Automatic powder supply and circular treatment device and method for additive manufacturing equipment

Abstract

The invention relates to an automatic powder supply and circular treatment device and method for additive manufacturing equipment, belongs to the technical field of additive manufacturing, and solves one of the problems of high supply interruption risk, low cleaning efficiency and insufficient automation degree when a powder supply and circular treatment technology in the prior art is adaptive to oversized additive manufacturing equipment. The device comprises a feeding system, a powder overflowing system, a suction powder cleaning system, a screening system and a pipeline conveying system. The two sets of feeding systems are respectively communicated with the powder feeding tank and are used for conveying powder into the powder feeding tank; the powder overflowing system, the suction powder cleaning system and the powder falling system jointly achieve powder cleaning, powder is conveyed to the screening system through the pipeline conveying system, the screened powder is conveyed into a new powder tank of the feeding system, and cyclic utilization of the powder is achieved. By arranging the two feeding systems, cooperative relay or parallel powder supply of the two feeding systems is achieved, and the risk of interruption of powder supply is reduced; by arranging the powder falling system, the powder cleaning efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, and in particular to an automatic powder supply and recycling device and method for additive manufacturing equipment. Background Technology

[0002] With the increasing demand for large and ultra-large precision components in industrial manufacturing, the forming size of additive manufacturing equipment continues to grow towards ultra-large sizes. Currently, ultra-large-size equipment with a paper size of 2000mm*2000mm*3000mm (powder processing capacity of approximately 12000L) has emerged. Compared to conventional-sized equipment (such as 1000mm*1000mm*1000mm), ultra-large-size additive manufacturing equipment faces an exponentially increased workload in powder processing. Existing technologies are insufficient to meet its practical application needs, mainly due to the following two key issues:

[0003] Regarding powder supply, existing additive manufacturing equipment mainly employs two methods: one is a semi-closed-loop supply and recycling system with manual intervention. This method involves a high degree of human involvement, resulting in low supply efficiency and easy exposure of the powder to the external environment. This can lead to powder moisture and contamination, affecting powder quality and subsequent molding accuracy, and may also pose health and safety hazards to operators. The other method is a fully closed-loop supply and recycling system designed for small and medium-sized equipment. This system can only meet the supply needs of a small amount of powder and cannot adapt to the dramatically increased powder consumption per unit time of ultra-large equipment. For conventional large-size equipment, the industry typically uses a single feeding system to alleviate the powder shortage problem by increasing the feeding frequency. However, for ultra-large equipment, the powder consumption is more than double that of conventional large-size equipment. Simply increasing the feeding frequency of a single feeding system is ineffective—prolonged high-frequency operation of a single feeding system will cause serious overheating problems, requiring shutdown for cooling, leading to powder supply interruption, which in turn affects the continuity of the printing process and may even cause defects in the molded components.

[0004] Regarding post-printing powder cleaning, after printing on ultra-large format machines, the amount of residual powder inside the cylinder and around the components is enormous, making conventional cleaning methods (such as manual powder removal and suction) inapplicable. Firstly, the forming space of ultra-large format machines is vast, with some areas difficult to reach manually, especially for components with special structures like cylinders, where manual powder removal is insufficient to clean residual powder. Secondly, suction methods are far less efficient than gravity-feed powder, and handling 12,000L of powder would consume a significant amount of time, severely impacting subsequent production plans. Conventional large-format machines improve cleaning efficiency by increasing manual powder removal stations and adding more overflow tanks, but for ultra-large format machines, this requires dozens of powder storage tanks, occupying considerable space and increasing the frequency of tank replacements, further reducing production efficiency. Furthermore, if residual powder cannot be cleaned quickly and thoroughly, it can cause surface damage to components due to powder accumulation, affecting product quality.

[0005] In summary, existing powder supply and recycling technologies suffer from problems such as high risk of supply interruption, low cleaning efficiency, and insufficient automation when adapted to ultra-large additive manufacturing equipment. These issues severely restrict the industrial application of ultra-large additive manufacturing equipment, necessitating the development of an automated powder supply and recycling solution that can meet the needs of ultra-large equipment. Summary of the Invention

[0006] Based on the above analysis, the present invention aims to provide an automatic powder supply and recycling device and method for additive manufacturing equipment, in order to solve one of the problems of high risk of supply interruption, low cleaning efficiency and insufficient automation in existing powder supply and recycling technologies when adapted to ultra-large-size additive manufacturing equipment.

[0007] On the one hand, the present invention provides an automatic powder supply and circulation device for additive manufacturing equipment, including a feeding system. The feeding system is provided in two sets, which are respectively connected to the powder tank to transport powder into the powder tank.

[0008] Furthermore, each of the aforementioned feeding systems includes a blower, a new powder tank, and a butterfly valve.

[0009] Furthermore, the blower is connected to the new powder tank via a pipeline, and a butterfly valve is installed in the pipeline.

[0010] Furthermore, the outputs of both feeding systems are connected to the upper powder tank via a passage of a three-way valve, simultaneously or alternately feeding powder into the upper powder tank.

[0011] Furthermore, each of the aforementioned feeding systems also includes a temperature sensing unit.

[0012] Furthermore, the temperature sensing unit is mounted on the fan.

[0013] Furthermore, each of the feeding systems also includes a cooling module for cooling the fan of the feeding system.

[0014] Furthermore, each of the aforementioned feeding systems also includes a balance monitoring unit.

[0015] Furthermore, the remaining amount monitoring unit is installed inside the new powder tank to monitor the amount of powder remaining in the new powder tank in real time.

[0016] Furthermore, it also includes an overflow system, a suction and cleaning system, a screening system, and a pipeline conveying system.

[0017] Furthermore, the powder overflow system includes two sets of powder storage tanks. The first set of powder storage tanks is connected to the first powder overflow trough in the printer's forming cavity, and the second set of powder overflow tanks is connected to the second powder overflow trough in the printer's cleaning chamber. The suction cleaning system includes a cleaning suction pipe and a third set of powder storage tanks. The cleaning suction pipe is installed in the printer's cleaning chamber and manually controls the suction of powder from the cleaning chamber to the third set of powder storage tanks. The sieving system is connected to the first, second, and third set of powder storage tanks via a pipeline conveying system. The powder in the aforementioned powder storage tanks and storage boxes is sieved and sent to the new powder tank of the feeding system, realizing the recycling of powder.

[0018] Furthermore, it also includes a powder-dropping system.

[0019] Furthermore, the powder dispensing system includes a powder dispensing pipe, a fourth set of powder storage tanks, and a powder storage box.

[0020] Furthermore, one end of the powder discharge pipe is connected to a powder discharge through hole provided on the substrate, and the other end is connected to the fourth set of powder storage tanks, which are connected to the powder storage box; the powder storage box is connected to the screening system through a pipeline conveying system.

[0021] Furthermore, the powder-falling through-hole is located at the center of the substrate.

[0022] Furthermore, the powder discharge hole is a round hole with a diameter of 50-150mm.

[0023] Furthermore, a through hole is provided on the lifting plate below the substrate, and a powder discharge pipe is arranged below the lifting plate.

[0024] Furthermore, the powder discharge pipe is connected to the lifting plate via a quick-release chuck, and a butterfly valve is installed on the powder discharge pipe.

[0025] Furthermore, a conical surface is provided at the top of the powder discharge through hole, the conical surface extending obliquely upward from the circumferential wall of the powder discharge through hole, and the inclination of the conical surface is 3°-5°.

[0026] Furthermore, an airflow nozzle is provided at the top of the printer's toner cleaning chamber. The airflow nozzle can spray high-pressure airflow into the cylindrical product, thereby blowing the toner into the toner discharge hole.

[0027] Furthermore, the angle of the central axis of the airflow nozzle relative to the vertical direction is adjustable.

[0028] Furthermore, the airflow nozzle is located at the end of the bellows and connected to the output end of the electric telescopic rod; the electric telescopic rod is located on the side of the bellows, and by extending or retracting the electric telescopic rod, the airflow nozzle can be driven to move, thereby changing the spray angle.

[0029] Furthermore, both the end of the corrugated pipe and the electric telescopic rod are mounted on the rotating base, which is located at the top center of the printer's toner cleaning chamber.

[0030] Furthermore, the rotating base can drive the bellows and airflow nozzles to rotate 360° around the vertical axis.

[0031] On the other hand, the present invention provides an automatic powder supply and recycling method for additive manufacturing equipment, characterized in that the powder is recycled using an automatic powder supply and recycling device for additive manufacturing equipment as described above.

[0032] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0033] (1) This invention sets up two feeding systems, which are connected to the toner canister of the printer using a three-way structure. Each feeding system is equipped with a butterfly valve, a temperature monitoring unit and a balance monitoring unit. The control system monitors the fan temperature and the remaining powder in the new powder canister in real time. When the fan temperature of a certain system exceeds the preset value or the remaining powder is lower than the preset value, the fan and butterfly valve of that system are automatically shut down, while the butterfly valve and fan of the other system are opened at the same time (or the abnormal system is suspended when both systems are feeding at the same time). This realizes the coordinated relay or parallel powder feeding of the two feeding systems, which has the effects of improving the continuity of feeding, improving the stability of equipment operation, extending the service life of the feeding system, and thus improving the overall efficiency of additive manufacturing.

[0034] (2) This invention opens a through hole in the center of the substrate and connects a matching pipeline to the bottom of the hole. A butterfly valve is installed on the pipeline. After printing, when the substrate carrying the product is transferred to the powder cleaning chamber, the butterfly valve is opened to allow residual powder to fall from the through hole, thus achieving powder cleaning. This solves the problem in the prior art that the powder at the center of cylindrical parts cannot be efficiently cleaned by manual stirring or conventional suction due to the obstruction of the cylindrical peripheral wall, resulting in extremely long cleaning time. It can significantly shorten the powder cleaning time, reduce the intensity of manual intervention, and improve the basic efficiency of powder cleaning operations.

[0035] (3) This invention provides a rotatable airflow nozzle located above the substrate and on the top of the powder cleaning chamber. The nozzle's spray angle is adjustable, enabling it to spray airflow around the product in a 360° circular motion, precisely targeting the inner wall of the product. This achieves targeted removal of residual powder around the central hole of the substrate that is close to the inner wall of the product, further improving the cleanliness of the powder cleaning process, adapting to the powder cleaning needs of cylindrical parts with different inner diameters, and enhancing the targeted nature of the powder cleaning operation.

[0036] (4) This invention provides a sloping structure around the central through-hole of the substrate, guiding the powder around the through-hole to automatically slide down into the through-hole. This achieves autonomous guidance and falling of the powder around the through-hole, thus improving the powder cleaning effect. It solves the problem in the prior art where the powder around the central hole of the substrate easily accumulates and is difficult to fall into the through-hole by its own gravity, requiring additional manual cleaning. This invention can further reduce powder cleaning dead zones, reduce the amount of residual powder, and improve the automation level and overall efficiency of powder cleaning.

[0037] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages may become apparent from the description or be learned by practicing the invention. The objects and other advantages of this invention can be realized and obtained from what is particularly pointed out in the description and drawings. Attached Figure Description

[0038] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0039] Figure 1 This is a schematic diagram of an automatic powder supply and recycling device for additive manufacturing equipment according to the present invention;

[0040] Figure 2 This is a schematic diagram (sectional view) of the printer powder cleaning chamber of an additive manufacturing equipment powder automatic supply and circulation device according to the present invention;

[0041] Figure 3 This is a top view of the substrate of an automatic powder supply and recycling device for additive manufacturing equipment according to the present invention;

[0042] Figure 4 This is a schematic diagram of the airflow nozzle of an automatic powder supply and circulation device for additive manufacturing equipment according to a specific embodiment of the present invention;

[0043] Figure 5 This is a schematic diagram of the position of the powder feeding pipe and substrate joint of an automatic powder supply and circulation device for additive manufacturing equipment according to the present invention.

[0044] Figure 6This is a schematic diagram of the powder feeding pipe and powder storage tank of an additive manufacturing equipment powder automatic supply and circulation processing device according to the present invention.

[0045] Figure label:

[0046] 100-Cylindrical product; 1-Baseboard; 2-Toner discharge through hole; 3-Printer toner cleaning chamber; 4-Lifting plate; 5-Quick-install chuck; 6-Toner discharge pipe; 7-Butterfly valve; 8-Toner storage tank; 9-Airflow nozzle; 10-Corrugated pipe; 11-Electric telescopic rod; 12-Rotating base. Detailed Implementation

[0047] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0048] Example 1

[0049] A specific embodiment of the present invention, such as Figure 1 The diagram discloses an automatic powder supply and recycling device for additive manufacturing equipment. The additive manufacturing equipment involved in this invention is a conventional large-scale additive manufacturing equipment, including a printer forming cavity and a printer powder cleaning chamber 3. The printer forming cavity is equipped with a powder loading tank, capable of storing powder supplied by the feeding system and performing powder spreading operations within the printer forming cavity. A first overflow trough is provided within the printer forming cavity for excess powder generated during printing to overflow. After printing is completed, the substrate 1, carrying the product, moves to the printer powder cleaning chamber 3 for powder cleaning. A second overflow trough is provided within the printer powder cleaning chamber 3 for powder overflow.

[0050] The automatic powder supply and recycling device in this embodiment includes a feeding system. Wherein, for example... Figure 1 As shown, the feeding system is set up in two sets, which are connected to the upper powder tank respectively, and convey the powder into the upper powder tank.

[0051] The feeding system supplies powder to the entire printer. There are two feeding systems: a first feeding system and a second feeding system.

[0052] Specifically, each feeding system includes a blower, a new powder tank, and a butterfly valve. The blower and the new powder tank are connected via a pipeline, which contains the butterfly valve. The other end of the pipeline is connected to the upper powder tank. The blower provides power to transport the powder, and the butterfly valve can be opened or closed to connect or disconnect the feeding system from the upper powder tank. The outputs of both feeding systems are connected to the upper powder tank via a passage of a three-way valve, allowing for simultaneous or alternating powder delivery to the upper powder tank.

[0053] The blower and the new powder tank, as well as the new powder tank and the upper powder tank, are connected by pipes. The blower of the feeding system blows the powder from the new powder tank into the upper powder tank.

[0054] In practice, the first and second feeding systems can be configured to supply powder simultaneously or alternately, depending on demand. When supplying powder, the butterfly valve is opened first, followed by the blower. When stopping powder supply, the blower is turned off first, followed by the butterfly valve.

[0055] Preferably, each feeding system also includes a temperature sensing unit. The temperature sensing unit is installed on the blower and is used to monitor the blower's temperature. When the blower's temperature is detected to exceed a preset safety threshold, the control module controls the feeding system to stop feeding powder.

[0056] Furthermore, each feeding system also includes a cooling module, which is used to cool the fan. If the temperature exceeds a preset safety threshold, the cooling module can be activated or its heat exchange efficiency can be increased (e.g., by increasing the efficiency of the cooling fan, the flow rate of the cooling fluid, or reducing the temperature of the fluid).

[0057] Preferably, each feeding system also includes a balance monitoring unit. This unit is located inside the new powder tank and is used to monitor the amount of powder remaining in the new powder tank in real time. When the remaining powder in the new powder tank falls below a preset safety threshold, the control module controls the feeding system to stop feeding powder and notifies the new powder tank of that feeding system to replenish powder. Simultaneously, it controls another feeding system to start feeding or continue feeding.

[0058] This invention solves the problem of "high-frequency operation, overheating, and shutdown" of a single feeding system for ultra-large-size equipment by simultaneously supplying powder to the additive manufacturing equipment through two feeding systems. The two feeding systems work in relay / parallel, reducing printing interruptions caused by overheating and shutdown of a single system, ensuring uninterrupted printing of ultra-large-size equipment, and improving the efficiency of additive manufacturing.

[0059] Furthermore, the additive manufacturing equipment powder automatic supply and circulation processing device of the present invention also includes an overflow powder system, a suction and cleaning powder system, a powder dropping system, a sieving system, and a pipeline conveying system.

[0060] The toner overflow system includes two sets of toner storage tanks. The first set of toner storage tanks is connected to the first toner overflow trough in the printer's forming cavity, and the second set of toner overflow tanks is connected to the second toner overflow trough in the printer's toner cleaning chamber 3. The suction toner cleaning system includes a toner cleaning suction pipe and a third set of toner storage tanks. The toner cleaning suction pipe is located inside the printer's toner cleaning chamber 3 and manually controls the suction of toner from the toner cleaning chamber 3 and delivers it to the third set of toner storage tanks. The toner discharge system includes a toner discharge pipe, a fourth set of toner storage tanks, and a toner storage box. One end of the toner discharge pipe is connected to a toner discharge through-hole 2 on the base plate 1, and the other end is connected to the fourth set of toner storage tanks. The fourth set of toner storage tanks is connected to the toner storage box. The sieving system is connected to the first set of toner storage tanks, the second set of toner storage tanks, the third set of toner storage tanks, and the toner storage box via a pipeline conveying system. The system sieves the toner in the toner storage tanks and the toner storage box and sends it to the new toner tank of the feeding system, realizing the recycling of toner.

[0061] The toner overflow system is a system for collecting toner that overflows during the printing and toner cleaning processes. The suction toner cleaning system is a system for cleaning excess toner from the toner cleaning chamber using a suction tube after printing. The toner overflow trays in the printer's forming cavity and toner cleaning chamber, as well as the toner cleaning suction tube in the printer's toner cleaning chamber, all use existing technology and will not be described in detail here.

[0062] The powder removal system is used to clean the powder in the center of cylindrical products. In the prior art, the powder in the center of cylindrical products cannot be manually moved into the overflow trough due to the obstruction of the cylindrical wall, nor can it be easily removed by the powder removal suction pipe. Even if it is managed to be suctioned out by the powder removal suction pipe, it takes a long time to empty the product. To solve this technical problem of low cleaning efficiency, the present invention provides a powder removal system.

[0063] Specifically, a powder-feeding through-hole 2 is provided in the center of substrate 1, such as... Figure 2 , Figure 3 As shown, a powder discharge hole 2 is opened at the center of the substrate 1, and a powder discharge pipe 6 and a butterfly valve 7 are arranged accordingly. When cleaning is required, the butterfly valve 7 is opened to allow the powder to flow along the central hole and the powder discharge pipe 6 into the powder storage tank 8 below. With this configuration, the powder at the center of the cylindrical product 100 automatically falls under the action of gravity, greatly shortening the powder cleaning time and solving one of the problems of low cleaning efficiency and insufficient automation in existing powder supply and circulation technologies when adapted to ultra-large-size additive manufacturing equipment.

[0064] In the preferred embodiment, the powder-feeding through hole 2 is located in the center of the substrate 1. It is a round hole with a diameter between 50-150mm. This can prevent the powder from not falling due to the hole being too small, and also prevent the hole from being too large and affecting the printing area.

[0065] The lifting plate 4 below the substrate 1 has corresponding circular holes of the same diameter. A quick-release chuck 5 is welded below the lifting plate 4. Figure 5As shown. A powder-feeding pipe 6 is arranged below the lifting plate 4, and the powder-feeding pipe 6 is connected to the lifting plate 4 via a quick-connect chuck 5. The other end of the powder-feeding pipe 6 is connected to a powder cart or powder storage tank 8, and a butterfly valve 7 is installed on the powder-feeding pipe 6, such as... Figure 6 As shown. The connection and disconnection of the powder-feeding pipe 6 are achieved through the butterfly valve 7. During operation, the butterfly valve 7 can be closed to seal the pipe. When spreading powder, the pipe below the substrate 1 is first filled, and then the operation process is the same as that of the substrate 1 without holes.

[0066] Furthermore, since the diameter of the powder discharge hole 2 is fixed, for some cylindrical products 100 with a larger inner diameter, a large amount of powder can still easily remain in the area between the outer periphery of the powder discharge hole 2 and the inner wall of the cylindrical product 100.

[0067] To address this technical issue, a preferred solution is to incorporate a large-diameter conical surface at the top of the toner discharge hole 2. This conical surface extends upwards at an angle of 3°-5° from the circumferential wall of the toner discharge hole 2. This design ensures that the quality of the printed product is not affected, while simultaneously enabling more thorough cleaning of the toner inside the cylindrical product 100, thus improving cleaning efficiency.

[0068] Another preferred solution is to install airflow nozzles 9 at the top of the printer's toner cleaning chamber, such as... Figure 2 , Figure 4 As shown. The airflow nozzle 9 can spray high-pressure airflow into the interior of the cylindrical product 100, thereby blowing the powder into the powder discharge hole 2 to achieve powder cleaning.

[0069] Furthermore, to address the issue of powder being lifted and reducing cleaning efficiency due to an inappropriate airflow spray angle, the angle of the airflow nozzle 9 is adjustable; that is, the angle of the central axis of the airflow nozzle 9 relative to the vertical direction is adjustable. In this way, the spray angle of the airflow nozzle 9 can be changed, ensuring the airflow is aligned with the height of the powder within the inner wall of the cylindrical product 100. This prevents the powder at the bottom from being lifted due to an inappropriate blowing direction, and also prevents the airflow from blowing outside the cylindrical product 100.

[0070] Specifically, see Figure 4 The airflow nozzle 9 is located at the end of the bellows 10 and is connected to the output end of the electric telescopic rod 11. The electric telescopic rod 11 is located on the side of the bellows 10. By extending or retracting the electric telescopic rod 11, the airflow nozzle 9 can be moved, thereby changing the spray angle.

[0071] Furthermore, to address the issue of airflow being directed in only one direction, resulting in dead zones during toner cleaning, both the end of the corrugated pipe 10 and the electric telescopic rod 11 are mounted on the rotating base 12, which is located at the top center of the printer's toner cleaning chamber 3. The rotating base 12 has a connector for rotatable connection to a high-pressure air source pipeline. The rotating base 12 can drive the corrugated pipe 10 and the airflow nozzle 9 to rotate 360° around the vertical axis. This achieves thorough cleaning of the entire circumference of the cylindrical product 100, further accelerating the toner cleaning process.

[0072] A more preferred option is to simultaneously provide the aforementioned conical surface and airflow nozzle 9.

[0073] In some alternative solutions, for powder near the edge of the cylindrical product 100 that cannot flow down by its own gravity, the following method can be used for cleaning: Multiple air vents are installed on the top of the printer's toner cleaning chamber 3. After most of the powder has flowed down, the substrate 1 is first raised to a position approximately flush with the printer's toner cleaning chamber 3. Then, depending on the diameter of the cylindrical product 100, different air vents are selectively opened to blow air into the cylinder, creating an airflow inside. This causes the powder that cannot flow down completely by gravity to converge towards the area around the vents, thus allowing this portion of the powder to flow out through the vents.

[0074] The screening system is used to screen all the collected powder before conveying it to the new powder tank of the feeding system. The screening system can use conventional existing technology and will not be described in detail here.

[0075] During powder cleaning, containers are needed to store the large amount of powder. The conventional method for storing large equipment involves setting up multiple powder storage stations and multiple powder storage tanks (8). When one tank (8) is full, the next one is moved to the next, and the full tank (8) is then sieved at the screening station. However, due to the extremely large size of the equipment, even setting up 9-10 powder storage stations is insufficient to meet the usage requirements. At least dozens of powder storage tanks (8) are needed to meet the powder storage needs of such a large-scale equipment. This not only occupies a significant amount of space but also increases the frequency with which workers need to change the overflow tanks. To solve this problem, this invention designs two large powder storage devices to store these large quantities of powder.

[0076] In the preferred embodiment, a large powder storage box is set up in a separate area, with the powder storage tank 8 serving as a transfer station. When powder is manually dispensed, released, or sucked up, once the powder storage tank 8 is full, it is manually or using an AGV to transfer the full powder storage tank 8 to the large powder storage box. The powder in the large powder storage box is then sent for sieving. The large powder storage box is used to achieve both powder storage and transfer before sieving. Only a few small powder storage boxes are needed.

[0077] In another solution, to address the insufficient automation of existing powder supply and recycling technologies when adapting to ultra-large additive manufacturing equipment, an ultra-large powder storage tank and a powder transfer system can be installed in a separate area. The powder storage tank 8, the powder storage box, and the powder transfer system are interconnected by pipes and valves. The powder storage tank 8 is equipped with a level sensor. When the powder storage tank 8 is full, it triggers a high-level signal. Once the high-level signal is triggered, the fan in the powder transfer system starts, transferring the powder from the powder storage tank 8 to the large powder storage box, thus achieving powder storage and transfer within the ultra-large powder box.

[0078] A sieving device can also be installed in a large powder storage box to store the transferred powder while simultaneously sieving it, eliminating the need for a separate sieving station.

[0079] Compared with existing technologies, the additive manufacturing equipment powder automatic supply and recycling device and method provided in this embodiment can realize the automatic supply and recycling of large quantities of powder through mechanisms such as a power source and a powder discharge cart. This method improves the efficiency of powder transfer and processing, and enhances the automation level of powder supply and processing.

[0080] This invention enables automatic powder supply and recycling in ultra-large additive manufacturing equipment. The internal structure is simple, facilitating processing, assembly, and maintenance.

[0081] Example 2

[0082] Another specific embodiment of the present invention discloses an automatic powder supply and recycling method for additive manufacturing equipment, which uses the automatic powder supply and recycling device for additive manufacturing equipment according to Embodiment 1 to recycle the powder.

[0083] The automatic powder supply and recycling method for additive manufacturing equipment in this embodiment specifically includes the following steps:

[0084] S1: The feeding system supplies powder to the powder filling tank of the printer's forming cavity;

[0085] S2: During the powder spreading and printing process, excess powder enters the first set of powder storage tanks of the powder overflow system from the first powder overflow trough;

[0086] S3: After printing is completed, the substrate 1, along with the printed workpiece and powder, is transferred to the printer cleaning chamber 3.

[0087] S4: Final toner cleaning: Inside the printer toner cleaning chamber 3, the toner powder leaves the printer toner cleaning chamber 3 from the second overflow trough, the toner cleaning suction tube and the toner drop hole 2, respectively.

[0088] S5: The powder is collected and stored in multiple powder storage tanks and / or powder storage boxes, and then transported to the screening system through pipelines. After screening, it is sent to the feeding system to achieve recycling.

[0089] The method according to this embodiment can solve one of the problems of high supply interruption risk, low cleanup efficiency, and insufficient automation in the prior art.

[0090] Step S1 specifically includes:

[0091] S11: System initialization. The control module detects the remaining amount of new powder in the two feeding systems, the status of the blowers, and the position of the valves to confirm that the equipment is in a ready-to-feed state.

[0092] S12: Select the toner supply mode according to printing needs. It can be switched to two systems supplying toner simultaneously or in turn.

[0093] S13: Powder supply start-up. Open the butterfly valve of the corresponding material supply system in the order of "open the butterfly valve first, then start the blower" and start the blower at the same time to provide conveying power.

[0094] S14: The butterfly valve opens intermittently, continuously blowing the powder from the new powder tank into the powder filling tank of the printer's forming cavity.

[0095] S15: During the feeding process, the temperature sensing unit monitors the fan temperature in real time, and the remaining quantity monitoring unit provides real-time feedback on the powder storage in the new powder tank.

[0096] S16: If the fan temperature exceeds the preset threshold, the control module will start the cooling module to reduce the temperature. If the temperature continues to exceed the standard, the system will stop supplying powder. If the remaining powder in the new powder tank is lower than the safety threshold, the system will stop supplying powder and issue a powder replenishment notice. Another system will automatically take over the powder supply.

[0097] S17: When the powder supply is completed or needs to be paused, close the relevant components in the order of "turn off the fan first, then close the butterfly valve" to end the powder supply process.

[0098] The solution in step S1 of this embodiment solves the problem of "high-frequency operation and overheating shutdown" of a single feeding system for ultra-large size equipment. It achieves continuous powder supply by having two feeding systems work together. The two feeding systems work in relay / parallel, reducing printing interruptions caused by overheating shutdown of a single system, ensuring uninterrupted printing process for ultra-large size equipment and improving the efficiency of additive manufacturing.

[0099] After the toner application is complete, and all other conditions are met, printing begins. Step S2 specifically includes:

[0100] S21: The powder tank delivers powder to the printer's forming cavity, and the powder spreading mechanism spreads the powder evenly into a powder layer of a preset thickness.

[0101] S22: Heat sources such as lasers or electron beams selectively melt the powder layer along the printing path to form a single layer structure of the product.

[0102] S23: Excess powder generated during the powder spreading and melting process flows into the first overflow trough in the molding cavity under the push of the powder spreading mechanism.

[0103] S24: The first overflow tank guides excess powder through a pipeline into the first set of powder storage tanks of the overflow system, completing the initial collection.

[0104] Step S2 addresses the issue of excess powder accumulation affecting powder uniformity and printing accuracy during the printing process, thus preventing powder waste. Real-time collection of excess powder maintains a clean environment inside the forming cavity, ensuring powder spreading quality and printing accuracy. Simultaneously, it achieves initial powder recovery, laying the foundation for subsequent recycling.

[0105] After printing, the cylinder, along with the powder-coated workpiece, moves to the powder cleaning station for powder removal. S3 specifically includes:

[0106] S31: After all layers of the product have been printed, the molding cavity stops operating, and the system confirms that the printing process has terminated.

[0107] S32: The substrate 1 in the forming cylinder carries the formed product and unmelted residual powder, and leaves the forming cavity area under the drive of the transmission mechanism.

[0108] S33: The forming cylinder carries the base plate 1 and moves it to the printer cleaning chamber 3 along a preset trajectory. After it is in place, the transmission mechanism locks and the printer cleaning chamber 3 closes to form a closed working environment.

[0109] Step S4 specifically includes:

[0110] S41: Powder cleaning starts. By manually removing the powder, most of the powder flows into the second overflow trough under gravity and is then introduced into the second set of powder storage tanks.

[0111] S42: Simultaneously open the butterfly valve 7 of the powder feeding system, and the powder in the center of the cylindrical product 100 flows into the powder feeding pipe 6 through the powder feeding through hole 2 in the center of the substrate 1 under the action of gravity.

[0112] S43: If it is a large inner diameter cylindrical product 100, start the airflow nozzle 9 on the top of the powder cleaning chamber, adjust the nozzle angle with the electric telescopic rod 11, rotate the seat 12 to drive the nozzle to rotate 360°, and spray high-pressure airflow to blow the residual powder toward the powder drop hole 2.

[0113] S44: After being temporarily stored in the fourth set of powder storage tanks, the powder in the powder drop tube is transported to the powder storage box for centralized storage.

[0114] S45: The manually controlled suction and cleaning system uses a suction pipe to target and remove powder from the surface of substrate 1 and the gaps between products. The powder is then transported to the third set of powder storage tanks.

[0115] Step S4 addresses the problem of difficult-to-clean residual powder on the center and inner wall of the cylindrical product 100, resulting in low powder cleaning efficiency. It reduces the time-consuming and labor-intensive nature of manual powder cleaning, which often fails to achieve thorough cleaning. By using multi-channel collaborative powder cleaning, efficient and thorough cleaning of residual powder on the product and substrate 1 is achieved, significantly shortening the powder cleaning time and improving the automation and cleanliness of the powder cleaning operation.

[0116] Step S5 specifically includes:

[0117] S51: All recovered powder collected by the first, second, and third powder storage tanks and boxes is monitored by a level sensor to measure the storage volume.

[0118] S52: When the powder storage tank reaches the preset full threshold, if it is in automatic transfer mode, the fan of the powder transfer system will start and transport the powder in the powder storage tank to the ultra-large powder storage box through the pipeline; if it is in manual mode, the full powder storage tank will be transferred to the ultra-large powder storage box for unloading by AGV.

[0119] S53: Powder in the extra-large powder storage box (or powder directly exported from each powder storage tank) enters the screening system through the pipeline conveying system.

[0120] S54: The sieving system classifies and screens the powder to remove impurities, agglomerated particles, and powder that does not meet the size requirements.

[0121] S55: The qualified powder after screening is transported to the new powder tank of the feeding system, waiting for the powder to be supplied again, completing the closed loop.

[0122] Step S5 addresses the issues of requiring numerous powder storage tanks for storing recycled powder in ultra-large-sized equipment, resulting in space occupation and frequent replacements. It also resolves the problem of impurities in the recycled powder affecting print quality. This embodiment achieves centralized powder storage through an ultra-large powder storage box, reducing the number of storage tanks and space occupation, and decreasing the frequency of manual operation. The sieved powder ensures the quality for recycling, significantly improving powder utilization, reducing production costs, and achieving green production.

[0123] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. An automatic powder supply and recycling device for additive manufacturing equipment, characterized in that, It includes a feeding system, which has two sets, each connected to the upper powder tank, to transport powder into the upper powder tank.

2. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 1, characterized in that, Each of the aforementioned feeding systems includes a blower, a new powder tank, and a butterfly valve.

3. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 2, characterized in that, The blower is connected to the new powder tank via a pipeline, and a butterfly valve is installed in the pipeline.

4. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 2 or 3, characterized in that, The outputs of both feeding systems are connected to the powder tank via a passage of a three-way valve, and powder is fed to the powder tank simultaneously or alternately.

5. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 4, characterized in that, Each of the aforementioned feeding systems also includes a temperature sensing unit.

6. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 5, characterized in that, The temperature sensing unit is mounted on the fan.

7. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 6, characterized in that, Each of the feeding systems also includes a cooling module for cooling the fan of the feeding system.

8. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 4, characterized in that, Each of the aforementioned feeding systems also includes a balance monitoring unit.

9. The automatic powder supply and recycling device for additive manufacturing equipment according to claim 8, characterized in that, The remaining amount monitoring unit is installed inside the new powder tank to monitor the amount of powder remaining in the new powder tank in real time.

10. A method for automatic powder supply and recycling in additive manufacturing equipment, characterized in that, The powder is circulated using the automatic powder supply and circulation device of the additive manufacturing equipment according to any one of claims 1-9.

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