Intelligent control of laser welding and additive device and method

Abstract

The present application relates to the technical fields of laser welding and additive manufacturing, and discloses an intelligent control wire-powder co-feed laser welding and additive device and method, which comprises a cover body, a fiber laser transmission assembly, a powder feeding mechanism, a wire feeding mechanism, a detection mechanism and a control mechanism. The powder feeding mechanism comprises an annular support plate, a main powder feeding pipe, multiple secondary powder feeding pipes, a first angle adjusting assembly, a second angle adjusting assembly and an angle collaborative connecting assembly detachably connected between the first angle adjusting assembly and the multiple second angle adjusting assemblies. The wire feeding mechanism comprises a wire feeding gun and a third angle adjusting assembly connecting the wire feeding gun and the cover body. The present application obtains the welding angle through the detection mechanism, and the control mechanism adaptively controls the angles of the powder feeding pipe and the wire feeding gun according to the different welding angles, realizes the control in the flat welding, flat-angle welding and overhead welding scenes, and adjusts to the optimal angle matching the current welding direction under large-angle deflection, thereby overcoming the problem of uneven powder feeding caused by gravity.

Description

Technical Field

[0001] This invention relates to the field of laser welding and additive manufacturing technology, specifically to an intelligent control device and method for co-feeding wire powder in laser welding and additive manufacturing. Background Technology

[0002] With the development of marine resources and the rapid advancement of nuclear power, extreme environment welding and additive manufacturing technologies play a crucial role in the construction and maintenance of marine engineering and nuclear power plants. Laser welding and additive manufacturing technologies can rapidly process and repair complex parts and structures by accumulating materials layer by layer through wire feeding or powder feeding. They offer low material costs, high manufacturing efficiency, and promising application prospects.

[0003] However, previous extreme environment laser welding and additive manufacturing devices either achieved wire filling or powder feeding, which were relatively simple in form. Some alloys, due to their composition and processing methods, could not be drawn into wires or prepared into powders with uniform particle size. This made it difficult to diversify the alloy composition in the hot working area, which seriously restricted the development of high-performance alloys and the processing and manufacturing of high-quality welds.

[0004] To improve material utilization, the advantages of both wire-feed additive manufacturing and powder-feed additive manufacturing have been combined, leading to the emergence of the technology of simultaneous wire and powder feeding additive manufacturing. This technology typically consists of a coaxial powder feeding structure and a lateral wire feeding structure. The coaxial powder feeding structure precisely delivers metal powder along the circumference of the laser beam to the laser focal spot to form a molten pool, while the lateral wire feeding mechanism continuously feeds metal wire into the molten pool area from the side of the laser beam. The wire and powder melt and mix synchronously under the high temperature of the laser. Through the spreading and solidification of the molten pool, the material is deposited layer by layer. This technology not only relies on the powder feeding process to achieve flexible control of the cladding layer composition, but also uses the wire feeding process to improve the material deposition efficiency and forming density, thus achieving the complementary advantages of the two additive manufacturing processes.

[0005] However, in some practical manufacturing applications, such as curved surface tooling, the welding angle needs to be varied, and the optimal powder feeding angle differs for different welding directions (e.g., the optimal powder feeding angle for flat welding is 30°~50°, while the optimal powder feeding angle for fillet welding will differ due to the change in welding angle). In wire and powder feeding systems, the coaxial powder feeding structure is mostly a fixed structure, lacking flexible adjustment functions for the powder feeding angle and powder coke length. It requires replacing the nozzles with different structures to match the process parameters, and each time the nozzle is disassembled and reassembled, the laser focal spot, the powder convergence point, and the wire feeding structure must be recalibrated. The process of controlling core parameters such as angles is complicated, time-consuming, and labor-intensive, which significantly reduces processing efficiency and increases operational difficulty. At the same time, in situations with large tilt angles, such as overhead welding and large-angle deflection welding, the powder feeding pipes distributed in a coaxial ring have different spatial positions, and the degree of influence of gravity on the powder varies. The fixed coaxial powder feeding structure cannot independently compensate for the actual impact on each powder feeding pipe, which easily leads to powder falling and scattering, resulting in uneven overall powder feeding effect, causing defects such as uneven alloy composition in the welding area, porosity in the cladding layer, and lack of fusion. Summary of the Invention

[0006] The purpose of this invention is to provide an intelligent control device and method for co-feeding wire and powder laser welding and additive manufacturing, so as to solve the problem that existing co-feeding wire and powder laser welding and additive manufacturing devices are difficult to adjust the optimal powder feeding angle in a timely manner when the welding angle changes, and are difficult to independently compensate for the actual impact on each powder feeding tube, resulting in uneven powder feeding effect.

[0007] The technical solution of this invention is: A smart controlled wire powder co-feeding laser welding and additive manufacturing device includes a housing, a fiber laser transmission component, a powder feeding mechanism, a wire feeding mechanism, a detection mechanism, and a control mechanism. The housing is used to connect to the end effector of an external robotic arm. The fiber laser transmission component is located at the center of the housing and is used to focus laser energy. The powder feeding mechanism includes an annular support plate coaxially connected to the fiber laser transmission component, a main powder feeding pipe and multiple secondary powder feeding pipes surrounding the annular support plate, a first angle adjustment component connecting the main powder feeding pipe and the annular support plate, multiple second angle adjustment components correspondingly connecting each of the secondary powder feeding pipes to the annular support plate, and an angle coordination connection component detachably connected between the first angle adjustment component and the multiple second angle adjustment components. The wire feeding mechanism has a wire feeding gun, and a third angle adjustment component is provided between the wire feeding gun and the housing. The detection mechanism includes an attitude detection module and multiple... An angle detection module is installed on the cover, and multiple angle detection modules are respectively installed on the main powder feeding pipe, each secondary powder feeding pipe, and the wire feeding gun. A control mechanism is electrically connected to the attitude detection module, multiple angle detection modules, a first angle adjustment component, a second angle adjustment component, an angle coordination connection component, and a third angle adjustment component. The control mechanism is preset with powder and wire feeding angle adjustment process parameters that match the welding angle. The attitude detection module detects the welding angle in real time and feeds it back to the control mechanism. After receiving the signal, the control mechanism sends corresponding adjustment commands to the first angle adjustment component, the second angle adjustment component, the angle coordination connection component, and the third angle adjustment component to adjust the powder and wire feeding angle. The angle detection module detects in real time whether the tilt angle of the main powder feeding pipe, secondary powder feeding pipe, and wire feeding gun is adjusted in place and feeds it back to the control mechanism for closed-loop adjustment.

[0008] Preferably, as a further improvement of the present invention, the first angle adjustment assembly includes a first connecting rod, a second connecting rod, and a first electric push rod; one end of the first connecting rod is hinged to the bottom of the annular support plate; one end of the second connecting rod is hinged to the other end of the first connecting rod, and the other end of the second connecting rod is fixed to the main powder feeding pipe; one end of the first electric push rod is fixed to the bottom of the annular support plate, and the other end of the first electric push rod is fixed to a first mounting seat provided on the main powder feeding pipe.

[0009] Preferably, as a further improvement of the present invention, the second angle adjustment assembly includes a third link, a fourth link, and a second electric push rod; one end of the third link is hinged to the bottom of the annular support plate; one end of the fourth link is hinged to the other end of the third link, and the other end of the fourth link is provided with a rotatable clamping plate; a second mounting seat is fixed on the outer wall of the secondary powder feeding pipe, and the second mounting seat has a slot for engaging with the clamping plate; one end of the second electric push rod is fixed to the bottom of the annular support plate, and the other end of the second electric push rod is fixed to the third mounting seat provided on the secondary powder feeding pipe.

[0010] Preferably, as a further improvement of the present invention, the angle-coordinated connection assembly includes a rotation drive and an annular snap-fit ​​plate; the rotation drive is disposed on the first mounting base; the outer peripheral wall of the annular snap-fit ​​plate is connected to the output end of the rotation drive through a connecting ear plate, and is inserted into the slot of the second mounting base on each of the secondary powder feeding pipes under the drive of the rotation drive.

[0011] Preferably, as a further improvement of the present invention, the third angle adjustment assembly includes a fourth electric push rod, a fifth connecting rod, and a sixth connecting rod. One end of the fifth connecting rod is hinged to the cover, one end of the sixth connecting rod is hinged to the fifth connecting rod, and the sixth connecting rod is fixed to the wire feeding gun. One end of the fourth electric push rod is fixed to the cover, and the other end of the fourth electric push rod is hinged to the side wall of the wire feeding gun.

[0012] Preferably, as a further improvement of the present invention, it also includes a height adjustment component, which includes two sets of linear modules and a displacement sensor. Both sets of linear modules are arranged along the central axis of the cover. The guide rail of one set of linear modules is connected to the fiber laser transmission component, and the slider of the linear module is fixed to the outer wall of the annular support plate. The guide rail of the other set of linear modules is fixed to the inner wall of the cover, and the slider of the other set of linear modules is hinged to one end of the fifth connecting rod and fixed to one end of the fourth electric push rod. The slider of each linear module is equipped with the displacement sensor, and the displacement sensor is electrically connected to the control mechanism.

[0013] Preferably, as a further improvement of the present invention, the top of the cover is provided with two vent holes, which are connected to a protective gas device through pipes.

[0014] Based on the same inventive concept, this invention also discloses an intelligent controlled wire powder co-feeding laser welding and additive manufacturing method, implemented using the aforementioned intelligent controlled wire powder co-feeding laser welding and additive manufacturing device, comprising the following steps: S1. The attitude detection module obtains the spatial pose data of the cover in real time to obtain the angle at which welding is performed. S2. Based on the obtained welding angle, the control mechanism determines the target tilt angle of the powder feeding tube and the target tilt angle of the wire feeding gun corresponding to the current welding angle, according to the preset mapping relationship between the welding angle and the powder feeding and wire feeding angle process parameters. S3. The control mechanism generates and sends drive commands to the first angle adjustment component, the second angle adjustment component, the angle coordination connection component and the third angle adjustment component based on the target tilt angle of the powder feeding tube and the target tilt angle of the wire feeding gun. S31. When the welding angle is within the first preset range for flat welding, the control mechanism controls the angle coordination connection component to connect the first angle adjustment component and each of the second angle adjustment components, and sends a drive command to the first angle adjustment component, so that the main powder feeding pipe drives each of the secondary powder feeding pipes to adjust their angles synchronously, and the angle detection module detects the angle between the main powder feeding pipe and each of the secondary powder feeding pipes in real time. When the main powder feeding pipe and each of the secondary powder feeding pipes are adjusted to the correct position, the control mechanism controls the third angle adjustment component to adjust the angle of the wire feeding gun to match the current powder feeding angle. S32. When the welding angle is within the second preset range for flat fillet welding or overhead welding, the control mechanism controls the angle coordination connection component to disconnect the first angle adjustment component from each of the second angle adjustment components, and sends independent drive commands to the first angle adjustment component and each of the second angle adjustment components respectively, so that the main powder feeding pipe and each of the secondary powder feeding pipes can be adjusted in angle respectively, and the angle detection module detects the angle between the main powder feeding pipe and each of the secondary powder feeding pipes in real time. When the main powder feeding pipe and each of the secondary powder feeding pipes are adjusted to the correct position, the control mechanism controls the third angle adjustment component to adjust the angle of the wire feeding gun to match the current powder feeding angle.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. By setting up an attitude detection module to acquire the spatial pose data of the cover in real time to obtain the welding angle, the control mechanism automatically generates drive commands for the first angle adjustment component, the second angle adjustment component, the angle coordination connection component, and the third angle adjustment component based on the preset mapping relationship between the welding angle and process parameters. This realizes the automatic adjustment of the powder feeding tube and wire feeding gun tilt angle. This eliminates the need for operators to disassemble and replace nozzles to adjust the wire feeding angle, and eliminates the need to recalibrate the laser focal spot, powder convergence point, and adjust the angle of the wire feeding structure during welding. This significantly simplifies the equipment adjustment process and improves welding efficiency and process consistency.

[0016] 2. By setting up a detachable angle-coordinated connection component, multiple powder feeding pipes can be selectively connected or disconnected according to the welding posture. In flat welding and small-angle deflection ranges, the angle-coordinated connection component connects the main powder feeding pipe with each secondary powder feeding pipe. Only the first angle adjustment component needs to be adjusted individually to achieve synchronous angle adjustment of multiple powder feeding pipes, ensuring the consistency of powder convergence. In large-angle deflection or overhead welding conditions, the angle-coordinated connection component is disconnected, and each secondary powder feeding pipe is independently driven by its own second angle adjustment component, which can be adjusted to the optimal angle matching the current welding direction. This effectively overcomes the problem of uneven powder feeding caused by gravity and broadens the process applicability range of the device. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the main cross-sectional structure of an intelligent control wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention.

[0018] Figure 2 This is a top cross-sectional view of an intelligent control wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention.

[0019] Figure 3 This is a bottom cross-sectional view of an intelligent control wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the powder feeding component in an intelligent controlled wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the structure of the annular snap-fit ​​plate and the slot snap-fit ​​in an intelligent control wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of the structure of a smart control wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention, showing the plate detaching from the slot.

[0023] Figure 7 This is a schematic diagram of the structure of the clamping plate and the slot in an intelligent control wire powder co-feeding laser welding and additive manufacturing device according to an embodiment of the present invention. Detailed Implementation

[0024] The following is combined with Figures 1-7The specific embodiments of the present invention will be described in detail below. In the description of the invention, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the mechanism or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0025] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; in the description of the invention, unless otherwise stated, "a plurality of" means two or more.

[0026] Example 1 like Figures 1-7 As shown, this embodiment of the invention provides an intelligent controllable wire powder co-feeding laser welding and additive manufacturing device, including a cover 1, a fiber laser transmission component 2, a powder feeding mechanism, a wire feeding mechanism, a detection mechanism, and a control mechanism.

[0027] The enclosure 1 is a key component of the laser welding and additive manufacturing device, providing contact with the workpiece and creating a stable working environment. The outer wall of the enclosure 1 is connected to the end effector of an external robotic arm. The robotic arm adjusts the orientation of the enclosure 1 and positions it over the surface of the workpiece to be welded. The enclosure 1 is an octagonal structure made of corrosion-resistant metal. Considering that laser welding and additive manufacturing devices are generally difficult or impossible to operate directly in extreme environments (including but not limited to underwater environments, high-humidity environments, high-salt environments, and high-wind-speed environments on land), special protective devices are needed to create a locally dry and stable welding and additive manufacturing environment when performing laser welding and additive manufacturing in extreme environments. Therefore, two vents are provided at the top of the enclosure 1, connected to a protective gas device. By introducing protective argon gas, the water or air inside the enclosure 1 is vented, forming a locally dry underwater cavity. A flexible sealing ring is embedded at the bottom edge of the enclosure 1 to form a watertight contact with the workpiece surface, thereby preventing the influence of high humidity and high-salt atmospheres on the welding and additive manufacturing process.

[0028] The fiber laser transmission assembly 2 is located at the center of the housing 1 and includes an energy transmission fiber, a central connecting base, and a laser path cylinder. The energy transmission fiber passes through the interior of the central connecting base, and the end of the energy transmission fiber is connected to a collimating and focusing lens group. The laser energy generated by the external laser passes through the laser path cylinder at its bottom and is focused at a predetermined focal point in the local dry cavity created by the housing 1. The laser path cylinder at the bottom of the fiber laser transmission assembly 2 is combined with the powder feeding mechanism to form a laser processing head.

[0029] The powder feeding mechanism includes an annular support plate 31, a main powder feeding pipe 32 and multiple secondary powder feeding pipes 33, a first angle adjustment component 34, multiple second angle adjustment components 35, and an angle coordination connection component 36. The annular support plate 31 is coaxially connected to the lower part of the laser path cylinder. The main powder feeding pipe 32 and multiple secondary powder feeding pipes 33 are evenly distributed and arranged around the lower part of the annular support plate 31. Each powder feeding pipe is connected to a powder storage tank and a precision powder feeding valve through a protective gas pipe to realize the conveying of powder and its ejection from the nozzle at the outlet of the powder feeding pipe. The first angle adjustment component 34 connects the main powder feeding pipe 32 and the annular support plate 31 and is used to adjust the main powder feeding pipe. The angle is 32; the number of second angle adjustment components 35 is the same as the number of secondary powder feeding pipes 33, and they are connected one-to-one between each secondary powder feeding pipe 33 and the annular support plate 31 to adjust the angle of the secondary powder feeding pipe 33; the angle coordination connection component 36 is detachably connected between the first angle adjustment component 34 and multiple second angle adjustment components 35. Through the angle coordination connection component 36, the first angle adjustment component 34 and multiple second angle adjustment components 35 can be connected together according to the welding angle posture, so that the angle of the main powder feeding pipe 32 and multiple secondary powder feeding pipes 33 can be synchronously adjusted by only operating the first angle adjustment component 34.

[0030] The wire feeding mechanism is located next to the powder feeding mechanism and has a wire feeding gun 41. The inlet of the wire feeding gun 41 is connected to the external welding wire conveying structure. The welding wire conveying structure is existing technology and is not shown in the figure. A third angle adjustment component 42 is provided between the wire feeding gun 41 and the cover 1. The tilt angle of the wire feeding gun 41 is adjusted by the third angle adjustment component 42.

[0031] The detection mechanism includes an attitude detection module and multiple angle detection modules. The attitude detection module is set on the cover 1 and is used to detect the overall movement attitude of the cover 1. The multiple angle detection modules are respectively set on the main powder feeding pipe 32, the secondary powder feeding pipe 33 and the wire feeding gun. The multiple angle detection modules are used to detect the tilt angle of the main powder feeding pipe 32, the secondary powder feeding pipe 33 and the wire feeding gun 41 in real time.

[0032] The control mechanism is electrically connected to the attitude detection module, the first angle adjustment component 34, the second angle adjustment component 35, the angle coordination connection component 36, the third angle adjustment component 42, and multiple angle detection modules. The control mechanism receives the position and posture data of the cover 1 sensed by the attitude detection module to obtain the welding angle. According to the preset mapping relationship between the welding angle and the powder and wire feeding angle process parameters, it generates drive commands for the first angle adjustment component 34, the second angle adjustment component 35, the angle coordination connection component 36, and the third angle adjustment component 42. It adaptively adjusts the angles of the main powder feeding pipe 32, the secondary powder feeding pipe 33, and the wire feeding gun 41 to match the welding angle. The angle detection module is used to detect the tilt angle of the main powder feeding pipe 32, the secondary powder feeding pipe 33, and the wire feeding gun 41 in real time and feeds it back to the control mechanism for closed-loop adjustment to determine whether the adjustment is in place, thereby achieving more precise adjustment. The control mechanism adopts a central controller.

[0033] During operation, the spatial pose data of the housing 1 is collected in real time through the attitude detection module, recording the angular displacement of the robotic arm-driven device around the X, Y, and Z axes, thereby obtaining the welding angle α of the laser processing head. The control mechanism determines the current welding method based on the range of this welding angle α. For example, when 0°≤α<15°, it corresponds to flat welding; when 15°≤α<90°, it corresponds to fillet welding; and when 90°≤α<180°, it corresponds to overhead welding. The control mechanism calls a preset process parameter reference table, which is generated based on the orthogonal test results of the influence of the powder feeding tube angle, wire feeding gun angle 41, and powder feeding speed on the sample processing and forming under different welding positions. From this table, the optimal process parameters corresponding to the current tilt angle are matched, including the main powder feeding tube angle 32, the angles of each secondary powder feeding tube 33, the wire feeding gun angle 41, and the powder feeding speed. Subsequently, the control mechanism sends drive commands to the first angle adjustment component 34, the second angle adjustment component 35, the angle coordination connection component 36, and the third angle adjustment component 42, while adjusting the air valve to change the protective airflow speed and making real-time adjustments to the powder feeding and wire feeding process parameters.

[0034] When the attitude detection module detects that the device is within a 15° deviation from the flat welding position, taking a coaxial powder feeding mechanism including one main powder feeding pipe 32 and two secondary powder feeding pipes 33 as an example, although the horizontal angles of the three powder feeding pipes are different, they can be approximately regarded as being in the same state according to experimental test results, and angle synchronization adjustment is required. In this state, the angle coordination connection component 36 is in the connected state, and the first angle adjustment component 34 of the main powder feeding pipe 32 and the second angle adjustment components 35 of each secondary powder feeding pipe 33 are linked through the angle coordination connection component 36. At this time, the first angle adjustment component 34 acts as an active adjustment mechanism, and the multiple second angle adjustment components 35 no longer play an angle adjustment role, but passively follow the first angle adjustment component 34 to move, thereby driving the main powder feeding pipe 32 and the two secondary powder feeding pipes 33 to synchronously adjust their angles.

[0035] When the attitude detection module detects that the device is in a position range more than 15° off from the flat welding position, the powder feeding effect of the three powder feeding pipes cannot be approximated due to the large difference in horizontal angles. Therefore, the tilt angle of each powder feeding pipe needs to be adjusted independently. In this state, the control mechanism disconnects the angle coordination connection component 36, allowing the first angle adjustment component 34 and each of the second angle adjustment components 35 to perform independent angle adjustments. Based on the optimal process parameters corresponding to the current attitude, the control mechanism sends different drive commands to the first angle adjustment components 34 and each of the second angle adjustment components 35 corresponding to the three powder feeding pipes, independently adjusting the angles of the main powder feeding pipe 32 and each of the secondary powder feeding pipes 33 to meet the optimal powder feeding requirements under different welding directions.

[0036] Specifically, the first angle adjustment assembly 34 includes a first connecting rod 341, a second connecting rod 342, and a first electric push rod 343. One end of the first connecting rod 341 is hinged to the bottom of the annular support plate 31 via a damping pivot. One end of the second connecting rod 342 is hinged to the other end of the first connecting rod 341 via a damping pivot, and the other end of the second connecting rod 342 is fixed to the main powder feeding pipe 32. One end of the first electric push rod 343 is fixed to the bottom of the annular support plate 31, and the other end of the first electric push rod 343 is fixed to the first mounting seat 321 provided on the main powder feeding pipe 32. The first connecting rod 341 and the second connecting rod 342 form a hinged adjustment joint. Under the extension and retraction movement of the first electric push rod 343, the hinged adjustment joint bends, thereby adjusting the tilt angle of the main powder feeding pipe 32. The damping pivot itself has damping force, which can ensure that the adjusted angle remains unchanged.

[0037] Specifically, the second angle adjustment assembly 35 includes a third connecting rod 351, a fourth connecting rod 352, and a second electric push rod 353; one end of the third connecting rod 351 is hinged to the bottom of the annular support plate 31 via a damping shaft; one end of the fourth connecting rod 352 is hinged to the other end of the third connecting rod 351 via a damping shaft, and the other end is fixed to a second mounting seat 331 provided on the outer wall of the secondary powder feeding pipe 33, the second mounting seat 331 having a slot; one end of the second electric push rod 353 is fixed to the bottom of the annular support plate 31, and the other end is provided with a rotary motor, the housing of the rotary motor being connected to the second electric push rod 353. The end face of the push rod 353 is fixed, the output shaft of the rotary motor is fixed to the clamping plate 354, and the rotary motor is electrically connected to the control mechanism; the third link 351 and the fourth link 352 form a hinged adjustment joint. Under the extension and retraction of the second electric push rod 353, the hinged adjustment joint is driven to bend, thereby adjusting the tilt angle of the secondary powder feeding pipe 33. By controlling the rotary motor to drive the clamping plate 354 to rotate, it can realize the insertion slot or the exit from the slot. The damping shaft itself has a damping force, which can ensure that the third link 351 and the fourth link 352 maintain the current angle unchanged after the clamping plate 354 exits the slot.

[0038] Specifically, the angle coordination connection component 36 includes a rotation drive component 361 and an annular snap-fit ​​plate 362. The rotation drive component 361 is mounted on the first mounting base 321 and is a servo motor. The servo motor is electrically connected to the control mechanism. One end of the annular snap-fit ​​plate 362 is connected to the output shaft of the servo motor through a connecting ear plate.

[0039] When the attitude detection module detects that the device is within a position range of 15° from the flat welding position, it first drives the rotary motor to rotate the clamping plate 354 and remove it from the slot, so that the hinged adjustment joints of each powder feeding pipe 33 are not connected to their respective second electric push rods 353. Then, it drives the servo motor, which, driven by the rotation drive component 361, causes the annular clamping plate 362 to be inserted into the slot of the second mounting seat 331 on each powder feeding pipe 33, connecting the hinged adjustment joints of the main powder feeding pipe 32 and the secondary powder feeding pipe 33 into a whole. At this time, it is only necessary to drive the main powder feeding pipe 32 to rotate through the first electric push rod 343. At the same time, the main powder feeding pipe 32 drives the two secondary powder feeding pipes 33 to adjust their angles synchronously through the annular clamping plate 362, so as to achieve synchronous adjustment of the angles of the three powder feeding pipes. When the attitude detection module detects that the device is in a position range more than 15° deviated from the flat welding position, the control mechanism controls the rotation drive 361 to drive the annular snap-fit ​​plate 362 to retract from the slots of each second mounting base 331, disconnecting the connection between the main powder feeding pipe 32 and each secondary powder feeding pipe 33. The rotary motor in each second angle adjustment assembly then drives the snap-fit ​​plate 354 to rotate and re-insert into the slots of the second mounting base 331, allowing the second electric push rod 353 to re-maintain its connection with the hinged adjustment joint. Based on the optimal process parameters corresponding to the current attitude, the control mechanism sends different drive commands to the electric push rods corresponding to the three powder feeding pipes, independently adjusting the angles of the main powder feeding pipe 32 and each secondary powder feeding pipe 33 to meet the optimal powder feeding requirements under different welding directions.

[0040] Specifically, the third angle adjustment assembly 42 includes a fourth electric push rod 421, a fifth connecting rod 422, and a sixth connecting rod 423. One end of the fifth connecting rod 422 is hinged to the cover 1, and one end of the sixth connecting rod 423 is hinged to the fifth connecting rod 422. The sixth connecting rod 423 is fixed to the wire feeding gun 41. One end of the fourth electric push rod 421 is fixed to the cover 1, and the other end of the fourth electric push rod 421 is hinged to the side wall of the wire feeding gun 41. The fifth connecting rod 422 and the sixth connecting rod 423 form a hinged adjustment joint. Under the extension and retraction movement of the fourth electric push rod 421, the hinged adjustment joint bends, thereby adjusting the tilt angle of the wire feeding gun 41.

[0041] Specifically, the attitude detection module is a gyroscope 61, installed inside the housing 1. The gyroscope 61 is bolted to the housing 1, with a silicone shock-absorbing pad sandwiched between them to effectively buffer high-frequency vibration interference from the movement of the robotic arm and external water flow. The gyroscope 61 can record the angular displacement of the housing 1 around the X, Y, and Z axes in real time and with high precision. When the robotic arm moves the device close to the workpiece, the housing 1 engages with the repair area. When the robotic arm moves the housing 1 to change its posture, the gyroscope 61 transmits the perceived posture change information of the housing 1 to the detection mechanism of the intelligent control system, providing an absolute reference for the subsequent automatic alignment of the powder feeding pipe.

[0042] Specifically, the angle detection module is a tilt sensor 62, and multiple tilt sensors 62 are respectively connected to the main powder feeding pipe 32, multiple secondary powder feeding pipes 33 and the wire feeding gun 41.

[0043] In another embodiment of the present invention, in order to ensure that the powder and filament are always precisely focused on the laser focal spot, a height adjustment component is also provided. The height adjustment component includes two sets of linear modules 5 and displacement sensors. Both sets of linear modules 5 are arranged along the central axis of the cover 1. The guide rail of one set of linear modules 5 is connected to the outer wall of the laser path cylinder in the fiber laser transmission component 2, and the slider of this linear module 5 is fixed to the outer wall of the annular support plate 31. The guide rail of the other set of linear modules 5 is fixed to the inner wall of the cover 1, and the slider of this linear module 5 is hinged to one end of the fifth connecting rod 422 and fixed to one end of the fourth electric push rod 421. Each linear module 5 slider is equipped with a displacement sensor, and the displacement sensor... The device is electrically connected to the control mechanism. A height adjustment component allows for 10mm displacement adjustment of the entire powder feeding tube and wire feeding gun 41 along their guide rails. This ensures that even after adjusting the angles of each powder feeding tube and wire feeding gun 41, the powder and wire remain precisely focused on the laser focal spot. Displacement sensors on the linear module 5 feed the height changes of the powder feeding tube and wire feeding gun back to the central controller. Orthogonal experimental results on the influence of powder feeding height and speed on sample processing are generated, allowing for the matching of optimal process parameters corresponding to the current tilt angle, including the main powder feeding tube angle, the angles of each secondary powder feeding tube, the wire feeding gun angle, the powder feeding height, and the powder feeding speed. Subsequently, the control mechanism sends drive commands to the first angle adjustment component 34, the second angle adjustment component 35, the angle coordination connection component 36, the third angle adjustment component 42, and the height adjustment component to adjust the powder and wire feeding process parameters in real time.

[0044] Each powder feeding pipe is fitted with a water-cooled jacket, which uses circulating cooling water to prevent overheating and avoids powder blockage and adhesion caused by overheating of the powder feeding pipes during the welding process.

[0045] Example 2 This embodiment, based on Embodiment 1, discloses an intelligent controlled wire powder co-feeding laser welding and additive manufacturing method, implemented using the aforementioned intelligent controlled wire powder co-feeding laser welding and additive manufacturing device, and includes the following steps: S1: The spatial pose data of the cover 1 is obtained in real time through the attitude detection module to obtain the welding angle.

[0046] Specifically, the cover 1 is placed on the surface of the workpiece to be welded under the posture adjustment of the external robotic arm. The external robotic arm can adjust the tilt angle of the laser processing head on the cover 1. The spatial pose data of the cover 1 is collected in real time through the posture detection module, and the angular displacement of the device driven by the robotic arm around the X, Y and Z axes is recorded to obtain the welding angle α of the laser processing head. The welding angle α when the laser processing head is perpendicular to the horizontal plane is set to 0°. When 0°≤α<15°, it is flat welding operation; when 15°≤α<90°, it is flat fillet welding operation; and when 90°≤α<180°, it is overhead welding operation.

[0047] S2: Based on the obtained welding angle, the control mechanism determines the target tilt angle of the powder feeding tube and the target tilt angle of the wire feeding gun corresponding to the current welding angle, according to the preset mapping relationship between the welding angle and the powder and wire feeding angle process parameters.

[0048] Specifically, after obtaining the welding angle α of the laser processing head through the attitude detection module, the control mechanism calls the preset process parameter reference table. This reference table is generated based on the orthogonal test results of the influence of the powder feeding tube angle, wire feeding gun 41 angle, and powder feeding speed on the sample processing and forming under different welding positions. From this, the optimal process parameters corresponding to the current tilt angle are matched. For example, when 0°≤α<15° is in flat welding operation, the optimal powder feeding angle corresponding to flat welding is 30°~50°. So that the angle of each powder feeding tube can be adjusted accordingly by the first angle adjustment component 34 and the second angle adjustment component 35, and the angle of the wire feeding gun 41 can be adjusted by the third angle adjustment component 42, so that the powder and wire are always concentrated on the laser focal spot. Similarly, the optimal powder feeding angle of flat fillet welding operation and overhead welding operation will be different from that of flat welding due to the change of welding angle. The angle of each powder feeding tube and the wire feeding gun 41 are adjusted according to the corresponding optimal powder feeding angle.

[0049] S3. The control mechanism generates and sends drive commands to the first angle adjustment component 34, the second angle adjustment component 35, the angle coordination connection component 36 and the third angle adjustment component 42 based on the target tilt angle of the powder feeding tube and the target tilt angle of the wire feeding gun.

[0050] S31: When the welding angle is within the first preset range for flat welding, the control mechanism controls the angle coordination connection component 36 to connect the first angle adjustment component 34 and each of the second angle adjustment components 35, and sends a drive command to the first angle adjustment component 34, so that the main powder feeding pipe 32 drives each of the secondary powder feeding pipes 33 to adjust their angles synchronously. The angle detection module detects the angles of the main powder feeding pipe 32 and each of the secondary powder feeding pipes 33 in real time. When the main powder feeding pipe 32 and each of the secondary powder feeding pipes 33 are adjusted to the correct position, the control mechanism controls the third angle adjustment component 42 to adjust the angle of the wire feeding gun 41 to match the current powder feeding angle.

[0051] Specifically, when a flat welding operation is detected (0°≤α<15°), the control mechanism sends a drive command to the corresponding first angle adjustment component 34, second angle adjustment component 35, and angle coordination connection component 36. This drives the rotary motor in the second angle adjustment component 35 to rotate the clamping plate 354, causing it to retract from the slot of the second mounting seat 331 on each of the secondary powder feeding pipes 33. Simultaneously, it drives the rotation drive component 361 in the angle coordination connection component 36 to rotate the annular clamping plate 362, connecting it to each secondary powder feeding pipe 33. The detection mechanism only sends... The first electric push rod 343 sends a command and adjusts the angle of the main powder feeding tube 32. At the same time, the angle coordination connection component 36 synchronously drives each secondary powder feeding tube 33 to move with the main powder feeding tube 32 to adjust the angle. The tilt sensor 62 detects the angle between the main powder feeding tube 32 and each secondary powder feeding tube 33 in real time. When the main powder feeding tube 32 and each secondary powder feeding tube 33 are detected to be adjusted in place, the control mechanism controls the fourth electric push rod 421 to extend and retract, thereby driving the hinge-type adjustment joint to bend and adjust the tilt angle of the wire feeding gun 41 to match the current powder feeding angle.

[0052] S32: When the welding angle is within the second preset range for flat fillet welding or overhead welding, the control mechanism controls the angle coordination connection component 36 to disconnect the first angle adjustment component 34 from each of the second angle adjustment components 35, and sends independent drive commands to the first angle adjustment component 34 and each of the second angle adjustment components 35 respectively, so that the main powder feeding pipe 32 and each of the secondary powder feeding pipes 33 can be adjusted in angle respectively, and the angle detection module detects the angle of the main powder feeding pipe 32 and each of the secondary powder feeding pipes 33 in real time. When the main powder feeding pipe 32 and each of the secondary powder feeding pipes 33 are adjusted to the correct position, the control mechanism controls the third angle adjustment component 42 to adjust the angle of the wire feeding gun 41 to match the current powder feeding angle.

[0053] Specifically, when the angle is detected as 15°≤α<90° for fillet welding and 90°≤α<180° for overhead welding, the control mechanism sends drive commands to the corresponding first angle adjustment component 34, second angle adjustment component 35, and angle coordination connection component 36. This causes the annular locking plate 362 to retract from the slot of the second mounting seat 331 on each powder feeding pipe 33. Simultaneously, the second electric push rod 353, with a rotatable locking plate 354 at its bottom, connects to each powder feeding pipe 33. The control mechanism then sends commands to the first electric push rod 343 and the second electric push rod 362. 53 sends a command to extend and retract the hinge-type adjustment joint to bend, thereby adjusting the angles of the main powder feeding tube 32 and the secondary powder feeding tube 33 respectively. The angle detection module detects the angles of the main powder feeding tube 32 and each secondary powder feeding tube 33 in real time, and the tilt sensor 62 detects the angles of the main powder feeding tube 32 and each secondary powder feeding tube in real time. When the main powder feeding tube 32 and each secondary powder feeding tube are detected to be adjusted to the correct position, the control mechanism controls the fourth electric push rod 421 to extend and retract, thereby bending the hinge-type adjustment joint to adjust the tilt angle of the wire feeding gun 41 to match the current powder feeding angle.

[0054] The above-disclosed embodiments are merely preferred embodiments of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A smart controlled wire powder co-feeding laser welding and additive manufacturing device, comprising a housing connected to the end effector of an external robotic arm and a fiber laser transmission assembly disposed on the housing, characterized in that, Also includes: The powder feeding mechanism includes an annular support plate coaxially connected to the lower part of the fiber laser transmission component, a main powder feeding pipe and a plurality of secondary powder feeding pipes surrounding the lower part of the annular support plate, a first angle adjustment component connecting the main powder feeding pipe and the annular support plate, a plurality of second angle adjustment components correspondingly connecting each of the secondary powder feeding pipes and the annular support plate, and an angle coordination connection component detachably connected between the first angle adjustment component and the plurality of second angle adjustment components. The wire feeding mechanism includes a wire feeding gun, and a third angle adjustment component is provided between the wire feeding gun and the cover. The detection mechanism includes an attitude detection module and multiple angle detection modules. The attitude detection module is located on the cover, and the multiple angle detection modules are respectively located on the main powder feeding pipe, each secondary powder feeding pipe and the wire feeding gun. The control mechanism is electrically connected to the attitude detection module, multiple angle detection modules, the first angle adjustment component, the second angle adjustment component, the angle coordination connection component, and the third angle adjustment component. The control mechanism is preset with powder and wire feeding angle adjustment process parameters that match the welding angle. The attitude detection module detects the welding angle in real time and feeds it back to the control mechanism. After receiving the signal, the control mechanism sends corresponding adjustment commands to the first angle adjustment component, the second angle adjustment component, the angle coordination connection component, and the third angle adjustment component to adjust the powder and wire feeding angle. The angle detection module detects in real time whether the tilt angle of the main powder feeding pipe, the secondary powder feeding pipe, and the wire feeding gun is adjusted in place and feeds it back to the control mechanism for closed-loop adjustment. The first angle adjustment component includes: The first link is hinged at one end to the bottom of the annular support plate via a damping pivot. The second connecting rod has one end hinged to the other end of the first connecting rod via a damping pivot, and the other end fixed to the main powder feeding pipe. The first electric push rod has one end fixed to the bottom of the annular support plate and the other end fixed to the first mounting seat provided on the main powder feeding pipe; The second angle adjustment component includes: The third link is hinged at one end to the bottom of the annular support plate via a damping pivot. The fourth link has one end hinged to the other end of the third link via a damping shaft, and the other end fixed to a second mounting seat provided on the outer wall of the secondary powder feeding pipe. The second mounting seat has a slot. The second electric push rod has one end fixed to the bottom of the annular support plate and the other end provided with a rotatable locking plate, which matches the slot. The angle-coordinated connection component includes: A rotation drive component is mounted on the first mounting base; The annular snap-fit ​​plate has its outer peripheral wall connected to the output end of the rotary drive through a connecting ear plate, and is inserted into the slot of the second mounting seat on each of the secondary powder feeding pipes under the drive of the rotary drive.

2. The intelligent control wire powder co-feeding laser welding and additive manufacturing device according to claim 1, characterized in that, The third angle adjustment assembly includes a fourth electric push rod, a fifth connecting rod, and a sixth connecting rod. One end of the fifth connecting rod is hinged to the cover, and one end of the sixth connecting rod is hinged to the fifth connecting rod. The sixth connecting rod is fixed to the wire feeding gun. One end of the fourth electric push rod is fixed to the cover, and the other end of the fourth electric push rod is hinged to the side wall of the wire feeding gun.

3. The intelligent control wire powder co-feeding laser welding and additive manufacturing device according to claim 2, characterized in that, It also includes a height adjustment assembly, which comprises two sets of linear modules and displacement sensors. Both sets of linear modules are arranged along the central axis of the cover. The guide rail of one set of linear modules is connected to the fiber laser transmission assembly, and the slider of this linear module is fixed to the outer wall of the annular support plate. The guide rail of the other set of linear modules is fixed to the inner wall of the cover, and the slider of this linear module is hinged to one end of the fifth connecting rod and fixed to one end of the fourth electric push rod. The slider of each linear module is equipped with the displacement sensor, and the displacement sensor is electrically connected to the control mechanism.

4. The intelligent control wire powder co-feeding laser welding and additive manufacturing device according to claim 1, characterized in that, The top of the cover has two ventilation holes, which are connected to a protective gas device through pipes.

5. A method for intelligent control of wire powder co-feeding laser welding and additive manufacturing, implemented using the intelligent control of wire powder co-feeding laser welding and additive manufacturing device as described in any one of claims 1 to 4, characterized in that, Includes the following steps: S1. The attitude detection module obtains the spatial pose data of the cover in real time to obtain the angle at which welding is performed. S2. Based on the obtained welding angle, the control mechanism determines the target tilt angle of the powder feeding tube and the target tilt angle of the wire feeding gun corresponding to the current welding angle, according to the preset mapping relationship between the welding angle and the powder feeding and wire feeding angle process parameters. S3. The control mechanism generates and sends drive commands to the first angle adjustment component, the second angle adjustment component, the angle coordination connection component and the third angle adjustment component based on the target tilt angle of the powder feeding tube and the target tilt angle of the wire feeding gun. S31. When the welding angle is within the first preset range for flat welding, the control mechanism controls the angle coordination connection component to connect the first angle adjustment component and each of the second angle adjustment components, and sends a drive command to the first angle adjustment component, so that the main powder feeding pipe drives each of the secondary powder feeding pipes to adjust their angles synchronously, and the angle detection module detects the angle between the main powder feeding pipe and each of the secondary powder feeding pipes in real time. When the main powder feeding pipe and each of the secondary powder feeding pipes are adjusted to the correct position, the control mechanism controls the third angle adjustment component to adjust the angle of the wire feeding gun to match the current powder feeding angle. S32. When the welding angle is within the second preset range for flat fillet welding or overhead welding, the control mechanism controls the angle coordination connection component to disconnect the first angle adjustment component from each of the second angle adjustment components, and sends independent drive commands to the first angle adjustment component and each of the second angle adjustment components respectively, so that the main powder feeding pipe and each of the secondary powder feeding pipes can be adjusted in angle respectively, and the angle detection module detects the angle between the main powder feeding pipe and each of the secondary powder feeding pipes in real time. When the main powder feeding pipe and each of the secondary powder feeding pipes are adjusted to the correct position, the control mechanism controls the third angle adjustment component to adjust the angle of the wire feeding gun to match the current powder feeding angle.

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