Online monitoring device for ultrasonic metal additive manufacturing

Abstract

The utility model discloses an ultrasonic metal additive manufacturing on-line monitoring device which comprises a base, a product positioning mechanism, an ultrasonic welding mechanism, a temperature monitoring mechanism and a control unit, wherein the product positioning mechanism, the ultrasonic welding mechanism, the temperature monitoring mechanism and the control unit are arranged on the base. The product positioning mechanism comprises a three-dimensional force sensor arranged on the base and a welding seat arranged on the three-dimensional force sensor; the ultrasonic welding mechanism comprises a welding head connected with the ultrasonic module and a displacement sensor acting along with the welding head to monitor the thickness change of a machined workpiece. The temperature monitoring mechanism comprises a multi-degree-of-freedom workbench and an infrared thermometer arranged on the multi-degree-of-freedom workbench; the control unit is used for controlling and analyzing monitoring data of the three-dimensional force sensor, the displacement sensor and the infrared thermometer and adjusting welding parameters of the ultrasonic module in real time according to the monitoring data. According to the utility model, key parameters in the metal additive manufacturing process can be monitored in real time, and manufacturing parameters can be adjusted in time through data collected by the system, so that the product quality is optimized.

Description

Technical Field

[0001] The utility model belongs to the technical field of processing and manufacturing of metal parts, and specifically relates to an ultrasonic metal additive manufacturing online monitoring device for online monitoring of key parameters of a manufacturing process. Background Art

[0002] Ultrasonic additive manufacturing uses high-power ultrasonic energy, metal foil as raw material, and the heat generated by the vibration and friction between metal layers to promote the mutual diffusion of metal atoms between interfaces and form solid metallurgical bonds, thereby achieving layer-by-layer additive manufacturing.

[0003] Due to its high-speed, high-frequency characteristics and the closed nature of the consolidation interface formation site, traditional monitoring equipment is difficult to accurately monitor key parameters such as material stress, temperature and thickness changes, which limits the real-time evaluation and control of welding quality. In addition, due to the extremely high frequency of changes in key parameters during ultrasonic additive manufacturing, the data acquisition frequency should be more than 5 times the signal frequency, that is, more than 100KHz, in order to accurately obtain the corresponding data; however, ultra-high frequency sampling frequency will cause excessive data volume, so accurately controlling the data acquisition time and achieving efficient and accurate data acquisition is of great significance to reducing data processing pressure. Summary of the invention

[0004] In order to overcome the above-mentioned defects, the utility model provides an ultrasonic metal additive manufacturing online monitoring device to monitor the key parameters in the metal additive manufacturing process in real time, and through the data collected by the system, the manufacturing parameters can be adjusted in time to optimize product quality.

[0005] The technical solution adopted by the utility model to solve the technical problem is: to provide an ultrasonic metal additive manufacturing online monitoring device, comprising a base, and a product positioning mechanism, an ultrasonic welding mechanism and a temperature monitoring mechanism arranged on the base;

[0006] The product positioning mechanism includes a three-dimensional force sensor disposed on a base, and a welding seat disposed on the three-dimensional force sensor for supporting a processed workpiece;

[0007] The ultrasonic welding mechanism is mounted on one side of the product positioning mechanism through a machine frame, and includes a welding head connected to the ultrasonic module for welding the workpiece, and a displacement sensor that moves with the welding head to monitor the thickness change of the workpiece;

[0008] The temperature monitoring mechanism is arranged on the other side of the product positioning mechanism, and comprises a multi-degree-of-freedom workbench arranged on the base, and an infrared thermometer arranged on the multi-degree-of-freedom workbench for monitoring the welding temperature;

[0009] It also includes a control unit, which is used to control and analyze the monitoring data of the three-dimensional force sensor, the displacement sensor and the infrared thermometer, and adjust the welding parameters of the ultrasonic module in real time according to the monitoring data.

[0010] As a further improvement of the present invention, the ultrasonic module includes an ultrasonic generator, a transducer and a horn, the transducer is arranged on the frame in a horizontal direction, the two ends of the horn are respectively connected to the transducer and the welding head, the welding head can perform high-frequency vibration under the control of the ultrasonic generator, and the ultrasonic generator is connected to the control unit.

[0011] As a further improvement of the present invention, one end of the transducer is fixed to the frame through a transducer fixing member, and the other end is connected to the amplitude transformer through a fixing seat; the displacement sensor is arranged on the fixing seat of the transducer by magnetic adsorption or bolt connection.

[0012] As a further improvement of the present invention, the multi-degree-of-freedom workbench is connected to the control unit, and includes a three-dimensional translation module. The three-dimensional translation module is arranged on the base and can be translated along three-dimensional directions relative to the base.

[0013] As a further improvement of the present invention, the multi-degree-of-freedom workbench includes a dual-axis rotation module, which is arranged on the three-dimensional translation module and can rotate along two axial directions relative to the three-dimensional translation module. The infrared thermometer is arranged on the dual-axis rotation module.

[0014] As a further improvement of the present invention, the control unit is an industrial computer, having a multi-channel data acquisition system, an ultrasonic signal generating system and a parallel trigger switch. The multi-channel data acquisition system is used to collect monitoring data of the three-dimensional force sensor, the displacement sensor and the infrared thermometer in real time, and the ultrasonic signal generating system is used to adjust the output current of the ultrasonic generator according to the monitoring data.

[0015] As a further improvement of the utility model, the multi-channel data acquisition system and the ultrasonic signal generating system are connected in parallel and connected to a parallel trigger switch to enable the multi-channel data acquisition system to automatically start collecting data when the ultrasonic signal generating system is operating, and automatically stop collecting data when the ultrasonic signal generating system stops after the welding operation is completed.

[0016] The beneficial effect of the utility model is that by setting up a three-dimensional force sensor, a displacement sensor and an infrared thermometer, it is possible to comprehensively monitor and control the force, displacement and temperature parameters of the ultrasonic metal additive process, and timely adjust the welding parameters through the control unit to ensure the controllability of the production process and the reliability of product quality, thereby significantly improving the monitoring capability in the ultrasonic metal additive manufacturing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the structure of the utility model;

[0018] Figure 2 This is a schematic diagram of the structure of the ultrasonic module of the utility model.

[0019] Combined with the accompanying drawings, the following description is given:

[0020] 1. Base; 2. Product positioning mechanism; 21. Three-dimensional force sensor; 22. Welding seat; 3. Ultrasonic welding mechanism; 31. Frame; 32. Ultrasonic module; 321. Ultrasonic generator; 322. Transducer; 3221. Transducer fixture; 3222. Fixing seat; 323. Amplitude transformer; 33. Welding head; 34. Displacement sensor; 4. Temperature monitoring mechanism; 41. Infrared thermometer; 42. Three-dimensional translation module; 43. Dual-axis rotation module; 5. Control unit; 51. Multi-channel data acquisition system; 52. Ultrasonic signal generation system; 53. Parallel trigger switch. DETAILED DESCRIPTION

[0021] A preferred embodiment of the present utility model is described in detail below in conjunction with the accompanying drawings.

[0022] See also Figures 1 to 2 The utility model provides an ultrasonic metal additive manufacturing online monitoring device, which includes a base 1, and a product positioning mechanism 2, an ultrasonic welding mechanism 3, a temperature monitoring mechanism 4 and a control unit 5 arranged on the base 1.

[0023] The product positioning mechanism 2 includes a three-dimensional force sensor 21 disposed on the base 1, and a welding seat 22 disposed on the three-dimensional force sensor 21 for supporting a workpiece to be processed;

[0024] The ultrasonic welding mechanism 3 is disposed on one side of the product positioning mechanism 2 through a frame 31, and includes a welding head 33 connected to an ultrasonic module 32 for welding a workpiece, and a displacement sensor 34 that moves with the welding head 33 to monitor the thickness change of the workpiece;

[0025] The temperature monitoring mechanism 4 is arranged on the other side of the product positioning mechanism 2, and includes a multi-degree-of-freedom workbench arranged on the base 1, and an infrared thermometer 41 arranged on the multi-degree-of-freedom workbench for monitoring the welding temperature;

[0026] The control unit 5 is used to control and analyze the monitoring data of the three-dimensional force sensor 21 , the displacement sensor 34 and the infrared thermometer 42 , and adjust the welding parameters of the ultrasonic module 32 in real time according to the monitoring data.

[0027] The control unit 5 is an industrial computer capable of high-speed data collection and analysis, supporting real-time data processing and feedback, and having a multi-channel data acquisition system 51 for real-time acquisition of monitoring data of the three-dimensional force sensor 21, the displacement sensor 34, and the infrared thermometer 42, and an ultrasonic signal generating system 52 for controlling the output current of the ultrasonic generator 321. In addition, the multi-channel data acquisition system 51 and the ultrasonic signal generating system 52 are connected in parallel and connected to a parallel trigger switch 53, so that the multi-channel data acquisition system 51 automatically starts to collect data when the ultrasonic signal generating system 52 is in operation, and automatically stops collecting data when the ultrasonic signal generating system 52 stops after the welding operation is completed.

[0028] Specifically, according to Shannon's law, the sampling frequency ensures that at least 5 data are collected in one cycle, so the sampling frequency of the multi-channel data acquisition system 51 is at least 100KHz, and can be adjusted within 100KHz to 1MHz according to demand. At the same time, the multi-channel data acquisition system 51 and the ultrasonic signal generation system 52 can automatically start data acquisition when the ultrasonic module 32 starts working through a parallel trigger switch 53, and automatically stop collecting data when the ultrasonic module 32 stops ultrasonic vibration at the end of material addition. Therefore, it is possible to control the amount of data collection while ensuring efficient data collection.

[0029] In addition, the three-dimensional force sensor 21 is installed below the welding area and is connected to the base 1 and the welding seat 22 by bolts to ensure the stability of the three-dimensional force sensor 21, wherein the signal in the Z direction of the three-dimensional force sensor 21 is the longitudinal pressure signal received by the three-dimensional force sensor, and the signal in the X direction and the signal in the Y direction are two orthogonal load signals in the horizontal plane direction received by the three-dimensional force sensor; the three-dimensional force sensor 21 can collect the load signal of the vibration borne by the workpiece during the welding process in real time, and send the load signal obtained after processing by the transmitter to the signal transmission and control principle of the multi-channel data acquisition system 51 of the control unit 5, which is the same as the prior art and will not be repeated here.

[0030] Further, the ultrasonic module 32 includes an ultrasonic generator 321, a transducer 322 and a horn 323. The transducer 322 is arranged on the frame 31 in the horizontal direction. The two ends of the horn 323 are respectively connected to the transducer 322 and the welding head 33. The welding head 33 can vibrate at a high frequency under the control of the ultrasonic generator 321. The ultrasonic generator 321 is connected to the control unit 5. The transducer 322 includes a fixing seat 3221 for connecting the horn 323. The displacement sensor 34 is arranged on the fixing seat 3221 of the transducer 322 by magnetic adsorption or bolt connection. The displacement sensor 34 is a high-precision displacement sensor to ensure that the displacement and thickness change of the material can be accurately measured. Specifically, the ultrasonic signal generating system 52 controls the ultrasonic generator 321 to convert the 50 / 60 Hz current into high-frequency electrical energy. The converted high-frequency electrical energy is converted into mechanical motion of the same frequency again through the transducer 322. The mechanical motion is then transmitted to the welding head 33 through the amplitude transformer 323. The welding head 33 is then used to transmit ultrasonic waves to the welding area between the workpiece A and the workpiece B, thereby achieving the purpose of welding.

[0031] Furthermore, the multi-degree-of-freedom workbench is connected to the control unit 5, and includes a three-dimensional translation module 42 and a two-axis rotation module 43 provided on the three-dimensional translation module 42. The three-dimensional translation module 42 is provided on the base 1 and can translate relative to the base 1 along three dimensions (X, Y, Z). The two-axis rotation module 43 can rotate relative to the three-dimensional translation module 42 along two axial directions, and the infrared thermometer 42 is provided on the two-axis rotation module 43. This enables the infrared thermometer 42 to change its position in all directions, monitor the temperature distribution of the welding area in real time, and ensure comprehensive monitoring of the temperature distribution of the welding area.

[0032] To sum up, the ultrasonic metal additive manufacturing online monitoring device provided by the utility model can realize comprehensive monitoring and control of the force, displacement and temperature parameters of the ultrasonic metal additive process by setting a three-dimensional force sensor, a displacement sensor and an infrared thermometer, and timely adjust the welding parameters through the control unit to ensure the controllability of the production process and the reliability of product quality, which significantly improves the monitoring capability in the ultrasonic metal additive manufacturing process, makes the production process more controllable and the product quality more reliable, so that it can be used in fields with extremely high requirements on precision and product quality.

[0033] In the above description, many specific details are described to facilitate a full understanding of the present invention. However, the above description is only a preferred embodiment of the present invention. The present invention can be implemented in many other ways different from those described herein, so the present invention is not limited by the specific implementation disclosed above. At the same time, any person familiar with the technical field can make many possible changes and modifications to the technical solution of the present invention by using the methods and technical contents disclosed above without departing from the scope of the technical solution of the present invention, or modify it into an equivalent embodiment of equivalent changes. Any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still falls within the scope of protection of the technical solution of the present invention.

Claims

1. An ultrasonic metal additive manufacturing online monitoring device, characterized in that: It comprises a base (1), and a product positioning mechanism (2), an ultrasonic welding mechanism (3) and a temperature monitoring mechanism (4) arranged on the base (1); The product positioning mechanism (2) comprises a three-dimensional force sensor (21) arranged on the base (1), and a welding seat (22) arranged on the three-dimensional force sensor (21) for supporting a workpiece to be processed; The ultrasonic welding mechanism (3) is arranged on one side of the product positioning mechanism (2) through a frame (31), and comprises a welding head (33) connected to an ultrasonic module (32) for welding a workpiece, and a displacement sensor (34) that moves with the welding head (33) to monitor a change in thickness of the workpiece; The temperature monitoring mechanism (4) is arranged on the other side of the product positioning mechanism (2), and comprises a multi-degree-of-freedom workbench arranged on the base (1), and an infrared thermometer (41) arranged on the multi-degree-of-freedom workbench for monitoring the welding temperature; It also includes a control unit (5), which is used to control and analyze the monitoring data of the three-dimensional force sensor (21), the displacement sensor (34) and the infrared thermometer (41), and adjust the welding parameters of the ultrasonic module (32) in real time according to the monitoring data.

2. The ultrasonic metal additive manufacturing online monitoring device according to claim 1, characterized in that: The ultrasonic module (32) comprises an ultrasonic generator (321), a transducer (322) and an horn (323); the transducer (322) is arranged on the frame (31) in a horizontal direction; two ends of the horn (323) are respectively connected to the transducer (322) and the welding head (33); the welding head (33) can perform high-frequency vibration under the control of the ultrasonic generator (321); and the ultrasonic generator (321) is connected to the control unit (5).

3. The ultrasonic metal additive manufacturing online monitoring device according to claim 2 is characterized in that: One end of the transducer (322) is fixed to the frame (31) via a transducer fixing member (3221), and the other end is connected to the amplitude transformer (323) via a fixing seat (3222); the displacement sensor (34) is arranged on the fixing seat (3222) of the transducer (322) by means of magnetic adsorption or bolt connection.

4. The ultrasonic metal additive manufacturing online monitoring device according to claim 3 is characterized in that: The multi-degree-of-freedom workbench is connected to the control unit (5), and comprises a three-dimensional translation module (42). The three-dimensional translation module (42) is arranged on the base (1) and can be translated along three-dimensional directions relative to the base (1).

5. The ultrasonic metal additive manufacturing online monitoring device according to claim 4, characterized in that: The multi-degree-of-freedom workbench comprises a dual-axis rotation module (43), wherein the dual-axis rotation module (43) is arranged on the three-dimensional translation module (42) and can rotate along two axial directions relative to the three-dimensional translation module (42), and the infrared thermometer (41) is arranged on the dual-axis rotation module (43).

6. The ultrasonic metal additive manufacturing online monitoring device according to claim 5, characterized in that: The control unit (5) is an industrial computer having a multi-channel data acquisition system (51), an ultrasonic signal generation system (52) and a parallel trigger switch (53); the multi-channel data acquisition system (51) is used to collect monitoring data of the three-dimensional force sensor (21), the displacement sensor (34) and the infrared thermometer (41) in real time; and the ultrasonic signal generation system (52) is used to adjust the output current of the ultrasonic generator (321) according to the monitoring data.

7. The ultrasonic metal additive manufacturing online monitoring device according to claim 6, characterized in that: The multi-channel data acquisition system (51) and the ultrasonic signal generating system (52) are connected in parallel and then connected to a parallel trigger switch (53) so that the multi-channel data acquisition system (51) automatically starts collecting data when the ultrasonic signal generating system (52) is operating, and automatically stops collecting data when the ultrasonic signal generating system (52) stops after the welding operation is completed.

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