Multi-tool-head intelligent three-dimensional printing system and printing method

Abstract

The invention discloses a multi-tool-head intelligent three-dimensional printing system and method. The multi-tool-head intelligent three-dimensional printing system comprises a printer body, and a main control unit, a motion module, a tool head interface node module, a plurality of sets of intelligent tool heads and a printing platform are arranged on the printer body; the tool head interface node module is installed on the motion module, and the tool head interface node module and the multiple sets of intelligent tool heads form a multi-path switchable connection structure. The intelligent tool head is an independent autonomous module. The multi-path switchable connecting structure and the rapid switching mechanical structure matched with the multiple tool heads are adopted, repeated switching of five or more tool heads is supported, the repeated positioning precision is not affected by the increase of the number of the tool heads, and through cooperation of the pre-positioning structure and the secondary locking structure, the repeated positioning precision is not affected by the increase of the number of the tool heads. The accuracy and reliability of connection between the tool head and the motion module are ensured, the switching efficiency is greatly improved, and the requirement for multi-material and multi-process continuous printing is met.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, specifically to a multi-tool head intelligent 3D printing system and printing method. Background Technology

[0002] With the continuous development of additive manufacturing technology, 3D printing has gradually expanded towards printing multi-materials, high-performance materials, flexible materials, and composite materials, and its application in industrial production, product development, and other fields is becoming increasingly widespread. To meet the needs of continuous manufacturing of multi-materials and complex processes, multi-tool head 3D printing equipment has emerged. By equipping multiple tool heads with different functions, it can switch between printing different materials or different processes, thereby improving the flexibility and versatility of printing to a certain extent.

[0003] However, existing multi-tool head printing equipment still has many shortcomings in practical applications: the number of tool heads is limited by structural design and control logic, resulting in poor scalability and difficulty in meeting the simultaneous application of more materials or processes; the tool head switching process relies on the judgment and control of a centralized main control unit, lacking independent safety redundancy design, leading to insufficient system safety and stability; the precision requirements for repeated tool head installation are extremely high, and offset errors in the XY directions are difficult to eliminate effectively, affecting print quality; different types of tool heads (such as rigid material tool heads, flexible material tool heads, and high-wear material tool heads) differ in structure and working principle, making unified management and efficient adaptation difficult; after quick tool head replacement, manual intervention or recalibration through complex processes is often required, which is not only time-consuming and labor-intensive but may also further affect print quality due to improper calibration. When the number of tool heads increases to five or more, the above problems will be further amplified, severely restricting the reliability of the system and the feasibility of industrial applications.

[0004] Therefore, there is an urgent need for an intelligent 3D printing system that can support the stable operation of five or more tool heads, and has the capabilities of rapid tool head switching, automatic calibration, safe autonomy, and multi-type material adaptation, in order to address the shortcomings of existing technologies and promote the widespread application of 3D printing technology in multi-material, large-scale industrial production. Summary of the Invention

[0005] The purpose of this invention is to provide a multi-tool head intelligent 3D printing system and printing method to solve the problems existing in the prior art mentioned in the background section.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a multi-tool head intelligent 3D printing system, comprising a printer body, wherein the printer body is provided with a main control unit, a motion module, a tool head interface node module, several sets of intelligent tool heads and a printing platform;

[0007] The tool head interface node module is installed on the motion module, and the tool head interface node module and several sets of intelligent tool heads form a multi-channel switchable connection structure.

[0008] The intelligent tool head is an independent autonomous module. The intelligent tool head has the ability to recognize identity, detect status and autonomous security veto. Several groups of the intelligent tool heads are independent of each other in terms of physical structure, electrical connection and communication logic.

[0009] The motion module and the smart tool head are provided with a quick switching mechanical structure, an automatic XY axis calibration structure, and an automatic Z-axis height calibration structure. The multi-tool head intelligent 3D printing system can automatically perform XYZ three-axis comprehensive calibration after the smart tool head is switched, and the parameters of each smart tool head are stored independently and can be automatically loaded.

[0010] Preferably, the intelligent tool head includes a tool head mechanical body, a tool head local control unit, a tool head identification module, a tool head status detection module, and a tool head execution component, wherein:

[0011] The tool head local control unit, tool head identification module, tool head status detection module, and tool head execution component are all integrated or fixed on the tool head mechanical body;

[0012] The tool head local control unit is the core control component of the smart tool head, and it establishes signal connections with the tool head identification module, the tool head status detection module, and the tool head execution component, respectively.

[0013] The tool head identification module stores the unique identification number of the smart tool head, the type of the smart tool head, and the supported consumable types and parameter ranges, and outputs the above parameter information to the outside under the control of the tool head local control unit;

[0014] The tool head status detection module detects the heating status, actuator working condition and locking connection reliability of the smart tool head in real time, and feeds the detection signal back to the tool head local control unit, which then determines whether the status is normal.

[0015] The tool head execution component receives control commands from the tool head local control unit and performs actions such as feeding, heating, and spraying required for printing to achieve the printing function.

[0016] Preferably, the rapid switching mechanical structure includes a pre-positioning structure and a secondary locking structure, wherein:

[0017] The pre-positioning structure is provided with at least two non-collinear mechanical reference planes, an anti-misassembly geometry, and a primary pre-positioning guide structure.

[0018] The secondary locking structure is an active electronically controlled locking mechanism, or a mechanism combining elastic pre-tightening and mechanical locking. This structure supports repeated switching of several tool heads, and the repeatability and positioning accuracy are not affected by the increase in the number of tool heads.

[0019] Preferably, the automatic calibration structure in the XY direction includes a geometric self-centering mechanism and an XY offset detection and compensation unit, wherein:

[0020] The geometric self-centering mechanism is a conical protrusion with a conical / frustum-shaped mating hole, a cylindrical / spherical / arc mating structure, or an equivalent geometric structure with radial automatic alignment capability, which can correct the X and Y plane offset errors through axial force;

[0021] The automatic Z-axis height calibration structure includes a tactile sensing device mounted on the tool head, which is a pressure sensor, a strain sensor, or an equivalent contact detection structure.

[0022] Preferably, the smart tool head includes a flexible material tool head and / or a high-abrasion material tool head;

[0023] The flexible material tool head is equipped with a dual active feeding mechanism, a low compression ratio clamping structure, and a short flow channel zoned temperature control hot end, and is suitable for 55A–95A flexible materials.

[0024] The high-abrasion material tool head is equipped with a wear-resistant nozzle, a reinforced drive structure, and a high-temperature heating component;

[0025] The intelligent tool head independently stores the printing temperature curve, feeding parameters, retraction model, calibration parameters, and safety thresholds.

[0026] A printing method based on any of the multi-tool head intelligent 3D printing systems includes the following steps:

[0027] S1) Select the target intelligent tool head according to the printing task requirements, and connect and fix the target tool head and the motion module by quickly switching the mechanical structure;

[0028] S2) The system automatically performs XYZ three-axis comprehensive calibration to correct tool head positioning offset;

[0029] S3) The main control unit automatically loads the printing parameters stored in the target toolhead;

[0030] S4) The target toolhead determines its own status through autonomous security logic. If the status is normal, it executes the printing task; if the status is abnormal, it rejects the printing command.

[0031] S5) During the printing process, the tool head status and printing parameters are monitored in real time, and a safety veto and exception handling mechanism is triggered when an abnormality occurs.

[0032] Preferably, the specific process of the fast switching is as follows:

[0033] The tool head and motion module are initially positioned by a pre-positioning structure. The positioning accuracy is ensured by using a non-collinear mechanical reference plane and an anti-misassembly geometry. The tool head is then fixed to the motion module by a secondary locking structure, thus completing a reliable connection.

[0034] Preferably, the specific process of the XYZ triaxial integrated calibration is as follows:

[0035] The X and Y plane offset errors are automatically corrected by the XY direction geometric self-centering mechanism, and the compensation unit generates XY offset compensation parameters.

[0036] The Z-axis tactile sensing device detects the initial contact position between the tool head and the printing platform, and calculates the height offset in the Z direction.

[0037] The system calculates the three-axis offset parameters based on the above results and binds and stores the parameters with the current tool head.

[0038] Preferably, the specific process of automatically loading the printing parameters is as follows:

[0039] The intelligent tool head outputs a unique identification number, tool head type, and supported consumable parameters to the main control unit through the identification module. The main control unit matches the corresponding intelligent tool head based on the identification information and automatically loads the printing temperature curve, feeding parameters, retraction model, calibration parameters, and safety thresholds stored inside the tool head, without the need for manual intervention.

[0040] Preferably, in steps S4 and S5, the specific process of the autonomous security logic and exception handling is as follows:

[0041] The tool head uses a status detection module to detect the heating status, actuator operating condition and locking connection reliability in real time, and combines the self-test results and XY / Z axis offset to determine whether the preset safety threshold is met.

[0042] If any of the following occurs: tool head self-test failure, XY / Z axis offset exceeding limits, or locking abnormality, the tool head or interface node module will output an abnormal status signal. Upon receiving this signal, the system will stop printing and trigger an alarm.

[0043] Compared with the prior art, the beneficial effects of the present invention are:

[0044] 1) This application adopts a multi-channel switchable connection structure and a quick switching mechanical structure that can adapt to several tool heads. It supports repeated switching of five or more tool heads, and the repeatability positioning accuracy is not affected by the increase in the number of tool heads. The cooperation between the pre-positioning structure and the secondary locking structure ensures the accuracy and reliability of the connection between the tool head and the motion module, greatly improves the switching efficiency, and meets the needs of continuous printing of multiple materials and multiple processes.

[0045] 2) Through the synergistic effect of the XY-direction geometric self-centering mechanism and the Z-axis tactile sensing device, the system can automatically perform XYZ three-axis comprehensive calibration after tool head switching. It can correct the X and Y plane offsets and Z-axis height offsets without manual intervention, which completely solves the problem of high accuracy requirements for repeated tool head installation and the difficulty in eliminating offset errors in traditional equipment, and significantly improves the dimensional accuracy and forming quality of printed products.

[0046] 3) The intelligent tool head of this application adopts an independent autonomous design and stores exclusive parameters such as printing temperature curve and feeding parameters internally. When the main control unit switches tool heads, it can automatically load the corresponding parameters without manual reset. At the same time, the special tool head designed for special materials such as flexible materials and high wear materials can adapt to the printing needs of different materials through personalized structural configuration, which broadens the material application range of the system and provides strong support for printing complex multi-material products.

[0047] 4) Each intelligent tool head in this application has identity recognition, status detection and autonomous security veto capabilities. It can monitor its own working status in real time through the local control unit. When a self-test failure, locking abnormality or offset exceeds the limit occurs, it actively outputs an "unavailable" status and refuses the printing command. The system-level security veto and abnormal handling mechanism further blocks printing operations under abnormal working conditions, avoids printing failure or equipment damage caused by tool head failure, and greatly improves the system's security redundancy and operational reliability.

[0048] 5) The system of this application adopts distributed control logic and modular design. Each intelligent tool head is independent of each other in terms of physical structure, electrical connection and communication logic. It is easy to increase or decrease the number of tool heads or replace different types of tool heads according to actual printing needs without making major adjustments to the overall system structure. At the same time, the automated switching, calibration and parameter loading process reduces the intensity of manual operation and improves production efficiency. It can be well adapted to industrial-grade mass production scenarios and promote the large-scale application of 3D printing technology in the industrial field. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of one structure of this application;

[0050] Figure 2 This is another structural diagram of this application;

[0051] Figure 3 This is a structural diagram of several sets of intelligent toolheads and toolhead interface node modules in this application;

[0052] Figure 4 This is a schematic diagram of the structure of the intelligent tool head of this application;

[0053] Figure 5 This is a schematic diagram of the structure of the intelligent tool head after removing the non-collinear mechanical reference plane;

[0054] Figure 6 This is a structural diagram of the tool header interface node module of this application;

[0055] Figure 7 This is a partial structural diagram of the smart tool head of this application;

[0056] Figure 8 This is a schematic diagram of the printer body after the printing platform has been removed;

[0057] Figure 9 This is a flowchart of the printing method of this application.

[0058] In the picture:

[0059] 1. Printer body; 2. Motion module; 3. Tool head interface node module; 4. Intelligent tool head; 5. Printing platform; 6. Pre-positioning structure; 61. Non-collinear mechanical reference surface; 62. Anti-misassembly geometry; 63. Primary pre-positioning guide structure; 7. Secondary locking structure; 8. Geometric self-centering mechanism; 9. Z-axis height automatic calibration structure. Detailed Implementation

[0060] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0061] In the description of the invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0062] In the description of the invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0063] In the description of the invention, it should be noted that the execution order of the steps is not limited by the sequence number. The possible changes in the order of some steps, the synchronous execution of steps, and the split execution of steps are all within the scope of protection of this application.

[0064] Please see Figure 1-9 The present invention provides a technical solution: a multi-tool head intelligent 3D printing system, including a printer body, a main control unit, a motion module, a tool head interface node module, several sets of intelligent tool heads and a printing platform.

[0065] The tool head interface node module is installed on the motion module, and the tool head interface node module and several sets of intelligent tool heads form a multi-channel switchable connection structure.

[0066] The intelligent tool head is an independent autonomous module. The intelligent tool head has the ability to identify, detect status and veto autonomous security. Several sets of intelligent tool heads are independent of each other in terms of physical structure, electrical connection and communication logic.

[0067] The motion module and the smart tool head are equipped with a quick switching mechanism, an automatic XY axis calibration structure, and an automatic Z-axis height calibration structure. The multi-tool head intelligent 3D printing system can automatically perform XYZ three-axis comprehensive calibration after switching smart tool heads, and the parameters of each smart tool head are stored independently and can be automatically loaded.

[0068] Specifically, this application solves the core bottleneck of existing multi-tool head printing devices by integrating the main control unit, motion module, tool head interface node module, several replaceable intelligent tool heads, and printing platform into a unified architecture. Each intelligent tool head is independent in physical structure, electrical connection, and communication logic, and possesses identification, status detection, and autonomous security veto capabilities. This breaks the limitations of traditional devices, which have a limited number of tool heads and poor scalability, supporting stable operation of five or more tool heads. When the demand for tool heads increases, seamless adaptation can be achieved by adjusting the printer's core specifications. Simultaneously, by setting up a quick-switching mechanical structure, an automatic XY-axis calibration structure, and an automatic Z-axis height calibration structure between the motion module and the intelligent tool heads, combined with the system's automatically executed XYZ three-axis comprehensive calibration function, manual calibration or complex calibration processes are completely eliminated, effectively eliminating offset errors caused by repeated tool head installation. Furthermore, the design of independently storing and automatically loading parameters for each intelligent tool head avoids manual parameter settings after tool head switching, improving operational convenience. The overall architecture enables reliable management, rapid switching, automatic calibration, and secure autonomy of multiple tool heads, significantly enhancing the system's scalability, maintainability, and industrial applicability, and providing a stable hardware and logical foundation for multi-material, large-scale printing.

[0069] The intelligent tool head includes a tool head mechanical body, a tool head local control unit, a tool head identification module, a tool head status detection module, and a tool head execution component, wherein:

[0070] The tool head local control unit, tool head identification module, tool head status detection module, and tool head execution components are all integrated or fixed on the tool head mechanical body;

[0071] The tool head local control unit is the core control component of the intelligent tool head, and it establishes signal connections with the tool head identification module, the tool head status detection module, and the tool head execution component, respectively.

[0072] The tool head identification module stores the unique identification number of the smart tool head, the type of the smart tool head, and the types and parameter ranges of supported consumables, and outputs the above parameter information to the outside under the control of the tool head local control unit;

[0073] The tool head status detection module monitors the heating status of the smart tool head, the operating condition of the actuator, and the reliability of the locking connection in real time, and feeds the detection signal back to the tool head local control unit, which then determines whether the status is normal.

[0074] The tool head execution component receives control commands from the tool head local control unit and performs actions such as feeding, heating, and spraying required for printing to achieve the printing function.

[0075] Specifically, the tool head mechanical body serves as the mounting foundation for all sub-components, ensuring the stability and compactness of the integrated components. The tool head local control unit, as the core control component, establishes signal connections with the identification module, status detection module, and execution components, enabling coordinated operation of all functional modules and solving the problem of unified management of different types of tool heads in existing technologies. The identification module accurately outputs the tool head's unique identification number, type, and consumable parameters, providing data support for rapid tool head matching and automatic parameter loading. The status detection module provides real-time feedback on heating status, actuator operating conditions, and locking reliability, which, combined with the judgment function of the local control unit, gives the tool head the ability to autonomously perceive its operating status. The execution components accurately respond to control commands, ensuring stable execution of printing actions. This modular and collaborative design makes each tool head a unit with independent operation and safety judgment capabilities, not only improving the reliability of the tool head itself but also reducing the burden on the main control unit, enhancing system safety redundancy, and preventing the overall system operation from being affected by the failure of a single tool head.

[0076] Reference manual attached Figure 3-6 The rapid switching mechanical structure includes a pre-positioning structure and a secondary locking structure, wherein:

[0077] The pre-positioning structure is provided with at least two non-collinear mechanical reference planes, an anti-misassembly geometry, and a primary pre-positioning guide structure;

[0078] The secondary locking structure is an active electronic locking mechanism or a mechanism that combines elastic pre-tightening with mechanical locking. This structure supports repeated switching of several tool heads and the repeatability of positioning accuracy is not affected by the increase in the number of tool heads.

[0079] Reference manual attached Figure 3-4 and instruction manual attached Figure 6 The non-collinear mechanical reference plane is set on the side of the intelligent tool head near the tool head interface node module, and the tool head interface node module has an external structure that is adapted to the non-collinear mechanical reference plane. Through the precise fit of the two side structures, a reliable geometric reference is provided for the primary positioning of the tool head and the motion module, ensuring the accuracy and consistency of the positioning process.

[0080] Reference manual attached Figure 3-4 and instruction manual attached Figure 6 The anti-misinstallation geometry is set on a non-collinear mechanical reference surface. The anti-misinstallation geometry consists of several annular protrusions, while the tool head interface node module has several grooves that are adapted to the anti-misinstallation geometry. Only when the annular protrusions and the corresponding grooves are fully engaged can the primary positioning be completed. This accurately avoids the situation of incorrect or reversed tool head installation from a physical perspective, effectively reducing equipment failure or printing deviation caused by misinstallation, and improving the reliability and efficiency of tool head switching.

[0081] Reference manual attached Figure 3-6 The primary pre-positioning guide structure is a three-point positioning guide protrusion. The tool head interface node module has three sets of slots that are compatible with the primary pre-positioning guide structure. The three-point distributed protrusions and slots form a stable positioning support, which can guide the tool head to quickly enter the preset installation position, while reducing lateral offset during the installation process and further improving the accuracy of pre-positioning.

[0082] Reference manual attached Figure 3-6 The secondary locking structure shown in the diagram is an active electronically controlled locking mechanism. This mechanism responds quickly and has controllable locking force. It can quickly and firmly fix the tool head after it has completed its pre-positioning. It can also provide feedback on the locking status through electrical signals, ensuring the reliability of the connection between the tool head and the motion module. This effectively prevents the tool head from becoming loose or displaced due to factors such as vibration and motion impact during the printing process.

[0083] Specifically, the pre-positioning structure incorporates at least two non-collinear mechanical reference planes to ensure accurate primary positioning. The anti-misinstallation geometry physically prevents incorrect tool head installation, while the primary pre-positioning guide structure reduces installation difficulty and improves switching convenience. The secondary locking structure combines active electronic locking or elastic pre-tightening with mechanical locking, further enhancing the connection reliability between the tool head and the motion module based on pre-positioning, preventing tool head loosening or displacement during printing. Crucially, this structure supports repeated switching of multiple tool heads without affecting repeatability, overcoming the bottleneck of decreased accuracy due to an increased number of tool heads in existing technologies. This provides structural support for continuous printing of multiple materials and processes, significantly improving switching efficiency and system scalability, and meeting the dual demands of rapid head changing and stable accuracy in industrial production.

[0084] The automatic calibration structure in the XY direction includes a geometric self-centering mechanism and an XY offset detection and compensation unit, wherein:

[0085] The geometric self-centering mechanism is a conical protrusion with a conical / frustum-shaped mating hole, a cylindrical / spherical / arc mating structure, or an equivalent geometric structure with radial automatic alignment capability, which can correct the X and Y plane offset errors through axial force;

[0086] The Z-axis height automatic calibration structure includes a tactile sensing device mounted on the tool head, which can be a pressure sensor, a strain sensor, or an equivalent contact detection structure.

[0087] Reference manual attached Figure 2 and instruction manual attached Figure 8The geometric self-centering mechanism shown in the diagram is a conical protrusion. The geometric self-centering mechanism is set on the base for mounting the printing platform. The bottom of the printing platform has a matching conical mating hole. When the printing platform is assembled with the base, the conical protrusion and the conical mating hole form a precise guide through axial contact force, which can automatically offset the installation deviation in the XY plane, ensuring the levelness and positioning consistency of the printing platform. This provides a precise benchmark for the Z-axis height detection of the tool head and subsequent triaxial comprehensive calibration, further ensuring the dimensional accuracy and forming stability of the printed products.

[0088] Specifically, the XY offset detection and compensation unit is not shown in the diagram. During the locking process, the automatic calibration structure in the XY direction automatically corrects the offset error of the tool head in the X and Y planes through the action of axial force. After the tool head is locked, the system can generate the corresponding XY offset compensation parameters through the position detection device or the geometric constraint results. These parameters can complement the correction effect of the XY direction geometric self-centering mechanism, accurately offsetting the small offset errors remaining during the tool head installation process. This ensures that a unified XY positioning reference can be maintained after each tool head is switched, effectively avoiding the accumulation of positioning deviations caused by the alternating use of multiple tool heads.

[0089] Reference manual attached Figure 7 The automatic Z-axis height calibration structure (i.e., tactile sensing device) shown in the diagram is an eddy current sensor. Each smart tool head is equipped with an eddy current sensor, which features rapid response, high detection accuracy, and strong anti-interference capabilities. It can accurately capture the position signal at the moment of contact between the tool head and the printing platform, quickly calculate the height offset in the Z direction, and is unaffected by factors such as ambient temperature and printing filament residue. This ensures the consistency and accuracy of Z-axis positioning after switching between smart tool heads, effectively avoiding problems such as uneven printing surface, uneven layer thickness, or tool head collision with the platform caused by height deviation. It provides accurate Z-axis data support for comprehensive calibration of the XYZ axes, further ensuring the stability of the printing quality of multi-tool head printing.

[0090] Specifically, the geometric self-centering mechanism (such as tapered fit, cylindrical surface fit, etc.) in the XY-direction automatic calibration structure can automatically correct the X and Y plane offset errors through axial force. Combined with the compensation parameters generated by the XY offset detection and compensation unit, it achieves dual correction of offset errors, completely solving the problem of inaccurate control of XY-direction offset in traditional equipment. The Z-axis height automatic calibration structure, through tactile sensing devices such as pressure sensors and strain sensors on the tool head, can accurately calculate the Z-direction height offset based on the initial contact detection between the tool head and the printing platform, eliminating the need for manual measurement and adjustment. The collaborative design of these two calibration structures enables fully automated positioning calibration after tool head switching, significantly reducing manual operation intensity and avoiding subjective errors caused by manual calibration, ensuring that each tool head is in a precise printing position after switching.

[0091] Intelligent tool heads include flexible material tool heads and / or high-abrasion material tool heads;

[0092] The flexible material tool head is equipped with a dual active feeding mechanism, a low compression ratio clamping structure, and a short flow channel zoned temperature control hot end, and is suitable for 55A–95A flexible materials;

[0093] The tool head for high-abrasion materials is equipped with a wear-resistant nozzle, a reinforced drive structure, and a high-temperature heating component.

[0094] The intelligent tool head independently stores the printing temperature profile, feeding parameters, retraction model, calibration parameters, and safety thresholds.

[0095] Specifically, intelligent tool heads include flexible material tool heads and / or high-wear material tool heads. The basic structure and conventional functions of these two types of tool heads are within the scope of existing technology. Their general composition and basic working principle are known to those skilled in the art and can be implemented with reference to existing technology. Therefore, this article will not elaborate on their non-improved conventional structure and basic working logic.

[0096] Specifically, the flexible material tool head's dual active feeding mechanism, low compression ratio clamping structure, and short-channel zoned temperature-controlled hot end can accurately adapt to the printing needs of 55A–95A flexible materials, solving the problems of difficult feeding and uneven heating of flexible materials. The high-wear material tool head's wear-resistant nozzle, reinforced drive structure, and high-temperature heating components effectively address the wear and tear on the tool head caused by highly abrasive materials and the demands of high-temperature printing, extending the tool head's lifespan. Simultaneously, the intelligent tool head's internal independent storage of printing temperature curves, feeding parameters, retraction models, calibration parameters, and safety thresholds enables parameters to be "stored and loaded with the tool head," avoiding the tedious process of manually setting parameters when switching tool heads, reducing printing failures caused by parameter setting errors, and ensuring accurate parameter adaptation when printing different materials and different types of tool heads, providing strong support for high-quality printing of complex products using multiple materials.

[0097] According to another aspect of this application, a printing method for a multi-tool intelligent 3D printing system is also provided, comprising the following steps:

[0098] S1) Select the target intelligent tool head according to the printing task requirements, and connect and fix the target tool head and the motion module by quickly switching the mechanical structure;

[0099] S2) The system automatically performs XYZ three-axis comprehensive calibration to correct tool head positioning offset;

[0100] S3) The main control unit automatically loads the printing parameters stored in the target toolhead;

[0101] S4) The target toolhead determines its own status through autonomous security logic. If the status is normal, it executes the printing task; if the status is abnormal, it rejects the printing command.

[0102] S5) During the printing process, the tool head status and printing parameters are monitored in real time, and a safety veto and exception handling mechanism is triggered when an abnormality occurs.

[0103] In step S1, the specific process of rapid switching is as follows:

[0104] The tool head and motion module are initially positioned by a pre-positioning structure. The positioning accuracy is ensured by using a non-collinear mechanical reference plane and an anti-misassembly geometry. The tool head is then fixed to the motion module by a secondary locking structure, thus completing a reliable connection.

[0105] Specifically, the primary positioning of the tool head and the motion module utilizes a non-collinear mechanical reference plane to ensure geometric accuracy. An anti-misinstallation geometry structure eliminates the risk of incorrect tool head installation from the outset, while the primary pre-positioning guide structure simplifies installation and improves switching speed. A secondary locking structure then secures the tool head to the motion module, ensuring reliable connection during printing and preventing loosening or displacement due to vibration or movement. This solves the problems of ambiguous tool head switching positioning and insecure fixation in existing technologies, ensuring consistency and stability when repeatedly switching between multiple tool heads and improving switching efficiency.

[0106] In step S2, the specific process of XYZ triaxial integrated calibration is as follows:

[0107] The X and Y plane offset errors are automatically corrected by the XY direction geometric self-centering mechanism, and the compensation unit generates XY offset compensation parameters.

[0108] The Z-axis tactile sensing device detects the initial contact position between the tool head and the printing platform, and calculates the height offset in the Z direction.

[0109] The system calculates the three-axis offset parameters based on the above results and binds and stores the parameters with the current toolhead.

[0110] Specifically, the XY-axis geometric self-centering mechanism automatically corrects the X and Y plane offset errors and generates XY offset compensation parameters, achieving automatic correction and parameter compensation for XY-axis offsets. Then, a Z-axis tactile sensing device detects the initial contact position and accurately calculates the Z-axis height offset. Finally, the system comprehensively calculates the three-axis offset parameters and stores them in conjunction with the tool head, ensuring the uniqueness and traceability of the calibration parameters. This process is clear and logically rigorous, solving the problems of complexity, insufficient accuracy, and easily confused parameters in existing calibration procedures. Through step-by-step calibration and parameter binding, it ensures that the calibration parameters of each tool head are stored independently and accurately retrieved, avoiding interference between calibration parameters of different tool heads. This ensures that the positioning accuracy remains consistent after tool head switching, thereby guaranteeing the dimensional consistency and forming quality of printed products. Furthermore, it eliminates the need for manual calibration calculations and parameter recording, improving operational convenience.

[0111] In step S3, the specific process of automatically loading print parameters is as follows:

[0112] The intelligent tool head outputs a unique identification number, tool head type, and supported consumable parameters to the main control unit through the identification module. The main control unit matches the corresponding intelligent tool head based on the identification information and automatically loads the printing temperature profile, feeding parameters, retraction model, calibration parameters, and safety thresholds stored inside the tool head, without the need for manual intervention.

[0113] Specifically, the tool head identification module outputs a unique identification number, tool head type, and supported consumable parameters to the main control unit, providing a clear basis for the main control unit to accurately match the tool head. Based on this identification information, the main control unit automatically loads the tool head's internally stored parameters without manual intervention, solving the problems of cumbersome and error-prone parameter settings during tool head switching in existing technologies. This automatic parameter loading process not only saves manual setting time and improves production efficiency but also ensures precise matching of printing parameters with tool head and consumable types, avoiding printing defects caused by parameter mismatches (such as poor material adhesion, nozzle clogging, and product deformation). This guarantees the stability of the printing process and the consistency of printed product quality, providing efficient parameter support for rapid switching between multiple tool heads and materials.

[0114] The specific processes for autonomous security logic and exception handling in steps S4 and S5 are as follows:

[0115] The tool head uses a status detection module to detect the heating status, actuator operating condition and locking connection reliability in real time, and combines the self-test results and XY / Z axis offset to determine whether the preset safety threshold is met.

[0116] If any of the following occurs: tool head self-test failure, XY / Z axis offset exceeding limits, or locking abnormality, the tool head or interface node module will output an abnormal status signal. Upon receiving this signal, the system will stop printing and trigger an alarm.

[0117] Specifically, this application uses a tool head status detection module to monitor the heating status, actuator operating condition, and locking connection reliability in real time. Combined with self-test results and XY / Z axis offset judgments, it comprehensively covers key safety nodes in tool head operation. When tool head self-test failure, XY / Z axis offset exceeding limits, or locking abnormalities occur, the tool head or interface node module promptly outputs an abnormal status signal. The system responds quickly and stops further printing, while simultaneously triggering an alarm. This real-time monitoring and emergency handling safety mechanism solves the problem of existing multi-tool head devices relying on centralized main control judgment and lacking sufficient safety redundancy. It enables each tool head to have independent safety judgment and risk prevention capabilities, proactively eliminating potential safety hazards during the printing process and preventing printing failures, product scrapping, or even equipment damage due to tool head abnormalities, significantly improving the safety and reliability of system operation.

[0118] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-tool intelligent 3D printing system, comprising a printer body, characterized in that, The printer body is equipped with a main control unit, a motion module, a tool head interface node module, several sets of intelligent tool heads, and a printing platform. The tool head interface node module is installed on the motion module, and the tool head interface node module and several sets of intelligent tool heads form a multi-channel switchable connection structure. The intelligent tool head is an independent autonomous module, and several groups of intelligent tool heads are independent of each other in terms of physical structure, electrical connection and communication logic; The motion module and the smart tool head are provided with a quick switching mechanical structure, an automatic XY axis calibration structure, and an automatic Z-axis height calibration structure. The multi-tool head intelligent 3D printing system can automatically perform XYZ three-axis comprehensive calibration after the smart tool head is switched, and the parameters of each smart tool head are stored independently and can be automatically loaded.

2. The multi-tool intelligent 3D printing system according to claim 1, characterized in that, The intelligent tool head includes a tool head mechanical body, a tool head local control unit, a tool head identification module, a tool head status detection module, and a tool head execution component, wherein: The tool head local control unit, tool head identification module, tool head status detection module, and tool head execution component are all integrated or fixed on the tool head mechanical body; The tool head local control unit establishes signal connections with the tool head identification module, the tool head status detection module, and the tool head execution component, respectively. The tool head identification module stores the unique identification number of the smart tool head, the type of the smart tool head, and the supported consumable types and parameter ranges, and outputs parameter information to the outside under the control of the tool head local control unit; The tool head status detection module detects the heating status, actuator working condition and locking connection reliability of the smart tool head in real time, and feeds the detection signal back to the tool head local control unit, which then determines whether the status is normal. The tool head execution component receives control commands from the tool head local control unit and performs actions such as feeding, heating, and spraying required for printing to achieve the printing function.

3. The multi-tool intelligent 3D printing system according to claim 1, characterized in that, The rapid switching mechanical structure includes a pre-positioning structure and a secondary locking structure, wherein: The pre-positioning structure is provided with at least two non-collinear mechanical reference planes, an anti-misassembly geometry, and a primary pre-positioning guide structure. The secondary locking structure is an active electronically controlled locking mechanism, or a mechanism that combines elastic pre-tensioning with mechanical locking.

4. The multi-tool intelligent 3D printing system according to claim 1, characterized in that, The automatic calibration structure in the XY direction includes a geometric self-centering mechanism and an XY offset detection and compensation unit, wherein: The geometric self-centering mechanism is a conical protrusion with a conical / frustum-shaped mating hole, a cylindrical / spherical / arc mating structure, or an equivalent geometric structure with radial automatic alignment capability, which corrects the X and Y plane offset errors through axial force; The automatic Z-axis height calibration structure includes a tactile sensing device mounted on the tool head, which is a pressure sensor, a strain sensor, or an equivalent contact detection structure.

5. The multi-tool intelligent 3D printing system according to claim 1, characterized in that, The intelligent tool head includes a flexible material tool head and / or a high-abrasion material tool head; The flexible material tool head is equipped with a dual active feeding mechanism, a low compression ratio clamping structure, and a short flow channel zoned temperature control hot end, and is suitable for 55A–95A flexible materials. The high-abrasion material tool head is equipped with a wear-resistant nozzle, a reinforced drive structure, and a high-temperature heating component; The intelligent tool head independently stores the printing temperature curve, feeding parameters, retraction model, calibration parameters, and safety thresholds.

6. A printing method based on the multi-tool intelligent 3D printing system according to any one of claims 1-5, characterized in that, Includes the following steps: S1) Select the target intelligent tool head according to the printing task requirements, and connect and fix the target tool head and the motion module by quickly switching the mechanical structure; S2) The system automatically performs XYZ three-axis comprehensive calibration to correct tool head positioning offset; S3) The main control unit automatically loads the printing parameters stored in the target toolhead; S4) The target toolhead determines its own status through autonomous security logic. If the status is normal, it executes the printing task; if the status is abnormal, it rejects the printing command. S5) During the printing process, the tool head status and printing parameters are monitored in real time, and a safety veto and exception handling mechanism is triggered when an abnormality occurs.

7. The multi-tool intelligent 3D printing method according to claim 6, characterized in that, In step S1, the specific process of the fast switching is as follows: The tool head and motion module are initially positioned by a pre-positioning structure. The positioning accuracy is ensured by using a non-collinear mechanical reference plane and an anti-misassembly geometry. The tool head is then fixed to the motion module by a secondary locking structure, thus completing a reliable connection.

8. The multi-tool intelligent 3D printing method according to claim 6, characterized in that, In step S2, the specific process of the XYZ triaxial comprehensive calibration is as follows: The X and Y plane offset errors are automatically corrected by the XY direction geometric self-centering mechanism, and the compensation unit generates XY offset compensation parameters. The Z-axis tactile sensing device detects the initial contact position between the tool head and the printing platform, and calculates the height offset in the Z direction. The system calculates the three-axis offset parameters based on the above results and binds and stores the parameters with the current tool head.

9. The multi-tool intelligent 3D printing method according to claim 6, characterized in that, In step S3, the specific process of automatically loading the printing parameters is as follows: The intelligent tool head outputs a unique identification number, tool head type, and supported consumable parameters to the main control unit through the identification module. The main control unit matches the corresponding intelligent tool head based on the identification information and automatically loads the printing temperature profile, feeding parameters, retraction model, calibration parameters, and safety thresholds stored inside the tool head.

10. The multi-tool intelligent 3D printing method according to claim 6, characterized in that, In steps S4 and S5, the specific processes of the autonomous security logic and exception handling are as follows: The tool head uses a status detection module to detect the heating status, actuator operating condition and locking connection reliability in real time, and combines the self-test results and XY / Z axis offset to determine whether the preset safety threshold is met. If any of the following occurs: tool head self-test failure, XY / Z axis offset exceeding limits, or locking abnormality, the tool head or interface node module will output an abnormal status signal. Upon receiving this signal, the system will stop printing and trigger an alarm.

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