A continuous feeding device for coiled aluminum alloy disc rounds for friction stir deposition additive and a control method thereof

Abstract

The application discloses a continuous feeding device for a coiled aluminum alloy disc for friction stir deposition additive and a control method thereof. The feeding device comprises a coiled material suspension and unwinding structure, a primary pulling mechanism, an intelligent tension closed-loop regulation and control module, a secondary pulling mechanism, a straightening mechanism, a fixed-length cutting mechanism, an additive mechanism and a liftable movable workbench. The device uses a large-length coiled aluminum rod material as raw material, and through multi-stage path adjustment, intelligent tension control, fixed-length cutting and end face butt joint feeding cooperation, forms an automatic feeding system with closed-loop linkage and beat matching in the whole process from unwinding to additive, realizes continuous and stable feeding of the material, and significantly improves additive forming efficiency and structural quality.

Description

Technical Field

[0001] This invention relates to the field of metal additive manufacturing technology, and in particular to a continuous feeding device for coiled aluminum alloy discs used in friction stir deposition additive manufacturing and its control method. Background Technology

[0002] Friction stir deposition (AFSD) is a novel solid-phase additive manufacturing technology derived from friction stir welding. The process involves feeding metal wires or rods into a rotating hollow stirring head. Under the combined action of the feed force and the rotational friction of the stirring shoulder, the material undergoes thermoplasticization, migration, and deposition, combining with a substrate or existing additive layer. This process is repeated layer by layer to form the final component. This technology is particularly suitable for the additive manufacturing of large-size components from lightweight alloys such as aluminum, magnesium, and titanium alloys. Its advantages include high additive efficiency, short manufacturing cycle, uniform and dense microstructure, and no need for a vacuum environment or atmosphere protection. It has significant advantages and engineering application potential in the manufacturing of large lightweight alloy reinforcing components. Currently, AFSD processes primarily use 1-3 mm wires. The feeding method involves intermittent filling of filaments or single bars, and the individual bars require machining and manual loading, which severely restricts the manufacturing efficiency of the AFSD process. This method of continuous filament or intermittent bar filling has the following limitations: ① Continuous filament feeding is prone to jamming and has low manufacturing efficiency for large-sized components in the meter range; ② The bar filling process is highly dependent on manual labor: For large gantry-type AFSD equipment, manual labor is required to climb the gantry and repeatedly intervene, resulting in high labor intensity; ③ The additive manufacturing zone at the connection between the end faces of the two bars fluctuates: The material switching stage can easily lead to uneven filling or the introduction of oxides on the end faces of the bars, resulting in additive manufacturing defects; ④ Large-scale production cycle time is limited: Frequent feeding operations make it impossible to maintain a stable process cycle time.

[0003] In view of the above, it is necessary to improve the existing additive feeding method to adapt it to the current needs of additive feeding. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a continuous feeding device for coiled aluminum alloy discs used in friction stir deposition additive manufacturing, comprising: The coil suspension and unwinding structure is used to provide support and stable unwinding of the wound material; The primary pulling mechanism is installed at the outlet of the coil suspension and unfolding structure for active feeding; The path adjustment and guidance module is located on one side of the primary pulling mechanism and is used to guide and adjust the feeding direction of the aluminum rod; The intelligent tension closed-loop control module is set in the feeding path to monitor the tension state of the aluminum rod in the feeding path in real time. The secondary pulling mechanism is located at the end of the path adjustment and serves as the primary material source to provide continuous thrust. The straightening mechanism is located on one side of the secondary pulling mechanism to straighten the bar. A fixed-length cutting mechanism is installed on one side of the straightening mechanism for cutting bars to a fixed length. An additive manufacturing mechanism, located at the end of a structure, is used for additive manufacturing of materials. The liftable worktable is positioned below the additive manufacturing mechanism to facilitate its operation.

[0005] As a further supplement to this technical solution, the coil suspension and unfolding structure includes a support frame, a hollow rotating shaft disposed on the support frame, a reel disposed on the hollow rotating shaft, and an adjustable damping braking device disposed on the support frame and located at one end of the hollow rotating shaft, wherein the hollow rotating shaft is rotatably mounted on the support frame.

[0006] As a further supplement to this technical solution, the primary pulling mechanism includes a machine base, a first servo motor mounted on the machine base, and a double pressure roller structure connected to the first servo motor, wherein the first servo motor is mounted on the machine base.

[0007] As a further supplement to this technical solution, the path adjustment and guiding module consists of four sets of guide wheel clamping mechanisms. The four sets of guide wheel clamping mechanisms are arranged along the same plane and form an inverted U-shaped path. The guide wheel clamping mechanism consists of four rollers arranged symmetrically at the top and bottom.

[0008] As a further supplement to this technical solution, the intelligent tension closed-loop control module consists of a tension sensor, a tension controller, and a servo drive unit.

[0009] As a further supplement to this technical solution, the secondary pulling mechanism is located between the end of the path adjustment and the straightening unit. The secondary pulling mechanism includes a second servo motor and a roller assembly connected to the second servo motor. The clamping force of the roller assembly is automatically adjusted by spring loading.

[0010] As a further supplement to this technical solution, the straightening mechanism includes a screw lifting mechanism, a straightening wheel disposed on the screw lifting mechanism, and a straightening block disposed on the machine platform and located on one side of the secondary pulling mechanism. The screw lifting mechanism is fixedly installed on the machine platform, the straightening wheel is fixedly installed on the screw lifting mechanism, the straightening block is fixedly installed on the machine platform, and the fixed-length cutting mechanism is installed on the screw lifting mechanism.

[0011] As a further supplement to this technical solution, the screw lifting mechanism is also provided with a roller pressing mechanism, which is located between the cutting unit and the additive manufacturing mechanism, and the roller pressing mechanism consists of multiple sets of rollers arranged vertically.

[0012] Further supplementing this technical solution, a Y-axis moving mechanism is provided below the liftable worktable, an X-axis moving mechanism is provided below the Y-axis moving mechanism, and a Z-axis lifting mechanism is provided below the X-axis moving mechanism to drive the entire liftable worktable and its upper mechanism to move up and down along the Z-axis direction. A control method for a continuous feeding device for coiled aluminum alloy discs used in friction stir deposition additive manufacturing is also provided. The control system establishes real-time data connections with the drivers, sensors, and actuators of each functional module through a multi-channel communication interface to achieve system-level information integration and control logic arrangement. The system control method includes: (1) Tension closed-loop control: Connect the path adjustment module and the tension sensor, implement the PID tension adjustment algorithm, adjust the speed of the pulling mechanism in real time, and stabilize the feeding tension; (2) Cutting cycle control: Combined with the signal of the feeding and length measuring unit, the synchronous follow saw blade start, feed and return actions are controlled to ensure that the saw blade and the bar are at the same speed, so as to achieve “relative static” cutting; (3) Dating and Coordination Control: The system monitors the usage progress of the additive bar according to the set remaining length threshold. When the set threshold is reached, a cutting command is immediately triggered. At the same time, the docking roller pressing structure is coordinated to promote the seamless bonding of the new bar with the end face of the old bar. (4) Rotational synchronous propulsion: The controller, based on the spindle signal of the additive manufacturing equipment, links the feeding system to match the rotational speed and the propulsion speed, so that the upper and lower bars rotate synchronously and are conveyed downwards, ensuring the continuous and stable additive layer; (5) Abnormal monitoring and alarm: Monitoring channels are set up for situations such as excessive pulling load, bar jamming, excessive tension fluctuation, abnormal feeding, cutting failure, and misalignment, and an audible and visual alarm and emergency stop response mechanism are provided. (6) Cycle learning and remote operation and maintenance: The system supports the self-learning function of feeding cycle, automatically optimizes the rhythm parameters according to the actual additive progress, and provides equipment maintenance reminders, operation log recording and remote fault diagnosis interface.

[0013] Its beneficial effects are that by using long-length coiled aluminum rods as raw materials, and through multi-level path adjustment, intelligent tension control, fixed-length cutting and end-face feeding coordination, an automated feeding system with closed-loop linkage and cycle matching is formed from unfolding to additive manufacturing, so as to achieve continuous and stable material supply and significantly improve additive manufacturing efficiency and structural quality. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention from a first angle; Figure 2 This is a schematic diagram of the overall structure of the present invention from a second angle; Figure 3 This is the present invention. Figure 2 A magnified schematic diagram of the structure of part A in the diagram; In the diagram, 1. Coil suspension and unfolding structure; 2. Primary pulling mechanism; 3. Path adjustment and guiding module; 4. Secondary pulling mechanism; 5. Straightening mechanism; 6. Fixed length cutting mechanism; 7. Additive manufacturing mechanism; 8. Liftable and movable worktable; 9. Roll pressing mechanism; 10. Screw lifting mechanism; 11. Y-axis moving mechanism; 12. X-axis moving mechanism; 13. Z-axis lifting mechanism. Detailed Implementation

[0015] To facilitate a clearer understanding of this technical solution for those skilled in the art, the following will be described in conjunction with the appendix. Figure 1-3 The technical solution of the present invention is described in detail below: A continuous feeding device for coiled aluminum alloy disks used in friction stir deposition additive manufacturing includes: The coil suspension and unfolding structure 1 is used to provide support and stable unfolding of the wound material; The primary pulling mechanism 2 is installed at the outlet of the coil suspension and unfolding structure 1 for active feeding; The path adjustment and guidance module 3 is located on one side of the primary pulling mechanism 2 and is used to guide and adjust the feeding direction of the aluminum rod; The intelligent tension closed-loop control module is set in the feeding path to monitor the tension state of the aluminum rod in the feeding path in real time. The secondary pulling mechanism 4 is located at the end of the path adjustment and serves as the primary material source to provide continuous thrust. The straightening mechanism 5 is located on one side of the secondary pulling mechanism 4 to straighten the bar. The fixed-length cutting mechanism 6 is located on one side of the straightening mechanism 5 and is used to cut the bar into fixed lengths. Additive manufacturing mechanism 7 is located at the end of the structure and is used for additive manufacturing of materials; The liftable and movable worktable 8 is located below the additive manufacturing mechanism 7 to facilitate the operation of the additive manufacturing mechanism 7.

[0016] The coil suspension and unwinding structure 1 will be described in detail below. The coil suspension and unwinding structure 1 includes a support frame, a hollow rotating shaft mounted on the support frame, a reel mounted on the hollow rotating shaft, and an adjustable damping brake device mounted on the support frame and located at one end of the hollow rotating shaft. The hollow rotating shaft is rotatably mounted on the support frame. A 15mm diameter aluminum rod is solidly wound onto a circular reel with a diameter of approximately 3mm. The reel is mounted on the support frame via the hollow rotating shaft. One end of the rotating shaft is connected to the adjustable damping brake device, which applies a constant reverse torque to the rotating shaft during unwinding, providing tension to the aluminum alloy rod. This device uses a mechanical friction plate structure, and the resistance can be set by adjusting the spring tension. In this way, rapid idling of the reel due to inertia and material ejection are effectively suppressed, and sudden tension during the pulling process is avoided, ensuring the stability and controllability of the subsequent feeding process. The support frame body is a modular adjustable height structure, compatible with reels of different diameters and weights. The unfolding process is triggered by the primary pulling mechanism 2, forming a synchronous release and material supply linkage.

[0017] The structure of the primary pulling mechanism 2 will be described in detail below. The primary pulling mechanism 2 includes a machine base, a first servo motor mounted on the machine base, and a double pressure roller structure connected to the first servo motor. The first servo motor is mounted on the machine base, and this mechanism is installed in front of the coil outlet. The first servo motor drives the double pressure roller structure to clamp the coiled aluminum rod and push it forward. It has active feeding capability and can be adjusted by the floating of the pressure rollers and the response of the motor to achieve flexible adaptation when the path tension fluctuates. The distance between the pressure rollers is controlled by a cylinder to achieve rapid opening and closing, which is convenient for feeding and changing materials. The pulling mechanism is equipped with a tension limit clutch, which can sense the output torque in real time during the pulling process. When the pulling tension exceeds the preset safety value due to the aluminum rod being blocked or the path being abnormal, the clutch will automatically disengage or slip, thereby interrupting the transmission of pulling force and preventing the aluminum rod from breaking, deforming, or being damaged by continued forced traction.

[0018] The path adjustment and guidance module 3 consists of four sets of guide wheel clamping mechanisms. The four sets of guide wheel clamping mechanisms are arranged along the same plane and form an inverted U-shaped path, which is used to guide and adjust the feeding direction of the aluminum rod. Each set of guide wheels consists of four rollers arranged symmetrically, forming a closed clamping channel for double-sided clamping of the bar stock, ensuring stable operation. The multiple zigzags in the path buffer the tension pulses generated by the release of the coiled material, and tension buffering is achieved by increasing the path length, reducing the risk of localized tension concentration in the material. The guide wheel surface is covered with a wear-resistant elastic coating, which protects the bar stock surface and improves clamping stability. Each guide wheel clamping mechanism is mounted on an adjustable slide rail bracket with graduated markings. The bracket structure supports sliding positioning and locking. Operators can flexibly adjust the spacing and angle of the guide wheels according to the radius of the bar stock conveying path or the tension distribution requirements, and can fine-tune the angle and spacing according to the path requirements. A pair of tension sensors are configured in the middle of the module, respectively located at the inlet and outlet sections, to collect real-time changes in feeding tension and feed them back to the tension control module, providing data support for downstream drive speed regulation and tension control.

[0019] The intelligent tension closed-loop control module monitors the tension of the aluminum rod in the feeding path in real time and dynamically adjusts the speed of the pulling mechanism to ensure that the feeding process remains within a stable tension range. The module consists of a tension sensor, a tension controller, and a servo drive unit. The tension sensor, using a resistance strain gauge structure, is installed at key nodes in the guide path to continuously collect force data on the aluminum rod during operation. This data is converted from analog to digital and sent to the controller. The controller then runs a tension adjustment program based on a PID algorithm, comparing the actual tension with a preset tension window and automatically adjusting the drive speed of the secondary pulling mechanism 4: when excessive tension is detected, the feeding speed is reduced to release the tension; conversely, the speed is increased to compensate for the tension, achieving stable and flexible feeding control. The system also features tension anomaly alarm and emergency stop linkage functions, automatically interrupting operation in the event of severe tension anomalies to ensure equipment and material safety.

[0020] The secondary pulling mechanism 4 is located between the end of the path adjustment unit and the straightening unit. The secondary pulling mechanism 4 includes a second servo motor and a roller assembly connected to the second servo motor. The servo motor and roller assembly are independently controlled, with tension adjustment feedback, providing continuous thrust as the main feeding source. The roller clamping force is automatically adjusted via spring loading to accommodate different diameter tolerances of the aluminum rods, ensuring non-slip feeding.

[0021] The straightening mechanism 5 includes a screw lifting mechanism 10, a straightening wheel mounted on the screw lifting mechanism 10, and a straightening block mounted on the machine platform and located on one side of the secondary pulling mechanism 4. The screw lifting mechanism 10 is fixedly installed on the machine platform, the straightening wheel is fixedly installed on the screw lifting mechanism 10, the straightening block is fixedly installed on the machine platform, and the fixed-length cutting mechanism 6 is installed on the screw lifting mechanism 10. The screw lifting mechanism 10 can drive the straightening block and the straightening wheel to move up and down, realizing online adjustment of the wheel spacing. The control system automatically sets the pre-pressure spacing of the straightening wheel based on the path attitude monitoring results, realizing adaptive correction for materials with different curvatures. The inlet and outlet of the mechanism are equipped with positioning guide rings to prevent the straightened bar from bending again due to rebound.

[0022] Fixed-length cutting mechanism 6: This module consists of a length measuring unit (encoding wheel + Hall sensor), a synchronous following cutting device (tungsten carbide saw blade or mechanical shearing structure), and a docking guide structure. The length measuring unit monitors the feed length of the bar in real time. Whenever the cumulative length reaches 1 meter, the control system issues a cutting preparation command. To ensure a flat and perpendicular cut, the saw blade and the bar maintain synchronous movement during the cutting process. That is, the saw blade moves at a uniform speed along the feed direction, keeping the bar stationary relative to the bar during cutting. Before the cutting is completed, the bar only moves downwards at the feed speed without coaxial rotation. This method can significantly reduce burrs on the cut and improve docking accuracy. After the cutting is completed, the saw blade returns to the initial position along the original trajectory, waiting for the next round of cutting. The bar is then directly fed into the downstream docking roller pressing structure, waiting to be seamlessly docked with the previous bar being used in additive manufacturing. The entire process is precisely matched with the additive manufacturing cycle.

[0023] Furthermore, the screw lifting mechanism 10 is also equipped with a roller pressing mechanism 9, which is located between the cutting unit and the additive manufacturing mechanism 7. The roller pressing mechanism 9 consists of multiple sets of rollers arranged vertically. In addition to providing downward rolling force, the roller sets also clamp the bar stock and rotate it around the central axis. The cut bar stock is pushed into this channel and rotates while being conveyed downwards, precisely docking with the tail end of the bar stock that is currently being compressed downwards by the additive manufacturing process. This structure compensates for the gaps caused by the saw blade cutting through a limiting and constant force variable speed drive device, ensuring that the end faces of the two bars are perpendicularly attached and advance synchronously under the guidance, realizing a continuous feeding method of "seamless end-to-end connection of new and old bars". The control system precisely adjusts the feeding speed to keep the two bars at a consistent rate, avoiding misalignment in the transition zone or uneven heat input, and ensuring the stability of the deposition quality and structural integrity. The roller pressing area also serves as the direct channel for additive manufacturing materials. The structure internally accommodates two bar sections simultaneously: the lower section contains the bar currently being used for additive manufacturing, and the upper section contains a newly cut and joined bar. The end faces of both sections are in contact, and they rotate synchronously and descend at a uniform speed via guide wheels and a clamping mechanism. During additive manufacturing, the material is gradually softened and extruded and consumed. The system, in conjunction with the cutting and feeding system, continuously feeds the upper bar downwards at the same feed rate, thus achieving a continuous operation mode of "two-section material combined feeding and synchronous additive manufacturing," eliminating time delays and discontinuous additive manufacturing issues caused by material changes.

[0024] The liftable mobile worktable 8 is provided with a Y-axis moving mechanism 11 below it, an X-axis moving mechanism 12 below it, and a Z-axis lifting mechanism 13 below it to drive the entire liftable mobile worktable 8 and its upper mechanism to move up and down along the Z-axis direction, so as to achieve height adjustment and deposition layer thickness control; the three-axis linkage is used to achieve precise positioning of the additive head in three-dimensional space.

[0025] This system is the core coordinating unit of the entire continuous feeding device. It uses a PLC as the main control platform, combined with a touch-screen human-machine interface for parameter setting and operational status monitoring. The control system establishes real-time data connections with the drivers, sensors, and actuators of each functional module through multi-channel communication interfaces, achieving system-level information integration and control logic arrangement. The system control methods include: (1) Tension closed-loop control: Connect the path adjustment module and the tension sensor, implement the PID tension adjustment algorithm, adjust the speed of the pulling mechanism in real time, and stabilize the feeding tension; (2) Cutting cycle control: Combined with the signal of the feeding and length measuring unit, the synchronous follow saw blade start, feed and return actions are controlled to ensure that the saw blade and the bar are at the same speed, so as to achieve “relative static” cutting; (3) Dating and Coordination Control: The system monitors the usage progress of the additive bar according to the set remaining length threshold. When the set threshold is reached, a cutting command is immediately triggered. At the same time, the docking roller pressing structure is coordinated to promote the seamless bonding of the new bar with the end face of the old bar. (4) Rotational synchronous propulsion: The controller, based on the spindle signal of the additive manufacturing equipment, links the feeding system to match the rotational speed and the propulsion speed, so that the upper and lower bars rotate synchronously and are conveyed downwards, ensuring the continuous and stable additive layer; (5) Abnormal monitoring and alarm: Monitoring channels are set up for situations such as excessive pulling load, bar jamming, excessive tension fluctuation, abnormal feeding, cutting failure, and misalignment, and an audible and visual alarm and emergency stop response mechanism are provided. (6) Cycle learning and remote operation and maintenance: The system supports the self-learning function of feeding cycle, automatically optimizes the rhythm parameters according to the actual additive progress, and provides equipment maintenance reminders, operation log recording and remote fault diagnosis interface.

[0026] The above technical solutions only embody the preferred technical solutions of the present invention. Any modifications that may be made by those skilled in the art to certain parts thereof embody the principles of the present invention and fall within the protection scope of the present invention.

Claims

1. A continuous feeding device for coiled aluminum alloy discs used in friction stir deposition additive manufacturing, characterized in that, include: A coil suspension and unfolding structure (1) is used to provide support and stable unfolding of the coiled aluminum alloy disc; The primary pulling mechanism (2) is located at the outlet of the coil suspension and unfolding structure (1) and is used to pull the unfolded aluminum alloy coil and actively feed it. The path adjustment and guidance module (3) is located on one side of the primary pulling mechanism (2) and is used to guide and adjust the feeding direction of the aluminum alloy disc. The intelligent tension closed-loop control module is set in the feeding path to monitor the tension state of the aluminum rod in the feeding path in real time. The secondary pulling mechanism (4) is located at the end of the path adjustment and guiding module (3) and is used to provide continuous feeding thrust; A straightening mechanism (5) is provided on one side of the secondary pulling mechanism (4) for straightening aluminum alloy discs to form rods that can be used for friction stir deposition additive manufacturing. The straightening mechanism (5) includes a screw lifting mechanism (10) and a roller pressing mechanism (9) is also provided on the screw lifting mechanism (10). A fixed-length cutting mechanism (6) is provided on one side of the straightening mechanism (5) for cutting the straightened bar into fixed lengths; The additive manufacturing mechanism (7) is located downstream of the fixed-length cutting mechanism (6) and is used to perform agitation and friction deposition additive manufacturing on the rod. A liftable movable worktable (8) is located below the additive manufacturing mechanism (7) and cooperates with the additive manufacturing mechanism (7) to perform additive forming; The path adjustment and guiding module (3) consists of four sets of guide wheel clamping mechanisms. The four sets of guide wheel clamping mechanisms are arranged along the same plane and form an inverted U-shaped feeding path. The multiple folding structure of the path can buffer the tension pulse generated by the release of the coil. The guide wheel clamping mechanism consists of four rollers arranged symmetrically on the upper and lower sides, which are used to clamp and guide the aluminum alloy coil. A pair of tension sensors are configured in the middle of the module, which are respectively arranged at the inlet section and the outlet section to collect the changes in feeding tension in real time and feed them back to the tension control module, providing data support for downstream drive speed regulation and tension control. The intelligent tension closed-loop control module consists of a tension sensor, a tension controller, and a servo drive unit. The tension sensor adopts a resistance strain gauge structure and is installed at key nodes of the guide path to continuously collect the force data of the aluminum rod during operation. The fixed-length cutting mechanism (6) includes a length measuring unit, a synchronous following cutting device, and a docking guide structure; the length measuring unit is used to detect the feeding length of the bar. The synchronous following cutting device includes a saw blade, which moves synchronously along the bar feeding direction during the cutting process, so that the saw blade is in a stationary state relative to the bar to complete the fixed-length cutting; the docking guide structure is used to guide the cut second bar into the roller pressing mechanism (9) and make the end face of the second bar dock with the end face of the first bar. The roller pressing mechanism (9) is located between the cutting unit and the additive manufacturing mechanism (7). The roller pressing mechanism (9) consists of multiple sets of rollers arranged vertically. The multiple sets of rollers simultaneously apply downward roller feeding force and rotation driving force around the central axis to the bar. The roller pressing structure accommodates two bar sections at the same time: the lower part is the bar section being used for additive manufacturing, and the upper part is the newly cut and joined bar section. The end faces of the two sections are in contact. The guide wheel and clamping mechanism achieve synchronous rotation and uniform descent. During the additive manufacturing process, the material is gradually softened and extruded and consumed. The system is linked with the cutting and feeding system to continuously feed the upper bar section downward at the same feed speed, thereby realizing the continuous operation mode of "two-section material combined feeding and synchronous additive manufacturing". The control system establishes real-time data connections with the drivers, sensors, and actuators of each functional module through multi-channel communication interfaces, achieving system-level information integration and control logic arrangement; the system control methods include: (1) Tension closed-loop control: Connect the path adjustment module and the tension sensor, implement the PID tension adjustment algorithm, adjust the speed of the pulling mechanism in real time, and stabilize the feeding tension; (2) Cutting cycle control: Combined with the signal of the feeding and length measuring unit, the synchronous follow saw blade start, feed and return actions are controlled to ensure that the saw blade and the bar are at the same speed, so as to achieve "relative static" cutting; (3) Dating and Coordination Control: The system monitors the usage progress of the additive bar according to the set remaining length threshold. When the set threshold is reached, a cutting command is immediately triggered. At the same time, the docking roller pressing structure is coordinated to promote the seamless bonding of the new bar with the end face of the old bar. (4) Rotational synchronous propulsion: The controller, based on the spindle signal of the additive manufacturing equipment, links the feeding system to match the rotational speed and the propulsion speed, so that the upper and lower bars rotate synchronously and are conveyed downwards, ensuring the continuous and stable additive layer; (5) Abnormal monitoring and alarm: A monitoring channel is set up for situations such as excessive pulling load, bar jamming, excessive tension fluctuation, abnormal feeding, cutting failure, and misalignment, and an audible and visual alarm and emergency stop response mechanism is provided. (6) Cycle learning and remote operation and maintenance: The system supports the self-learning function of feeding cycle, automatically optimizes the rhythm parameters according to the actual additive progress, and provides equipment maintenance reminders, operation log recording and remote fault diagnosis interface.

2. The continuous feeding device for coiled aluminum alloy discs for friction stir deposition additive manufacturing according to claim 1, characterized in that, The coil suspension and unwinding structure (1) includes a support frame, a hollow rotating shaft on the support frame, a coil on the hollow rotating shaft, and an adjustable damping brake device on the support frame and located at one end of the hollow rotating shaft. The hollow rotating shaft is rotatably mounted on the support frame, and the adjustable damping brake device is used to adjust the rotational damping during the unwinding process of the coil.

3. The continuous feeding device for coiled aluminum alloy discs for friction stir deposition additive manufacturing according to claim 1, characterized in that, The primary pulling mechanism (2) includes a machine base, a first servo motor mounted on the machine base, and a double pressure roller structure connected to the first servo motor; the double pressure roller structure is used to clamp the unfolded aluminum alloy disc and actively pull and feed the aluminum alloy disc under the drive of the first servo motor.

4. The continuous feeding device for coiled aluminum alloy discs for friction stir deposition additive manufacturing according to claim 1, characterized in that, The secondary pulling mechanism (4) is located between the end of the path adjustment and guiding module (3) and the straightening mechanism (5); the secondary pulling mechanism (4) includes a second servo motor and a roller assembly connected to the second servo motor; the roller assembly is used to clamp the bar and continuously feed it in the direction of the straightening mechanism (5), and the clamping force of the roller assembly is automatically adjusted by spring loading.

5. The continuous feeding device for coiled aluminum alloy discs for friction stir deposition additive manufacturing according to claim 3, characterized in that, The straightening mechanism (5) includes a straightening wheel disposed on the screw lifting mechanism (10) and a straightening block disposed on the machine platform and located on one side of the secondary pulling mechanism (4); the screw lifting mechanism (10) is fixedly installed on the machine platform, the straightening wheel is fixedly installed on the screw lifting mechanism (10), and the straightening block is fixedly installed on the machine platform; the fixed-length cutting mechanism (6) is installed on the screw lifting mechanism (10).

6. The continuous feeding device for coiled aluminum alloy discs for friction stir deposition additive manufacturing according to claim 1, characterized in that, The liftable mobile worktable (8) is provided with a Y-axis moving mechanism (11) below it, an X-axis moving mechanism (12) is provided below the Y-axis moving mechanism (11), and a Z-axis lifting mechanism (13) is provided below the X-axis moving mechanism (12). The Z-axis lifting mechanism (13) is used to drive the liftable mobile worktable (8) and its upper mechanism to move up and down along the Z-axis direction.

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