A fault detection and handling system and method for an FDM printer

Abstract

The application relates to a fault detection and processing system and method of an FDM printer, and the system comprises: a multimodal fault detection module, which is used for monitoring whether a fault occurs in real time during the printing process of the FDM printer; if a fault occurs, a fault signal is generated and sent to a main controller module; the main controller module is used for continuously recording printing data in the printing process, and interrupting the printing work of the FDM printer according to the fault signal; and a fault processing and printing resuming module is used for acquiring a power-off snapshot when the fault occurs, and controlling the FDM printer to continue printing according to the power-off snapshot after the fault is eliminated. The system has high automation degree in fault detection, shutdown, breakpoint recording and printing resuming, and a user only needs to issue a printing resuming instruction after eliminating a physical fault, so that the operation is simple and intuitive; through real-time recording and saving of the power-off snapshot, accurate positioning and resuming of printing after the fault is eliminated are realized, and waste of materials, time and energy is minimized.

Description

Technical Field

[0001] This invention belongs to the field of fused deposition modeling technology, and particularly relates to a fault detection and handling system and method for an FDM printer. Background Technology

[0002] Fused Deposition Modeling (FDM) 3D printers often encounter two typical failures that lead to printing failures: nozzle clogging and feed tube interruption.

[0003] Nozzle clogging: Due to material impurities, abnormal temperature, or carbonization from prolonged printing, the printhead nozzles may become partially or completely clogged, preventing the filament from being extruded properly.

[0004] Feed tube interruption: Due to the high brittleness of the consumable and the excessive bending of the feed tube, the consumable may break inside the feed tube, preventing it from being fed into the hot end.

[0005] Currently, most consumer-grade FDM printers lack effective real-time detection mechanisms. Operators typically only discover the problem after the printed model exhibits obvious defects (e.g., large areas of missed prints and stringing) or stops completely. By then, printing has already failed, resulting in a waste of materials, time, and electricity.

[0006] Existing technology can determine whether there is a blockage by monitoring the current of the feeding motor; however, when the blockage is not serious or the material interruption occurs in the feed pipe, this method is not sensitive enough and is prone to misjudgment or missed judgment.

[0007] Installing a photoelectric sensor at the feed inlet to detect material interruption; however, this method can only detect material interruption at the feed inlet and cannot detect nozzle blockage or material interruption in the pipe, and it increases hardware cost and structural complexity.

[0008] More importantly, even when a fault is detected and the machine is stopped, existing technologies generally lack the ability to accurately record the print position at the time of the fault. This means that after troubleshooting, users cannot continue printing from the breakpoint and must instead discard the already printed portion and start over, resulting in significant waste.

[0009] Therefore, there is an urgent need in this field for a comprehensive solution that can reliably and in real time detect the two types of faults mentioned above, and can accurately resume printing after the faults are resolved. Summary of the Invention

[0010] To address the aforementioned technical problems, this invention provides a fault detection and handling system and method for FDM printers.

[0011] The technical solution adopted in this invention is:

[0012] Firstly, a fault detection and handling system for an FDM printer is provided, applicable to an FDM printer. The system includes:

[0013] Multimodal fault detection module, main controller module, and fault handling and resuming module;

[0014] The multimodal fault detection module is used to monitor for faults in real time during the FDM printer printing process; if a fault occurs, it generates and sends a fault signal to the main controller module.

[0015] The main controller module is used to continuously record printing data during the printing process and interrupt the FDM printer's printing job based on fault signals;

[0016] The fault handling and resume printing module is used to obtain a snapshot of the power outage when the fault occurs, and to control the FDM printer to continue printing based on the power outage snapshot after the fault is resolved.

[0017] Furthermore, the multimodal fault detection module includes:

[0018] The motor load monitoring unit is used to monitor the working data of the feed stepper motor of the FDM printer in real time when the FDM printer is performing a printing job. The working data includes the working current value or torque value.

[0019] The fault diagnosis unit is used to determine whether the working data is within the preset normal fluctuation range. If it is within the preset normal fluctuation range, it is determined that no fault has occurred; if it is not within the preset normal fluctuation range, it is determined that a fault has occurred.

[0020] The fault signal generation and transmission unit is used to generate and send fault signals to the main controller module when a fault occurs.

[0021] Furthermore, the preset normal fluctuation range has an upper threshold and a lower threshold.

[0022] The fault determination unit is also used to determine that the fault is a nozzle blockage fault when the working data is greater than the upper limit threshold, and to determine that the fault is a material interruption fault when the working data is less than the lower limit threshold.

[0023] Furthermore, the multimodal fault detection module also includes:

[0024] The feed confirmation sensor unit is used to monitor the presence of printing consumables in real time when a feed failure occurs. This is done by using a microswitch or photoelectric sensor installed at the feeder outlet or feed tube inlet of the FDM printer. If no printing consumables are present, the feed failure is confirmed as correct; if printing consumables are present, the feed failure is confirmed as incorrect.

[0025] Furthermore, the main controller module includes:

[0026] The information recording unit is used to continuously record printing data during the printing process, including printing position and printing status;

[0027] The control unit is used to generate an emergency stop command based on the fault signal, and to interrupt the printing job of the FDM printer based on the emergency stop command.

[0028] Furthermore, the fault handling and resume calling module includes:

[0029] The power failure snapshot generation and saving unit is used to obtain the fault printing location and fault printing status when the fault occurs through the information recording unit, generate a breakpoint snapshot based on the fault printing location and fault printing status, and save it to non-volatile memory.

[0030] The print recovery unit is used to receive a resume printing command from the user after the fault has been resolved.

[0031] The resume printing unit is used to read the breakpoint snapshot from the non-volatile memory according to the resume printing instruction, and control the FDM printer to continue printing according to the power failure snapshot.

[0032] Furthermore, the execution steps of the continuing unit include:

[0033] The breakpoint snapshot is read from the non-volatile memory according to the continue printing instruction, and the fault printing location and fault printing status are obtained by parsing the breakpoint snapshot.

[0034] Control the FDM printer's printhead to move to a safe starting position;

[0035] Start the FDM printer's extruder to perform an air extrusion operation for a preset time, causing the printing filament in the nozzle to melt and flow smoothly;

[0036] Control the printhead to move from the safe starting position to the faulty printing position;

[0037] Control the FDM printer to continue printing according to the faulty printing status.

[0038] Furthermore, the fault print location includes the fault layer height of the print layer at the time of the fault and the horizontal coordinates of the faulty printhead.

[0039] The reprint unit is also used to determine the printed area based on the fault floor height and fault horizontal plane coordinates, and select a point at a preset distance above the printed area as a safe starting position.

[0040] Secondly, a fault detection and handling method for an FDM printer is provided, applied to the fault detection and handling system for the FDM printer mentioned in the first aspect above. The method includes:

[0041] During the FDM printer printing process, the multimodal fault detection module monitors in real time whether a fault occurs;

[0042] In the event of a fault, a fault signal is generated and sent to the main controller module.

[0043] The main controller module continuously records the printing data during the printing process and interrupts the FDM printer's printing job based on fault signals;

[0044] The fault handling and resume call module obtains a snapshot of the power outage at the time of the fault occurrence.

[0045] After troubleshooting, the FDM printer resumes printing based on the power outage snapshot.

[0046] Furthermore, based on the power outage snapshot, the FDM printer can continue printing, including:

[0047] Analyze the breakpoint snapshot to obtain the fault print location and fault print status;

[0048] Control the FDM printer's printhead to move to a safe starting position;

[0049] Start the FDM printer's extruder to perform an air extrusion operation for a preset time, causing the printing filament in the nozzle to melt and flow smoothly;

[0050] Control the printhead to move from the safe starting position to the faulty printing position;

[0051] Control the FDM printer to continue printing according to the faulty printing status.

[0052] The beneficial effects achieved by this invention are as follows:

[0053] The system comprises a multimodal fault detection module, a main controller module, and a fault handling and resume printing module. The multimodal fault detection module monitors for faults in real-time during FDM printing; if a fault occurs, it generates and sends a fault signal to the main controller module. The main controller module continuously records printing data and interrupts the FDM printer's printing job based on the fault signal. The fault handling and resume printing module acquires a power-off snapshot at the time of the fault and, after troubleshooting, controls the FDM printer to continue printing based on the power-off snapshot.

[0054] The multimodal detection scheme, which uses motor load as the main component and feed confirmation sensor as the auxiliary component, can effectively distinguish and detect two faults with different mechanisms, namely nozzle blockage and material interruption, with high sensitivity and low false alarm rate.

[0055] By recording and saving power outage snapshots in real time, precise positioning and printing recovery were achieved after troubleshooting, minimizing the waste of materials, time and energy.

[0056] The multimodal detection solution is based on existing motor monitoring, requires no or only a small number of low-cost sensors, makes minimal changes to the existing FDM printer structure, is easy to modify and implement, and has high commercial potential.

[0057] The system is highly automated in fault detection, shutdown, breakpoint recording, and print recovery. Users only need to troubleshoot the physical fault and then issue a resume printing command, making the operation simple and intuitive. Attached Figure Description

[0058] Figure 1 This is an overall structural diagram of the fault detection and handling system for the FDM printer of the present invention;

[0059] Figure 2 This is a first structural diagram of the fault detection and handling system for the FDM printer of the present invention;

[0060] Figure 3 This is a second structural diagram of the fault detection and handling system for the FDM printer of the present invention;

[0061] Figure 4 This is a third structural diagram of the fault detection and handling system for the FDM printer of the present invention;

[0062] Figure 5 This is a flowchart of the fault detection and handling method for the FDM printer of the present invention. Detailed Implementation

[0063] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0064] like Figure 1 As shown, this embodiment of the invention provides a fault detection and handling system for an FDM printer, applied to an FDM printer, comprising:

[0065] Multimodal fault detection module 101, main controller module 102 and fault handling and resuming module 103;

[0066] The multimodal fault detection module 101 is used to monitor whether a fault occurs in real time during the printing process of the FDM printer; if a fault occurs, it generates and sends a fault signal to the main controller module.

[0067] The main controller module 102 is used to continuously record printing data during the printing process and interrupt the printing job of the FDM printer according to the fault signal.

[0068] The fault handling and resume printing module 103 is used to obtain a power outage snapshot when the fault occurs, and to control the FDM printer to continue printing based on the power outage snapshot after the fault is cleared.

[0069] In the above Figure 1 In the illustrated embodiment, by recording and saving power outage snapshots in real time, precise positioning and printing recovery after troubleshooting are achieved, minimizing the waste of materials, time, and energy.

[0070] In summary Figure 1 The embodiments shown are preferred embodiments of the present invention, such as... Figure 2 As shown, the multimodal fault detection module 101 includes:

[0071] The motor load monitoring unit 201 is used to monitor the working data of the FDM printer's feed stepper motor in real time during printing operations. The working data includes the working current value or torque value. The pattern observed in practical applications is as follows: when the nozzle is clogged, the extrusion resistance of the printing filament increases, and the feed stepper motor needs to provide greater torque. At this time, the torque value increases, and the working current also increases significantly. When filament interruption occurs, the extrusion resistance disappears, and the torque value decreases, and the working current also decreases significantly.

[0072] The fault judgment unit 202 is used to determine whether the working data is within the preset normal fluctuation range. If it is within the preset normal fluctuation range, it is determined that no fault has occurred; if it is not within the preset normal fluctuation range, it is determined that a fault has occurred. The preset normal fluctuation range has an upper threshold and a lower threshold. When the working current value or torque value is greater than the upper threshold, the fault is determined to be a nozzle blockage fault; when the working current value or torque value is less than the lower threshold, the fault is determined to be a material interruption fault. It should be noted that during the judgment, a duration greater than the upper threshold or less than the lower threshold also needs to be set.

[0073] The fault signal generation and transmission unit 203 is used to generate and send a fault signal to the main controller module when a fault occurs.

[0074] The feeding confirmation sensing unit 204 is used to monitor the presence of printing consumables in real time by using a micro switch or photoelectric sensor installed at the feeder outlet or feed tube inlet of the FDM printer when the fault judgment unit 202 determines that a material shortage fault has occurred. If no printing consumables are present, the material shortage fault is correctly identified; if printing consumables are present, the material shortage fault is incorrectly identified.

[0075] In summary Figure 2 The embodiments shown are preferred embodiments of the present invention, such as... Figure 3 As shown, the main controller module 102 includes:

[0076] The information recording unit 301 is used to continuously record printing data during the printing process. The printing data includes printing position and printing status. The printing position can be the current layer height (which can be used as the Z-axis coordinate) and the horizontal plane coordinates of the printing layer where the print head is located (including X-axis and Y-axis coordinates). The printing status includes the executed G-code line number, extruder status, and printing speed parameters. The G-code is the execution code of the FDM printer for this printing job. The information recording unit 301 can be the memory built into the FDM printer or an external mobile storage device (e.g., a USB flash drive or a portable hard drive).

[0077] The control unit 302 is used to generate an emergency stop command based on the fault signal and to interrupt the printing job of the FDM printer based on the emergency stop command.

[0078] In summary Figure 3 The embodiments shown are preferred embodiments of the present invention, such as... Figure 4 As shown, the fault handling and resuming call module 103 includes:

[0079] The power failure snapshot generation and saving unit 401 is used to obtain the fault printing location and fault printing status when the fault occurs through the information recording unit 301, generate a breakpoint snapshot based on the fault printing location and fault printing status, and save it to non-volatile memory; the non-volatile memory is specifically an SD card or printer motherboard flash memory.

[0080] The print recovery unit 402 is used to receive a resume printing command issued by the user after troubleshooting; specifically, it can be done by displaying a "Resume Printing" option on the FDM printer's exchange interface, and triggering a resume printing command when the user clicks it.

[0081] The resume printing unit 403 is used to read the breakpoint snapshot from the non-volatile memory according to the resume printing instruction, and control the FDM printer to continue printing according to the power failure snapshot.

[0082] Preferably, the execution steps of the continuing unit 403 include:

[0083] S1, read the breakpoint snapshot from the non-volatile memory according to the resume printing instruction, and parse the breakpoint snapshot to obtain the fault printing location and fault printing status; the fault printing location includes the fault layer height of the printing layer when the fault occurred and the fault horizontal plane coordinates of the print head.

[0084] S2 controls the FDM printer's printhead to move to the safe starting position. The safe starting position is set by determining the printed area based on the fault layer height and fault horizontal plane coordinates, and selecting a point at a preset distance above the printed area as the safe starting position.

[0085] S3: Start the FDM printer's extruder to perform an air extrusion operation for a preset time, so that the printing filament in the nozzle melts and flows smoothly, avoiding material shortage at the start of continuous printing;

[0086] S4 controls the printhead to move from the safe starting position to the faulty printing position, enabling the FDM printer to continue executing subsequent G-code from the breakpoint.

[0087] The above embodiments describe a fault detection and handling system for an FDM printer. The following embodiments illustrate a fault detection and handling method for an FDM printer applied to the above system.

[0088] like Figure 5 As shown, this embodiment of the invention provides a fault detection and handling method for an FDM printer, including:

[0089] 501. During the FDM printer printing process, the multimodal fault detection module monitors in real time whether a fault has occurred.

[0090] If a fault occurs, proceed to step 502; if no fault occurs, no further steps will be executed, and the multimodal fault detection module will continue monitoring.

[0091] 502, generates and sends a fault signal to the main controller module;

[0092] 503, The main controller module continuously records the printing data during the printing process and interrupts the FDM printer's printing job based on the fault signal;

[0093] 504, the fault handling and resume module obtains a snapshot of the power outage at the time of the fault;

[0094] 505. After troubleshooting, the FDM printer will continue printing based on the power outage snapshot.

[0095] According to the resume printing instruction, the breakpoint snapshot is read from the non-volatile memory, and the breakpoint snapshot is parsed to obtain the fault printing location and fault printing status; the fault printing location includes the fault layer height of the printing layer when the fault occurred and the fault horizontal plane coordinates of the print head.

[0096] Control the FDM printer's printhead to move to the safe starting position; the safe starting position is set by determining the printed area based on the fault layer height and fault horizontal plane coordinates, and selecting a point at a preset distance above the printed area as the safe starting position;

[0097] Start the FDM printer's extruder to perform an air extrusion operation for a preset time, allowing the printing filament in the nozzle to melt and flow smoothly, thus avoiding insufficient filament at the start of subsequent printing.

[0098] Control the printhead to move from the safe starting position to the faulty printing position, so that the FDM printer can continue to execute subsequent G-code from the breakpoint.

[0099] In summary, the FDM printer fault detection and handling system and method described above achieve the following beneficial effects:

[0100] (i) The multi-modal detection scheme, which uses motor load as the main component and feed confirmation sensor as the auxiliary component, can effectively distinguish and detect two faults with different mechanisms, namely nozzle blockage and material interruption, with high sensitivity and low false alarm rate.

[0101] (ii) By recording and saving power outage snapshots in real time, precise positioning and printing recovery were achieved after troubleshooting, minimizing the waste of materials, time and energy;

[0102] (III) The multimodal detection solution is based on existing motor monitoring, requires no or only a small number of low-cost sensors, requires little modification to the existing FDM printer structure, is easy to modify and implement, and has high commercial potential.

[0103] (iv) The system has a high degree of automation in fault detection, shutdown, breakpoint recording and print recovery. Users only need to eliminate physical faults and issue a resume printing command. The operation is simple and intuitive.

[0104] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0105] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0106] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0107] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0108] The above are merely embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of the claims of the present invention pending approval.

Claims

1. A fault detection and handling system for an FDM printer, characterized in that, The system, applied to an FDM printer, includes: Multimodal fault detection module, main controller module, and fault handling and resuming module; The multimodal fault detection module is used to monitor whether a fault occurs in real time during the printing process of the FDM printer; if a fault occurs, it generates and sends a fault signal to the main controller module. The main controller module is used to continuously record printing data during the printing process and interrupt the printing job of the FDM printer according to the fault signal; The fault handling and resume printing module is used to obtain a power outage snapshot when the fault occurs, and after the fault is cleared, control the FDM printer to continue printing based on the power outage snapshot.

2. The fault detection and handling system for an FDM printer according to claim 1, characterized in that, The multimodal fault detection module includes: The motor load monitoring unit is used to monitor the working data of the feed stepper motor of the FDM printer in real time when the FDM printer is performing a printing job. The working data includes the working current value or torque value. The fault determination unit is used to determine whether the working data is within the preset normal fluctuation range. If it is within the preset normal fluctuation range, it is determined that no fault has occurred; if it is not within the preset normal fluctuation range, it is determined that a fault has occurred. The fault signal generation and transmission unit is used to generate and send a fault signal to the main controller module when a fault occurs.

3. The fault detection and handling system for an FDM printer according to claim 1, characterized in that, The preset normal fluctuation range has an upper threshold and a lower threshold; The fault determination unit is further configured to determine that the fault is a nozzle blockage fault when the working data is greater than the upper limit threshold, and to determine that the fault is a material breakage fault when the working data is less than the lower limit threshold.

4. The fault detection and handling system for an FDM printer according to claim 3, characterized in that, The multimodal fault detection module also includes: The feed confirmation sensing unit is used to monitor the presence of printing consumables in real time when the feed failure occurs by using a microswitch or photoelectric sensor installed at the feeder outlet or feed tube inlet of the FDM printer. If the printing consumables are not present, the feed failure is confirmed to be correct; if the printing consumables are present, the feed failure is confirmed to be incorrect.

5. The fault detection and handling system for an FDM printer according to claim 1, characterized in that, The main controller module includes: An information recording unit is used to continuously record printing data during the printing process, including printing position and printing status; The control unit is used to generate an emergency stop command based on the fault signal, and to interrupt the printing job of the FDM printer based on the emergency stop command.

6. The fault detection and handling system for an FDM printer according to claim 5, characterized in that, The fault handling and resume calling module includes: The power failure snapshot generation and saving unit is used to obtain the fault printing location and fault printing status when the fault occurs through the information recording unit, generate a breakpoint snapshot based on the fault printing location and the fault printing status, and save it to non-volatile memory. The print recovery unit is used to receive a resume printing command from the user after the fault has been resolved. The resume printing unit is used to read the breakpoint snapshot from the non-volatile memory according to the resume printing instruction, and control the FDM printer to continue printing according to the power failure snapshot.

7. The fault detection and handling system for an FDM printer according to claim 6, characterized in that, The steps of the continuous calling unit include: According to the resume printing instruction, the breakpoint snapshot is read from the non-volatile memory, and the breakpoint snapshot is parsed to obtain the fault printing location and the fault printing status; Control the printhead of the FDM printer to move to a safe starting position; The FDM printer's extruder is started to perform an air extrusion operation for a preset time, causing the printing consumables in the nozzle to melt and flow smoothly; Control the print head to move from the safe starting position to the faulty printing position; Control the FDM printer to continue printing according to the faulty printing status.

8. The fault detection and handling system for an FDM printer according to claim 7, characterized in that, The fault printing location includes the fault layer height of the printing layer when the fault occurred and the fault horizontal plane coordinates of the print head. The reprinting unit is also used to determine the printed area based on the fault floor height and the fault horizontal plane coordinates, and select a point at a preset distance above the printed area as a safe starting position.

9. A method for fault detection and handling of an FDM printer, characterized in that, The fault detection and handling system for the FDM printer according to any one of claims 1-8, the method comprising: During the FDM printer printing process, the multimodal fault detection module monitors in real time whether a fault occurs; In the event of a fault, a fault signal is generated and sent to the main controller module. The main controller module continuously records the printing data during the printing process and interrupts the printing job of the FDM printer according to the fault signal; The fault handling and resume call module obtains a snapshot of the power outage at the time of the fault occurrence. After the fault is resolved, the FDM printer is controlled to continue printing based on the power failure snapshot.

10. The method for fault detection and handling of an FDM printer according to claim 9, characterized in that, The step of controlling the FDM printer to continue printing based on the power outage snapshot includes: The fault printing location and fault printing status are obtained by parsing the breakpoint snapshot; Control the printhead of the FDM printer to move to a safe starting position; The FDM printer's extruder is started to perform an air extrusion operation for a preset time, causing the printing consumables in the nozzle to melt and flow smoothly; Control the print head to move from the safe starting position to the faulty printing position; Control the FDM printer to continue printing according to the faulty printing status.

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