Multi-heat-source shape follow-up additive manufacturing device for special-shaped curved surface component

Abstract

The invention discloses a multi-heat-source shape-following additive manufacturing device for a special-shaped curved surface component, and relates to the technical field of heat treatment. The multi-heat-source shape-following additive manufacturing device comprises a machine body frame, a five-axis linkage mechanism and an additive cladding mechanism; the additive cladding mechanism comprises a multi-heat-source support, an opposite assembly, double additive nozzles, an air cooling assembly, an airflow assembly, an air guide assembly and a magnetic control assembly. The opposite assembly drives the double additive nozzles to adjust the distance so as to self-adaptively repair the width of a path; the air flow assembly and the air guide assembly are controlled in a linkage mode through the magnetic control assembly according to the distance between the spray heads, the cooling air flow guide mode is switched, focusing heat dissipation and air curtain isolation are formed in the narrow distance, and overall heat dissipation and uniform heat distribution of the mechanism are achieved in the wide distance. According to the device, one-time clamping and full-area self-adaptive high-quality repairing of the variable-cross-section special-shaped curved surface component are achieved, and the device has the advantages of being efficient, precise, intelligent and optimized in heat management.

Description

A multi-heat source conformal additive manufacturing apparatus for irregular curved surface components Technical Field

[0001] This invention relates to the field of heat treatment technology, and more specifically, to a multi-heat-source conformal additive manufacturing apparatus for irregular curved surface components. Background Technology

[0002] In the energy and aerospace industries, many critical components, such as aero-engine blades and long blades in the last stage of steam turbines, operate under extreme environments of high temperature, high pressure, and high stress. For example, as shown in Figure 1 of the manual, specific areas of the last-stage steam turbine blade, such as the leading edge, blade tip, and tenon, are highly susceptible to failure due to erosion, wear, and the propagation of microcracks. These components are typically expensive and have long manufacturing cycles; therefore, precise additive manufacturing repair of damaged areas to restore their geometry and performance has significant economic value.

[0003] However, existing additive repair technologies face numerous challenges when handling such complex, irregularly shaped curved components. The vulnerable parts of these components exhibit highly variable geometry; for example, the inlet and outlet edges of a blade may show continuous variations in width, thickness, narrowness, and thinness from the blade root to the tip. Traditional additive repair methods struggle to adaptively and efficiently repair repair paths of varying widths without altering process parameters. Furthermore, most existing repair devices are fixed single-head or simple parallel multi-head systems, lacking the ability to dynamically adjust based on the characteristics of the repair path. The entire repair process often requires interruption to replace the nozzle or replan the path, resulting in low levels of automation and intelligence, making it difficult to meet the demand for continuous, full-area repair of complex curved components in a single setup.

[0004] In summary, there is an urgent need for an intelligent heat treatment production line that can adaptively adjust the distribution pattern and heat input state of the heat source according to the geometric characteristics of the repair area of ​​irregular curved surface components. This would ensure repair quality while balancing repair efficiency and accuracy, and effectively solve the problem of heat accumulation when multiple heat sources work together. Therefore, we propose a multi-heat-source conformal additive manufacturing device for irregular curved surface components. Summary of the Invention

[0005] The purpose of this invention is to provide a multi-heat-source conformal additive manufacturing apparatus for irregular curved surface components, so as to solve the technical problem that existing devices are unable to dynamically optimize the heat source action mode according to the geometric characteristics of the additive repair path.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a multi-heat source conformal additive manufacturing device for irregular curved surface components, comprising a frame, a five-axis linkage mechanism within the frame, and an additive cladding mechanism at the output end of the five-axis linkage mechanism; the additive cladding mechanism comprises a multi-heat source support, a counter-axis component, an additive nozzle, an air-cooling component, an airflow component, an air-conducting component, and a magnetic control component; the multi-heat source support is located at the output end of the five-axis linkage mechanism, the counter-axis component is located on the multi-heat source support, the additive nozzle is located on the counter-axis component, and the air-cooling component is located on the multi-heat source support. At the bottom, the airflow assembly is mounted on the multi-heat source bracket, the air guide assembly is sleeved on the additive nozzle, and the magnetic control assembly is fixedly mounted on the airflow assembly near the air guide assembly. The opposing assembly is used to drive at least two additive nozzles to adjust their relative distance. The airflow assembly is used to generate cooling airflow. The air guide assembly is used to guide the flow direction of the cooling airflow. The magnetic control assembly is used to change the guiding direction of the cooling airflow by the air guide assembly according to the relative distance between the additive nozzles, thereby dynamically adjusting the thermal management effect of the cooling airflow between the two additive nozzles.

[0007] Preferably, the frame of the machine body is further provided with a lifting mechanism, the output end of the lifting mechanism is provided with a placement platform, the placement platform is provided with a workpiece clamp, and the workpiece clamp is used to clamp and fix the irregular curved surface component to be repaired by additive manufacturing.

[0008] Preferably, the multi-heat source bracket includes a first support plate, a support column, a second support plate, and guide holes. The first support plate is fixedly connected to the output end of the five-axis linkage mechanism. The support column is fixedly connected to the bottom end of the first support plate. The second support plate is fixedly connected to the end of the support column away from the first support plate. The guide holes are symmetrically opened on the first support plate and the second support plate. The opposing component and the additive nozzle are movably disposed on the guide holes.

[0009] Preferably, the opposing assembly includes a motor, a gear, opposing blocks, and a tooth groove. The motor is fixedly mounted on the multi-heat source bracket, the gear is fixedly sleeved on the output end of the motor, a plurality of opposing blocks are movably mounted on the multi-heat source bracket, and the tooth groove is formed on the opposing block and meshes with the gear.

[0010] Preferably, the additive nozzle is fixedly connected to the bottom end of the opposing block, and the additive nozzle is also movably inserted into a plurality of the guide holes.

[0011] Preferably, the air-cooled assembly includes a heat dissipation bracket, a heat absorption chamber, a fan, and heat conduction holes. The heat dissipation bracket is suspended at the bottom of the multi-heat source support. The heat absorption chamber is symmetrically opened on the heat dissipation bracket. The fan is symmetrically arranged on the heat dissipation bracket. The heat conduction holes are symmetrically opened on the inner wall of the heat dissipation bracket near the additive nozzle and the air conduction assembly.

[0012] Preferably, the airflow assembly includes a mounting plate, an installation plate, an airflow nozzle, and a motor. The mounting plate is symmetrically arranged on the multi-heat source bracket, the installation plate is symmetrically arranged on the mounting plate, the airflow nozzle is rotatably arranged between the two installation plates, the motor is fixedly arranged on the installation plate and its output end is fixedly connected to the airflow nozzle, and the airflow nozzle is connected to an external air supply mechanism through a hose.

[0013] Preferably, the air guiding assembly includes an air guiding ring, a fixed cylinder, a horizontal flow groove, and a flow deflector. The air guiding ring is rotatably sleeved on the additive nozzle, the fixed cylinder is fixedly sleeved on the additive nozzle, the horizontal flow groove is formed at one end of the outer wall of the air guiding ring, and the flow deflector is formed at the other end of the outer wall of the air guiding ring.

[0014] Preferably, a limiting rod is fixedly provided at the bottom end of the air guide ring, a limiting arc groove is provided on the fixed cylinder, the limiting rod is movably inserted into the limiting arc groove, and a spring is also provided in the limiting arc groove. One end of the spring is fixedly connected to the limiting rod, and the other end of the spring is fixedly connected to the inner wall of the limiting arc groove.

[0015] Preferably, the magnetic control component includes an electromagnet, an electromagnetic coil, and a permanent magnet. The electromagnet is fixedly disposed on the airflow component near the air guide ring, the electromagnetic coil is embedded in the electromagnet, and the permanent magnet is fixedly disposed on the advection channel.

[0016] Compared with existing technologies, the beneficial effects of this invention are as follows: 1. This invention solves the fundamental contradiction of traditional repair devices when dealing with continuous variable-width repair paths by integrating a five-axis linkage mechanism, adjustable-gap dual heat sources, and an intelligent airflow thermal management collaborative control system. The device can dynamically adjust the heat source distribution and heat input state according to the geometric characteristics of the real-time repair path without interrupting the process or changing the nozzle, seamlessly switching between wide-area high-efficiency parallel cladding and narrow-area high-precision cladding modes. This enables continuous full-area repair of complex components such as turbine blades, from the blade root to the blade tip damage area, with a single clamping, greatly improving repair efficiency, automation, and process consistency.

[0017] 2. This invention also achieves continuous, synchronous, and high-precision linear control of the relative distance between the two additive nozzles. The mechanical structure is responsive and rigid, ensuring the stability of the nozzle movement at various spacings. This allows a single device to dynamically cover a process range from single-pass narrow cladding to double-pass wide cladding, flexibly adapting to changes in the width of the repair path, providing a core hardware foundation for conformal repair.

[0018] 3. This invention achieves precise, on-demand allocation of heat dissipation targets by constructing a dual-mode intelligent airflow thermal management system. The cooperation between the airflow component and the air guide component is the core of the thermal management of this invention. Through the two guiding structures of horizontal flow grooves and deflection grooves on the air guide ring, combined with steerable airflow nozzles, the system realizes two distinct airflow modes. In the wide-spacing state, the airflow is guided to circulate and cool the key components of the device and distribute the system heat evenly, ensuring the thermal stability of the equipment itself. In the narrow-spacing state, the airflow is guided to collide head-on, forming focused heat dissipation and dynamic air curtain isolation between the two heat sources, directly overcoming the problem of heat accumulation.

[0019] 4. This invention also utilizes the principle of non-contact interaction between an electromagnet and a permanent magnet in its magnetic control component. By controlling the current, the air guide ring can be remotely driven to rotate, switching the flow channels. This method eliminates mechanical wear, provides millisecond-level response, and offers precise control, making it particularly suitable for harsh working environments with high temperatures and high dust levels. More importantly, it can be seamlessly integrated with the main control system, directly responding to the spacing signal of the additive nozzle. This achieves fully automatic and intelligent closed-loop linkage between heat source layout and thermal management strategies, making it a key control node for realizing the adaptive function of this invention. Attached Figure Description

[0020] Figure 1 is a schematic diagram of the structure of the last stage long blade of the steam turbine targeted by the device of the present invention; Figure 2 is a schematic diagram of the overall structure of the present invention; Figure 3 is a schematic diagram of the internal structure of the fuselage frame of the present invention; Figure 4 is a schematic diagram of the structure of the five-axis linkage mechanism and additive cladding mechanism of the present invention; Figure 5 is a schematic diagram of the structure of the additive cladding mechanism of the present invention; Figure 6 is a schematic diagram of the disassembled structure of the additive cladding mechanism of the present invention; Figure 7 is a schematic diagram of the structure of the multi-heat source support, opposing components and air guiding components of the present invention; Figure 8 is a schematic diagram of the structure of the airflow component and air guiding component of the present invention; Figure 9 is a schematic diagram of the structure of the airflow component and magnetic control component of the present invention; Figure 10 is a schematic diagram of the structure of the air guiding ring and the fixed cylinder of the present invention; Figure 11 is a schematic diagram of the cross-sectional disassembled structure of the air guiding ring and the permanent magnet structure of the present invention; Figure 12 is a schematic diagram of the wide-spacing state of the additive nozzle of the present invention and the airflow guidance diagram; Figure 13 is a schematic diagram of the narrow-spacing state of the additive nozzle of the present invention and the airflow guidance diagram.

[0021] Explanation of the numbers in the diagram: 1. Machine frame; 2. Lifting mechanism; 3. Storage platform; 4. Workpiece fixture; 5. Five-axis linkage mechanism; 6. Additive cladding mechanism; 601. Multi-heat source support; 602. Opposing assembly; 603. Additive nozzle; 604. Air-cooled assembly; 605. Airflow assembly; 606. Air guide assembly; 607. Magnetic control assembly; 6011. First support plate; 6012. Support column; 6013. Second support plate; 6014. Guide hole; 6021. Motor; 6022. Gear; 6 023, Opposing block; 6024, Tooth groove; 6041, Heat dissipation bracket; 6042, Heat absorption chamber; 6043, Fan; 6044, Heat conduction hole; 6051, Mounting plate; 6052, Mounting plate; 6053, Airflow nozzle; 6054, Motor; 6061, Air guide ring; 6062, Fixing cylinder; 6063, Flow channel; 6064, Flow deflector; 6065, Limiting rod; 6066, Limiting arc groove; 6071, Electromagnet; 6072, Electromagnetic coil; 6073, Permanent magnet. Detailed Implementation

[0022] As shown in Figures 2 to 13, the present invention relates to a multi-heat source conformal additive manufacturing apparatus for irregular curved surface components, comprising a frame 1, a five-axis linkage mechanism 5 disposed within the frame 1, and an additive cladding mechanism 6 disposed at the output end of the five-axis linkage mechanism 5; the additive cladding mechanism 6 comprises a multi-heat source support 601, a counter-axis assembly 602, an additive nozzle 603, an air-cooling assembly 604, an airflow assembly 605, an air-conducting assembly 606, and a magnetic control assembly 607. The multi-heat source support 601 is disposed at the output end of the five-axis linkage mechanism 5, the counter-axis assembly 602 is disposed on the multi-heat source support 601, the additive nozzle 603 is disposed on the counter-axis assembly 602, and the air-cooling assembly 604 is disposed on the multi-heat source support 607. At the bottom of the heat source bracket 601, the airflow assembly 605 is mounted on the multi-heat source bracket 601, the air guide assembly 606 is sleeved on the additive nozzle 603, and the magnetic control assembly 607 is fixedly mounted on the airflow assembly 605 near the air guide assembly 606; the opposing assembly 602 is used to drive at least two additive nozzles 603 to adjust their relative distance; the airflow assembly 605 is used to generate cooling airflow; the air guide assembly 606 is used to guide the flow direction of the cooling airflow; the magnetic control assembly 607 is used to change the guiding direction of the cooling airflow by the air guide assembly 606 according to the relative distance of the additive nozzles 603, thereby dynamically adjusting the thermal management effect of the cooling airflow between the two additive nozzles 603.

[0023] This invention drives two additive nozzles 603 to adjust their relative distance through the opposing component 602, enabling the device to adapt to changes in the width of the repair path. Specifically, when repairing a wide area, the nozzle spacing is increased to improve efficiency; when repairing a narrow area, the nozzle spacing is decreased to maintain accuracy. This is applicable to the continuous change in width and thickness of the inlet and outlet edges of the long blades in the last stage of a steam turbine from the blade root to the blade tip.

[0024] Meanwhile, the magnetic control component 607 intelligently changes the direction of the air guide component 606 in guiding the cooling airflow according to this spacing change. When the nozzle is close, the airflow direction is adjusted to enhance the isolation and heat dissipation of the overlapping heat zone between the two heat sources; when the nozzle is far away, the overall airflow direction is adjusted to distribute the airflow, prioritizing the heat exchange airflow towards the air-cooling component 604, so as to balance the heat distribution and enhance the overall heat dissipation.

[0025] Therefore, this device achieves dynamic and collaborative optimization of heat source spatial distribution and airflow thermal management strategy based on the real-time geometric characteristics of the repair path without interrupting the process or replacing components. This ensures repair quality while balancing efficient repair in wide areas and precise repair in narrow areas, effectively solving the problem of heat accumulation when multiple heat sources work together, and realizing full-area adaptive additive repair of complex components in a single clamping operation.

[0026] In an embodiment of the present invention, a lifting mechanism 2 is also provided inside the frame 1, and a placement platform 3 is provided at the output end of the lifting mechanism 2. A workpiece clamp 4 is provided on the placement platform 3, and the workpiece clamp 4 is used to clamp and fix the irregular curved surface component to be repaired by additive manufacturing.

[0027] The lifting mechanism 2, the placement platform 3, and the workpiece fixture 4 used in this invention are all existing technologies in conventional fields. Their main purpose is to combine the five-axis linkage mechanism 5 and the additive cladding mechanism 6 to form a complete and flexible repair workstation. This allows the device to not only handle complex curved surfaces such as blades, but also to keep the repair path in the optimal process position by adjusting the workpiece posture and the repair head trajectory. This significantly improves the automation level and applicability of the repair process, providing a solid foundation for achieving full-area repair with a single clamping.

[0028] In an embodiment of the present invention, the multi-heat source bracket 601 includes a first support plate 6011, a support column 6012, a second support plate 6013, and a guide hole 6014. The first support plate 6011 is fixedly connected to the output end of the five-axis linkage mechanism 5. The support column 6012 is fixedly connected to the bottom end of the first support plate 6011. The second support plate 6013 is fixedly connected to the end of the support column 6012 away from the first support plate 6011. The guide hole 6014 is symmetrically opened on the first support plate 6011 and the second support plate 6013. The opposing component 602 and the additive nozzle 603 are movably disposed on the guide hole 6014.

[0029] This invention utilizes a specially designed multi-heat source support structure 601, namely a rigid frame composed of a first support plate 6011, a pillar 6012, and a second support plate 6013, along with symmetrically opened guide holes 6014. This structure provides a stable mounting base and precise linear motion guidance for the opposing assembly 602 and the additive nozzle 603. This structure ensures the rigidity and stability of the dual nozzles during high-speed, high-precision opposing movement, preventing trajectory deviations caused by vibration or deformation, thereby guaranteeing the consistency of the cladding trajectory. It serves as a reliable mechanical basis for the device to achieve adaptive widening repair.

[0030] In another embodiment of the present invention, the opposing component 602 includes a motor 6021, a gear 6022, opposing blocks 6023 and a tooth groove 6024. The motor 6021 is fixedly mounted on the multi-heat source bracket 601, the gear 6022 is fixedly sleeved on the output end of the motor 6021, a plurality of opposing blocks 6023 are movably mounted on the multi-heat source bracket 601, and the tooth groove 6024 is formed on the opposing blocks 6023, and the tooth groove 6024 is meshed with the gear 6022.

[0031] In this invention, the motor 6021 drives the gear 6022 to rotate, which meshes with the toothed groove 6024 on the opposing block 6023, precisely controlling the movement of the two opposing blocks 6023 towards or in opposite directions along the guide hole 6014. This design efficiently and synchronously converts the rotational motion of a single motor into the precise linear displacement of the dual nozzles. It has a compact structure, simple control, and fast response speed, and can reliably achieve continuous and adjustable nozzle spacing. It is the core actuator for dynamically adjusting the heat source distribution pattern of the device.

[0032] In another embodiment of the present invention, the additive nozzle 603 is fixedly connected to the bottom end of the opposing block 6023, and the additive nozzle 603 is also movably inserted into a plurality of guide holes 6014.

[0033] The additive manufacturing nozzle 603 in this invention is fixed to the opposing block 6023 and movably inserted into the guide hole 6014. This connection ensures that the nozzle movement is completely synchronized with the opposing block 6023, and the movement trajectory is doubly constrained by the opposing block and the guide hole, further enhancing the motion rigidity and positional accuracy. This design allows process modules such as powder or filament delivery and energy focusing to move as a whole with the nozzle, ensuring that each heat source maintains an independent and stable process state at any spacing, thus guaranteeing high-quality cladding.

[0034] In an embodiment of the present invention, the air-cooled component 604 includes a heat dissipation bracket 6041, a heat absorption chamber 6042, a fan 6043, and heat conduction holes 6044. The heat dissipation bracket 6041 is suspended at the bottom of the multi-heat source support 601. The heat absorption chamber 6042 is symmetrically opened on the heat dissipation bracket 6041. The fan 6043 is symmetrically arranged on the heat dissipation bracket 6041. The heat conduction holes 6044 are symmetrically opened on the inner wall of the heat dissipation bracket 6041 near the additive nozzle 603 and the air conduction component 606.

[0035] In this invention, the heat dissipation bracket 6041 is arranged close to the heat source and absorbs the radiant heat and conductive heat generated by the additive nozzle 603 and air guide assembly 606 during operation through the heat conduction hole 6044 and the heat absorption cavity 6042; the symmetrically arranged fan 6043 generates forced convection and quickly removes the heat in the heat absorption cavity 6042 through the heat conduction hole 6044.

[0036] In an embodiment of the present invention, the airflow assembly 605 includes a mounting plate 6051, a mounting plate 6052, an airflow nozzle 6053, and a motor 6054. The mounting plate 6051 is symmetrically arranged on the multi-heat source bracket 601, the mounting plate 6052 is symmetrically arranged on the mounting plate 6051, the airflow nozzle 6053 is rotatably arranged between the two mounting plates 6052, the motor 6054 is fixedly arranged on the mounting plate 6052 and its output end is fixedly connected to the airflow nozzle 6053, and the airflow nozzle 6053 is connected to an external air supply mechanism through a hose.

[0037] In this invention, the airflow assembly 605 is driven by a motor 6054 to rotate the airflow nozzle 6053, allowing for flexible adjustment of the cooling airflow's injection angle. This design provides initial direction adjustment capability for the cooling airflow, which can be coordinated with or prepared for the guiding function of the air guide assembly 606. For example, before a change in nozzle spacing, the angle of the airflow nozzle 6053 can be pre-adjusted to align it with the optimal incident area of ​​the air guide assembly 606, thereby optimizing airflow utilization efficiency, enhancing the response speed and effectiveness to thermal management state switching, and improving the flexibility and adaptability of the entire thermal management system.

[0038] In another embodiment of the present invention, the air guiding assembly 606 includes an air guiding ring 6061, a fixed cylinder 6062, a horizontal flow groove 6063, and a flow deflector 6064. The air guiding ring 6061 is rotatably sleeved on the additive nozzle 603, the fixed cylinder 6062 is fixedly sleeved on the additive nozzle 603, the horizontal flow groove 6063 is formed at one end of the outer wall of the air guiding ring 6061, and the flow deflector 6064 is formed at the other end of the outer wall of the air guiding ring 6061.

[0039] In this invention, the air guide ring 6061 fitted onto the additive nozzle 603 is rotatable, and the horizontal flow groove 6063 and the deflection groove 6064 formed on its outer wall constitute two different airflow guiding structures. When the air guide ring 6061 rotates to align the different grooves with the airflow direction of the airflow nozzle 6053, the cooling airflow will be guided into horizontal flow parallel to the nozzle axis or into deflection flow with a specific direction.

[0040] When the baffle grooves 6064 of the two symmetrically arranged air guide rings 6061 rotate to the angle shown in Figure 12, the motor 6054 drives the two airflow nozzles 6053 to deflect towards the baffle grooves 6064. The airflow nozzles 6053 spray airflow containing cooling medium towards the baffle grooves 6064, and then the airflow is guided by the shape of the baffle grooves 6064 to the heat conduction holes 6044 on the heat dissipation bracket 6041 and enters the heat absorption chamber 6042. Finally, the heat is discharged by the fan 6043. The above process optimizes the overall temperature distribution of the mechanism under the premise of targeted heat dissipation, breaks the pattern of heat accumulation in local areas, realizes the uniform redistribution of heat inside the system, and reduces the overall thermal stress.

[0041] As shown in Figure 13, when the horizontal flow channels 6063 of the two symmetrically arranged air guide rings 6061 rotate to face each other, the motor 6054 drives the two airflow nozzles 6053 to also face each other. The two opposing airflows flow along the straight inner wall of the horizontal flow channel 6063. When the two airflows converge in the middle, the collided and diffused airflow is still constrained by the horizontal flow channel 6063 and guided in a linear direction. This causes most of the cooling airflow to be retained at the heat overlap area of ​​the two closely spaced additive nozzles 603, forming targeted heat dissipation. The above process causes a large amount of cooling medium to be forcibly retained and violently disturbed in the core high-temperature area where the heat overlaps between the two nozzles, achieving targeted and efficient forced convection heat dissipation and directly removing the energy of the overlapping heat source. At the same time, the continuously flowing cooling airflow forms a stable positive pressure zone in the central area, forming a dynamic air curtain barrier that effectively blocks direct heat radiation and heat convection between the two molten pools, preventing heat accumulation and superposition.

[0042] In another embodiment of the present invention, a limiting rod 6065 is fixedly provided at the bottom end of the air guide ring 6061, and a limiting arc groove 6066 is provided on the fixed cylinder 6062. The limiting rod 6065 is movably inserted into the limiting arc groove 6066, and a spring is also provided in the limiting arc groove 6066. One end of the spring is fixedly connected to the limiting rod 6065, and the other end of the spring is fixedly connected to the inner wall of the limiting arc groove 6066.

[0043] In this invention, the limiting rod 6065 of the air guide ring 6061 is movably inserted into the limiting arc groove 6066, while the fixed cylinder 6062 is fixedly connected to the additive nozzle 603, so that the air guide ring 6061 can only rotate 90 degrees, as shown in Figures 12 and 13, while the spring helps the air guide ring 6061 to reset.

[0044] In an embodiment of the present invention, the magnetic control component 607 includes an electromagnet 6071, an electromagnetic coil 6072, and a permanent magnet 6073. The electromagnet 6071 is fixedly disposed on the airflow component 605 near the air guide ring 6061, the electromagnetic coil 6072 is embedded in the electromagnet 6071, and the permanent magnet 6073 is fixedly disposed on the advection channel 6063.

[0045] This invention controls the on / off state or direction of the current in the electromagnetic coil 6072, thereby altering the interaction force (attraction or repulsion) between the magnetic poles of the electromagnet 6071 and the permanent magnet 6073 fixed on the air guide ring 6061, thus driving the air guide ring 6061 to rotate non-contactly. This achieves clean, fast, and precise remote control of the air guide ring 6061's operating state without cables or direct mechanical connections. This structure has a fast response speed and is particularly suitable for high-temperature, dusty additive manufacturing environments.

[0046] Working Principle: This embodiment provides a method for using a multi-heat source conformal additive manufacturing device for irregularly shaped curved surface components, including the following steps: Step 1, workpiece clamping and path planning; The irregularly shaped curved surface component to be repaired, such as a long blade of the last stage of a steam turbine, is fixed on the placement platform 3 using a workpiece clamp 4. Through the control system, a repair trajectory program is generated based on the three-dimensional model of the component and the geometric characteristics of the damaged area, especially the continuous change in the repair path width from the blade root to the blade tip. This program also includes the motion path of the five-axis linkage mechanism 5, the spacing adjustment command of the opposing components 602, and the switching logic of the airflow thermal management mode.

[0047] Step 2: Adaptive Heat Source Spacing Adjustment; During the repair process, the control system sends commands to the motor 6021 of the opposing component 602 according to the real-time executed repair path program. The motor 6021 drives the gear 6022 to rotate, and through meshing with the toothed groove 6024 on the opposing block 6023, precisely controls the two opposing blocks 6023 to move synchronously towards or in opposite directions along the guide hole 6014 on the multi-heat source bracket 601. This causes the two additive nozzles 603 fixed at the bottom of the opposing block 6023 to adjust their relative distance: when repairing a wider area, such as the thicker part in the middle of the blade, the spacing between the two additive nozzles 603 is increased to achieve high-efficiency, wide-area parallel cladding; when repairing a narrower area, such as the leading edge or thin wall of the blade tip, the spacing between the two additive nozzles 603 is decreased to achieve high-precision narrow-channel cladding and avoid over-melting.

[0048] Step 3: Intelligent airflow thermal management mode coordinated switching; The airflow thermal management system intelligently switches between two working modes based on the real-time spacing between the two additive nozzles 603 through the coordinated action of the magnetic control component 607 and the airflow component 605: Step 3.1: In narrow-spacing mode, focused heat dissipation and air curtain isolation; Triggering condition: When the spacing between the two additive nozzles 603 decreases to a preset narrow zone threshold, the control system energizes the electromagnetic coil 6072 of the magnetic control component 607 to generate a magnetic field in a specific direction, driving the permanent magnet 6073 fixed on the horizontal groove 6063 of the air guide ring 6061, causing the two air guide rings 6061 to rotate synchronously until their horizontal grooves 6063 are precisely aligned, as shown in Figure 13. At the same time, the motor 6054 of the control airflow component 605 drives the two airflow nozzles 6053 to rotate to an opposing angle.

[0049] Working effect: Two cooling airflows ejected from the airflow nozzles 6053 are guided into the opposing horizontal flow channels 6063. The airflows converge along the straight inner wall of the horizontal flow channel 6063, colliding head-on in the narrow central area between the two nozzles. The turbulence generated by the collision, constrained by the horizontal flow channel 6063, creates forced stagnation and intense disturbance in the core area where heat overlaps, achieving efficient and targeted heat dissipation. At the same time, the continuously flowing airflow forms a stable dynamic air curtain, isolating the thermal interaction between the two molten pools and preventing heat accumulation.

[0050] Step 3.2: In wide-spacing mode, overall heat dissipation and heat distribution are optimized; trigger condition: when the spacing between the two additive nozzles 603 increases to a preset wide-area threshold. The control system changes the current direction of the magnetic control component 607 or shuts it off. Under the action of the spring, the air guide ring 6061 resets and rotates, so that its deflector groove 6064 faces the heat dissipation bracket 6041, as shown in Figure 12. At the same time, the control motor 6054 drives the airflow nozzle 6053 to deflect, directing the airflow towards the deflector groove 6064.

[0051] Working effect: The cooling airflow is directed towards the baffle 6064, and after being guided by its profile, it is precisely directed to the heat conduction holes 6044 on the heat dissipation bracket 6041. The airflow enters the heat absorption chamber 6042 through the heat conduction holes 6044, carrying away the heat conducted to the heat dissipation bracket by components such as the additive nozzle 603 and the air guide ring 6061, and is finally discharged by the fan 6043. This mode achieves active circulating cooling of the actuator itself and uniform distribution of system heat, ensuring the stability and accuracy of the equipment during long-term operation.

[0052] Step 4: Continuous Repair and Dynamic Following; The five-axis linkage mechanism 5 drives the entire additive cladding mechanism 6 to move along a complex curved surface trajectory. The processes in Steps 2 and 3 are dynamically, in real-time, and automatically cycled according to the changes in the width of the repair path's geometric characteristics, without interrupting processing or requiring manual intervention. The air-cooling component 604 continuously operates, providing basic heat dissipation for the additive cladding mechanism 6.

[0053] Step 5: Complete the repair; Once the entire repair path is completed, the device stops all heat sources and airflow, completing a one-time, adaptive, high-quality additive repair of the damaged area of ​​the irregular curved surface component from wide to narrow and from thick to thin.

[0054] The embodiments disclosed in this invention are preferred embodiments, but are not limited thereto. Those skilled in the art can easily understand the spirit of this invention based on the above embodiments and make different extensions and variations, but as long as they do not depart from the spirit of this invention, they are all within the protection scope of this invention.

Claims

1. A multi-heat source conformal additive manufacturing apparatus for irregularly shaped curved surface components, characterized in that, The system includes a fuselage frame (1), within which a five-axis linkage mechanism (5) is provided. The output end of the five-axis linkage mechanism (5) is provided with an additive cladding mechanism (6). The additive cladding mechanism (6) includes a multi-heat source bracket (601), a counter-rotating component (602), an additive nozzle (603), an air-cooling component (604), an airflow component (605), an air-conducting component (606), and a magnetic control component (607). The multi-heat source bracket (601) is located at the output end of the five-axis linkage mechanism (5), the counter-rotating component (602) is located on the multi-heat source bracket (601), the additive nozzle (603) is located on the counter-rotating component (602), the air-cooling component (604) is located at the bottom end of the multi-heat source bracket (601), and the airflow component (605)... The air guide assembly (606) is mounted on the multi-heat source bracket (601) and sleeved on the additive nozzle (603). The magnetic control assembly (607) is fixedly mounted on the airflow assembly (605) near the air guide assembly (606). The opposing assembly (602) is used to drive at least two additive nozzles (603) to adjust their relative distance. The airflow assembly (605) is used to generate cooling airflow. The air guide assembly (606) is used to guide the flow direction of the cooling airflow. The magnetic control assembly (607) is used to change the guiding direction of the air guide assembly (606) on the cooling airflow according to the relative distance between the additive nozzles (603), thereby dynamically adjusting the thermal management effect of the cooling airflow between the two additive nozzles (603).

2. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 1, characterized in that, The frame (1) is also provided with a lifting mechanism (2), the output end of the lifting mechanism (2) is provided with a placement platform (3), the placement platform (3) is provided with a workpiece clamp (4), the workpiece clamp (4) is used to clamp and fix the irregular curved surface component to be repaired by additive manufacturing.

3. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 1, characterized in that, The multi-heat source bracket (601) includes a first support plate (6011), a support column (6012), a second support plate (6013), and a guide hole (6014). The first support plate (6011) is fixedly connected to the output end of the five-axis linkage mechanism (5). The support column (6012) is fixedly connected to the bottom end of the first support plate (6011). The second support plate (6013) is fixedly connected to the end of the support column (6012) away from the first support plate (6011). The guide hole (6014) is symmetrically opened on the first support plate (6011) and the second support plate (6013). The opposing component (602) and the additive nozzle (603) are movably disposed on the guide hole (6014).

4. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 3, characterized in that, The opposing assembly (602) includes a motor (6021), a gear (6022), opposing blocks (6023), and a toothed groove (6024). The motor (6021) is fixedly mounted on the multi-heat source bracket (601). The gear (6022) is fixedly sleeved on the output end of the motor (6021). A plurality of opposing blocks (6023) are movably mounted on the multi-heat source bracket (601). The toothed groove (6024) is formed on the opposing block (6023) and meshes with the gear (6022).

5. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 4, characterized in that, The additive nozzle (603) is fixedly connected to the bottom end of the opposing block (6023), and the additive nozzle (603) is also movably inserted into a plurality of the guide holes (6014).

6. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 1, characterized in that, The air-cooled assembly (604) includes a heat dissipation bracket (6041), a heat absorption chamber (6042), a fan (6043), and heat conduction holes (6044). The heat dissipation bracket (6041) is suspended at the bottom of the multi-heat source bracket (601). The heat absorption chamber (6042) is symmetrically opened on the heat dissipation bracket (6041). The fan (6043) is symmetrically arranged on the heat dissipation bracket (6041). The heat conduction holes (6044) are symmetrically opened on the inner wall of the heat dissipation bracket (6041) near the additive nozzle (603) and the air conduction assembly (606).

7. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 1, characterized in that, The airflow assembly (605) includes a mounting plate (6051), a mounting plate (6052), an airflow nozzle (6053), and a motor (6054). The mounting plate (6051) is symmetrically arranged on the multi-heat source bracket (601), and the mounting plate (6052) is symmetrically arranged on the mounting plate (6051). The airflow nozzle (6053) is rotatably arranged between the two mounting plates (6052). The motor (6054) is fixedly arranged on the mounting plate (6052) and its output end is fixedly connected to the airflow nozzle (6053). The airflow nozzle (6053) is connected to an external air supply mechanism through a hose.

8. The multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 1, characterized in that, The air guiding assembly (606) includes an air guiding ring (6061), a fixed cylinder (6062), a horizontal flow groove (6063), and a flow deflector (6064). The air guiding ring (6061) is rotatably sleeved on the additive nozzle (603), the fixed cylinder (6062) is fixedly sleeved on the additive nozzle (603), the horizontal flow groove (6063) is opened at one end of the outer wall of the air guiding ring (6061), and the flow deflector (6064) is opened at the other end of the outer wall of the air guiding ring (6061).

9. A multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 8, characterized in that, The bottom end of the air guide ring (6061) is fixedly provided with a limiting rod (6065), and a limiting arc groove (6066) is opened on the fixed cylinder (6062). The limiting rod (6065) is movably inserted into the limiting arc groove (6066). A spring is also provided in the limiting arc groove (6066). One end of the spring is fixedly connected to the limiting rod (6065), and the other end of the spring is fixedly connected to the inner wall of the limiting arc groove (6066).

10. A multi-heat source conformal additive manufacturing apparatus for irregular curved surface components according to claim 8, characterized in that, The magnetic control assembly (607) includes an electromagnet (6071), an electromagnetic coil (6072), and a permanent magnet (6073). The electromagnet (6071) is fixedly disposed on the airflow assembly (605) near the air guide ring (6061). The electromagnetic coil (6072) is embedded in the electromagnet (6071), and the permanent magnet (6073) is fixedly disposed on the advection channel (6063).

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