Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a device and a method for repairing 3D printing defects in real time.
The invention is realized by the following technical scheme:
the utility model provides a device of real-time repair 3D printing defect, includes digit control machine tool, numerical control system, control computer and PLC controller, and the PLC controller is connected with the control computer electricity, and numerical control system is connected with control computer and PLC controller electricity respectively, still includes rangefinder and laser printer head, rangefinder installs on digit control machine tool, and rangefinder is connected with the PLC controller electricity, and rangefinder includes and takes out structure and interior structure outward, takes out structure sliding connection outward on taking out the structure, and it has the through-hole to open outward to take out on the structure, and the through-hole that takes out the structure outward runs through to take out the structure to print the head structure, laser printer head installs on taking out the structure outward and is provided with the arc clamp plate device that is used for compressing tightly outward to take out the structure, it has circular tray to weld on the structure to take out in, is fixed with adjustable anchor clamps on the circular tray and is provided with range sensor.
The arc pressing plate device comprises an arc pressing block, a fixing block and an arc pressing screw connected to the fixing block through threads, wherein the arc pressing block is fixedly connected with the arc pressing screw, and the fixing block is fixed on the side wall of the outer drawing structural member.
The distance measuring sensor is provided with a first inclined plane and a second inclined plane.
The number of the ranging sensors is 5, and the 5 ranging sensors are radially arranged in the circular tray.
The adjustable clamp comprises a clamping plate, a compression spring, a stop block, an upper stop screw, a lower stop screw and a vertical plate fixed on the outer wall of the circular tray, wherein the upper stop screw and the lower stop screw are connected to the vertical plate through threads, the upper stop screw is contacted with a first inclined plane of the ranging sensor, the lower stop screw is contacted with a second inclined plane of the ranging sensor, a clamping nut is arranged on the clamping plate, one end of the compression spring is connected with the ranging sensor, and the other end of the compression spring is connected with the stop block.
The upper stop screw and the lower stop screw are ball screws.
The printing head structural member comprises a small cylindrical section, a conical table section and a large cylindrical section from top to bottom in sequence, and the small cylindrical section, the conical table section and the large cylindrical section are formed by integrally forming.
The cambered surface briquetting contacts with the frustum section of the printing head structural member.
The distance between the distance measuring sensor and the laser printing head is 80-160mm.
A method of repairing 3D printing defects in real time, comprising the steps of:
a. 5 ranging sensors are adopted and are respectively arranged at the center of the circular tray and the edges of four quadrants according to the size of light spots;
b. collecting data of a ranging sensor every 0.01 second, performing spline fitting by adopting small line segments, generating 5 single-channel morphology curves, collecting coordinate values on a screen of a corresponding time point control system and storing the coordinate values in a database;
c. analyzing and judging 5 single-channel morphology curves, and identifying and extracting high points and low points on the single-channel morphology curves;
d. and calculating the defect quantity, comparing the defect quantity with preset data, selecting a multiplying power value, transmitting a position code and a speed signal to a numerical control system through a PLC (programmable logic controller) when the next layer is printed, and controlling a multiplying power switch of a machine tool through the numerical control system to finish the speed reduction or the speed increase.
The basic principle of the invention is as follows:
depending on the nature of the laser melt deposition technique, the print height is only related to the machine feed rate when the process parameter set is complete. Therefore, the adjustment magnification, the coordinate position at which the adjustment is started, and the coordinate position at which the adjustment is ended need only be determined. Since a change in the height of the surface of the printed part causes a change in the distance, the distance measuring sensor is designed and arranged from above Z, and when the height of the surface of the part increases, the distance between the measuring point and the distance measuring device decreases, and vice versa. In the whole printing process in the automatic mode, 5 acquisition points are designed by tracking the printing process and correcting and adjusting the feeding multiplying power of the machine tool in the next layer, and no matter the machine tool moves linearly or moves diagonally, the distance change can be detected by always keeping at least 3 points.
The method comprises the steps of tracking the movement of a laser printing head, collecting distance data of the surface of a part in real time in the process of printing the part, generating a shape graph, identifying the position of the defect through analysis and calculation, sending a position code and a speed signal to a numerical control system in the next layer of printing, and automatically correcting the feeding speed of a machine tool, so that the aim of repairing the defect is fulfilled.
The beneficial effects of the invention are mainly shown in the following aspects:
1. the invention discloses a distance measuring device which is arranged on a numerical control machine tool, the distance measuring device is electrically connected with a PLC (programmable logic controller), the distance measuring device comprises a printing head structural member, an outer drawing structural member and an inner drawing structural member, the inner drawing structural member is connected to the outer drawing structural member in a sliding way, a through hole is formed in the outer drawing structural member, the printing head structural member penetrates through the through hole of the outer drawing structural member, a laser printing head is arranged on the printing head structural member, an arc-shaped pressing plate device for pressing the outer drawing structural member is arranged on the outer drawing structural member, a circular tray is welded on the inner drawing structural member, an adjustable clamp is fixed on the circular tray, and a distance measuring sensor is arranged on the adjustable clamp.
2. According to the invention, the distance measuring device can rotate 360 degrees around the laser printing head, positioning is realized through the two conical structures, the arc-shaped pressing plate device is used for fixing in a friction clamping mode, the appearance of a single-channel light spot is conveniently collected, and the positioning device has the advantages of being reliable in positioning and convenient to adjust.
3. The adjustable clamp comprises a clamping plate, a compression spring, a stop block, an upper stop screw, a lower stop screw and a vertical plate fixed on the outer wall of a circular tray, wherein the upper stop screw and the lower stop screw are connected to the vertical plate through threads, the upper stop screw is contacted with a first inclined surface of a ranging sensor, the lower stop screw is contacted with a second inclined surface of the ranging sensor, a clamping nut is arranged on the clamping plate, one end of the compression spring is connected with the ranging sensor, the other end of the compression spring is connected with the stop block, a reset driving force is provided for the ranging sensor through the compression spring, the ranging sensor is continuously compressed through the cooperation of the vertical plate, the upper stop screw and the lower stop screw, so that the ranging sensor moves reversely along the clamping plate, the compression spring is forced to release by screwing out the upper stop screw and the lower stop screw, and the ranging sensor moves positively, and the requirement of 3D printing measurement is met.
4. The invention can effectively improve the inaccuracy of manual visual inspection and promote the degree of intellectualization and automation.
5. According to the invention, the upper stop screw and the lower stop screw are ball screws, and the ball screws are matched with the compression springs and the clamping plates, so that the angle adjustment and clamping of the distance measuring sensor can be realized, and the convenience of angle adjustment is improved.
6. According to the invention, the distance between the ranging sensor and the laser printing head is 80-160mm, so that the interference of laser strong light on the ranging sensor can be effectively improved.
Detailed Description
Example 1
Referring to fig. 1 and 2, a device for repairing 3D printing defects in real time comprises a numerical control machine 1, a numerical control system 5, a control computer 6 and a PLC controller 7, wherein the PLC controller 7 is electrically connected with the control computer 6, the numerical control system 5 is electrically connected with the control computer 6 and the PLC controller 7 respectively, the device further comprises a ranging device 2 and a laser printing head 3, the ranging device 2 is installed on the numerical control machine 1, the ranging device 2 is electrically connected with the PLC controller 7, the ranging device 2 comprises a printing head structural member 28, an outer drawing structural member 31 and an inner drawing structural member 33, the inner drawing structural member 33 is slidably connected on the outer drawing structural member 31, a through hole is formed in the outer drawing structural member 31, the printing head structural member 28 penetrates through the through hole of the outer drawing structural member 31, the laser printing head 3 is installed on the printing head structural member 28, an arc-shaped pressing plate device for pressing the outer drawing structural member 31 is arranged on the outer drawing structural member 31, a circular tray 36 is welded on the inner drawing structural member 33, an adjustable clamp is fixed on the circular tray 36, and a ranging sensor 29 is arranged on the adjustable clamp.
This embodiment is the most basic implementation, the range unit 2 is installed on digit control machine tool 1, range unit 2 is connected with PLC controller 7 electricity, range unit 2 includes printing head structure 28, take out structure 31 and interior take out structure 33, interior take out structure 33 sliding connection is on take out structure 31 outward, it has the through-hole to take out structure 31 outward, the through-hole that takes out structure 31 is run through to printing head structure 28, laser printer head 3 installs on printing head structure 28, be provided with the arc clamp plate device that is used for compressing tightly take out structure 31 outward on taking out structure 31 outward, the welding has circular tray 36 on the interior take out structure 33, be fixed with adjustable anchor clamps on the circular tray 36, be provided with range sensor 29 on the adjustable anchor clamps, compared with the prior art, can real-time feedback print the height, adjust the lathe feed speed when printing, reach the purpose of correction print the height, improve response print quality and the qualification rate of product.
Example 2
Referring to fig. 1-3, a device for repairing 3D printing defects in real time comprises a numerical control machine 1, a numerical control system 5, a control computer 6 and a PLC controller 7, wherein the PLC controller 7 is electrically connected with the control computer 6, the numerical control system 5 is electrically connected with the control computer 6 and the PLC controller 7 respectively, the device further comprises a ranging device 2 and a laser printing head 3, the ranging device 2 is installed on the numerical control machine 1, the ranging device 2 is electrically connected with the PLC controller 7, the ranging device 2 comprises a printing head structural member 28, an outer drawing structural member 31 and an inner drawing structural member 33, the inner drawing structural member 33 is slidably connected on the outer drawing structural member 31, a through hole is formed in the outer drawing structural member 31, the printing head structural member 28 penetrates through the through hole of the outer drawing structural member 31, the laser printing head 3 is installed on the printing head structural member 28, an arc-shaped pressing plate device for pressing the outer drawing structural member 31 is arranged on the outer drawing structural member 31, a circular tray 36 is welded on the inner drawing structural member 33, an adjustable clamp is fixed on the circular tray 36, and a ranging sensor 29 is arranged on the adjustable clamp.
The arc pressing plate device comprises an arc pressing block 35, a fixing block 37 and an arc pressing screw 30 which is connected to the fixing block 37 through threads, wherein the arc pressing block 35 is fixedly connected with the arc pressing screw 30, and the fixing block 37 is fixed on the side wall of the outer drawing structural member 31.
The ranging sensor 29 is provided with a first inclined surface 291 and a second inclined surface 292.
The number of the distance measuring sensors 29 is 5, and the 5 distance measuring sensors 29 are radially arranged in the circular tray 36.
The embodiment is a preferred embodiment, and the distance measuring device 2 can rotate 360 degrees around the laser printing head, realizes positioning through two conical structures, is fixed by adopting a friction clamping mode by virtue of the arc-shaped pressing plate device, is convenient to collect the appearance of a single-channel light spot, and has the advantages of reliable positioning and convenient adjustment.
Example 3
Referring to fig. 1-3, a device for repairing 3D printing defects in real time comprises a numerical control machine 1, a numerical control system 5, a control computer 6 and a PLC controller 7, wherein the PLC controller 7 is electrically connected with the control computer 6, the numerical control system 5 is electrically connected with the control computer 6 and the PLC controller 7 respectively, the device further comprises a ranging device 2 and a laser printing head 3, the ranging device 2 is installed on the numerical control machine 1, the ranging device 2 is electrically connected with the PLC controller 7, the ranging device 2 comprises a printing head structural member 28, an outer drawing structural member 31 and an inner drawing structural member 33, the inner drawing structural member 33 is slidably connected on the outer drawing structural member 31, a through hole is formed in the outer drawing structural member 31, the printing head structural member 28 penetrates through the through hole of the outer drawing structural member 31, the laser printing head 3 is installed on the printing head structural member 28, an arc-shaped pressing plate device for pressing the outer drawing structural member 31 is arranged on the outer drawing structural member 31, a circular tray 36 is welded on the inner drawing structural member 33, an adjustable clamp is fixed on the circular tray 36, and a ranging sensor 29 is arranged on the adjustable clamp.
The arc pressing plate device comprises an arc pressing block 35, a fixing block 37 and an arc pressing screw 30 which is connected to the fixing block 37 through threads, wherein the arc pressing block 35 is fixedly connected with the arc pressing screw 30, and the fixing block 37 is fixed on the side wall of the outer drawing structural member 31.
The ranging sensor 29 is provided with a first inclined surface 291 and a second inclined surface 292.
The number of the distance measuring sensors 29 is 5, and the 5 distance measuring sensors 29 are radially arranged in the circular tray 36.
Further, the adjustable clamp comprises a clamping plate 22, a compression spring 26, a stop block 27, an upper stop screw 24, a lower stop screw 25 and a vertical plate 23 fixed on the outer wall of the circular tray 36, wherein the upper stop screw 24 and the lower stop screw 25 are connected to the vertical plate 23 through threads, the upper stop screw 24 is in contact with a first inclined surface 291 of the distance measuring sensor 29, the lower stop screw 25 is in contact with a second inclined surface 292 of the distance measuring sensor 29, a clamping nut 21 is arranged on the clamping plate 22, one end of the compression spring 26 is connected with the distance measuring sensor 29, and the other end of the compression spring 26 is connected with the stop block 27.
In this embodiment, the adjustable clamp comprises a clamping plate 22, a compression spring 26, a stop block 27, an upper stop screw 24, a lower stop screw 25 and a vertical plate 23 fixed on the outer wall of the circular tray 36, wherein the upper stop screw 24 and the lower stop screw 25 are connected to the vertical plate 23 through threads, the upper stop screw 24 is in contact with a first inclined surface 291 of the distance measuring sensor 29, the lower stop screw 25 is in contact with a second inclined surface 292 of the distance measuring sensor 29, a clamping nut 21 is arranged on the clamping plate 22, one end of the compression spring 26 is connected with the distance measuring sensor 29, the other end of the compression spring 26 is connected with the stop block 27, a reset driving force is provided for the distance measuring sensor 29 through the compression spring 26, the distance measuring sensor 29 is continuously compressed by pushing the compression spring 26 through the cooperation of the vertical plate 23 and the upper stop screw 24 and the lower stop screw 25, the distance measuring sensor 29 is enabled to move reversely along the clamping plate 22, the distance measuring sensor 29 is enabled to be enabled to move forward by forcing the compression spring 26 to release by screwing out the upper stop screw 24 and the lower stop screw 25, and the distance measuring sensor 29 is enabled to meet the requirement of 3D printing measurement.
Example 4
Referring to fig. 1-4, a device for repairing 3D printing defects in real time comprises a numerical control machine 1, a numerical control system 5, a control computer 6 and a PLC controller 7, wherein the PLC controller 7 is electrically connected with the control computer 6, the numerical control system 5 is electrically connected with the control computer 6 and the PLC controller 7 respectively, the device further comprises a ranging device 2 and a laser printing head 3, the ranging device 2 is installed on the numerical control machine 1, the ranging device 2 is electrically connected with the PLC controller 7, the ranging device 2 comprises a printing head structural member 28, an outer drawing structural member 31 and an inner drawing structural member 33, the inner drawing structural member 33 is slidably connected on the outer drawing structural member 31, a through hole is formed in the outer drawing structural member 31, the printing head structural member 28 penetrates through the through hole of the outer drawing structural member 31, the laser printing head 3 is installed on the printing head structural member 28, an arc-shaped pressing plate device for pressing the outer drawing structural member 31 is arranged on the outer drawing structural member 31, a circular tray 36 is welded on the inner drawing structural member 33, an adjustable clamp is fixed on the circular tray 36, and a ranging sensor 29 is arranged on the adjustable clamp.
The arc pressing plate device comprises an arc pressing block 35, a fixing block 37 and an arc pressing screw 30 which is connected to the fixing block 37 through threads, wherein the arc pressing block 35 is fixedly connected with the arc pressing screw 30, and the fixing block 37 is fixed on the side wall of the outer drawing structural member 31.
The ranging sensor 29 is provided with a first inclined surface 291 and a second inclined surface 292.
The number of the distance measuring sensors 29 is 5, and the 5 distance measuring sensors 29 are radially arranged in the circular tray 36.
The adjustable clamp comprises a clamping plate 22, a compression spring 26, a stop block 27, an upper stop screw 24, a lower stop screw 25 and a vertical plate 23 fixed on the outer wall of a circular tray 36, wherein the upper stop screw 24 and the lower stop screw 25 are connected to the vertical plate 23 through threads, the upper stop screw 24 is in contact with a first inclined surface 291 of a distance measuring sensor 29, the lower stop screw 25 is in contact with a second inclined surface 292 of the distance measuring sensor 29, a clamping nut 21 is arranged on the clamping plate 22, one end of the compression spring 26 is connected with the distance measuring sensor 29, and the other end of the compression spring 26 is connected with the stop block 27.
The upper and lower stop screws 24, 25 are ball screws.
The print head structural member 28 sequentially comprises a small cylindrical section 281, a frustum section 282 and a large cylindrical section 283 from top to bottom, and the small cylindrical section 281, the frustum section 282 and the large cylindrical section 283 are integrally formed.
The arcuate face compact 35 contacts the frustum section 282 of the printhead structure 28.
The distance between the distance measuring sensor 29 and the laser print head 3 is 80mm.
The embodiment is another preferred implementation manner, so that inaccuracy of manual visual inspection can be effectively improved, and the degree of intellectualization and automation can be improved.
Example 5
Referring to fig. 1-5, a device for repairing 3D printing defects in real time comprises a numerical control machine 1, a numerical control system 5, a control computer 6 and a PLC controller 7, wherein the PLC controller 7 is electrically connected with the control computer 6, the numerical control system 5 is electrically connected with the control computer 6 and the PLC controller 7 respectively, the device further comprises a ranging device 2 and a laser printing head 3, the ranging device 2 is installed on the numerical control machine 1, the ranging device 2 is electrically connected with the PLC controller 7, the ranging device 2 comprises a printing head structural member 28, an outer drawing structural member 31 and an inner drawing structural member 33, the inner drawing structural member 33 is slidably connected on the outer drawing structural member 31, a through hole is formed in the outer drawing structural member 31, the printing head structural member 28 penetrates through the through hole of the outer drawing structural member 31, the laser printing head 3 is installed on the printing head structural member 28, an arc-shaped pressing plate device for pressing the outer drawing structural member 31 is arranged on the outer drawing structural member 31, a circular tray 36 is welded on the inner drawing structural member 33, an adjustable clamp is fixed on the circular tray 36, and a ranging sensor 29 is arranged on the adjustable clamp.
The arc pressing plate device comprises an arc pressing block 35, a fixing block 37 and an arc pressing screw 30 which is connected to the fixing block 37 through threads, wherein the arc pressing block 35 is fixedly connected with the arc pressing screw 30, and the fixing block 37 is fixed on the side wall of the outer drawing structural member 31.
The ranging sensor 29 is provided with a first inclined surface 291 and a second inclined surface 292.
The number of the distance measuring sensors 29 is 5, and the 5 distance measuring sensors 29 are radially arranged in the circular tray 36.
The adjustable clamp comprises a clamping plate 22, a compression spring 26, a stop block 27, an upper stop screw 24, a lower stop screw 25 and a vertical plate 23 fixed on the outer wall of a circular tray 36, wherein the upper stop screw 24 and the lower stop screw 25 are connected to the vertical plate 23 through threads, the upper stop screw 24 is in contact with a first inclined surface 291 of a distance measuring sensor 29, the lower stop screw 25 is in contact with a second inclined surface 292 of the distance measuring sensor 29, a clamping nut 21 is arranged on the clamping plate 22, one end of the compression spring 26 is connected with the distance measuring sensor 29, and the other end of the compression spring 26 is connected with the stop block 27.
The upper and lower stop screws 24, 25 are ball screws.
Further, the print head structural member 28 includes a small cylindrical section 281, a frustum section 282, and a large cylindrical section 283 from top to bottom, and the small cylindrical section 281, the frustum section 282, and the large cylindrical section 283 are integrally formed.
The arcuate face compact 35 contacts the frustum section 282 of the printhead structure 28.
The distance between the distance measuring sensor 29 and the laser print head 3 is 160mm.
In this embodiment, the upper stop screw 24 and the lower stop screw 25 are ball screws, and the ball screws are matched with the compression springs 26 and the clamping plates 22 to realize the angle adjustment and clamping of the distance measuring sensor 29, so that the convenience of angle adjustment is improved.
Example 6
Referring to fig. 1 and 2, a method for repairing a 3D printing defect in real time includes the steps of:
a. 5 distance measuring sensors 29 are adopted and are respectively arranged at the center of the circular tray 36 and the four quadrant edges according to the size of the light spots;
b. collecting data of the ranging sensor 29 every 0.01 second, performing spline fitting by adopting small line segments, generating 5 single-channel morphology curves, collecting coordinate values on a screen of the corresponding time point control system 5, and storing the coordinate values in a database;
c. analyzing and judging 5 single-channel morphology curves, and identifying and extracting high points and low points on the single-channel morphology curves;
d. and (3) calculating the defect amount, comparing the defect amount with preset data, selecting a multiplying power value, transmitting a position code and a speed signal to the numerical control system 5 through the PLC 7 when the next layer is printed, and controlling a multiplying power switch of the machine tool through the numerical control system 5 to finish the speed reduction or the speed increase.
The automatic repair calibration and working flow of the invention are as follows:
before automatic repair is used, calibration of the ranging sensor 29 and related parameter setting are performed, and the calibration distance of the ranging sensor 29 is related to the powder feeding nozzle, and if the powder feeding nozzle is replaced, the calibration is needed again. Calibration of the ranging sensor 29 is completed when the focus is uniformly set to zero. Values of relevant parameters, such as print layer height, range ratio and fitting parameters, are preset in the automatic repair. And pressing a start key on the machine tool, and simultaneously starting the printing program and the automatic repair of the part 4, wherein the automatic repair still operates when the printing program is suspended, and the automatic repair is automatically closed when the printing program is completed.
The ranging device 2 works as follows:
the distance measuring device 2 converts the measured distance into an analog signal and sends the analog signal to the PLC 7, the PLC 7 restores the analog signal into a digital signal and sends the digital signal to the control computer 6, the control computer 6 fits the received 5 data into a single-channel morphology curve by using small line segments, and when the 5 curves are all in a set range, the default printing height is consistent and no signal is output; the control computer 6 collects X coordinate values and Y coordinate values of the machine tool at corresponding time points, the X coordinate values and the Y coordinate values are stored in a database, when more than 3 curves fluctuate beyond a set range, the control computer 6 judges high points and low points, calculates defect quantity and compares the defect quantity with preset conditions, selects a multiplying value, adjusts the speed of a feeding shaft of the machine tool according to the corresponding X coordinate values and Y coordinate values during printing of the next layer, increases the speed at a higher part, and reduces the speed at a lower part.