Additively manufactured modular end effector assembly

Abstract

The device may include a robotic actuator. The device may include an end effector assembly mounted to the robotic actuator, the end effector assembly including: a modular interface having a set of connection points, the set of connection points circumferentially arranged about a modular interface central axis; a hot wire torch coupled to the modular interface and having a hot wire torch endpoint; and one or more sensors fixedly attached to the modular interface via the connection points and positioned to generate data based on observation of an observation position, the observation position being offset relative to the hot wire torch endpoint.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 378,975, entitled "Additively Manufactured Modular End Effector Assembly," filed October 10, 2022, U.S. Provisional Patent Application No. 63 / 488,435, entitled "Additively Manufactured Modular End Effector Assembly," filed March 3, 2023, and U.S. Provisional Patent Application No. 63 / 493,683, filed March 31, 2023, the disclosures of which are incorporated herein by reference in their entireties for all purposes.

[0002] The present invention relates generally to robotic wire arc additive manufacturing (WAAM) systems. [Background technology]

[0003] Additive manufacturing is a process in which a product or part is produced by adding one layer of material onto another in a sequence or pattern that results in a solid part being built. This manufacturing method is commonly referred to as three-dimensional or 3D printing and can be done with different materials, including plastics and metals. Wire arc additive manufacturing (WAAM) is a manufacturing process used to 3D print and / or repair metal parts using a metal wire feedstock and an electric arc as the energy source.

[0004] WAAM typically involves creating a weld pool using an energy source to feed a metal wire (feed material) through a print head or print head nozzle into the weld pool. Energy (i.e., electrical current carried by the feed wire) is used to create the weld pool. The print head, and subsequently the weld pool, can be moved. As the print head and weld pool move, the trailing edge of the pool cools and solidifies. This process of gradually moving the print head along a path can result in a fully printed part.

[0005] The process by which material is deposited can be controlled by the use of a shielding gas around the feed material. The shielding gas can help create a better weld pool for an overall better part. The shielding gas can protect the weld pool from corrosive gases and moisture. Summary of the Invention

[0006] In some embodiments, a device may be configured to increase the accuracy of an additive manufacturing process. In one embodiment, the device includes a robotic actuator and an end effector assembly. The end effector assembly includes a modular interface. The modular interface includes a set of connection points. The set of connection points are circumferentially arranged about a central axis of the modular interface. The modular interface further includes a clamping device centered relative to the set of connection points and a hot wire torch. The hot wire torch is attached to the modular interface via the clamping device. The clamping device applies a clamping force to the hot wire torch along a plane substantially perpendicular to the hot wire torch axis. The hot wire torch includes a hot wire torch end point and a hot wire torch base unit. The end effector assembly further includes one or more sensors fixedly attached to the modular interface via the connection points. The one or more sensors are positioned to generate data based on observations of observation positions. The observation positions are offset relative to the hot wire torch end point. The end effector assembly further includes a cold wire assembly. The cold wire assembly is attached to the modular interface via a connection point, with the cold wire torch axis configured to intersect the hot wire torch axis at the hot wire torch terminus. The cold wire assembly includes a cold wire actuator movably attached to the cold wire assembly, a cold wire terminus, and a cold wire base unit. The movably attached is configured to change the relative position of the cold wire terminus with respect to the hot wire torch terminus. The end effector assembly further includes a mounting assembly. The mounting assembly includes a base plate. The base plate mounts the cold wire base unit and the hot wire torch base unit, and the base plate is rigidly attached to the robot actuator. The mounting assembly further includes one or more riser plates fixedly attached to and extending vertically from the base plate.The riser plate is fixedly attached to the modular interface such that the connection plane is perpendicular to a base plate plane defined by the base plate. The end effector assembly further includes a local fume extraction assembly. The local fume extraction assembly includes a rail fixedly attached to one or more riser plates. The rail is arranged parallel to the base plate. The local fume extraction assembly further includes a fume hood and a positioning arm. The positioning arm is configured to translate along the rail, the translation being perpendicular to the connection plane, and the positioning arm is connected to the fume hood at an end. The end effector assembly further includes a control assembly. The control assembly includes a memory and a processor. The processor is configured to receive sensor data generated by the one or more sensors and generate a profile. The profile is generated based on the sensor data and an offset associated with the observation position. The processor is further configured to determine a center of the part and determine an x-offset. The x-offset is determined based on the profile, the center of the part, and the sensor data. The processor is further configured to cause the robotic actuator to move the hot wire torch endpoint to a new position based on the x-offset.

[0007] In a further embodiment, the positioning arm is connected at its distal end to the fume hood by a socket joint.

[0008] In another embodiment, the hot wire torch end point is centrally located relative to the set of connection points.

[0009] In yet another embodiment, the clamping device comprises a fiberglass-epoxy laminate.

[0010] In yet another embodiment, the clamping device electrically isolates the hot wire torch from the modular interface.

[0011] In yet another alternative embodiment, the clamping device may include a v-cut jog.

[0012] In yet another alternative embodiment, the hot wire is clamped closer to the modular central interface axis compared to the set of connection points.

[0013] In yet another embodiment, the clamping plane is parallel to and spaced apart from the connecting plane.

[0014] In yet another embodiment, the one or more sensors each have a type selected from the list including a welding camera, an infrared camera, a visible light camera, and a laser sensor.

[0015] In an additional further embodiment, the one or more sensors comprise a welding camera mounted to the modular interface at the 12 o'clock position.

[0016] In an additional further embodiment, the one or more sensors comprise a welding camera mounted to the modular interface at the 6 o'clock position.

[0017] In another additional further embodiment, the one or more sensors comprise a laser sensor attached to the modular interface at the two o'clock position.

[0018] In yet another further embodiment, the one or more sensors comprise a laser sensor attached to the modular interface at the 10 o'clock position.

[0019] In another additional further embodiment, the one or more sensors comprise a visible light camera mounted to the modular interface at the 8 o'clock position.

[0020] In still other further embodiments, attaching via the connection points includes fixedly attaching via the connection points.

[0021] In another further embodiment, the cold wire assembly is connected via two connection points.

[0022] In another alternative embodiment, the cold wire assembly is connected to the modular interface via a first connection point at the 11 o'clock position, and the cold wire assembly is connected to the modular interface via a second connection point at the 1 o'clock position.

[0023] In yet another embodiment, the one or more sensors include a sensor positioned to observe a point on the workpiece, the point being offset from the hot wire torch end point.

[0024] In yet another alternative embodiment, the one or more sensors include a sensor positioned to view a point on the workpiece, the point being offset from the hot wire torch end point by approximately 2 inches.

[0025] In yet another alternative embodiment, the one or more sensors include a sensor positioned to view a point on the workpiece, the point being offset from the hot wire torch end point by approximately 2.1 inches.

[0026] In yet another alternative embodiment, the cold wire can be rotated three degrees relative to the hot wire torch.

[0027] In yet another embodiment, the set of connection points comprises 12 connection points.

[0028] In yet another alternative embodiment, the one or more sensors include a welding camera mounted to a first connection point, the first connection point being located between a second connection point and a third connection point, the second connection point and the third connection point mounting a cold wire assembly.

[0029] In yet another alternative embodiment, the one or more sensors include a welding camera mounted such that the cold wire assembly and the welding camera share a plane of symmetry.

[0030] In another further embodiment, the one or more riser plates comprises two riser plates.

[0031] In yet another further embodiment, the one or more riser plates comprise a first riser plate and a second riser plate, the first riser plate and the second riser plate being spaced apart and parallel to one another.

[0032] In yet another further embodiment, the one or more riser plates comprise a first riser plate and a second riser plate, the first riser plate and the second riser plate being spaced apart, and the hot wire torch extending through a space between the first riser plate and the second riser plate.

[0033] In yet another further embodiment, the local fume extraction assembly further comprises a second fume hood.

[0034] In yet another further embodiment, the fume hood comprises a flat front portion.

[0035] In yet another further embodiment, the fume hood also includes a flat front-mounted shield.

[0036] In another further embodiment, the positioning arm includes four links connected by joints.

[0037] Similarly, in another further embodiment, the positioning arm includes one or more ball joints.

[0038] In additional further embodiments, the local fume extraction assembly further comprises a second positioning arm.

[0039] In additional further embodiments as well, determining the x offset is further based on the received simulation.

[0040] In some embodiments, a device may be configured to increase accuracy of an additive manufacturing process. In one embodiment, the device includes a modular interface. The modular interface includes a set of connection points. The set of connection points are circumferentially arranged about a modular interface central axis. The set of connection points are configured to fixedly mount one or more sensors. The modular interface further includes a clamping device centered relative to the set of connection points. The clamping device is configured to fixedly mount an additive manufacturing applicator.

[0041] In an additional embodiment, the clamping device is configured to allow the hot wire torch end point to be centrally mounted relative to the set of connection points.

[0042] In other additional embodiments, the clamping device comprises a fiberglass-epoxy laminate.

[0043] In another additional embodiment, the clamping device electrically isolates the hot wire torch from the modular interface.

[0044] In another additional embodiment, the clamping device may include a V-cut tool.

[0045] In yet another additional embodiment, the set of connection points is further configured to mount a tool actuator.

[0046] In an additional embodiment, the clamping device also includes a centrally located through-hole.

[0047] In another additional embodiment, the device further includes a hot wire torch fixedly attached to the modular interface via a clamping arrangement, the hot wire torch comprising a hot wire torch terminus and a hot wire torch longitudinal axis.

[0048] In yet an additional embodiment, the clamping device includes clamping points, the clamping points being offset from and parallel to the connection point plane, and the connection point plane intersecting the set of connection points.

[0049] In various embodiments, a device can be configured to locally extract fumes generated in an additive manufacturing process. In one embodiment, the device includes a local fume extraction assembly. The local fume extraction assembly includes a rail fixedly attached to one or more riser plates. The rail is positioned parallel to the base plate. The device further includes a fume hood and a positioning arm. The positioning arm is configured to translate along the rail, and the positioning arm is connected to the fume hood at an end. The positioning arm includes one or more joints and links.

[0050] In some further embodiments, the device further includes an arc protection assembly.

[0051] In some further embodiments, the device further includes an arc protection assembly, the arc protection assembly including a bracket slidably mounted to the rail and a shield fixedly mounted to the bracket.

[0052] In some other further embodiments, the positioning arms are attached to the crossbar.

[0053] Also in any further embodiment, the local fume extraction assembly further comprises a crossbar, the positioning arm being attached to one end of the crossbar using a joint and the second positioning arm being attached to a second end of the crossbar using a second joint.

[0054] In additional any further embodiment, the local fume extraction assembly is fixedly coupled to the additive manufacturing end effector.

[0055] In any other further embodiment as well, the local fume extraction assembly further comprises a second fume hood.

[0056] In any further embodiment, the fume hood also includes a flat front.

[0057] In yet some other embodiments, the fume hood includes a flat front-mounted shield.

[0058] Similarly in any other further embodiment, the positioning arm includes four links connected by joints.

[0059] In some other further embodiments, the positioning arm includes one or more ball joints.

[0060] Similarly in any other further embodiment, the local fume extraction assembly further comprises a second positioning arm.

[0061] In numerous embodiments, the device can be configured to mount and actuate an additive manufacturing tool. In one embodiment, the device includes an actuator. The actuator is movably mounted to a drive motor, a frame, and a tool mount. The drive motor is configured to drive the actuator. The frame is fixedly attached to the drive motor. The frame includes connection points configured to mount the actuator to an interface. The actuator is configured to adjust a position of an endpoint of the additive manufacturing applicator. The position is adjusted by driving a mechanical linkage using the drive motor.

[0062] In another additional embodiment, the frame further comprises a second connection point.

[0063] In yet another additional embodiment, the frame may further comprise a second connection point, and the actuator may be configured to allow the sensor to be attached to an interface between the first and second connection points.

[0064] In yet another additional embodiment, the frame further comprises a first connection point and a second connection point, the first connection point and the second connection point being at a first end of the first arm and a second end of the second arm. In yet another additional embodiment, the mechanical linkage is a four bar linkage.

[0065] Similarly in yet another additional embodiment, the mechanical linkage is configured to allow the axis of the endpoint of the additive manufacturing applicator to rotate 3 degrees relative to the axis of the endpoint of the second additive manufacturing applicator.

[0066] In yet another additional embodiment, the additive manufacturing applicator is a cold wire.

[0067] In yet another additional embodiment, the second additive manufacturing applicator is a hot wire torch.

[0068] In numerous embodiments, a device can be configured to perform an additive manufacturing process. In one embodiment, the device includes a robotic actuator and an interface attached to an end of the robotic actuator. The interface includes a clamping point and first through seventh connection points. The first through seventh connection points are arranged circumferentially about a central axis in numerical order. The clamping point is centrally located relative to the first through seventh connection points. The device further includes a first sensor fixedly attached to the first connection point, a second sensor fixedly attached to the second connection point, a third sensor fixedly attached to the third connection point, a fourth sensor fixedly attached to the fourth connection point, and a fifth sensor fixedly attached to the sixth connection point. The device further includes an additive manufacturing applicator, the additive manufacturing applicator including a first part and a second part. The first part is fixedly attached to the fifth and seventh connection points. The second part is movably coupled to the first part and is capable of changing the relative position of the endpoint of the additive manufacturing applicator with respect to the modular interface.

[0069] Similarly in yet another additional embodiment, the fifth sensor is a welding camera.

[0070] In yet another additional embodiment, the fourth sensor is a laser sensor as well.

[0071] In yet an additional embodiment, the third sensor is a visible light camera.

[0072] In yet another additional embodiment, the second sensor is a welding camera.

[0073] In another further additional embodiment, the first sensor is a laser sensor.

[0074] In yet another additional embodiment, a fifth sensor is also located at the 12 o'clock position.

[0075] In yet another additional embodiment, a fourth sensor is positioned at the 10 o'clock position as well.

[0076] Similarly, in another additional embodiment, a third sensor is located at the 8 o'clock position.

[0077] In yet another additional embodiment, a second sensor is located at the 6 o'clock position.

[0078] In yet another additional embodiment, the first sensor is located at the 2 o'clock position.

[0079] Similarly in other yet additional embodiments, the additive manufacturing applicator is a cold wire.

[0080] Similarly, in another further additional embodiment of the hand, the first components are fixedly attached at the 11 o'clock and 12 o'clock positions.

[0081] In some further additional embodiments, a fifth sensor is positioned between the first connection point and the second connection point on the additive manufacturing applicator.

[0082] In some further additional embodiments, the interface is a modular interface.

[0083] In many embodiments, the device can be configured to send commands to the robot to position the robot relative to the workpiece. In one embodiment, the device includes a robot actuator, a memory, and a processor. The processor is configured to receive sensor data generated by one or more sensors and generate a profile. The profile is generated based on the sensor data. The processor is further configured to determine a center of the part and determine an x-offset. The x-offset is determined based on the profile, the center of the part, and the sensor data. The processor is further configured to cause the robot actuator to move the hot wire torch endpoint to a new position based on the x-offset.

[0084] In still yet further embodiments, the one or more sensors include a laser sensor.

[0085] In another yet further embodiment, determining the x offset is further based on the received simulation.

[0086] In another still further embodiment, the processor moves the robot actuator while an additive manufacturing applicator associated with the robot actuator is off.

[0087] Similarly, in another yet further embodiment, the processor moves the robot actuator while an additive manufacturing applicator associated with the robot actuator is active.

[0088] Similarly in other still further embodiments, generating the profile includes filtering the raw profile, the raw profile being based on the sensor data.

[0089] In another yet still further embodiment, filtering the profile includes filtering any values ​​that are outside the accuracy limits of the laser sensor.

[0090] Similarly in another yet further embodiment, filtering the profile includes removing outliers by calculating a delta around each point, and a point can be removed if the delta exceeds a threshold.

[0091] In another still further embodiment, the processor can be further configured to receive hot wire torch endpoint position data, and causing the robotic actuator to move the hot wire torch endpoint to a new position is further based on the hot wire torch endpoint position data.

[0092] In some embodiments, the technology described herein relates to a device configured to perform an additive manufacturing process. In one embodiment, the device includes: a robotic actuator; an end effector assembly attached to the robotic actuator, the end effector assembly including a modular interface including a set of connection points, the set of connection points being circumferentially arranged about a modular interface central axis; a hot wire torch coupled to the modular interface and including a hot wire torch endpoint; and one or more sensors fixedly attached to the modular interface via the set of connection points and positioned to generate data based on observations of observation positions, the observation positions being offset relative to the hot wire torch endpoint.

[0093] Similarly in other still further embodiments, the hot wire torch is attached via a clamping device that is centered relative to the set of connection points, and the clamping device applies a clamping force to the hot wire torch along a plane that is approximately perpendicular to the hot wire torch axis.

[0094] In another embodiment, the device may further include a cold wire assembly that is attached to the modular interface via a set of connection points.

[0095] Similarly, in another embodiment, the device may further include a local fume extraction assembly fixedly mounted to the robotic actuator, the local fume extraction assembly including a fume hood and a positioning arm, the positioning arm including a proximal end coupled to the robotic actuator and a distal end coupled to the fume hood.

[0096] Similarly, in another further embodiment, the first end of the positioning arm is translatable along a rail, the rail being coupled to a robotic actuator.

[0097] In another further embodiment, the fume hood includes a flat front portion.

[0098] In another yet still further embodiment, the fume hood includes a flat front-mounted shield.

[0099] In another further embodiment, the positioning arm includes four links connected by joints.

[0100] In yet another further embodiment, the device can further include a control assembly including a memory and a processor configured to receive sensor data generated by the one or more sensors, generate a profile based on an offset associated with the observed position and based on the sensor data, determine a center of the part, determine an x-offset based on the profile, the center of the part, and the sensor data, and cause a robotic actuator to move the hot wire torch endpoint to a new position based on the x-offset.

[0101] Similarly in other still further embodiments, the hot wire torch end point is centrally located relative to the set of connection points.

[0102] Similarly in yet another yet further embodiment, each of the one or more sensors has a type selected from the list including a welding camera, an infrared camera, a visible light camera, and a laser sensor.

[0103] In yet another further embodiment, the wire arc additive manufacturing nozzle is attached to the modular interface by at least one connection point.

[0104] In yet another further embodiment, the observation location is offset from the hot wire torch end point by approximately 2 inches.

[0105] In another yet further embodiment, the observation location is offset from the hot wire torch end point by about 2.1 inches.

[0106] Similarly in another yet further embodiment, the set of connection points includes 12 connection points.

[0107] In some embodiments, the device is configured to perform an additive manufacturing process. In one embodiment, the device includes a robotic actuator and an end effector assembly mounted to the robotic actuator, the end effector assembly including an interface, a hot wire torch coupled to the interface and including a hot wire torch endpoint, and one or more sensors fixedly attached to the interface and positioned to generate data based on observations of an observation position, the observation position being offset relative to the hot wire torch endpoint.

[0108] Similarly in another yet still further embodiment, the observation location is offset from the hot wire torch end point by about 2 inches.

[0109] Similarly in yet another even further embodiment, the device further includes a control assembly including a memory and a processor configured to receive sensor data generated by the one or more sensors, generate a profile based on offsets associated with observed positions, determine a center of the part based on the sensor data, determine an x-offset based on the profile, the center of the part, and the sensor data, and cause a robotic actuator to move the hot wire torch endpoint to a new position based on the x-offset.

[0110] In numerous embodiments, the device is configured to increase the accuracy of an additive manufacturing process. In one embodiment, the device includes a modular interface including a set of connection points circumferentially arranged about a modular interface central axis and configured to fixedly mount one or more sensors, and a clamping device centered relative to the set of connection points and configured to fixedly mount an additive manufacturing applicator.

[0111] Similarly in yet another yet further embodiment, the additive manufacturing applicator includes a hot wire torch.

[0112] The description and claims will be more fully understood with reference to the following figures and data graphs, which are presented as exemplary embodiments of the invention and should not be construed as a complete recitation of the scope of the invention. [Brief explanation of the drawings]

[0113] [Figure 1A] 1 illustrates conceptually an additively manufactured end effector assembly. [Figure 1B] 1 illustrates conceptually an additively manufactured end effector assembly. [Figure 1C] 1 illustrates conceptually an additively manufactured end effector assembly. [Figure 2] 1 conceptually illustrates an example of a modular interface. [Figure 3] 10 conceptually illustrates an example of a modular interface with an attached applicator actuator. [Figure 4] 1 conceptually illustrates an example of an end effector that includes an additive manufacturing applicator fixedly and centrally mounted to a modular interface. [Figure 5] 1 illustrates conceptually an example of a modular interface with a centrally mounted additive manufacturing applicator. [Figure 6] 10 conceptually illustrates an example of a configuration in a modular interface. [Figure 7] 1 conceptually illustrates an example of a local fume extractor. [Figure 8] 1 conceptually illustrates an example of an arc protection assembly. [Figure 9] 1 conceptually illustrates an example process for generating a profile in a part during a welding-based additive manufacturing process. [Figure 10] 1 conceptually illustrates an example of a process for commanding a robot to assume a new position based on a determined x-offset. [Figure 11] 10 conceptually illustrates the position of the laser scan relative to the additive manufacturing nozzle. [Figure 12] 1 conceptually illustrates an additively manufactured end effector assembly configured to mount to a robotic actuator. [Figure 13] 1 conceptually illustrates an example of a computer system. [Figure 14] 1 conceptually illustrates a controller block diagram of an automated contact tip-workpiece compensation process. [Figure 15] 1 conceptually illustrates an example of a WAAM nozzle assembly mounted to an end effector assembly. DETAILED DESCRIPTION OF THE INVENTION

[0114] In robotic manufacturing, an end effector can be a device attached to the end of a robotic arm designed to interact with the environment and perform manufacturing tasks. End effectors are sometimes called end-of-arm tooling ("EOAT").

[0115] In some embodiments, an additive manufacturing end effector is configured to achieve improvements in speed, precision, accuracy, and part size of wire arc additive manufacturing (WAAM) processes. In various embodiments, a modular interface can be included in the end effector. The modular interface can be a mechanical interface (also referred to herein as an "interface") that can enable integrated electronics, sensor infrared and visible light cameras, laser profile sensors, support for multiple hot and cold welding wires, multi-axis positioning of one or more cold wires, local arc shielding for human observation, and local fume extraction.

[0116] According to some embodiments of the present invention, the end effector assembly can be positioned closer to the weld pool than previous end effectors, increasing system stiffness and reducing relative movement between the sensing hardware, the additive manufacturing applicator (e.g., a hot wire torch), and the weld pool. This increased stiffness and reduced relative movement can improve the precision and accuracy of 3D printed products, increasing throughput and enabling the production of more complex shapes. Various embodiments increase the accuracy of measurements taken during the printing process, thereby reducing print misalignment and reducing motion stalls, further increasing printing speeds.

[0117] In some embodiments, the modular interface is configured to allow the sensor to be relocated to an optimal position based on the robot's reach, travel requirements, and print cell boundaries. The modular interface can be particularly beneficial for horizontal printing applications involving multiple manufacturing robots.

[0118] In some embodiments, a tool actuator associated with a cold wire additive manufacturing applicator can have two-axis control of one or more cold wires. This can enable rapid manipulation during the manufacturing (e.g., welding) process to adjust the wire contact area, manipulate the wire to achieve a specific wetting action, manipulate the wire to shape the weld pool, and / or control the feed rate to increase printing speed. The tool actuator provides more control over the entire weld pool. In some embodiments, dragging the cold wire along the base weld before entering the weld pool can result in a different wetting action compared to entering the weld pool directly, and the tool actuator can rapidly control this during the WAAM process to enable improved control of the welding process. In various embodiments, two-axis control of the cold wire can enable a robotic welder to have greater control.

[0119] Integrated sensors (e.g., cameras and laser position sensors) allow the end effector to perform a restart in some embodiments. A restart can include the end effector automatically aligning itself to the x-axis. Automating restart can allow an operation to begin or restart without human input, thereby further increasing production rates by reducing downtime from a restart. In some embodiments, dynamic restart can be performed dynamically while a manufacturing operation is in progress. Dynamic restart can improve production accuracy.

[0120] Typically, fume extraction and arc shielding are performed by a system separate from the end effector. Fume extraction systems are bulky and present a barrier to increasing production rates and part sizes in horizontal WAAM processes. Arc shielding is typically limited to basic panels or interfaces that must be moved when the WAAM product grows in the horizontal printing direction or if the robot is repositioned. According to numerous embodiments of the present invention, local arc shielding and / or fume extraction can be fixedly coupled to the additive manufacturing applicator. This can improve production rates by eliminating the need to reposition the fume extraction or arc protection system. In some embodiments, the fume extractor and / or arc protection assembly can be attached to the end effector of the additive manufacturing robot. Including the shielding and fume extraction in the end effector itself can eliminate the need for human intervention to reposition the fume extraction and arc shielding system. Local arc shielding allows humans to approach the robot performing WAAM without specialized equipment or production shutdowns. Achieving local arc shielding and fume extraction requires experimental solutions to issues involving the interaction of fume system suction with the weld purge gas supply. The investigation involved several iterations of arc shield gap sizing and experimentation with flexible and rigid shields to achieve a system that did not obstruct purge gas flow or line of sight, and also adequately removed welding fumes.

[0121] In various embodiments, the devices and processes may be used with a WAAM. The additive manufacturing applicator in a WAAM system may be a hot wire torch or a cold wire. The hot wire torch may have a base unit, a longitudinal axis, and an end point. The cold wire may have an end point and a base unit.

[0122] Throughout this specification, the term fixedly can be used to indicate a rigid attachment (e.g., no relative movement) during operation. Fixedly attached can refer to a state in which parts are connected in a way that prevents relative movement during operation, and fixedly can include cases where the parts are simultaneously removable.

[0123] The additive manufacturing device can utilize an end effector assembly mounted to a robotic actuator. The additive manufacturing end effector assembly is conceptually shown in FIG. 1. The assembly 100 can include a base plate 102. The base plate 102 can be fixedly coupled to a first additive manufacturing applicator 104 (e.g., a hot wire torch) at the base of the first additive manufacturing applicator. The base plate 102 can be fixedly coupled to a second additive manufacturing applicator 106 (e.g., a cold wire applicator) at the base of the second additive manufacturing applicator. A riser plate 108 can extend vertically from the base plate 102. The riser plate 108 can be fixedly coupled to the base plate 102. Two riser plates 108 can extend vertically from the base plate 102. In various embodiments, the base plate can be configured to connect to a robotic actuator. In many embodiments, the base plate 102 can be a mount for electronics. An interface plate 110 (eg, a modular interface) may be attached (eg, fixedly) to the riser plate 108 .

[0124] The interface 110 may include a set of connection points 112. The set of connection points 112 may be arranged circumferentially around a central axis. The connection points comprising the set of connection points 112 may all lie on a plane, which may be referred to as a connection plane. The connection points may all lie along the circumference of a connection circle on the connection plane. The interface 110 may include a clamping point 113 that may be centered relative to the set of connection points 112. In various embodiments, the set of connection points may include 12 connection points. In some embodiments, each of the connection points may be configured to fixedly attach a device. Devices attachable to the connection points may include, but are not limited to, sensors, additive manufacturing applicators, and / or other devices. In the illustrated example, the interface 110 is fixedly coupled to a first sensor 114, a second sensor 116, a third sensor 118, a fourth sensor 120, and a fifth sensor 122. In various embodiments, each of the first through fifth sensors may be included or omitted. Each sensor may have a sensor type. Sensor types may include a laser sensor, a welding camera, an infrared camera, and / or a visible light camera. In some embodiments, the first sensor 114 may be a welding camera, the second sensor 116 may be a visible light camera, the third sensor 118 may be a laser sensor, the fourth sensor 120 may be a laser sensor, and the fifth sensor 122 may be a welding camera. The first additive manufacturing applicator (e.g., a hot wire torch for a WAAM system) 104 may be fixedly coupled (e.g., clamped) at clamping point 113. The clamping point may be attached near an end of the additive manufacturing applicator 104. Fixedly coupling both the first additive manufacturing applicator and the sensor to the modular interface may reduce relative movement between the sensor (e.g., sensors 114, 116, 118, 120, and / or 122) and the applicator (e.g., applicator 104) to improve additive manufacturing accuracy. The second additive manufacturing applicator 106 can be attached to an applicator actuator 124 .The applicator actuator 124 can have a frame and an actuation mechanism. The frame can be fixedly attached to the modular interface 110 using a set of connection points 112. In various embodiments, the applicator actuator can be attached using one, two, three, or another number of connection points. In the illustrated example, the applicator actuator 124 can be attached using two connection points. The sensor 122 can be attached to a connection point located between the two connection points used to attach the applicator actuator 124.

[0125] The rails 126 may be fixedly coupled to the riser plate 108. The rails may lie in parallel planes and be offset by a plane defined by the base plate 102. The rails 126 may extend linearly toward the modular interface 110. A shield holder 128 may be slidably coupled to the rails 126. The shield holder may be configured to hold and position a shield near and around a location of interest (e.g., an additive manufacturing deposition site, a weld pool). The shield holder 128 may be linearly translated along the rails 126. A fume extractor base 130 may be slidably coupled to the rails 126. The fume extractor base 130 may be movably attached to a fume extractor positioning arm assembly 132. A fume hood 134 is positionably attached to the distal end of the fume extractor positioning arm assembly. In various embodiments, localized fume extraction may be more energy efficient than room-wide fume extraction.

[0126] Modular Interface Various embodiments include features for reducing the size of the modular interface plate. Reducing the size of the interface plate is beneficial for enabling an additive manufacturing device to print a greater variety of parts. Reducing the size of the interface plate (and other components) can make the additive manufacturing end effector easier to maneuver due to its smaller size and / or weight. Various embodiments utilize geometric, component, configuration, and / or positional selection to reduce the size and / or weight of components.

[0127] Many embodiments include connection points arranged around a central axis. These connection points can share a universal connection. The use of a universal connection means allows for the repositioning of the attachable component (e.g., sensor and / or additive manufacturing applicator). According to some embodiments, the circular arrangement of connection points allows for consistent spacing constraints between attached components, since each of the connection points has a similar relative position set to the other connection points compared to each of the other connection points.

[0128] In some embodiments, the components attached to the interface plate may be rigidly attached. The attached devices may be sensors and additive manufacturing applicators. By rigidly attaching both the sensors and additive manufacturing applicators to (and in close proximity to) the same rigid body, relative motion between the sensors and / or additive manufacturing applicators is advantageously reduced. Reducing relative motion between the sensors and / or additive manufacturing applicators may reduce uncertainty in the sensor data associated with changes (e.g., small changes) in position between various sensors and / or additive manufacturing applicators.

[0129] Although specific processes and / or systems for additively manufactured end effector assemblies are described above, any of a variety of processes and / or systems can be utilized for additively manufactured end effector assemblies depending on the requirements of a particular application. In certain embodiments, the steps and / or components may be performed and / or arranged in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. While the above embodiments of the present invention are described with reference to additively manufactured end effector assemblies, the techniques disclosed herein may be used in any type of additively manufactured system. The techniques disclosed herein may be used in any of the additively manufactured modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0130] In some embodiments, the end effector assembly attached to the robot actuator can include a modular interface. The modular interface can be configured to interchangeably attach devices. Attachable devices can include, but are not limited to, sensors and / or additive manufacturing applicators. An example of a modular interface is conceptually shown in FIG. 2. The modular interface assembly 200 can include 12 connection points 202. Each connection point 202 can be connected to a protective cover block 204 or to a device (e.g., device including, but not limited to, an actuator, a sensor, and / or a nozzle assembly). The 12 connection points 202 form a connection point set. The connection points 202 can be coplanar with each other and located on a connection plane. Each of the connection points 202 is located circumferentially on the connection plane. The clamping device 206 can be centered relative to the connection points 202. In some embodiments, the clamping device can apply a clamping force to the hot wire torch. Such clamping force can be applied along a plane approximately perpendicular to the hot wire torch axis. The clamping device 206 may include a first block 208 and a second block 210. A through hole 212 may be present between the first block 208 and the second block 210. The peripheries of the first block 208 and the second block 210 may be rectangular. The mounting plate 214 may be centered relative to the connection point 202. The mounting plate 214 may be approximately dodecagonal and may include a slot 216. The slot 216 may be rectangular. The first block 208 and the second block 210 may be positioned (e.g., snap-fit) within the slot 216. The mounting plate 214 may have mechanical fasteners disposed on a surface thereof. The mounting plate 214 may be configured to attach to a riser plate (e.g., riser plate 108). The mounting plate 214 may include a center plate 218. According to many embodiments, the mounting plate (eg, mounting plate 214) and the center plate (eg, center plate 218) may be a single machined component.The center plate 218 may be a polygon (e.g., a regular dodecagon), where each side of the dodecagon may be parallel to a line defined as a tangent to a circle defined by the set of connection points.

[0131] The central plate 218 can be polygonal (e.g., a regular dodecagon). The central plate 218 can have edges that are parallel to and offset from a line that intersects the connection points and is tangent to the circle defined by the connection points 202. The mounting plate 214 can be polygonal (e.g., a regular dodecagon) except for the slots 216. The mounting plate 214 can be geometrically similar to the central plate 218 (except for the slots 216). The sides of the polygon associated with the mounting plate 214 can be parallel to the sides of the polygon associated with the central plate 218. The end faces of the first block 208 can be parallel to the sides of the polygon associated with the central plate 218. In various embodiments, the mounting plate can be polygonal around an outer edge.

[0132] The through holes 212 are inside the clamping points where the additive manufacturing applicator can be fixedly attached to the interface assembly 200 by a clamping device.

[0133] In some embodiments, the interface may have fewer than 12 or more than 12 connection points and / or polygonal sides.

[0134] In many embodiments, the interface can be sized and configured to direct each of one or more attached fixtures to an appropriate position relative to a point of interest (e.g., an intended weld pool location, an intended additive deposit location, and / or another point of interest). The appropriate position and orientation for each type of component can vary.

[0135] According to many embodiments of the present invention, the interface can be used to attach one or more different types of additive manufacturing nozzle assemblies (e.g., the WAAM plasma nozzle, WAAM dual plasma nozzle, described in U.S. Provisional Patent Application No. 63 / 482,763, filed February 1, 2023, which is incorporated herein by reference). In some embodiments, the additive manufacturing nozzle assembly can be attached to the interface using one or more connection points. Suitable fasteners for the connection points include quarter-turn fasteners. Suitably, in at least one embodiment, the nozzle assembly can be attached through the same connection points using the same fasteners used to attach the sensor and / or actuator. The additive manufacturing nozzle assembly can be attached to the interface using one, two, three, or another number of connection points according to embodiments of the present invention.

[0136] 3D printing of metal structures typically involves using an energy source to create a weld pool and feeding a metal wire (feed material) into the weld pool through a print head or print head nozzle. Energy is used to create the weld pool. Some systems use electricity, while others use a laser for the energy. Electrical systems typically pass an electric current through a feed wire into the weld pool. The print head, and subsequently the weld pool, can be moved. As the print head and weld pool move, the trailing edge of the pool cools and solidifies. This process of gradually moving the print head along a path can result in a fully printed part.

[0137] The process by which material is deposited can be controlled by the use of a shielding gas around the feed material. The shielding gas can help create a better weld pool for an overall better part. The shielding gas can protect the weld pool from corrosive gases and moisture.

[0138] In various embodiments, an additional arc (e.g., an ionizing arc capable of generating a plasma) can be introduced between an electrode (e.g., an electrode different from the feed wire, a tungsten electrode) and another surface (e.g., the nozzle during plasma ignition and / or the workpiece after ignition). The additional arc can generate an auxiliary plasma. The auxiliary plasma generated by the additional arc can be directed toward the workpiece. A WAAM nozzle capable of implementing an auxiliary plasma and a primary arc (emanating from the primary feed wire) can be referred to as a dual plasma nozzle.

[0139] According to an embodiment of the present invention, an auxiliary plasma may be positioned between the feed wire and the shielding gas. The auxiliary plasma may originate from an auxiliary plasma channel. The auxiliary plasma channel may have a circular outlet concentric with the feed wire. The feed wire may be concentric with the shielding gas outlet. The interior of the auxiliary plasma channel is formed from two electrically insulated surfaces. An electrode side of the channel may be electrically connected to the electrode. An outer body side of the channel may face the electrode side. The outer body side may have an insulating coating on a first portion of the channel located distal to the electrode. The outer body side may have an uninsulated second portion of the channel located proximal to the electrode.

[0140] In some embodiments, the torch is clamped using components machined from materials such as Gallolite (G10-FR4) and / or other fiberglass-epoxy laminates, other composite materials, and / or some combination thereof. According to some embodiments of the present invention, the surface that clamps the torch is electrically insulated. Electrical isolation from the torch can be advantageous to avoid damage to the sensor. In some embodiments, the clamping device can be similar to a V-block fixture to facilitate machining. In certain embodiments, the clamp can be a radiused clamp that matches the torch diameter.

[0141] In some embodiments, the two riser plates may be spaced apart by a minimum amount to allow the torch to extend between the two riser plates.

[0142] The torch, according to embodiments of the present invention, may be clamped by the modular interface at a height corresponding to the sensor mounting height or may be offset from this height. In some embodiments, the torch may be clamped as close as possible to the torch end point without interfering with the torch nozzle.

[0143] Although specific processes and / or systems for the modular interface are described above, any of a variety of processes and / or systems can be utilized for the modular interface as appropriate for the requirements of a particular application. In certain embodiments, the steps and / or components may be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. While the above embodiments of the present invention are described with reference to a modular interface, the techniques disclosed herein can be used in any type of additive manufacturing system. The techniques disclosed herein can be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0144] Cold Wire Actuator In some embodiments, the applicator actuator is fixedly mounted to the modular interface. In some embodiments, the applicator actuator can provide one or more degrees of freedom for moving the attached additive manufacturing applicator. According to various embodiments of the present invention, the applicator actuator can control where the cold wire is fed into the weld pool. This can enable higher temperature welds, rapid manipulation of the cold wire during the additive manufacturing process, and / or adjustable weld contact area. In some embodiments, the applicator actuator can be used to shape the weld pool and the feed rate of material for deposition. Various embodiments include the ability to move the additive manufacturing applicator to allow material to be added to the outside, inside, or center of a wall.

[0145] In some embodiments, an end effector assembly mounted to a robotic actuator can include a modular interface with an attached applicator actuator. The applicator actuator can be configured to actuate an additive manufacturing applicator in one or more degrees of freedom. An example of a modular interface with an attached applicator actuator is conceptually shown in FIG. 3 . An assembly 300 can include a modular interface 302. A tool actuator 304 can be fixedly mounted to the modular interface 302. A first sensor 306 and a second sensor 308 can be mounted to the modular interface 302.

[0146] Modular interface 302 may include a set of connection points 310 (e.g., a set of 12 connection points). In certain embodiments, the set of connection points may allow for connection between a front surface of the modular interface and a top surface of an attachment. Modular interface 302 may include a central opening 312. In some embodiments, the central opening may be configured to fixedly mount an additive manufacturing applicator (e.g., a hot wire torch). First sensor 306 and second sensor 308 may be mounted to a front surface of modular interface 302. In certain embodiments, the first sensor may be a laser sensor, a welding camera, an infrared camera, and / or a visible light camera. In many embodiments, the second sensor may be a laser sensor, a welding camera, an infrared camera, and / or a visible light camera.

[0147] The tool actuator 304 may be mounted to a front surface of the modular interface 302. The tool actuator 304 may have a first mounting arm 314 and a second mounting arm 316. The first mounting arm (e.g., first mounting arm 314) and the second mounting arm (e.g., second mounting arm 316) may be a single component according to embodiments of the present invention. The first mounting arm 314 and the second mounting arm 316 may be spaced apart. The spacing may be sufficient to allow the second sensor 308 to be attached to the modular interface 302 at a connection point located between the first mounting arm 314 and the second mounting arm 316. The first mounting arm 314 and the second mounting arm 316 are rigidly connected to a frame 318. The frame 318 may fixedly mount an actuating component 320. In some embodiments, the actuating component is an electric motor. The actuating component 320 is drivingly coupled to a movable link 322. The movable link 322 can form part of a closed movable linkage (e.g., a four-bar linkage). The closed movable linkage can include the movable link 322, a second movable link 324, a third movable link 326, and a fourth movable link in the form of a tool holder assembly 328. The closed movable linkage allows for control of the position of the tool holder assembly 328. The tool holder assembly 328 can hold, support, and / or position a tool 330. In some embodiments, the tool can be an additive manufacturing applicator. In some embodiments, the tool can be a cold wire applicator. According to embodiments of the present invention, the cold wire applicator can advance a cold wire. Advancing the cold wire can, in some embodiments, correspond to advancing the cold wire into a weld pool. In many embodiments, a second actuating component can be mounted to the frame for driving one or more movable links. According to some embodiments of the present invention, a tool mounted to the tool holder assembly can include an actuator capable of advancing the wire.As used herein, a "cold" wire refers to a feed wire that does not carry electrical energy into the weld pool or that carries less electrical energy than a "hot" wire, which is an electrode or feed wire that carries electrical energy into the weld pool. Cold wire may be preheated before being deposited. Using a cold wire in conjunction with a hot wire increases the mass of metal deposited in the weld pool. Cold wires are described in U.S. Patent Application No. 17 / 544,408, filed December 7, 2021 (published as U.S. Patent Application Publication No. 2023 / 0173601), and U.S. Patent Application No. 18 / 451,688, filed August 17, 2023, the entire contents of both of which are incorporated herein by reference.

[0148] Tool 330 can have an end point 332. End point 332 can be adjacent to the additive manufacturing deposition site. First sensor 306 and second sensor 308 are fixedly positioned relative to first mounting arm 314 and second mounting arm 316. In the configuration shown in FIG. 3 , second sensor 308 can be mounted at the 12 o'clock position, first mounting arm 314 and second mounting arm 316 can be mounted at the 11 o'clock and 1 o'clock positions, respectively, and / or the first sensor can be mounted at the 6 o'clock position.

[0149] In some embodiments, the sensor may be mounted between the mounting arms of the tool actuator. In some embodiments, when the sensor is mounted to the tool actuator, the sensor may be configured such that the tool mounted to the tool actuator and the sensor are aligned with each other (e.g., share a reflective surface, share a plane of symmetry, are aligned with each other along a plane).

[0150] In various embodiments, the tool actuator is configured to change the tilt angle between a reference plane and a longitudinal axis extending along the length of a tool attached to the tool actuator. In various embodiments, the reference plane may be a plane parallel to the front surface of the modular interface and may be directed to an endpoint of the tool. In some embodiments, the tool actuator is configured to translate the endpoint of the attached tool along a longitudinal axis extending along the length of the attached tool.

[0151] According to some embodiments of the present invention, one or more (e.g., 1, 2, 3, or another number) tool actuators can be attached to the modular interface. Each of the tool actuators can be connected to an additive manufacturing applicator (e.g., a cold wire for a WAAM system). The additive manufacturing applicator can include an adjustable protrusion distance for the cold wire. The tool actuator, in some embodiments, has a range of motion (e.g., about 3 degrees) relative to the hot wire torch end point. The range of motion can be movement to either side of a preselected angle according to embodiments of the present invention. The preselected angle can be preselected using a hole located on the surface of the tool actuator. In many embodiments, the preselected angle can be selected depending on the type of material being applied.

[0152] Although particular processes and / or systems for modular interfacing with an attached applicator actuator are described above, any of a variety of processes and / or systems can be utilized for modular interfacing with an attached applicator actuator, depending on the requirements of a particular application. In certain embodiments, the steps and / or components can be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components can be rearranged or omitted. While the above embodiments of the present invention are described with reference to modular interfacing with an attached applicator actuator, the techniques disclosed herein can be used in any type of additive manufacturing system. The techniques disclosed herein can be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0153] Torch Configuration In some embodiments, the additive manufacturing applicator is fixedly and centrally mounted to the modular interface. According to some embodiments of the present invention, various sensors and / or other tools (e.g., cold wire actuators) are arranged in a ring shape around the centrally mounted additive manufacturing applicator. In some embodiments, the mounted equipment is rigidly attached to the modular interface to minimize unintended relative movement between the various components (e.g., sensors, additive manufacturing applicators). Minimizing unintended relative movement between components can improve manufacturing accuracy by reducing systematic random measurement errors in the data received from the sensors.

[0154] In some embodiments, an end effector assembly attached to a robot actuator can include an additive manufacturing applicator fixedly and centrally mounted to a modular interface. An example of an end effector including an additive manufacturing applicator fixedly and centrally mounted to a modular interface is conceptually shown in FIG. 4 . The assembly 400 can include a modular interface 402. A tool actuator 404 can be fixedly mounted to the modular interface 402. A first sensor 406 and a second sensor 408 can be mounted to the modular interface 402. The additive manufacturing applicator 410 can be centrally located and protrude through a central opening 412. The additive manufacturing applicator 410 can include an end point 414. The end point 414 can be proximate an end point 416 associated with a tool 418 attached to the tool actuator 404. The first sensor 406 can be oriented to obtain sensory data based on observing a position proximate the end point 416. The second sensor 408 may be oriented to obtain sensory data based on observation of a position proximate the end point 414. The end points 414 and 416 may be approximately coincident. The angle between the longitudinal axis of the additive manufacturing applicator 410 and the longitudinal axis of the tool 418 may be adjusted using the tool actuator 404. The modular interface 402 may be fixedly attached to a first riser plate 420 and a second riser plate 422. The first riser plate 420 and the second riser plate 422 may be parallel and spaced apart from one another. The additive manufacturing applicator may extend through a space between the first riser plate 420 and the second riser plate 422. A cover 424 may be attached to the modular interface 402. According to embodiments of the present invention, the cover may protect portions of the modular interface that are not coupled to other components.

[0155] In various embodiments, the one or more sensors and / or tool actuators can be circumferentially arranged about a central opening of the modular interface. The central opening can include a clamping means configured to secure the position of the additive manufacturing applicator relative to the modular interface. In some embodiments, the sensor is configured to obtain a reading based on observing a position determined relative to an endpoint of the additive manufacturing applicator. In many embodiments, the position determined relative to an endpoint of the additive manufacturing applicator can be a position that coincides with the endpoint of the additive manufacturing applicator. In some embodiments, the additive manufacturing applicator is a hot wire torch. In various embodiments, the attached tool can be a cold wire and / or a hot wire torch.

[0156] Although particular processes and / or systems are described above for end effectors including additive manufacturing applicators fixedly and centrally mounted to modular interfaces, any of a variety of processes and / or systems can be utilized for end effectors including additive manufacturing applicators fixedly and centrally mounted to modular interfaces depending on the requirements of a particular application. In certain embodiments, steps and / or components may be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. While the above embodiments of the present invention are described with reference to end effectors including additive manufacturing applicators fixedly and centrally mounted to modular interfaces, the techniques disclosed herein can be used with any type of additive manufacturing system. The techniques disclosed herein may be used in any of the additively manufactured modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or restart automation systems described herein.

[0157] An example of a modular interface with a centrally mounted additive manufacturing applicator is conceptually illustrated in FIG. 5 . The assembly 500 can include a modular interface 502. The modular interface 502 can be attached to a first riser plate 504 and a second riser plate 506. The first riser plate 504 can be parallel to the second riser plate 506. The first riser plate 504 can be spaced apart from the second riser plate 506. The modular interface 502 can include a clamping point 508. The clamping point 508 can be centrally located relative to a set of circumferential connection points 510. The clamping point 508 can fixedly couple the modular interface 502 to an additive manufacturing applicator 512. The clamping point can include a first portion 514 and a second portion 516. The additive manufacturing applicator 512 can extend between the first riser plate 504 and the second riser plate 506. The additive manufacturing applicator 512 can extend through an opening 518 in the modular interface. In some embodiments, the endpoint of the additive manufacturing applicator can pass through the front of the modular interface 502. In some embodiments, the modular interface can be attached to the robot via one or more riser plates.

[0158] Although particular processes and / or systems for modular interfacing with a centrally mounted additive manufacturing applicator have been described above, any of a variety of processes and / or systems can be utilized for modular interfacing with a centrally mounted additive manufacturing applicator, depending on the requirements of a particular application. In certain embodiments, the steps and / or components may be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. Although the above embodiments of the present invention are described with reference to modular interfacing with a centrally mounted additive manufacturing applicator, the techniques disclosed herein can be used with any type of additive manufacturing system. The techniques disclosed herein may be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0159] End Effector Configuration In various embodiments, the modular interface can have a configuration selected to enable improved additive manufacturing accuracy. The location of the sensor relative to the site of interest (e.g., the additive manufacturing deposition site and / or weld pool) can affect the accuracy of measurements from the sensor.

[0160] In some embodiments, the sensors may be arranged circumferentially around a center point. The center point may correspond to the location of an endpoint of an additive manufacturing applicator. An example of a modular interface configuration is conceptually shown in FIG. 6. The assembly 600 includes a modular interface 602, a tool actuator 604, a first sensor 606, a second sensor 608, a third sensor 610, a fourth sensor 612, and a fifth sensor 614. The first sensor 606 may be located between a front surface of the modular interface 602 and an actuated tool-holding portion 605 of the tool actuator 604. In various embodiments, each of the sensors may have a type selected from the list of a laser sensor, a welding camera, an infrared camera, and / or a visible light camera. In some embodiments, the first sensor 606 is a welding camera. The first sensor 606 may be configured to be aimed at an endpoint 616. The endpoint 616 may be a hot wire torch. In various embodiments, the second sensor 608 can be a laser sensor. The second sensor 608 can be configured to be pointed at a position offset (e.g., about 2 inches, about 2.1 inches) from the endpoint 616. In various embodiments, the third sensor 610 can be a welding camera. The third sensor 610 can be configured to be pointed at the endpoint 616. In various embodiments, the fourth sensor 612 can be a visible light camera. The fourth sensor 612 can be configured to be pointed at the endpoint 616. In various embodiments, the fifth sensor 614 can be a laser sensor. The fifth sensor 614 can be configured to be pointed at a position offset (e.g., about 2 inches, about 2.1 inches). The sensors can be arranged circumferentially about a center point corresponding to the endpoint 616 of the additive manufacturing applicator 618.

[0161] In the illustrated configuration, the tool actuator 604 is attached to the modular interface at the 11 o'clock and 1 o'clock positions, a first sensor 606 is attached to the modular interface at the 12 o'clock position, a second sensor 608 is attached to the modular interface at the 2 o'clock position, a third sensor 610 is attached to the modular interface at the 6 o'clock position, a fourth sensor 612 is attached to the modular interface at the 8 o'clock position, and a fifth sensor 614 is attached to the modular interface at the 10 o'clock position, with the endpoint 616 being centered relative to the circumferential clock position. In some embodiments, the positions of the various components can be varied. The modular interface can support various configurations via circumferential connection points and a central clamping point. The various configurations can be useful to support additive manufacturing of a wide range of products.

[0162] Although specific processes and / or systems for configuration in a modular interface are described above, any of a variety of processes and / or systems can be utilized for configuration in a modular interface as appropriate for the requirements of a particular application. In certain embodiments, steps and / or components can be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or performed substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components can be rearranged or omitted. While the above embodiments of the present invention are described with reference to a configuration for a modular interface, the techniques disclosed herein may be used in any type of additive manufacturing system. The techniques disclosed herein may be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or restart automation systems described herein.

[0163] Local fume extraction and arc protection In various embodiments, additive manufacturing applicators may require fume extraction for proper use. In some embodiments, fume extraction is provided locally. Localized fume extraction can advantageously reduce capital investment and save energy compared to full-space fume extraction. In various embodiments, the localized fume extraction system can include a positionable arm. The use of a positionable arm can advantageously increase the variety of geometries in which a robot-mounted additive manufacturing applicator can be used. In various embodiments, localized fume extraction can be important in applications where printing is performed horizontally. Without localized fume extraction, horizontal printing can result in fumes being trapped inside the spaces of the part being manufactured (e.g., inside tubes and / or barrels).

[0164] In many embodiments, the arc protection assembly can protect people in the vicinity of the additive manufacturing robotic system from viewing the deposition site, hi certain embodiments, the arc protection assembly shields observers from the welding arc used during the additive manufacturing process.

[0165] In some embodiments, the local fume hood can be positioned in a customizable position relative to the modular interface using a positioning arm, which is advantageous for making the additive manufacturing end effector customizable and thereby adaptable to a wider range of product shapes.

[0166] In numerous embodiments, the local fume extractor can extract fumes during an additive manufacturing process. The local fume extractor can have a fixed relative position with respect to the additive manufacturing applicator. An example of a local fume extractor is conceptually shown in FIG. 7. An end effector assembly 700 can include a modular interface 702, a first riser plate 704, a second riser plate 706, a positioning rail 708, an arc protection bracket 710, and a local fume extraction assembly 712. The riser plates 704, 706 can be fixedly coupled to the modular interface 702. The positioning rail 708 can be fixedly coupled to the riser plates 704, 706. In certain embodiments, the modular interface has a fixed relative position with respect to the positioning rail. The arc protection bracket 710 can be slidably mounted to the positioning rail 708. The fume extraction assembly 712 can be mounted to the positioning rail 708. In various embodiments, the positioning rail allows translational movement of the fume extraction assembly and / or the arc protection bracket. According to some embodiments of the invention, the translational movement is along the longitudinal axis of the rail. In some embodiments, the longitudinal axis of the rail is perpendicular to a plane defined by the front faces of the modular interfaces (e.g., modular interfaces fixedly coupled to the rail). In some embodiments, the arc protection bracket is mounted near the modular interface of the fume extraction assembly.

[0167] The fume extraction assembly 712 can include a rail bracket 714 , a positioning arm center mount 716 , a first positioning arm 718 , a second positioning arm 720 , a first fume hood 722 , and a second fume hood 724 .

[0168] The rail bracket 714 may be slidably mounted to the positioning rail 708. The positioning arm center mount 716 may be rotatably mounted to the rail bracket 714. In certain embodiments, the longitudinal axis of the positioning arm center mount may be perpendicular and / or intersect with the longitudinal axis of the positioning rail. The center mount 716 may include a first joint 726 and a second joint 728. In various embodiments, the first joint and the second joint may be ball-and-socket joints. The first joint 726 may movably connect the first positioning arm 718 to the center mount 716 on a first side. The second joint 728 may movably connect the second positioning arm 720 to the center mount 716 on a second side. The first and second sides may be spaced apart by a bar 730, which may have a longitudinal axis. The longitudinal axis of the bar 730 may be perpendicular to the longitudinal axis of the center mount 716. The first and second positioning arms 718 and 720 may be connected to first and second fume hoods 722 and 724 .

[0169] In certain embodiments, each positioning arm connects to a fume hood at its distal end. In many embodiments, the positioned fume hood is fixed relative to the modular interface during at least a portion of the manufacturing process. According to certain embodiments of the present invention, the fume hood is configured to connect to a vacuum for fume removal. In certain embodiments, the fume extraction assembly is configured to enable positioning of the fume hood relative to the modular interface. In some embodiments, the local fume hood can be positioned in a customizable position relative to the modular interface using the positioning arms, which is advantageous for customizing the additive manufacturing end effector and thereby adapting to a wider range of product shapes. In various embodiments, the positioning arms can have 1, 2, 3, 4, 5, 6, or another number of links, joints, and / or degrees of freedom. In many embodiments, the arc protection bracket can be configured to fixedly mount the arc protection assembly. In various embodiments, the fume hood can have a flat leading edge, which can be advantageous for advancing the fume hood closer to the part for better fume extraction. One or more positioning arms and associated fume hoods can be included in the local fume extraction assembly. In some embodiments, the local fume extraction assembly can include one, two, three, four, or another number of positioning arms and fume hood combinations. The fume hoods according to various embodiments of the present invention can have a fixed relative position compared to the modular interface during the additive manufacturing process. In many embodiments, a removable weld curtain can be attached to the fume hood. In some embodiments, the weld curtain can be attached to a non-slip leading edge of the fume hood.

[0170] Although specific processes and / or systems for local fume extractors are described above, any of a variety of processes and / or systems can be utilized for local fume extractors, depending on the requirements of a particular application. In certain embodiments, the steps and / or components can be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components can be rearranged or omitted. While the above embodiments of the present invention are described with reference to local fume extractors, the techniques disclosed herein can be used in any type of additive manufacturing system. The techniques disclosed herein can be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0171] In many embodiments, an arc protection assembly can protect people near an additive manufacturing robotic system from viewing the deposition site. In certain embodiments, the arc protection assembly shields observers from the welding arc used during the additive manufacturing process. An example of an arc protection assembly is conceptually shown in FIG. 8 . The arc protection and fume extraction assembly 800 can include a first riser plate 802, a second riser plate 804, a fume extraction assembly 806, and an arc protection assembly 808. The fume extraction assembly 806 and the arc protection assembly 808 can translate relative to the first and second riser plates 802 and 804. The fume extraction assembly 806 can include a first curtain 810 and a second curtain 812, which can be attached to the front of first and second fume hoods 814 and 816. In various embodiments, the curtains can be made of rigid, transparent, opaque, and / or non-rigid materials.

[0172] The arc protection assembly can include a shield 816 and an arc protection bracket (e.g., arc protection bracket 710). The shield 816 can be attached to the arc protection bracket. The position of the shield 816 can be adjusted by adjusting the position of the arc protection bracket. In some embodiments, the shield can be made of an opaque material.

[0173] Although specific processes and / or systems for arc protection assemblies are described above, any of a variety of processes and / or systems can be utilized for arc protection assemblies, depending on the requirements of a particular application. In certain embodiments, steps and / or components can be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components can be rearranged or omitted. While the above embodiments of the present invention are described with reference to arc protection assemblies, the techniques disclosed herein may be used in any type of additive manufacturing system. The techniques disclosed herein may be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0174] Automated reboot A restart can be an alignment of a robot along an axis, such as an x ​​restart in the x-axis (e.g., radial axis) after a pause and / or during an additive manufacturing process. A restart can be an x ​​restart and / or can align the robot to the x-axis (e.g., radial axis) during a pause. For clarity and ease of describing embodiments, the description provided herein describes an automatic restart process applied to an x ​​restart, however, the processes, methods, apparatus, and systems described herein can be applied to automatic restart in any axis needed or desired during printing. For example, a coordinate transformation can be formed in conjunction with the following process to automate restart in any axis.

[0175] An x-restart robot command can be generated based on the x-offset value. To improve print quality, reduce work stoppages, and increase the range of parts that can be printed by an additive manufacturing system (e.g., a WAAM system), it is beneficial to align the robot in the x-axis before and during the start of printing.

[0176] In the WAAM process, the part being manufactured is allowed to cool and shrink after printing has stopped, allowing the part to become smaller than nominal in diameter.

[0177] In some embodiments, to improve print quality, the additive manufacturing applicator may be aligned to the part before printing begins and / or continuously during printing. An X-restart can be performed to align the applicator to the part before printing begins (e.g., static x-restart). In some embodiments, once printing begins, the part expands due to heat input. An X-restart can be used to continuously keep up with the expansion of the part (e.g., dynamic x-restart).

[0178] Without the automatic x restart, a manual restart may be required. The automatic x restart may improve accuracy compared to a manual x restart, and the automatic x restart may be performed dynamically. The manual x restart may be inaccurate and require additional, unexpected operations (e.g., machining). In certain embodiments, the X restart may eliminate the recovery period from errors associated with a manual x restart. In some embodiments, the X restart may allow the additive manufacturing process to restart with the click of a button. The X restart may be dynamic in some embodiments to improve print accuracy throughout the print.

[0179] In certain embodiments, X restart allows for automatic alignment of the part to the torch while the arc is off and / or keeps up with part expansion after the arc is on.

[0180] According to some embodiments of the present invention, the x-offset calculation can assume a circular cross-section of the part being printed. In some embodiments, the cross-section of the part can be perfectly circular when the arc is off.

[0181] In certain embodiments, when the arc is on, there is a local radial offset directly underneath the torch due to thermal expansion. In various embodiments, the thermal expansion offset varies depending on how far away from the rib (or other reinforcing section). The thermal expansion offset can be generated from a simulation.

[0182] In some embodiments, the best curve fit based on data from the thermal expansion simulation can be used in the x-restart process.

[0183] In some embodiments, a processor can receive data from a sensor and, based on the data, generate a spatial profile (also referred to herein as a “profile”), such as a point cloud, at points of interest on a part during an additive manufacturing process (e.g., a welding-based additive manufacturing (WAM) process, a wire arc additive manufacturing (WAAM) process). In another embodiment, the spatial profile can include a thickness profile. An example of a process for generating a profile of a part during a WAM process is conceptually illustrated in FIG. 9. Process 900 can receive a raw profile (902). In some embodiments, the profile can be received from a sensor (e.g., a laser sensor). Process 900 can convert the profile to a desired set of units (904). Process 900 can filter the profile (906). In certain embodiments, the profile can be filtered to remove outliers. Process 900 can interpolate the profile to obtain a profile estimate (908). Process 900 can apply a thickness offset (910). The thickness offset can be based on a simulation. Thickness offsets and associated simulations are further described elsewhere herein. The process 900 can transpose the profile (912). The process 900 can reduce the profile (914). The process 900 can command a robotic actuator to position the end effector based on the reduced profile (916).

[0184] Although specific processes and / or systems for generating part profiles during a WAAM process are described above, any of a variety of processes and / or systems can be utilized to generate part profiles during a WAAM process, depending on the requirements of a particular application. In certain embodiments, the steps and / or components may be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. While the above embodiments of the present invention are described with respect to generating part profiles during a WAAM process, the techniques disclosed herein can be used with any type of additive manufacturing system. The techniques disclosed herein can be used with any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or X-restart automation systems described herein.

[0185] In some embodiments, the processor can command the robot to assume a new position based on the determined x-offset. An example of a process for commanding the robot to assume a new position based on the determined x-offset is conceptually illustrated in FIG. 10. Process 1000 can obtain a profile (1002). The profile can be a reduced profile. In some embodiments, the profile can be obtained as described in connection with FIG. 9. Process 1000 can fit a line to each side of the wall of the printed part (1004). In certain embodiments, the fitted line is generated based on the profile and / or based on a simulation of the weld pool profile. Process 1000 can determine an intercept between the fitted line and an endpoint location (1006). The endpoint can be an endpoint of an additive manufacturing applicator (e.g., a hot wire torch). The endpoint location can correspond to a weld pool location. Process 1000 can calculate a center of the part relative to laser coordinates based on the determined intercept (1008). Based on the center of the part, process 1000 can determine 1010 an x-offset. In various embodiments, the x-offset is measured in the radial direction. Based on the determined x-offset, process 1000 can command the robot to assume a new position. In some embodiments, the robot is fixedly attached to an additively manufactured end effector assembly, as described herein.

[0186] In some embodiments, filtering the profile can include filtering any values ​​outside the accuracy limits of the laser sensor (e.g., model LJ V7080). Profile filtering can remove outliers by comparing the delta around each point. If the delta exceeds a threshold, the delta is considered an outlier and can be filtered out.

[0187] Reducing the profile, in some embodiments, can include calculating a derivative of the laser sensor profile. Based on the derivative, the process can determine whether the derivative passes one or more thresholds. In some embodiments, the thresholds can be determined based on the geometry of the part being manufactured. According to numerous embodiments of the present invention, the data can be reduced by using data (e.g., measured from data on the last printed surface) corresponding to a length (e.g., about 10 millimeters).

[0188] In some embodiments, the process can generate a fitted line for each side of the part wall. The fitted line can be in standard form (Ax+By+C=0) or another form. The intersection between the fitted line and the determined contact tip position can be determined. The contact tip position can refer to the endpoint of the additive manufacturing applicator.

[0189] In certain embodiments, the contact tip position (determined based on calibration) can be used to generate a horizontal line. Based on the horizontal line and the fitted line, and using Cramer's rule from their intersection, the midpoint x (e.g., the center of the part being manufactured) can be determined.

[0190] The distance from the laser to the contact tip can be obtained by calibration in various embodiments. The contact tip position can be determined by calibration. In certain embodiments, the process can be configured to receive geometric and other information about the part. In certain embodiments, the radius of the part (and / or other geometric description of the part) can be received by the process. The information can be received from a user (e.g., input by a user) or can be received in any other manner (e.g., via a network interface).

[0191] In some embodiments, the center of the part relative to the robot coordinates is: Robot_x=contact_tip_x_position-radius; and This can be determined by calculating Robot_y=laser_to_contact_tip_distance In some embodiments, Robot_z is not required. The x offset can be determined based on the calculated robot position. In some embodiments, the x offset is x_offset=(((midpoint_x-Robot_x) 2 +(0.0-Robot_y) 2 ) 1 / 2 -radius).

[0192] Various sensors can be used to collect data for calculating the x offset, and in some embodiments, a camera can be used to detect the part.

[0193] According to some embodiments of the present invention, a laser can be used to detect the part. In some embodiments, a laser can provide a more accurate x-offset calculation than a camera. Laser placement is important for obtaining high-quality data. If the laser sensor views an area too close to the arc, the generated data will be noisy. If the laser sensor views an area too far from the part, thermal expansion of the part can add uncertainty. In certain embodiments, the laser scanner is placed approximately 2 inches, approximately 2.1 inches, or another distance from the center of the arc. According to embodiments of the present invention, the optimal distance can vary depending on the characteristics of the additive manufacturing process (e.g., the WAAM system used, the power level used, the cold wire, etc.).

[0194] In some embodiments, the x-offset can be determined based on a thermal expansion simulation. The simulation can be pre-calculated to allow for the execution of the x-restart without delays due to waiting for the simulation to complete. In some embodiments, the simulation may require sensor positioning, laser sensor positioning, part geometry, cold wire inclusions, materials used, thermal effects from other sources (e.g., thermal effects from multiple robots printing simultaneously on a single part), and / or arc power levels as inputs for generation. The determined x-restart value can be based on the sensor positioning, laser sensor positioning, part geometry, cold wire inclusions, materials used, and / or arc power levels.

[0195] In some embodiments, two laser sensors (e.g., Keyence) can be used to generate data for determining the x-offset. For example, the laser sensors can include a Keyence LJ-V7080 sensor, other LJ-V7000 series sensors, other laser profiling sensors or line lasers, or some combination thereof.

[0196] Although particular processes and / or systems for commanding a robot to assume a new position based on a determined x-offset are described above, any of a variety of processes and / or systems can be utilized to command a robot to assume a new position based on a determined x-offset as appropriate for the requirements of a particular application. In certain embodiments, the steps and / or components may be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. Although the above embodiments of the present invention are described with respect to commanding a robot to assume a new position based on a determined x-offset, the techniques disclosed herein can be used in any type of additive manufacturing system. The techniques disclosed herein may be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0197] In some embodiments, the sensor can be positioned to target an observation point positioned relative to a point of interest. The location of the laser scan (e.g., endpoint) relative to the additive manufacturing nozzle is conceptually shown in FIG. 11. The nozzle 1100 is centered relative to the weld pool 1102. The sensor can be positioned to observe the laser scan location 1104. The laser scan location 1104 can be 2.1 inches or 55 millimeters from the central axis of the nozzle 1100. In some embodiments, the point of interest can correspond to the expected weld pool location. The weld pool can be concentric with the endpoint of the additive manufacturing applicator. In certain embodiments, the additive manufacturing applicator is a WAAM. When manufacturing is in progress, arcing can disrupt the accuracy of the sensor. In some embodiments, the sensor is positioned to observe at a location spaced apart from the endpoint of the additive manufacturing applicator (e.g., the source of the arc). In some embodiments, the sensor can be configured to perform the laser scan at an offset distance from the nozzle (e.g., approximately 2.1 inches or 55 millimeters). In various embodiments, the desired offset distance can be determined based on the materials being used, the power levels being used, the temperature, and other factors. In some embodiments, the optimal offset can be determined based on simulation results. In various embodiments, simulations can be used to generate profile shapes under various WAAM conditions. According to some embodiments of the present invention, the simulations can be calculated on the fly or can be pre-calculated.

[0198] Although particular processes and / or systems for positioning the laser scan relative to the additive manufacturing nozzle are described above, any of a variety of processes and / or systems for positioning the laser scan relative to the additive manufacturing nozzle can be utilized depending on the requirements of a particular application. In certain embodiments, the steps and / or components may be performed and / or configured in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or performed substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. While the above embodiments of the present invention are described with reference to positioning the laser scan relative to the additive manufacturing nozzle, the techniques disclosed herein can be used in any type of additive manufacturing system. The techniques disclosed herein can be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0199] Additive Manufacturing Robot System Additive manufacturing devices can utilize end effector assemblies mounted to robotic actuators. An additive manufacturing end effector assembly configured to mount to a robotic actuator is conceptually illustrated in FIG. 12. Assembly 1200 can include a robot mounting bracket 1202, a control module 1203, a first additive manufacturing applicator 1204, a second additive manufacturing applicator 1206, a sensor 1208, a fume extraction assembly 1210, and an arc protection assembly 1212. In some embodiments, the mounting bracket can be configured to attach to a robotic actuator (e.g., robot arm, robot cart). In some embodiments, the control module can include a computer system. According to various embodiments of the present invention, the control module can function to receive data from sensors, control equipment associated with the end effector (e.g., additive manufacturing applicator, sensor), and / or control the robotic actuator.

[0200] Although specific processes and / or systems for additively manufactured end effector assemblies configured to mount on robotic actuators have been described above, any of a variety of processes and / or systems can be utilized for additively manufactured end effector assemblies configured to mount on robotic actuators depending on the requirements of a particular application. In particular, all references to wire-arc additive manufacturing in this application are provided by way of example and should not be construed as limiting. The inventive concepts in this application are applicable to any directed energy deposition (DED) 3D printing process using a wire feedstock. Associated energy sources include plasma, arc, laser, etc. In certain embodiments, steps and / or components may be performed and / or arranged in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. Although the above embodiments of the present invention are described with reference to an additively manufactured end effector assembly configured to mount to a robotic actuator, the technology disclosed herein can be used in any type of additive manufacturing system. The technology disclosed herein can be used in any of the additively manufactured modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or automated restart systems described herein.

[0201] In some embodiments, a computer system can be used to store and execute instructions. An example of a computer system is conceptually illustrated in FIG. 13 . The computer system 1300 can include a processor 1302, a memory 1304, an output device 1306, an input device 1308, and a network interface 1310. The computer system 1300 can receive data from and / or transmit data to sensors 1312, a user, and / or other sources. The computer system 1300 can receive and / or transmit data to a robotic actuator 1314. In some embodiments, the robotic actuator can be configured to actuate an additive manufacturing end effector assembly. The computer system can be configured to instruct the robotic actuator. The computer system can be configured to execute executable code. The executable code can be stored in memory.

[0202] Although specific processes and / or systems for computer systems are described above, any of a variety of processes and / or systems can be utilized as a computer system suitable for the requirements of a particular application. In certain embodiments, steps and / or components may be performed and / or arranged in any order, sequence, and / or configuration, including but not limited to the order, sequence, and / or configuration shown and described. In some embodiments, some of the above steps may be performed or conducted substantially simultaneously or in parallel, where appropriate, to reduce latency and processing time. In some embodiments, one or more of the above steps and / or components may be rearranged or omitted. While the above embodiments of the present invention are described with reference to computer systems, the techniques disclosed herein may be used in any type of additive manufacturing system. The techniques disclosed herein may be used in any of the additive manufacturing modular end effector assemblies, modular interfaces, cold wire actuators, torch configurations, local fume extraction systems, arc protection systems, and / or restart automation systems described herein.

[0203] Automated Contact Tip-Work Distance Compensation (Automatic CTWD) In some embodiments, automated contact tip-to-work distance compensation (auto CTWD) can include a process for automatically maintaining a constant distance from the contact tip to the top edge of the printed part. CTWD measurements can be obtained from a laser scanner, such as one or more line lasers. In some embodiments, CTWD measurements can be obtained from a camera. Laser-based measurements for auto CTWD can have many advantages over camera-based methods. For example, an auto CTWD process based on laser measurements can be more robust to different lighting conditions, can be more functional during weaving, can achieve higher update frequencies, can allow for flexible measurement and / or control parameters, and can avoid and / or reduce steady-state errors and / or vibration responses. In some embodiments, the auto CTWD process can be configured as a closed control loop. An example of an AUTO CTWD process configured as a closed loop is conceptually shown in the controller block diagram of FIG. 14.

[0204] FIG. 14 conceptually illustrates a controller block diagram of an automated contact tip-workpiece compensation process. As shown in FIG. 14, path data 1401 for printing can be obtained. A welding configuration identifier (ID) 1403, along with any other relevant parameters, can be retrieved from a welding configuration manager 1402. The welding configuration manager can be configured to store and display the latest version of the welding configuration. The welding configuration ID 1403, along with the path data 1401, can include a welding configuration from the welding configuration manager 1402 that can be used for path planning. The path data 1401, the welding configuration ID 1403, and / or other relevant parameters from the welding configuration manager 1402 can be used to determine a desired contact to work distance (CTWD) 1404. Based on the desired CTWD 1404, an update setpoint command 1405 can be executed to update the current setpoint of the closed control loop. In various embodiments, the update setpoint command can include a function call.

[0205] In various embodiments, a proportional control (P control) 1407 can be implemented to apply a correction command to a robot dynamics hardware interface 1411. The correction command can be determined based on an error 1406. The error 1406 can be calculated as the difference between a desired CTWD 1404 and an actual / estimated CTWD 1414. The P control 1407 and lead control 1408 can instruct the robot dynamics hardware interface 1411 to update the printing / welding torch height. One or more laser sensor measurements 1412 can then be performed. In some embodiments, the laser sensor measurements can include 70 Hz raw data measurements. According to embodiments of the invention, the laser sensor measurements can be obtained from a line laser, such as a Keyence laser scanner. From the laser measurements 1412, a CTWD estimate calculation 1413 can be performed to obtain a CTWD estimate 1414. The current setpoint can be recorded as a previous CTWD 1415. The lead control 1408 can obtain a CTWD estimate 1414 and can use a previous CTWD function call 1409 to obtain a previous CTWD 1415. In many embodiments, the lead control can be the main program that controls the position of the additive manufacturing robotic system and keeps the robot on the path required to perform printing.

[0206] Dual Plasma WAAM Nozzle Assembly An example of a WAAM nozzle assembly mounted to an end effector assembly is conceptually shown in Figure 15. The dual plasma assembly 1500 can include a WAAM nozzle 1502 mounted to an interface 1504. The WAAM nozzle 1502 can include at least one connector 1506. The connector 1506 can be coupled to one or more connection points 1508, which are attached to the interface 1504.

[0207] While the above description contains many specific embodiments of the present invention, these should not be construed as limitations on the scope of the invention, but rather as examples of one embodiment thereof. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents.

Claims

1. 1. A device configured for additive manufacturing, comprising: A robot actuator; an end effector assembly attached to the robot actuator; a control assembly; the end effector assembly comprising: an additive manufacturing applicator comprising an applicator endpoint; one or more sensors positioned to generate data from observations of a part undergoing additive manufacturing; Equipped with The device is configured to perform an automatic restart to compensate for geometric deviations between a part undergoing additive manufacturing and a digital model from sensor-generated data after stopping the additive manufacturing process by adjusting the position of the applicator endpoint relative to the part.

2. The device of claim 1 , wherein the additive manufacturing applicator comprises a hot wire torch.

3. The one or more sensors Welding cameras, infrared cameras, visible light cameras, and laser sensors The device of claim 1 , comprising at least one sensor selected from the group consisting of:

4. The device of claim 1 , wherein the control assembly is configured to initiate the automatic restart based on data generated by the one or more sensors.

5. The device of claim 4 , wherein the automatic restart is performed in response to detection by the one or more sensors of the geometric deviation of the part exceeding a threshold value.

6. The device of claim 5 , wherein the threshold is determined based on a spatial profile of the part.

7. The device of claim 1 , wherein the device is further configured to dynamically compensate for thermally induced dimensional changes of the part during additive manufacturing.

8. The device of claim 4 , wherein the control assembly converts sensor data from the one or more sensors into a format for at least one restart alignment command.

9. 10. The device of claim 1, wherein the end effector assembly further comprises a modular interface comprising a set of connection points arranged circumferentially about a modular interface central axis, the additive manufacturing applicator being coupled to the modular interface and the one or more sensors being fixedly attached to the modular interface via the set of connection points.

10. The device of claim 1 , wherein the automatic restart is performed automatically at predetermined intervals during the additive manufacturing process.

11. The control assembly Memory and a processor; wherein the processor: receiving sensor data generated by the one or more sensors; generating a spatial profile of the part based on the sensor data; determining a restart offset from the spatial profile; commanding the robotic actuator to reposition the applicator endpoint based on the restart offset; The device of claim 1 configured to:

12. The device of claim 11 , wherein the control assembly is configured to filter the sensor data to remove at least one outlier before determining the restart offset.

13. The device of claim 11 , wherein the restart offset determination is continuously updated from the sensor data throughout the additive manufacturing process.

14. 1. A method of performing an additive manufacturing process, comprising: performing a build operation to additively build the part using a robotic actuator; stopping the build operation at a stop coordinate based on sensor data and a spatial profile of the part; determining a restart offset coordinate from the spatial profile, wherein generating the spatial profile comprises: receiving a raw spatial profile from one or more sensors; converting the raw spatial profile into units configured for the additive manufacturing process; filtering the spatial profile to remove outliers; interpolating the spatial profile to obtain a profile estimate; applying an offset based on the profile estimate; and transposing the spatial profile; reducing the spatial profile; The method is: restarting the building operation at a restart coordinate based on the stop coordinate and the restart offset coordinate.

15. The method of claim 14 , wherein filtering the spatial profile includes identifying and removing at least one anomalous data point.

16. The method of claim 14 , wherein the offset compensates for thermal expansion of the part during additive manufacturing.

17. The method of claim 14 , wherein reducing the spatial profile comprises optimizing at least one data point for the movement of the robotic actuator.

18. 15. The method of claim 14, wherein determining the restart offset coordinates is performed dynamically throughout the additive manufacturing process.

19. 15. The method of claim 14, further comprising continuously updating the spatial profile with sensor data during the additive manufacturing process.

20. The device of claim 1 , wherein the digital model includes a thermal data simulation.

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