column i (because the graph is undirected and the adjacency matrix is ​​symmetric) are set to 1, indicating that there is a connection. If d(i,j)>d0, then X i (i,j)=0. Thus we can get the graph adjacency matrix X of the graph structure i ; The generated graph adjacency matrix X i Including infrared thermal imaging adjacency matrix X F .

[0146] Step A3: For each graph structure, perform graph feature extraction to obtain an initialized graph feature matrix;

[0147] In this embodiment, the initialized image feature matrix includes an initialized pressure value image feature matrix, an initialized thickness value image feature matrix, and an initialized infrared thermal imaging image feature matrix.

[0148] In this embodiment, the LSTM and Transformer combination algorithm is used to calculate the pressure node matrix A. P Extract to the pressure node matrix A P Extract multiple signal features from the data fragment of each node in the data, arrange and connect the multiple features extracted from each fragment in chronological order to form a row of pressure feature vectors, and splice the feature vectors of all fragments along the row direction of the matrix to form the initialization pressure feature matrix X P0 ; Use LSTM and Transformer combination model to analyze the thickness node matrix A H Extract the thickness node matrix A H Extract multiple signal features from the data fragment of each node in the matrix, arrange and connect the multiple features extracted from each fragment in chronological order to form a row of thickness feature vectors, and splice the feature vectors of all fragments along the row direction of the matrix to form the initialization thickness feature matrix X H0 Firstly, the GraphSAGE algorithm is used to reduce the dimension of the infrared thermal imaging node matrix. Then the infrared thermal imaging node matrix A is F Extract multiple signal features of each node in the image, that is, calculate the statistical signal features of the time domain or frequency domain (such as mean, variance, peak, time difference, phase difference, frequency, zero-crossing rate, etc.) of each node's signal, aggregate the features of each node (for example, take the average), and obtain the final feature vector of each electrode. If there are N nodes and the length of the feature vector of each node is L, then these feature vectors can be arranged into an N×L matrix. The resulting matrix is ​​the infrared thermal imaging initial image feature matrix X F0 .

[0149] The thickness characteristic value H is used to analyze the deviation in the specific thickness of the strip, and adaptively adjust it by controlling the laying amount of the strip (such as the material extrusion power) and the pressure characteristic value P (the adjustment of the thickness characteristic value H can also be achieved by controlling the laying speed as a secondary factor) to maintain a normal thickness. The pressure applied to the strip is mainly controlled by controlling the height of the pressure-applying device; the strip gap error ΔL is used to analyze the specific spacing deviation of the strips, which facilitates the control of the relative position of the substrate 10 and the additive manufacturing device to achieve adaptive adjustment of the strip spacing.

[0150] Step A4: Use the initialized graph feature matrix and the graph feature learning model to obtain the graph embedding vector;

[0151] In this embodiment, the graph feature learning model mainly includes the Multi-GCN component. The Multi-GCN component contains three basic units: a graph convolutional network (GCN), a graph pooling layer, and a structure learning layer. The complete Multi-GCN component is constructed by stacking these three basic units. This process aims to extract more complex and abstract graph features from the initialized graph feature matrix, ultimately generating a fixed-size graph embedding vector.

[0152] Graph Convolutional Network (GCN) layer: First, each GCN layer receives the node feature matrix A and adjacency matrix X output by the previous layer. The core idea of ​​GCN is to update the feature representation of each node by aggregating the features of adjacent nodes. First, the adjacency matrix X is symmetrically normalized; secondly, the normalized adjacency matrix is ​​multiplied by the node feature matrix. This operation aggregates the features of each node with the features of its neighboring nodes to form a feature vector; then, the aggregated feature vector is passed through a linear layer to map the features to a new feature space; after that, the activation function ReLU is applied to the linearly transformed feature vector to introduce nonlinearity, enabling the network to learn more complex patterns. Finally, the updated node feature matrix is ​​obtained, which contains the richer feature representation learned by each node in the current layer. Output the updated node feature matrix.

[0153] Graph Pooling layer: Receives the node feature matrix and graph adjacency matrix output by the GCN layer. The purpose of graph pooling is to reduce the number of nodes in the graph, thereby reducing model complexity and reducing the risk of overfitting. First, a score is calculated for each node, which reflects the importance of the node information in the graph. Second, the k nodes with the highest scores are selected based on the node scores, where k is the number of nodes after pooling. Subsequently, the selected node features are extracted from the previously updated node matrix to form a new node feature matrix. After that, the adjacency matrix is ​​updated to retain only the connection relationships between the selected nodes. The pooled node feature matrix and graph adjacency matrix are obtained and output.

[0154] Structure Learning Layer: Receives the pooled node feature matrix and graph adjacency matrix. The structure learning layer aims to learn a finer graph structure after pooling and encode the potential relationships between nodes. First, a single-layer neural network with a weight vector a is used to calculate the similarity score between pairs of nodes. Second, the sparsification function sparsemax is used to convert the similarity score into a sparse distribution to avoid introducing too much noise. Finally, the sparsified similarity score is updated to the graph adjacency matrix to obtain a new graph adjacency matrix containing finer node connection relationships, which is then output. The parameter weights are mainly composed of slice-level attention and channel-level attention. Slice-level attention is mainly used for pressure and thickness data. Its purpose is to assign different weights to each pressure or thickness segment based on the trained weights. Channel-level attention acts on infrared thermal image data. Its purpose is to assign different weights to each channel (i.e., each frame) of the infrared thermal image based on the trained weights.

[0155] The above three steps (graph convolutional network (GCN) layer, graph pooling layer, structure learning layer) are repeated to gradually extract more complex and abstract graph features.

[0156] Obtaining a graph embedding vector specifically includes: receiving a node feature matrix output by a graph convolutional network (GCN) layer; dividing the node feature matrix according to subgraphs to obtain node feature matrices of different subgraphs; performing an aggregation operation on the node feature matrix of each subgraph to obtain an aggregated feature vector of each subgraph; and concatenating the aggregated feature vectors of all subgraphs to obtain a final graph embedding vector.

[0157] In the node feature matrix here, the feature vectors of all nodes are the rows of the node feature matrix, and the node feature matrix output by the GCN layer is the set of new feature vectors obtained after all nodes are processed by the GCN layer.

[0158] Before obtaining the graph embedding vector, it can also include: using a channel-level attention model and a slice-level attention model to process a portion of the feature vectors in the node feature matrix. Among them, the channel-level attention model processes the frame rate channel features in the infrared thermal imaging data, assigns different weights to different frame rate channels, so that the model pays more attention to channel features related to spacing, and uses a linear layer and an activation function to map the feature vector of each frame rate channel to an attention score, and then uses the softmax function to normalize these scores to obtain the final attention weight of each electrode channel. The slice-level attention model processes the time segment features in the pressure and thickness data, assigns different weights to different time segments, so that the model pays more attention to thickness-related features. Similar to the channel-level attention model, a linear layer and an activation function are used to map the feature vector of each time segment to an attention score, and then uses the softmax function to normalize these scores to obtain the final attention weight of each time segment.

[0159] The concat function is often used in the above steps. It's used to concatenate multiple matrices or vectors to form a larger matrix or vector. For example, when constructing the initial graph feature matrix, multiple features from each data segment are concatenated to form a feature vector, and then all feature vectors are concatenated to form the initial graph feature matrix. The concat function is often used before the softmax function. For example, when constructing a graph embedding vector, the concat function is first used to concatenate the average pooling and max pooling results of the subgraph and process them to obtain scores. The softmax function is then used to convert the node scores into probability distributions.

[0160] Step A5: Use the modal fusion module to concatenate and weighted-sum the image embedding vectors of the weighted pressure, thickness, and infrared thermal imaging images to obtain a fused feature vector; input the fused feature vector into the fully connected layer and the Softmax function to obtain the probability distribution of each category.

[0161] The output categories include the gap distance between adjacent strips, the thickness of the laid strips, and so on. Thus, the gap distance between adjacent strips is measured using infrared thermal imaging and a line laser sensor. By comparing this with the pre-designed spacing, the error spacing value is determined. The corresponding spacing error value is then adjusted by moving the substrate or stacking unit to restore the pre-designed spacing. Similarly, the thickness of the laid strips is measured using a pressure sensor and a line laser sensor. The error is compared with the preset thickness and the strip thickness is adjusted by adjusting the height of the pressure device to restore the preset value.

[0162] Specifically, infrared thermal imaging (assisted by a line laser sensor) measures the gap between adjacent strips and compares it to the predetermined gap. The resulting error represents the corresponding movement of the substrate or stacking unit. A positive error results in the stacking unit moving away from the already laid strips, or the substrate moving closer to them. A pressure sensor (assisted by a line laser sensor) measures the actual thickness of the laid strips and compares it to the preset thickness. If the actual thickness exceeds the preset thickness, the pressure device is lowered and the applied pressure increased. If the actual thickness falls below the preset thickness, the pressure device is raised and the applied pressure reduced. The output is submitted as fused data to the actuator, which then outputs the adjustment value.

[0163] The step A5 specifically includes:

[0164] Step A51: First, use the concat function to concatenate the image embedding vectors of the three modalities (pressure, thickness, and infrared thermal imaging), and then fuse them to obtain the final fused feature. During the fusion process, the importance weight of the image embedding vector of each modality is calculated for each of the three fused modalities through a feature-level attention mechanism. The importance weights are then used to perform a weighted sum of the image embedding vectors of different modalities to obtain the fused feature vector.

[0165] Step A52: Input the fused feature vector into a network consisting of one or more fully connected layers to obtain an output vector; then, pass the output vector through a Softmax function to convert it into a probability distribution of each category.

[0166] Among them, each fully connected layer performs a linear transformation (weighted sum plus bias) and a nonlinear activation (such as ReLU) on the input vector, and the output dimension of the last fully connected layer is usually set to the number of categories of the classification task, such as within the error range or beyond the error.

[0167] In step A52, the judgment results corresponding to the probability distribution of each category are as follows:

[0168] Thickness error category judgment result: The thickness of the strip laid in a certain layered structure of prefabricated components is H0, and the thickness of the strip laid predicted by line laser or collected by sensor is H. If If the thickness is less than 3.0%, the thickness of the laid strip is judged to be within the error range; otherwise, it is judged to be beyond the error range.

[0169] The result of judging the gap error category: the spacing between adjacent strips of a layered structure of a prefabricated component is pre-set as L0, and the spacing between adjacent strips measured by the thermal infrared sensor (thermal infrared camera) is L. If If the value is ≤5.0%, the stripe spacing is judged to be within the error range; otherwise, it is judged to be beyond the error range.

[0170] The discrimination results of each category correspond to different actuators.

[0171] Specifically, the strategy of the laminating unit corresponding to the thickness error category is as follows: according to the output of the data, it is determined whether the thickness of the laid strip is within the error range, if it is within the error range, the laminating unit keeps the state and continues to lay, if the strip thickness exceeds the error range, the amount of laid material is controlled by adjusting the power of the laminating unit 30, or the height of the pressure applying unit 40 is adjusted to further adjust the pressure applied to the upper surface of the laid strip, both of which control the thickness of the laid strip to restore the strip thickness to the error range.

[0172] The strategy of the displacement device corresponding to the gap error category is as follows: according to the output of the data, if it is determined whether the distance between adjacent laid strips is within the error range, if it is within the error range, the laminating unit 30 keeps the present situation and continues to lay, if the distance between adjacent strips exceeds the error, the displacement amount of the laminating unit 30 on the left and right sides of the strip laying feeding direction is adjusted to further adjust the distance between adjacent strips, and through the fine adjustment of the displacement amount, the distance is restored to the error range.

[0173] Step A6: During the running of steps A1-A5, the probability distribution of each category is obtained as experience, and reinforcement learning is performed on the strategy corresponding to the probability distribution of each category by sampling the experience.

[0174] The step A6 specifically includes:

[0175] Step A61: A plurality of actuators (such as industrial robots, extruders, etc.) simultaneously adjust the parameters according to the strategy corresponding to the probability distribution of each category of step A5, and obtain the probability distribution of each category before and after the parameter adjustment as experience and store it in the replay buffer.

[0176] Among them, the actuator can use its own strategy network copy to interact with the data, and collect the probability distribution of each category before and after the relevant behavior as observation results and rewards as experience. Among them, the replay buffer is to store the experience collected by the actuator, allowing the learner to learn from the experience of multiple time steps, and effectively using the data to avoid the correlation between the data.

[0177] Replicas of the policy network are created and trained using a distributed reinforcement learning (RL) framework. Using the Ray distributed computing framework, this paper creates multiple CPU-based executors and a GPU-based learner. The executors run in parallel on different fused data instances, exploring the environment, generating experience, and recording it in a buffer. The learner samples training batches from the buffer and updates the weights of the policy and critic networks. The probability distribution is stored in the buffer and can be retrieved.

[0178] The input of the strategy network includes: high-level instructions (Steering Command): the displacement and extrusion power of the stacking unit 30, the applied pressure of the pressure applying unit 40, and the proprioception signal, which is the fused data mentioned above; the output of the strategy network includes: the laying angle and laying speed of the stacking unit 30.

[0179] Step A62: The learner samples experience from the replay buffer: The learner samples training batches from the replay buffer and updates the weights of the policy network and the critic network; and the learner uses the deep reinforcement learning algorithm DMPO to optimize the policy network so that it can maximize the expected cumulative reward;

[0180] The DMPO algorithm uses a policy network to generate actions and a critic network to evaluate the value of the policy. It optimizes the policy network by maximizing the cumulative reward of the policy and uses out-of-distribution updates to improve the stability of the algorithm.

[0181] Step A63: The learner sends the updated weights of the policy network to the executor's copy of the policy network, enabling the executor to interact with the environment using the latest policy.

[0182] Step A64: Repeat steps A61-A63 until the executor's policy network replica converges. At this point, the executor can execute the corresponding strategy based on the output of the policy network replica, achieving adaptive placement of materials.

[0183] Therefore, once the adaptive paving method of the present invention detects abnormal signals such as strip thickness and strip spacing, the system will adjust the displacement, thickness, applied pressure and printing speed of the local layer by changing each actuator, and adaptively compensate for defects such as slits, pits and holes monitored in real time during the paving process through the adaptive repair instructions of the post-processing additive mechanism 60 and the post-processing subtractive mechanism 70, thereby reducing the porosity and dimensional errors in the component forming process.

[0184] It should be noted that the material composition of each strip here is not selected using an algorithm. Instead, it refers to selecting a single PEEK glass fiber thermoplastic prepreg tape, a single molten PEI material, or a composite of PEEK glass fiber thermoplastic prepreg tape and molten PEI based on the material properties of the component being manufactured and the component's local thermodynamic and mechanical properties, according to actual requirements. As described above, the influence of component forming factors such as the thickness of the component's layered structure, strip width, and laying method (including one or more of relative angles, strip distribution, and strip length) on the component's strength, stiffness, and thermodynamic properties is determined through finite element analysis and stress / thermodynamic modeling and optimization. The design results are the material and dimensional requirements for each strip, and no deep learning algorithm is used in this entire process. The material selection and strip lamination in this invention do not involve any deep learning algorithm, and the laying of multiple adjacent strips is also achieved through the hardware components of the composite additive manufacturing equipment. The purpose of the deep learning algorithm is to adjust for spacing errors / defects between adjacent strips in the same layered structure, as well as for adjusting thickness errors of the laid strips themselves.

[0185] The "adaptive laying" of the present invention refers only to the use of deep learning algorithms to adaptively adjust the process parameters of the strip laying device, compacting device, displacement device and post-processing device during the strip laying process of the material. The goal of the adaptive laying method is to minimize the dimensional error and the defects, so as to meet the dimensional requirements of each strip mentioned above.

[0186] The adaptive laying method can also be used as a part of the composite material additive manufacturing method based on dimensional error compensation of the present invention to overcome the problem of increased defects caused by the simultaneous laying of the composite material additive manufacturing method based on dimensional error compensation of the present invention.

[0187] In summary, the composite material additive manufacturing method based on dimensional error compensation of the present invention has the following advantages:

[0188] 1. The continuous fiber composite additive manufacturing is a single layer strip laying of multiple material combinations, which is accumulated layer by layer until the component is formed.

[0189] 2. During the additive manufacturing process of continuous fiber composites, the type and quantity of materials can be selected and laid in combination based on the material properties of the component being prepared and the local thermodynamic and mechanical properties of the component. Based on the feedback thickness, the applied pressure can be adaptively adjusted during the laying process.

[0190] 3. During the additive manufacturing process of continuous fiber composite materials, the material properties of the component being prepared, the local thermodynamic properties and mechanical properties of the component, the type and number of materials of adjacent strips or strips in adjacent layered structures, etc. can be selected to effectively control the material properties of the component to be prepared, as well as the local thermodynamic properties or mechanical properties of the component to be prepared.

[0191] 4. During the additive manufacturing process of continuous fiber composites, when errors occur in dimensions such as the thickness of the laid strips and the distance between adjacent strips, they can be adaptively adjusted to restore them to the preset values. This can effectively reduce the porosity caused by the layer-by-layer accumulation of continuous fiber composites and the accuracy of the overall dimensions of the component, thereby improving the strength and durability of the prepared component.

[0192] The composite material additive manufacturing method based on dimensional error compensation of the present application effectively combines various fiber composite material additive manufacturing methods, combines various materials and then lays them, so as to achieve the definition of material thickness, length, laying angle, dimensional accuracy and material type of each laying layer in the component molding and composite material manufacturing process by adopting different types of material laying devices, controlling the laying temperature and applying pressure. After the definition is clear, it can ensure that the distribution of fibers and the wetting effect of the matrix reach an ideal state.

[0193] In the additive manufacturing process of continuous fiber composite materials, the quantity, type and combination order of materials are selected from a variety of materials and then laid. This is conducive to controlling the material properties of the prepared components and regulating the local thermodynamic properties and mechanical properties of the prepared components; according to the dimensional error of the strip thickness or the spacing between adjacent strips of the required prepared components, their size is adaptively adjusted to keep it consistent with the setting, which is conducive to controlling and reducing the porosity of the prepared components and controlling the strength and durability of the components.

[0194] Example 1: Composite material additive manufacturing method based on dimensional error compensation

[0195] The composite material additive manufacturing method based on dimensional error compensation of the present invention selects polyetheretherketone PEEK glass fiber thermoplastic prepreg tape (such as Mitsubishi's Ketron™ GF30 polyetheretherketone PEEK) and granular polyetherimide PEI (such as SABIC's polyetherimide PEI-1010X) materials (containing 30% short-cut carbon fiber) for additive manufacturing of components. The structural schematic diagram of the corresponding composite material additive manufacturing equipment is shown as follows. Figure 9 As shown, it includes a laminating unit 30 and a pressure applying unit 40, and the laminating unit 30 adopts a melt extrusion mechanism 31 and an automatic placement mechanism 33. Among them, the PEEK glass fiber composite material can be purchased directly, and its thickness is finalized once purchased. The PEEK glass fiber thermoplastic prepreg tape material is placed by the automatic placement mechanism 33 (such as Figure 3The granular PEI material is laid out through a single screw extruder (as shown in the figure), and four different thicknesses of prepreg tapes, 0.5h3, h3, 1.5h3, and 2h3, are selected for selection through multiple feeding devices. Figure 4 After laying, the material is pressed into strips together with other materials by a compacting device.

[0196] In this embodiment, the stacking method involves simultaneously operating a melt extrusion mechanism and an automated placement mechanism in a stacking unit to stack components. The automated placement mechanism utilizes a thermoplastic composite fiber tape with a thickness of h3. The melt extrusion mechanism first lays down a PEI material in a flat cylindrical tape along a predetermined path and width as a primary layer. Subsequently, the automated placement mechanism tightly lays down a PEEK glass fiber thermoplastic prepreg tape in a rectangular braided tape on top of the primary layer as a secondary layer. Pressure is then applied to the upper surface of the secondary layer to form a laid strip. After the strip is laid down in the component's layered structure, the robot controlling the stacking unit moves the placement head to the left of the strip's direction of travel by a distance w + L (where L is the spacing between adjacent strips and w is the strip's width). The robot then returns to a predetermined starting position and repeats the above steps until the entire prefabricated component's layered structure is laid down. After a layered structure is laid down, the relative laying angles of the laid strips are adjusted using a rotating device connected to the stacking unit. The above steps are then repeated until the entire component is fabricated.

[0197] The material structure composition selection method of a single strip includes but is not limited to: (1) The melt extrusion mechanism and the automatic laying mechanism are simultaneously turned on in the stacking unit. First, the melt extrusion mechanism lays the PEI material in a flat cylindrical strip according to a preset path and width as a primary layer. Then, the automatic laying mechanism lays the PEEK glass fiber thermoplastic prepreg tape material with a thickness of h3 in a rectangular woven fiber strip on the top of the primary layer material as a secondary layer. Pressure is applied to the upper surface of the secondary layer to form a laid strip in the form of a material combination. (2) The melt extrusion mechanism and the automatic laying mechanism are turned on and off in sequence. First, the melt extrusion mechanism is turned on to lay the PEI material in a flat cylindrical strip according to a preset path and width on the upper surface of the substrate or the previous layer structure. Then, the melt extrusion mechanism is turned off and the automatic laying mechanism is turned on. The PEEK glass fiber thermoplastic prepreg tape material is laid in a rectangular woven fiber strip following the PEI flat cylindrical tape. The two are laid alternately in sequence. Then, a pressure roller is used to apply a compacting force to form a strip formed by the adjacent composite of the two materials.

[0198] The arrangement of strips of a single layered structure includes but is not limited to: (3) The strips of the layered structure are formed by stacking and combining the two structures shown in the figure, and the layered structure is completed by arranging and laying these strips in sequence. (4) The layered structure is prepared by using strips formed by stacking and combining and strips formed by adjacent combining, and the layered structure is prepared by arranging and laying these two strips in sequence alternately until the layered structure is formed. In addition, it must be ensured that the thickness of different strips of the same layered structure is the same. During the entire laying process, the line laser sensor in the post-processing subtractive mechanism monitors the thickness of the laid strips in real time to ensure that it always remains within the preset error range. This method is used for additive manufacturing of continuous fiber composite safety gear components, which can be used in aerospace, automobile manufacturing, medical equipment, industrial robots and other fields.

[0199] Example 2: A composite material additive manufacturing method based on dimensional error compensation

[0200] The present invention is based on a composite material additive manufacturing method for dimensional error compensation. Polyphenylene sulfide PPS carbon fiber thermoplastic prepreg tape (such as Toray's glass fiber reinforced material PPS-A504X90) and granular PPS (such as Toray's glass fiber + filler reinforced PPS-A310MX04) materials (containing 35% silica mineral fiber) are selected for additive manufacturing of components. The structural schematic diagram of the corresponding composite material additive manufacturing equipment is shown in FIG. Figure 9 As shown, the stacking unit 30 and the pressure applying unit 40 are included, and the stacking unit 30 adopts a melt extrusion mechanism 31 and an automatic laying mechanism 33, the PPS carbon fiber thermoplastic prepreg material is laid by the automatic laying mechanism 33, and the granular PPS material is extruded by a twin-screw extruder mechanism (its structure is as shown in FIG. Figure 4 The laying is carried out by a melt extrusion mechanism 31 in the form of (as shown in the middle part).

[0201] The material structure composition selection method of a single strip is the same as that of Example 1, and includes but is not limited to: (1) a laying strip in a form of a combination of a molten granular PPS flat cylindrical tape as the primary layer and a PPS carbon fiber thermoplastic prepreg rectangular woven tape with a thickness of h3. (2) a laying strip in a form of a combination of a molten granular PPS flat cylindrical tape as the primary layer and a PPS carbon fiber thermoplastic prepreg rectangular woven tape with a thickness of 0.5h3. (3) a laying strip in a form of a combination of two material structures: a molten granular PPS flat cylindrical tape with a thickness of H and a PPS carbon fiber thermoplastic prepreg rectangular woven tape with a thickness of H.

[0202] The strip arrangement of a single layered structure includes but is not limited to: (1) using the laying strips formed by the two methods (1) and (2), and the two strips are arranged alternately in sequence until the preparation of the layered structure is completed. (2) using the laying strips formed by the three stacking combinations of (1), (2) and (3), and the three strips are arranged alternately in sequence until the preparation of the layered structure is completed, forming a form of layered structure. During the laying process, the appropriate strip material combination method can be selected according to the actual mechanical and thermodynamic properties of the component, and the thickness of the laid strips in the same layered structure of the component can be ensured to be consistent. The other stacking methods are the same as in Example 1. This method can be used for additive manufacturing of composite rectangular panels, and can be used in the fields of electronics, machinery, automotive parts, aerospace, etc.

[0203] Example 3: A composite material additive manufacturing method based on dimensional error compensation

[0204] The present invention is a composite material additive manufacturing method based on dimensional error compensation, wherein granular PPS (such as Toray's glass fiber + filler reinforced PPS-A310MX04) material (containing 30% glass fiber) and 316L steel strip (such as Germany's ThyssenKrupp 0.1mm 316L stainless steel strip) are selected for the additive manufacturing of components, and the composite material additive manufacturing equipment used in the additive manufacturing laying process is as follows: Figure 10 As shown in the schematic diagram, it includes a pre-treatment unit 20, a lamination unit 30 and a pressure applying unit 40, and the lamination unit 30 adopts a melt extrusion mechanism 31 and an automatic laying mechanism 33. The granular PPS material is laid by a single-screw extrusion mechanism, and the 316L steel belt is laid by an automatic laying mechanism.

[0205] like Figure 10 As shown, the principle of selecting the material structure composition of a single strip is the same as that of Example 1. The strip of the combination of 316L steel strip and granular PPS material can be: (1) a laying strip in which a molten granular PPS flat cylindrical strip is used as the primary layer and a 316L rectangular metal steel strip with a thickness of h3 is combined. (2) a laying strip in which a molten granular PPS flat cylindrical strip with a thickness of H and a 316L rectangular metal steel strip with a thickness of H are arranged in sequence.

[0206] The strip arrangement of a single layered structure includes but is not limited to: (3) Selecting the laying strips formed by the combination of method (1), arranging and laying the strips in sequence adjacent to each other until the preparation of the component layered structure is completed, forming a layered structure of one form. (4) Selecting the two laying strips formed by the combination of methods (1) and (2), arranging and laying the strips in sequence adjacent to each other until the preparation of the component layered structure is completed, forming a layered structure of one form.

[0207] During the laying process, a suitable strip material combination can be selected based on the actual mechanical and thermodynamic properties of the component, and the thickness of the laid strips in the same layered structure of the component can be ensured to be consistent. The remaining stacking methods are the same as in Example 1. This method can be used for additive manufacturing of composite aircraft skeleton ribs and other components, and can be used in aerospace and other fields.

[0208] Example 4: A composite material additive manufacturing method based on dimensional error compensation

[0209] The present invention is a composite material additive manufacturing method based on dimensional error compensation, which selects PPA carbon fiber thermoplastic prepreg (such as the film material PPA-DA910 of Japan Daikin Company) and TPU film (such as TPU transparent film S95A of Germany BASF Company) for the additive manufacturing of components, and the composite material additive manufacturing equipment used in the additive manufacturing laying process is as follows: Figure 11 As shown in the schematic diagram, it includes a pre-treatment unit 20, a lamination unit 30 and a pressure applying unit 40, and the lamination unit 30 adopts two automatic laying mechanisms 33, and the PPA carbon fiber thermoplastic prepreg tape and TPU film are laid through the automatic laying mechanism 33.

[0210] The material structure of a single strip can be selected in the following ways: Figure 11 As shown, the first and second automatic laying mechanisms 33 are simultaneously activated. First, the second automatic laying mechanism lays a first material, a rectangular TPU film with a thickness of h1, onto the substrate or the previous layer structure according to a preset path and width to form a primary layer. Then, the first automatic laying mechanism lays a third material, a PPA carbon fiber thermoplastic prepreg rectangular woven tape with a thickness of h3, onto the top of the primary layer to form a secondary layer. Pressure is applied to the upper surface of the secondary layer to form a laying strip in the form of a material combination. Figure 11 As shown, the first and second automatic laying mechanisms are started alternately. First, the second automatic laying mechanism lays a rectangular TPU film with a thickness of the total thickness H of a single strip on the substrate or the previous layer structure according to a specific width and path. Immediately thereafter, the first automatic laying mechanism lays a PPA carbon fiber thermoplastic prepreg rectangular woven tape with a total thickness H of a single strip on the substrate or the previous layer structure, and applies a pressing force through the pressure roller to form a laying strip with a structural combination.

[0211] The strip arrangement of a single layered structure includes but is not limited to: Figure 11 As shown, two strips of methods (1) and (2) are selected and laid in sequence adjacent to each other until the preparation of the component layered structure is completed, forming a layered structure. Figure 11As shown, the strip of selection mode (2) is laid in sequence with the strips adjacent to each other until the preparation of the component layered structure is completed, forming another form of layered structure.

[0212] Thus, the thickness of the laid strip in the same layered structure is ensured to be consistent, and the remaining stacking mode is the same as that of Example 1. This method can be used for additive manufacturing of composite material instrument panels and the like, and can be used in the fields of electronics and electrical appliances, automobile parts, aerospace, etc.

[0213] Example 5: A composite material additive manufacturing method based on size error compensation

[0214] A composite material additive manufacturing method based on size error compensation of the present application selects PEEK glass fiber thermoplastic prepreg strips (such as Ketron™ GF30 polyether ether ketone PEEK of Mitsubishi) and PEEK micro powder (such as VESTA-KEEP powder of Evonik Company in Germany) for additive manufacturing of components, and the composite material additive manufacturing equipment used in the additive manufacturing laying process is, for example, Figure 12 as shown in the schematic diagram, wherein the stacking unit 30 and the pressure applying unit 40 are included, and the stacking unit 30 adopts a direct energy deposition mechanism 32 and an automatic laying mechanism 33, the PEEK glass fiber thermoplastic prepreg strip is laid through the automatic laying mechanism 33, and the PEEK powder is laid through the direct energy deposition mechanism 32.

[0215] As shown in Figure 12 the material structure composition selection mode of a single strip is not limited to: (1) the direct energy deposition mechanism and the automatic laying mechanism in the stacking unit are turned on at the same time, the PEEK micro powder is first laid in a rectangular pore-shaped strip on the substrate or the previous layered structure as a primary layer according to the preset path and width by the direct energy deposition mechanism, then the PEEK glass fiber thermoplastic prepreg strip material with a thickness of h3 is laid in a rectangular woven-shaped strip on the top of the primary layer material as a secondary layer by the automatic laying mechanism, and pressure is applied to the surface of the secondary layer to form a material combination form of the laid strip. (2) the direct energy deposition mechanism and the automatic laying mechanism are turned on in sequence, the PEEK micro powder with a thickness of H is first laid in a rectangular pore-shaped strip on the substrate or the previous structure according to a specific width and path by the direct energy deposition mechanism, and then the PEEK glass fiber thermoplastic rectangular prepreg woven-shaped strip with a thickness of H is laid on the substrate or the previous structure by the automatic laying mechanism, and pressure is applied by the pressure roller to form a structure combination mode of the laid strip.

[0216] The strip arrangement mode of a single layered structure includes but is not limited to: (3) two strips formed by combining the modes of (1) and (2), which are arranged and laid in sequence in mutual adjacency until the preparation of the layered structure of the component is completed, forming a form of layered structure. (4) strips formed by combining the mode of (1) in the text, which are arranged and laid in sequence in mutual adjacency until the preparation of the layered structure of the component is completed, forming another form of layered structure.

[0217] Thus, the thickness of the laid strip in the same layered structure is ensured to be consistent, and the remaining stacking mode is the same as that of Embodiment 1. This method can be used for additive manufacturing of composite material valve seats and other components, and can be used in the fields of automobile parts, aerospace, etc.

[0218] Embodiment 6: A composite material additive manufacturing method based on size error compensation

[0219] The composite material additive manufacturing method based on size error compensation of the application selects 316L steel strips (such as 0.1 mm 316L stainless steel strips of Thyssenkrupp, Germany) and PEEK micro powder (such as VESTA-KEEP powder of Evonik, Germany) for additive manufacturing of components, and the composite material additive manufacturing equipment used in the additive manufacturing and laying process is, for example, Figure 13 as shown in the schematic view, which includes a stacking unit 30 and a pressure applying unit 40, and the stacking unit 30 adopts a direct energy deposition mechanism 32 and an automatic laying mechanism 33, the 316L steel strip is laid through the automatic laying mechanism 33, and the PEEK powder is laid through the direct energy deposition mechanism 32.

[0220] As shown in Figure 13 the material structure composition selection mode of a single strip includes but is not limited to the following, and the principle is the same as that of Embodiment 5, and the combination of 316L steel strips and PEEK micro powder is: (1) PEEK micro powder in the form of a rectangular porous strip as a primary layer and a 316L rectangular metal steel strip with a thickness of h3 as a secondary layer to form a form of laid strip. (2) PEEK micro powder with a thickness of H in the form of a rectangular porous strip and a 316L rectangular metal steel strip with a thickness of H to form a form of laid strip.

[0221] The strip arrangement mode of a single layered structure includes but is not limited to: (3) two strips formed by combining the modes of (1) and (2), which are arranged and laid in sequence in mutual adjacency until the preparation of the layered structure of the component is completed, forming a form of layered structure. (4) strips formed by combining the mode of (1) in the text, which are arranged and laid in sequence in mutual adjacency until the preparation of the layered structure of the component is completed, forming another form of layered structure.

[0222] Therefore, during the laying process, an appropriate strip material combination can be selected based on the actual mechanical and thermodynamic properties of the component, and the thickness of the laid strips in the same layered structure of the component can be ensured to be consistent. The remaining stacking method is the same as in Example 1. This method can be used for additive manufacturing of composite door and window frame trim and other components, and can be used in the automotive parts, aerospace and other fields.

[0223] Example 7: A composite material additive manufacturing method based on dimensional error compensation

[0224] The present invention is a composite material additive manufacturing method based on dimensional error compensation, which selects PPS carbon fiber thermoplastic prepreg (such as Toray's glass fiber reinforced material PPS-A504X90), granular PPS (such as Toray's glass fiber + filler reinforced PPS-A310MX04) materials and 301H stainless steel strip (such as Nippon Steel's 0.2mm thick 301H stainless steel strip - HW45) for additive manufacturing of components, and the composite material additive manufacturing equipment used in the additive manufacturing laying process is as follows: Figure 14 As shown in the schematic diagram, it includes a lamination unit 30 and a pressure applying unit 40, and the lamination unit 30 adopts a melt extrusion mechanism 31 and two automatic laying mechanisms 33. The PPS carbon fiber thermoplastic prepreg tape and the 301H stainless steel tape are laid by the automatic tape laying mechanism 33 (the two automatic laying mechanisms are used to lay two different materials), and the granular PPS is laid by the melt extrusion mechanism 31 in the form of a single-screw extrusion mechanism.

[0225] like Figure 14As shown, a single strip is composed of three structural materials in different laying methods, including but not limited to the following forms: (1) the second automatic laying mechanism of the two automatic laying mechanisms 33 in the stacking unit is turned on, and the first automatic laying mechanism and the melt extrusion mechanism 31 are turned on alternately. First, the second automatic laying mechanism lays the 301H rectangular steel strip on the substrate or the previous layer structure as a primary layer according to a preset path, and then the first automatic laying mechanism and the melt extrusion mechanism 31 are turned on alternately, so that the flat cylindrical molten PPS tape and the PPS rectangular carbon fiber thermoplastic prepreg woven tape are alternately laid on the upper surface of the primary layer as a secondary layer, and pressure is applied to the upper surface of the secondary layer to form a laying strip in the form of a material combination. (2) The second automatic laying mechanism and the melt extrusion mechanism 31 of the automatic laying mechanism 33 are simultaneously turned on in the stacking unit, and these two mechanisms are turned on alternately with the first automatic laying mechanism. First, the second automatic laying mechanism lays the 301H rectangular steel tape on the substrate or the previous layer structure as a primary layer according to a preset path, and then the melt extrusion mechanism lays the flat cylindrical molten PPS tape on the top of the primary layer as a secondary layer. Only the first automatic laying mechanism is turned on to lay the PPS rectangular carbon fiber thermoplastic prepreg woven tape immediately thereafter, so that the PPS rectangular carbon fiber thermoplastic prepreg woven tape and the above-mentioned stacking tape are laid alternately, and a pressing force is applied to the upper surface of the stacking tape through a pressure device to form a laying strip together. (3) In the stacking unit, first, only the second automatic laying mechanism of the automatic laying mechanism 33 is turned on to lay the 301H rectangular steel strip on the substrate or the previous layer structure, and then the first automatic laying mechanism of the automatic laying mechanism 33 and the melt extrusion mechanism 31 are turned on at the same time to stack and lay the flat cylindrical molten PPS strip and the PPS rectangular carbon fiber thermoplastic prepreg woven strip, so that the two are laid alternately in sequence, and by applying a pressing force, a laying strip is formed together.

[0226] The strip arrangement of a single layered structure includes but is not limited to the following: (4) Selecting three strips of different structures formed by combining the methods of (1), (2) and (3), arranging and laying the three strips adjacent to each other in sequence until the preparation of the component layered structure is completed, forming another form of layered structure. (5) Selecting two strips of different structures formed by combining the methods of (1) and (2), arranging and laying the two strips adjacent to each other in sequence until the preparation of the component layered structure is completed, forming another form of layered structure.

[0227] This ensures that the thickness of the laid strips in the same layered structure remains consistent, and the rest of the stacking method is the same as in Example 1. This method can be used for additive manufacturing of composite material panels and other components with relatively complex shapes, which can be used in the manufacture of skateboards, sleds, etc.

[0228] Example 8: A composite material additive manufacturing method based on dimensional error compensation

[0229] The composite material additive manufacturing method based on dimensional error compensation of the present invention selects T2 copper foil (such as 0.05mm T2 copper foil of Nippon Mining and Metals), powdered PEEK (such as VESTA-KEEP powder of Evonik of Germany) and PPS carbon fiber thermoplastic prepreg (such as glass fiber reinforced material PPS-A504X90 of Toray Company) for additive manufacturing of components, and the composite material additive manufacturing equipment used in the additive manufacturing laying process is as follows: Figure 15 As shown in the schematic diagram, it includes a lamination unit 30 and a pressure applying unit 40, and the lamination unit 30 adopts a direct energy deposition mechanism 32 and two automatic laying mechanisms 33. The T2 copper foil tape material and the PPS carbon fiber thermoplastic prepreg tape material are laid by the automatic tape laying mechanism, and the powdered PEEK material is laid by the direct energy deposition mechanism.

[0230] like Figure 15 As shown, its principle is similar to that of Example 7, except that the melt extrusion mechanism is replaced with a direct energy deposition mechanism in the lamination unit. The combination of different laying methods of three structural materials for a single strip includes but is not limited to: (1) a rectangular PPS carbon fiber prepreg braided tape as the primary layer, a PEEK rectangular pore tape and a T2 rectangular copper tape alternately laid in sequence as the secondary layer, forming a form of laid strip. (2) a rectangular PPS carbon fiber prepreg braided tape as the primary layer, a T2 rectangular copper tape as the secondary layer, and a combination of the two and the PEEK rectangular pore tape alternately laid in sequence, forming a form of laid strip. (3) a rectangular PPS carbon fiber prepreg braided tape is laid on the previous layer of the substrate, and the PEEK rectangular pore tape is laid as the primary layer and the T2 rectangular copper tape as the secondary layer, and the strips are alternately laid in sequence, forming a form of laid strip.

[0231] The arrangement of strips of a single layered structure includes but is not limited to: (4) selecting strips of three different structures formed by combining the methods (1), (2) and (3), arranging and laying the strips adjacent to each other in sequence until the preparation of the component layered structure is completed, forming another form of layered structure. (5) selecting strips of two different structures formed by combining the methods (2) and (3) in the text, arranging and laying the strips adjacent to each other in sequence until the preparation of the component layered structure is completed, forming another form of layered structure.

[0232] During the laying process, it is necessary to select an appropriate strip material combination based on the actual mechanical and thermodynamic properties of the component, and ensure that the thickness of the laid strips in the same layered structure remains consistent. The rest of the stacking method is the same as in Example 1. This method can be used for additive manufacturing of components such as complex-shaped composite supports, and can be used in the fields of electronics, automotive parts, aerospace, etc.

[0233] Example 9: A composite material additive manufacturing method based on size error compensation

[0234] A composite material additive manufacturing method based on size error compensation of the present application, according to the above-mentioned selected materials, determine the composition of the additive manufacturing equipment, corresponding to determine the pre-processing unit 20 and post-processing unit, the pre-processing unit uses industrial hot air heater (such as Germany STEINEL company 220 double hot air heater HL1400S) for hot air heating, the detection mechanism 50 of the post-processing unit uses line laser sensor (such as Germany SICK company G6 series photoelectric sensor-GTB6-P4241) and infrared thermal camera (such as Germany Testo company infrared thermal imager testo865) composition, the post-processing subtractive mechanism 70 uses laser cutting device (such as bodor company fiber laser cutting machine). The additive manufacturing device moving relative to the substrate 10 is connected with the gantry system (such as Germany Zeiss large three coordinate measuring machine MMZ G gantry) through the rotating mechanism (such as new platform transmission company RR120-9W precision electric rotating platform) to lay up forming, such as Figure 17 shown, wherein the rotating mechanism is used to control the angle of the laying direction of the additive manufacturing device, forming the multi-angle staggered laying of the strip.

[0235] In terms of material selection, the system will analyze according to a variety of material categories and combination methods, and calculate the heating temperature required when the combined layer is laid. The system control signal is output to the heating equipment, and the heating temperature of the strip to be laid is adjusted by controlling the power of the pre-heating equipment, so as to improve the adhesion between the layers. Similarly, the system will also analyze according to a variety of continuous fiber composite material categories and combination methods, and calculate the pressure required when the layered structure strip is laid. By controlling the height of the pressing device, the system adjusts the pressure applied by the pressing device to reduce the porosity of the layer and layer combination and achieve better combination effect.

[0236] Example 10: A composite material additive manufacturing method based on size error compensation

[0237] The present invention provides a composite material additive manufacturing method based on dimensional error compensation. According to the above-selected materials, the composition of the additive manufacturing equipment is determined, and the pre-processing unit 20 and the post-processing unit are correspondingly determined. The pre-processing unit 20 uses a laser heater (such as the T-SMILS laser heating system L15570-111 of Hamamatsu Photonics Co., Ltd.) for heating. The detection mechanism 50 of the post-processing unit uses a point laser sensor (such as the optoNCDT ILD2300-2DR of Miiri Corporation, Germany) and a laser vision system (such as the 3D laser scanner ATOS of Zeiss, Germany). It is mainly used for real-time detection of the thickness of the laid strips and defects (slits, pits, etc.) and errors (strip spacing) in the layered structure during the laying process. The post-processing additive mechanism 60 can also select a light curing mechanism (such as Figure 6 ), UV photosensitive resin (such as pHROZEN's lake gray high-precision photosensitive resin) and filamentous carbon fiber materials (such as Japan's Toray's 6k carbon fiber filament-T300) are added to the device to fill defects (such as slits, pits, etc.) that appear during the laying process. When compensating, the photosensitive resin is used for filling in the form of a coating on the surface of the carbon fiber filament. The post-processing subtractive mechanism 70 uses an ultrasonic cutting device (such as the small cutting machine ZO-91 ultrasonic cutting knife of Honda Electronics Co., Ltd. in Japan) for subtractive manufacturing. It is mainly used to trim excess material caused by errors during the laying process. The overall additive manufacturing equipment is connected to a linear track-type KUKA robot (such as KUKA's KR_70_R2100_F robot) through a rotating platform for laying and forming. The laying path of the additive manufacturing equipment is controlled by controlling the movement trajectory of the robot, such as Figure 18 shown.

[0238] Example 11: A composite material additive manufacturing method based on dimensional error compensation

[0239] In this embodiment, the post-processing unit mainly consists of a post-processing detection mechanism, a post-processing material addition mechanism, and a post-processing material reduction mechanism. Its main functions are to repair thickness errors of laid strips, repair spacing errors between adjacent strips, and repair defects during the laying process.

[0240] like Figure 7AThe figure shows the post-processing process for fixing the thickness error of the laid strips. 6-1 is the stacking device, 6-2 is the first-line laser sensor, 6-3 is the previous layer of laid strips, 6-4 is the strip being laid, 6-5 is the micro-fused deposition mechanism, and 6-6 is the ultrasonic cutting machine. Due to the pressure applied during the laying process and the control of the stacking unit power, the thickness of the laid strips during the actual laying process will have errors compared to the preset thickness. Based on the post-processing monitoring device and adaptive adjustment such as the first-line laser sensor 6-2 (such as the ScanControl 2900-50 laser scanner from Mi-Iridium, Germany), the actual thickness of the laid strips can be adjusted as shown in the figure. Figure 7A As shown, irregularities occur. The actual thickness of the strip being laid is monitored in real time by a first-line laser sensor 6-2. The first-line laser sensor 6-2 locates and quantifies the error values ​​for areas where the lay thickness is below the preset thickness. The specific error values ​​for each area are determined, and the system calculates the amount of extruded material required to fill the error areas. An industrial robot or gantry system controls a micro-fused deposition mechanism 6-5 (such as the Stratasys F120 device from the Stratasys F123 series) in the post-processing additive device to quantitatively fill the error areas. The first-line laser sensor 6-2 locates and quantifies the error values ​​for areas where the lay thickness is above the preset thickness, and the system calculates the amount of material required to be trimmed within the strip error range. The industrial robot or gantry system controls an ultrasonic cutting device (such as the Suzuki SUW-30CMH automatic ultrasonic cutting machine from Japan) in the post-processing subtractive device to trim the excess thickness of the strip and any excess fill areas in the post-processing additive device until the thickness is within the preset error range.

[0241] like Figure 7B The figure shows a schematic diagram of post-processing and repairing the thickness error between adjacent strips. 6-7 is the second line laser sensor, 6-8 is the first thermal infrared scanner, 6-9 is the strip being laid in the same layered structure, 6-10 is the previous strip laid in the same layered structure, 6-11 is the first micro melt extrusion mechanism, and 6-12 is the micro laser cutting device. The boundaries of the laid strips are irregularly curved, and in the actual laying process, there are certain errors and defects between adjacent strips in the same layered structure, such as Figure 7BThe actual gap between two adjacent strips is shown. A first thermal infrared scanner 6-8 (a fixed-mount FLIR-A50 thermal imaging camera from Teledyne FLIR, USA) monitors the connection between the laid strips in real time, detecting areas adjacent to the laid strips. It locates any areas where the spacing between adjacent strips is erroneous. A second line laser sensor 6-7 (such as a ScanControl 2900-50 laser scanner from Miiris, Germany) quantifies the error in the spacing between adjacent strips. The system calculates the amount of extruded material required to compensate for the gap error. An industrial robot or gantry system controls a micro 3D printing mechanism in a post-processing additive device (such as a Tuozhu A1 mini 3D printer) to fill the error area with material corresponding to the laid strips. The area detected by the second-line laser sensor 6-7, which is lower than the adjacent strip spacing or even the strip overlaps, is located, and the detected error value is quantified by the second-line laser sensor 6-7 to determine the amount of material to be trimmed. The micro laser cutting device 6-12 (such as China Dazhu MPS-D series laser cutting machine) in the post-processing subtractive device is controlled by an industrial robot or gantry system to trim the strip spacing below the preset spacing error value, so that the strip spacing is within the error range.

[0242] like Figure 7CThe figure shows a schematic diagram of repairing defects that may occur in a layered structure during the actual installation of prefabricated components. 6-13 represents the laying strips within the layered structure, 6-14 represents the laser scanning imaging vision system, 6-15 represents the second thermal infrared scanner, 6-16 represents the second micro melt extrusion mechanism, 6-17 represents the small CNC milling mechanism, and 6-18 represents the micro laser cutting machine. After each prefabricated layer is laid, the laser scanning imaging vision system in the post-processing inspection mechanism scans and identifies the entire structure in real time, detecting the location and type of defects that may have occurred during the installation process. The second thermal infrared scanner 6-15 (a fixed-mounted FLIR-A50 infrared camera from Teledyne FLIR, USA) measures the temperature difference to quantify the type and value of the defect. For example, a laser scanning imaging vision system 6-14 detects the specific location of a pit during the paving process, and a second thermal infrared scanner 6-15 detects the temperature difference to determine the specific size of the pit. The system then calculates the specific amount of material required to fill the pit using a second micro melt extruder 6-16. An industrial robot or gantry system controls the second micro melt extruder 6-16 in a post-processing additive device (such as the Stratasys F120 device from the Stratasys F123 series) to repair the pit defect. A laser scanning imaging vision system 6-14 detects the specific location of a protrusion during the paving process, and a second thermal infrared scanner 6-15 detects the temperature difference to determine the specific size of the protrusion. The system then calculates the specific amount of material required to repair the protrusion. An industrial robot or gantry system controls a small CNC milling mechanism 6-17 in a post-processing subtractive device (such as the 350UPM machine head from Moore Group Nanotechnologies) to repair the protrusion and overfilled areas. Secondly, an industrial robot or gantry system is used to control a micro laser cutting machine 6-18 (such as China Han's MPS-D series laser cutting machine) to trim the excess part along the preset shape of the layered structure so that the error of its shape is within the preset range. The above repair process is repeated until the layered structure is laid.

[0243] Therefore, the detection mechanism 50 includes a first line laser sensor 6-2 for detecting the thickness of the laid strips in real time, a second line laser sensor 6-7 for detecting the spacing between the strips, a first thermal infrared scanner 6-8 for detecting defects in real time, a second thermal infrared scanner 6-15, and a laser scanning imaging vision system 6-14.

[0244] The post-processing unit also includes a post-processing additive mechanism 60, which includes a micro-fused deposition mechanism 6-5 (or a first micro-fused extrusion mechanism 6-11, or a second micro-fused extrusion mechanism 6-16) for filling defects, thickness, or gap errors during the laying process, and a micro 3D printing mechanism. The post-processing subtractive mechanism includes an ultrasonic cutting machine 6-6, a micro laser cutting device 6-12, a small CNC milling mechanism 6-17, and a micro laser cutting machine 6-18.

[0245] like Figure 7B As shown in the figure, when laying the strips, the boundaries of the strips usually have irregular curvatures (although the ideal situation is that the strips are all rectangular, the actual situation is often different from the ideal situation), which causes errors in the gaps between adjacent strips, and defects such as slits and protrusions will appear, affecting the porosity and mechanical properties of the component.

[0246] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. Various modifications are possible. Any simple, equivalent changes and modifications made in accordance with the claims and description of the present invention are within the scope of protection of the patent claims. Anything not fully described in this invention is conventional technology.

Claims

1. A composite material additive manufacturing method based on dimensional error compensation, characterized in that: include: Step S0: selecting the quantity, type and combination of materials required for the strips of each layered structure according to the material properties of the prepared component and the local thermodynamic properties and mechanical properties of the component; Step S1: laying all strips of a single layered structure simultaneously or individually in each round to form a single layered structure; at least one layered structure uses multiple strips at the same height and adjacent to each other; each strip is formed by laminating and / or adjacently laminating multiple materials of a single type and has a strip shape; Step S2: repeating step S1 so that the strips are laid layer by layer in the order of the layers of the layered structure until a component with a continuous layer structure is formed; In step S1, an adaptive paving method is performed based on data from various sensors during the paving process and detection mechanisms after paving; The adaptive paving method comprises: Step A1: Obtaining data of pressure, thickness, and infrared thermal imaging images, and performing data preprocessing on these data; Step A2: constructing a corresponding graph structure based on the data of pressure, thickness, and infrared thermal imaging images; Step A3: For each graph structure, perform graph feature extraction to obtain an initialized graph feature matrix; Step A4: Using the initialized graph feature matrix, the graph feature learning model is used to obtain the graph embedding vector; Step A5: Using the modal fusion module, the weighted image embedding vectors of pressure, thickness, and infrared thermal images are concatenated and weighted summed to obtain a fused feature vector. The fused feature vector is input into the fully connected layer and the Softmax function to obtain the probability distribution of each category. Step A6: During the execution of steps A1 to A5, the probability distribution of each category is obtained as experience, and the strategy corresponding to the probability distribution of each category is reinforced by sampling the experience.

2. The composite material additive manufacturing method based on dimensional error compensation according to claim 1, characterized in that: Step A6 includes: Step A61: Multiple executors simultaneously adjust parameters according to the strategies corresponding to the probability distributions of each category in step A5, obtain the probability distributions of each category before and after the parameter adjustment as experience and store them in the playback buffer; Step A62: Learner samples experience from the replay buffer: The learner samples training batches from the replay buffer and updates the weights of the policy network and the evaluation network; and the learner uses a deep reinforcement learning algorithm to optimize the policy network so that it can maximize the expected cumulative reward; Step A63: The learner sends the updated weights of the policy network to the executor's copy of the policy network, enabling the executor to interact with the environment using the latest policy. Step A64: Repeat steps A61-A63 until the policy network copies of the executors converge.

3. The composite material additive manufacturing method based on dimensional error compensation according to claim 1, characterized in that: At least one layered structure adopts a plurality of strips at the same height and adjacent to each other, and the remaining single layered structures adopt a single strip or a plurality of strips at the same height and adjacent to each other.

4. The composite material additive manufacturing method based on dimensional error compensation according to claim 1, characterized in that: When the strip is made of multiple layers of a single type of material, laying the strip includes: Step S11: Laying the primary layer material according to a predetermined design as a substrate to be laid; Step S12: Laying the secondary layer material on top of the entire substrate to be laid according to a predetermined design, and laminating and compounding the layers to obtain a new substrate to be laid; Step S13: Repeat step S12 until a predetermined number of layers are laid; Step S14: Laying the primary layer material on top of the substrate to be laid according to the pre-designed method, and laminating and compounding the materials to form a strip.

5. The composite material additive manufacturing method based on dimensional error compensation according to claim 1, characterized in that: The single type of material includes thermoplastic material, thermosetting material, fiber component, elastomer, fluoroplastic, fiber or metal foil; the stacking and compounding method includes one or more of melt co-extrusion, thermal pressing / welding, photocuring, and direct energy deposition.

6. The composite material additive manufacturing method based on dimensional error compensation according to claim 1, characterized in that: In step S2, during the process of laying the strips layer by layer, other component parts other than the strips are inserted / embedded to form a composite component; In step S2, before laying each strip of the layered structure, the top of the laid layered structure is preheated using laser, infrared heating, hot air, electromagnetic induction or electric heating tube, or the top of the laid layered structure is surface activated using plasma irradiation, deep ultraviolet irradiation or electron beam irradiation; In said step S2, after laying the strips, applying a compacting force to the top surface of the laid strips; In step S2, the strip laying operation is coupled with an additive manufacturing method such as fused deposition technology, digital light processing, stereolithography, and direct energy deposition, or coupled with a subtractive manufacturing method such as multi-axis milling, multi-axis grinding, laser cutting, water jet cutting, plasma cutting, and ultrasonic cutting to adjust the laid strips.

7. A composite material additive manufacturing device based on dimensional error compensation, characterized in that: It is used to perform the composite material additive manufacturing method based on dimensional error compensation according to any one of claims 1 to 6, comprising a substrate and an additive manufacturing device that moves relative to the substrate, wherein the additive manufacturing device comprises a stacking unit, and each stacking unit is configured to: when in use, lay a single or multiple materials on the top surface of the substrate or the layered structure to be laid to form a strip in combination.

8. The composite material additive manufacturing equipment based on dimensional error compensation according to claim 7, characterized in that: The laminating unit is used to lay only a single strip at a time or to lay multiple strips simultaneously, wherein the strips are made of a single material or a combination of multiple materials; The lamination unit includes at least one lamination composite unit, and the types of the lamination composite units include one or more combinations of melt extrusion mechanism, direct energy deposition mechanism, automatic placement mechanism, light curing mechanism, and inkjet mechanism.

9. The composite material additive manufacturing equipment based on dimensional error compensation according to claim 7, characterized in that: The additive manufacturing device also includes a pre-processing unit, a pressure applying unit and a post-processing unit; the pre-processing unit includes a heating device and / or an activation device; the pressure applying unit is used to apply a pressing force after laying the strip; the post-processing unit includes a detection mechanism, a post-processing additive mechanism and a post-processing subtractive mechanism.

10. The composite material additive manufacturing equipment based on dimensional error compensation according to claim 7, characterized in that: The composite material additive manufacturing device further includes a temperature and humidity control device, which is installed outside the additive manufacturing device; and / or The composite material additive manufacturing equipment also includes a displacement device for realizing relative movement of the substrate and the additive manufacturing device in multiple directions, and the displacement device includes a gantry system, an industrial robot system or a robot-gantry composite collaborative system.

Images