技术领域Technical Field
本发明涉及智能增材制造技术领域，具体为一种基于数据分析的智能增材制造流程控制方法及系统。The present invention relates to the technical field of intelligent additive manufacturing, and specifically to an intelligent additive manufacturing process control method and system based on data analysis.
背景技术Background Art
随着制造业的不断发展和技术的进步，增材制造作为一种通过逐层堆叠材料来制造三维物体的技术在多个领都有广泛的应用，在航空航天领域，增材制造可以用于制造无人机、卫星组件，有利于减轻无人机和卫星的重量，并且可以提高无人机和卫星性能、减少制造成本。传统的增材制造工艺流程容易受到温度等多种因素的影响，导致产品表面出现裂纹、孔洞的缺陷，影响产品的使用，降低材料的利用率，提高制造成本。随着信息技术的发展，数据分析技术能够根据材料生产流程监测得到的数据，分析出增材制造流程最适合的条件，从而提升增材材料的利用率。With the continuous development of the manufacturing industry and the advancement of technology, additive manufacturing, as a technology that manufactures three-dimensional objects by stacking materials layer by layer, has been widely used in many fields. In the field of aerospace, additive manufacturing can be used to manufacture drones and satellite components, which is conducive to reducing the weight of drones and satellites, and can improve the performance of drones and satellites and reduce manufacturing costs. The traditional additive manufacturing process is easily affected by various factors such as temperature, resulting in defects such as cracks and holes on the surface of the product, affecting the use of the product, reducing the utilization rate of materials, and increasing manufacturing costs. With the development of information technology, data analysis technology can analyze the most suitable conditions for the additive manufacturing process based on the data obtained from monitoring the material production process, thereby improving the utilization rate of additive materials.
现有技术如公告号为：CN116629128B的发明专利申请明公开了一种基于深度强化学习的控制电弧增材成型的方法，属于电弧增材制造技术领域。解决对复杂构件工艺参数难以确定，成型难以调控的问题。包括以下步骤：S1：对电弧增材过程进行数值模拟；S2：获取电弧增材过程数值模拟温度场信息并对其进行处理；S3：搭建电弧增材制造强化学习环境及智能体；S4：搭建价值网络及决策网络；S5：基于S3搭建的环境，利用S2获取的温度场信息对网络进行训练；S6：利用S5训练好的神经网络，实现自动调整电弧增材过程层积参数，保持层积层熔宽和熔深稳定。具有良好的泛化能力，适用于复杂形状的构件，校正数值模拟模型后将智能体执行的参数运用于实际电弧增材过程，减少探索工艺参数的时间成本和材料成本。Prior art, such as the invention patent application with announcement number: CN116629128B, discloses a method for controlling arc additive forming based on deep reinforcement learning, which belongs to the field of arc additive manufacturing technology. It solves the problem that it is difficult to determine the process parameters of complex components and difficult to control the forming. It includes the following steps: S1: numerically simulate the arc additive process; S2: obtain the numerical simulation temperature field information of the arc additive process and process it; S3: build an arc additive manufacturing reinforcement learning environment and intelligent agent; S4: build a value network and a decision network; S5: based on the environment built by S3, use the temperature field information obtained by S2 to train the network; S6: use the neural network trained by S5 to automatically adjust the arc additive process layer parameters to keep the layer width and depth stable. It has good generalization ability and is suitable for components with complex shapes. After correcting the numerical simulation model, the parameters executed by the intelligent agent are applied to the actual arc additive process, reducing the time cost and material cost of exploring process parameters.
现有技术如公告号为：CN113139314B的发明专利申请明公开了一种用于激光增材制造工艺的热源数值模拟方法，属于工艺热源数值模拟技术领域，包括以下步骤：确定工艺熔池区域的关键参数；构建初始热源数值模型；计算得到关于激光增材制造工艺热源计算温度分布以及关于热源的几何形貌尺寸；对初始热源数值模型中的关键参数进行校核，得到优化后的热源数值模型；根据所述优化后的热源数值模型，模拟得到关于热源的几何形貌尺寸。本发明通过以上设计，实现对各种不同厚度和零件尺寸的激光增材工艺成形数值计算，不仅能提高计算效率并且还具有流程化的优点，还能最大程度地提高激光增材制造中工艺温度场数值模拟热源模型建立的准确性。Prior art, such as the invention patent application with announcement number: CN113139314B, discloses a method for numerical simulation of heat sources for laser additive manufacturing process, which belongs to the technical field of numerical simulation of process heat sources, and includes the following steps: determining key parameters of the process molten pool area; constructing an initial heat source numerical model; calculating the temperature distribution of the heat source of the laser additive manufacturing process and the geometric shape and size of the heat source; verifying the key parameters in the initial heat source numerical model to obtain an optimized heat source numerical model; simulating the geometric shape and size of the heat source according to the optimized heat source numerical model. Through the above design, the present invention realizes the numerical calculation of laser additive process forming of various thicknesses and part sizes, which not only improves the calculation efficiency and has the advantages of process standardization, but also maximizes the accuracy of the establishment of the heat source model for numerical simulation of the process temperature field in laser additive manufacturing.
结合上述方案发现，当前在增材制造流程中，缺乏对增材材料沉积数据进行数据分析，导致缺乏对增材制造过程的全面了解，可能会影响增材材料的制造效率和生产效益，降低增材制造过程的质量和稳定性，并且少有对支撑结构生成数据进行监测分析，可能会导致构件产生形变、失真或结构不稳定等问题，影响最终构件的质量和性能，从而不能达到使用标准，降低材料的利用率，同时无法对增材制造流程中的工艺参数进行针对性修改，不能保证增材材料的成功率，增加增材材料的成本。Combined with the above scheme, it is found that in the current additive manufacturing process, there is a lack of data analysis of additive material deposition data, resulting in a lack of comprehensive understanding of the additive manufacturing process, which may affect the manufacturing efficiency and production benefits of additive materials and reduce the quality and stability of the additive manufacturing process. In addition, there is little monitoring and analysis of the support structure generation data, which may cause deformation, distortion or structural instability of the components, affecting the quality and performance of the final components, thereby failing to meet the use standards and reducing the utilization rate of materials. At the same time, it is impossible to make targeted modifications to the process parameters in the additive manufacturing process, and the success rate of the additive materials cannot be guaranteed, which increases the cost of the additive materials.
发明内容Summary of the invention
针对现有技术的不足，本发明提供了一种基于数据分析的智能增材制造流程控制方法及系统，能够有效解决上述背景技术中涉及的问题。In view of the deficiencies in the prior art, the present invention provides an intelligent additive manufacturing process control method and system based on data analysis, which can effectively solve the problems involved in the above-mentioned background technology.
为实现以上目的，本发明通过以下技术方案予以实现：一种基于数据分析的智能增材制造流程控制方法，包括通过云端获取增材材料的工艺参数，并将增材制造流程划分为增材材料沉积阶段和支撑结构生成阶段。To achieve the above objectives, the present invention is implemented through the following technical solutions: an intelligent additive manufacturing process control method based on data analysis, including obtaining the process parameters of the additive material through the cloud, and dividing the additive manufacturing process into an additive material deposition stage and a support structure generation stage.
对增材材料沉积阶段进行监测分析，得到增材材料的沉积质量表征值，匹配得到激光器的输出功率。The deposition stage of the additive material is monitored and analyzed to obtain the deposition quality characterization value of the additive material and match it to obtain the output power of the laser.
对支撑结构生成阶段进行监测分析，并根据激光器的输出功率，得到增材材料的支撑结构稳定表征值，并执行控制预警提示。The support structure generation stage is monitored and analyzed, and based on the output power of the laser, the stability characterization value of the support structure of the additive material is obtained, and control early warning prompts are executed.
进一步地，所述对增材材料沉积阶段进行监测分析，具体分析过程为：设置监测周期，在监测周期中设置若干监测时间段，在各监测时间段中统计增材材料在各监测时间段开始时间和结束时间点的沉积体积，提取监测时间段的时长，得到各监测时间段中增材材料的沉积速率，并提取工艺参数中增材材料的参照沉积速率，经处理得到增材材料的沉积速率均匀值。Furthermore, the deposition stage of the additive material is monitored and analyzed, and the specific analysis process is: setting a monitoring cycle, setting a number of monitoring time periods in the monitoring cycle, counting the deposition volume of the additive material at the start time and end time point of each monitoring time period in each monitoring time period, extracting the duration of the monitoring time period, obtaining the deposition rate of the additive material in each monitoring time period, and extracting the reference deposition rate of the additive material in the process parameters, and obtaining the uniform value of the deposition rate of the additive material after processing.
在各监测时间段中监测统计增材材料的加热源的平均温度和平均功率，并提取工艺参数中的加热源的参照平均温度和参照平均功率，经处理得到增材材料的加热源的运行稳定指数。The average temperature and average power of the heating source of the additive material are monitored and counted in each monitoring time period, and the reference average temperature and reference average power of the heating source in the process parameters are extracted, and the operation stability index of the heating source of the additive material is obtained after processing.
在各监测时间段中采集提取增材材料的表面扫描图像，与工艺参数中的增材材料标准表面扫描图像进行比对，由此统计识别增材材料表面裂纹、凹陷和气泡的总数量，并提取材料分析数据库中存储的单位裂纹数量对应的质量影响因子、界定凹陷数量和界定气泡数量，经处理得到增材材料的表面质量符合计量值。Surface scanning images of the additive material are collected and extracted in each monitoring time period, and compared with the standard surface scanning images of the additive material in the process parameters, so as to statistically identify the total number of cracks, depressions and bubbles on the surface of the additive material, and extract the quality influencing factors, defined depression numbers and defined bubble numbers corresponding to the unit crack number stored in the material analysis database. After processing, the surface quality of the additive material is obtained to meet the measurement value.
进一步地，所述得到增材材料的沉积质量表征值，匹配得到激光器的输出功率，具体匹配过程为：根据增材材料的沉积速率均匀值、增材材料的加热源的运行稳定指数以及增材材料的表面质量符合计量值，综合分析得到增材材料的沉积质量表征值。Furthermore, the deposition quality characterization value of the additive material is obtained and matched to obtain the output power of the laser. The specific matching process is: according to the uniform value of the deposition rate of the additive material, the operation stability index of the heating source of the additive material and the surface quality of the additive material meeting the measurement value, a comprehensive analysis is performed to obtain the deposition quality characterization value of the additive material.
根据增材材料的沉积质量表征值，与设定的各增材材料的沉积质量表征值区间对应的激光器的输出功率进行比对，得到激光器的输出功率。According to the deposition quality characterization value of the additive material, the output power of the laser corresponding to the set deposition quality characterization value interval of each additive material is compared to obtain the output power of the laser.
进一步地，所述增材材料的沉积质量表征值表示通过对增材材料沉积阶段进行监测分析，得到的用于分析增材制造过程中增材材料沉积的质量状况程度的量化结果，并作为激光器的输出功率的分析根据。Furthermore, the deposition quality characterization value of the additive material represents a quantitative result obtained by monitoring and analyzing the deposition stage of the additive material, which is used to analyze the quality status of the additive material deposition in the additive manufacturing process, and serves as a basis for analyzing the output power of the laser.
进一步地，所述得到增材材料的支撑结构稳定表征值，具体分析过程为：设置监测周期，在监测周期中对增材材料的支撑结构生成阶段进行监测分析，采集增材材料的三维图像，从增材材料的三维图像中提取增材材料的空隙率、支撑结构的数量和支撑结构的高度。Furthermore, the stability characterization value of the support structure of the additive material is obtained, and the specific analysis process is: setting a monitoring period, monitoring and analyzing the support structure generation stage of the additive material during the monitoring period, collecting a three-dimensional image of the additive material, and extracting the porosity of the additive material, the number of support structures, and the height of the support structures from the three-dimensional image of the additive material.
提取材料分析数据库中存储的参照空隙率、参照支撑结构的数量以及参照支撑结构的高度，经处理得到增材材料的支撑结构第一符合表征值。The reference porosity, the number of reference support structures, and the height of the reference support structures stored in the material analysis database are extracted and processed to obtain a first conforming characterization value of the support structure of the additive material.
从增材材料的三维图像中提取增材材料各支撑结构构件表面的直径和厚度，并提取材料分析数据库中存储的各支撑结构构件表面的参照直径和参照厚度，经处理得到增材材料的支撑结构第二符合表征值。The diameter and thickness of the surface of each supporting structure component of the additive material are extracted from the three-dimensional image of the additive material, and the reference diameter and reference thickness of the surface of each supporting structure component stored in the material analysis database are extracted, and the second conforming characterization value of the supporting structure of the additive material is obtained after processing.
根据增材材料的支撑结构第一符合表征值和增材材料的支撑结构第二符合表征值，整合分析得到增材材料的支撑结构稳定表征值。According to the first conforming characterization value of the support structure of the additive material and the second conforming characterization value of the support structure of the additive material, a stable characterization value of the support structure of the additive material is obtained through integrated analysis.
进一步地，所述增材材料的支撑结构稳定表征值表示通过对增材材料的支撑结构生成阶段，得到的用于分析增材材料在支撑结构生成阶段的质量稳定性的量化结果，并作为分析增材材料的质量反馈结果的依据。Furthermore, the support structure stability characterization value of the additive material represents a quantitative result obtained through the support structure generation stage of the additive material, which is used to analyze the quality stability of the additive material during the support structure generation stage, and serves as a basis for analyzing the quality feedback results of the additive material.
进一步地，所述执行控制预警提示，具体预警过程为：根据增材材料的支撑结构稳定表征值，与设定的增材材料的支撑结构稳定表征阈值进行对比，得到增材材料的质量反馈结果，增材材料的质量反馈结果为执行控制预警提示或不执行控制预警提示，若增材材料的支撑结构稳定表征值低于设定的增材材料的支撑结构稳定表征阈值，则执行控制预警提示，若增材材料的支撑结构稳定表征值不低于设定的增材材料的支撑结构稳定表征阈值，则不执行控制预警提示。Furthermore, the execution of the control warning prompt, the specific warning process is: according to the support structure stability characterization value of the additive material, the support structure stability characterization threshold of the set additive material is compared to obtain the quality feedback result of the additive material, the quality feedback result of the additive material is to execute the control warning prompt or not to execute the control warning prompt, if the support structure stability characterization value of the additive material is lower than the set support structure stability characterization threshold of the additive material, then the control warning prompt is executed, if the support structure stability characterization value of the additive material is not lower than the set support structure stability characterization threshold of the additive material, then the control warning prompt is not executed.
进一步地，所述增材材料的沉积质量表征值，具体分析条件为：Furthermore, the deposition quality characterization value of the additive material is specifically analyzed under the following conditions:
；式中，表示增材材料的沉积质量表征值，表示增材材料的沉积速率均匀值，表示设定的增材材料的沉积速率均匀值对应的权重因子，表示增材材料的加热源的运行稳定指数，表示设定的增材材料的加热源的运行稳定指数对应的权重因子，表示增材材料的表面质量符合计量值，表示设定的增材材料的表面质量符合计量值对应的权重因子，表示自然常数。 ; In the formula, represents the deposition quality characterization value of the additive material, represents the average value of the deposition rate of the additive material, Represents the weight factor corresponding to the average value of the deposition rate of the set additive material, Indicates the operational stability index of the heating source of the additive material, Indicates the weight factor corresponding to the operating stability index of the heating source of the set additive material, Indicates that the surface quality of the additive material meets the measured value, Indicates that the surface quality of the set additive material meets the weight factor corresponding to the measurement value, Represents a natural constant.
进一步地，所述增材材料的支撑结构稳定表征值，具体分析条件为：Furthermore, the support structure stability characterization value of the additive material is specifically analyzed under the following conditions:
；式中，表示增材材料的支撑结构稳定表征值，表示增材材料的支撑结构第一符合表征值，表示设定的增材材料的支撑结构第一符合表征值对应的权重因子，表示增材材料的支撑结构第二符合表征值，表示设定的增材材料的支撑结构第二符合表征值对应的权重因子。 ; In the formula, Indicates the stability characterization value of the support structure of the additive material, Indicates the first compliance characterization value of the support structure of the additive material, Indicates the weight factor corresponding to the first conformity characterization value of the support structure of the set additive material, Indicates the second most representative value of the support structure of the additive material, The weight factor corresponding to the second conformity characterization value of the support structure of the set additive material.
本发明第二方面提供一种基于数据分析的智能增材制造流程控制系统，包括：增材制造流程划分模块，用于通过云端获取增材材料的工艺参数，并将增材制造流程划分为增材材料沉积阶段和支撑结构生成阶段。The second aspect of the present invention provides an intelligent additive manufacturing process control system based on data analysis, including: an additive manufacturing process division module, which is used to obtain the process parameters of the additive material through the cloud, and divide the additive manufacturing process into an additive material deposition stage and a support structure generation stage.
增材材料沉积阶段监测分析模块，用于对增材材料沉积阶段进行监测分析，得到增材材料的沉积质量表征值，匹配得到激光器的输出功率。The additive material deposition phase monitoring and analysis module is used to monitor and analyze the additive material deposition phase, obtain the deposition quality characterization value of the additive material, and match the output power of the laser.
支撑结构生成阶段监测分析模块，用于对支撑结构生成阶段进行监测分析，并根据激光器的输出功率，得到增材材料的支撑结构稳定表征值，并执行控制预警提示。The support structure generation phase monitoring and analysis module is used to monitor and analyze the support structure generation phase, and obtain the support structure stability characterization value of the additive material according to the output power of the laser, and execute control early warning prompts.
一种基于基于数据分析的智能增材制造流程控制系统还包括材料分析数据库，用于存储的单位裂纹数量对应的质量影响因子、界定凹陷数量和界定气泡数量、参照空隙率、参照支撑结构的数量、参照支撑结构的高度及支撑结构构件表面的参照直径和参照厚度。An intelligent additive manufacturing process control system based on data analysis also includes a material analysis database, which is used to store the quality influence factor corresponding to the unit crack number, the defined number of depressions and the defined number of bubbles, the reference void ratio, the number of reference support structures, the reference support structure height, and the reference diameter and reference thickness of the support structure component surface.
本发明具有以下有益效果：The present invention has the following beneficial effects:
（1）本发明提供一种基于数据分析的智能增材制造流程控制方法及系统，首先对增材制造流程进行划分，分为增材材料沉积阶段和支撑结构生成阶段，对增材材料沉积阶段进行监测分析，得到增材材料的沉积质量表征值，能够更精确的调节激光器的输出功率，有助于实现更精细的沉积控制，提高构件的表面质量和几何精度，提高了生产能力和产量，同时对增材材料的支撑结构生成阶段进行监测分析，得到增材材料的支撑结构稳定表征值，进而提高增材材料表面直径和厚度的精确度，并执行控制预警提示。(1) The present invention provides an intelligent additive manufacturing process control method and system based on data analysis. First, the additive manufacturing process is divided into an additive material deposition stage and a support structure generation stage. The additive material deposition stage is monitored and analyzed to obtain a deposition quality characterization value of the additive material. The output power of the laser can be adjusted more accurately, which helps to achieve more precise deposition control, improve the surface quality and geometric accuracy of the component, and improve production capacity and output. At the same time, the support structure generation stage of the additive material is monitored and analyzed to obtain a stable characterization value of the support structure of the additive material, thereby improving the accuracy of the surface diameter and thickness of the additive material, and executing control early warning prompts.
（2）本发明通过对增材材料沉积阶段的数据进行监测分析，得到增材材料的沉积质量表征值，通过监测分析，可以及时调节激光器的输出功率等参数，以保证沉积质量，有助于提高的增材材料的沉积速率和制造效率，能够加快增材材料的生产速度，提高增材材料的制造效率和成品质量。(2) The present invention obtains a deposition quality characterization value of the additive material by monitoring and analyzing the data of the additive material deposition stage. Through monitoring and analysis, parameters such as the output power of the laser can be adjusted in time to ensure the deposition quality, which helps to improve the deposition rate and manufacturing efficiency of the additive material, accelerate the production speed of the additive material, and improve the manufacturing efficiency and finished product quality of the additive material.
（3）本发明对支撑结构生成阶段进行监测分析，得到增材材料的支撑结构稳定表征值，可以及时发现支撑结构的缺陷或不合理的地方，进而得到增材材料的质量反馈结果，有助于提高增材材料的质量和稳定性，减少制造过程中的废品率，能够提高增材材料的支撑结构的性能，提高增材材料制造流程的制造效率。(3) The present invention monitors and analyzes the support structure generation stage to obtain a stability characterization value of the support structure of the additive material, which can timely discover defects or unreasonable places in the support structure, and then obtain quality feedback results of the additive material, which helps to improve the quality and stability of the additive material, reduce the scrap rate in the manufacturing process, improve the performance of the support structure of the additive material, and improve the manufacturing efficiency of the additive material manufacturing process.
（4）本发明通过分析得到增材材料的质量反馈结果，根据增材材料的支撑结构稳定表征值，得到增材材料的质量反馈结果，并执行相应的控制预警提示，减少人为干预的需要，节省人力资源，降低了人为因素对质量控制的影响。(4) The present invention obtains quality feedback results of additive materials through analysis, obtains quality feedback results of additive materials according to the stability characterization value of the support structure of the additive materials, and executes corresponding control early warning prompts, thereby reducing the need for human intervention, saving human resources, and reducing the impact of human factors on quality control.
当然，实施本发明的任一产品并不一定需要同时达到以上所述的所有优点。Of course, any product implementing the present invention does not necessarily need to achieve all of the above-mentioned advantages at the same time.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明的方法流程示意图。FIG1 is a schematic flow chart of the method of the present invention.
图2为本发明的系统模块连接示意图。FIG. 2 is a schematic diagram showing the connection of system modules of the present invention.
具体实施方式DETAILED DESCRIPTION
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
在本发明的描述中，需要理解的是，术语“开孔”、“上”、“下”、“厚度”、“顶”、“中”、“长度”、“内”、“四周”等指示方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的组件或元件必须具有特定的方位，以特定的方位构造和操作，因此不能理解为对本发明的限制。In the description of the present invention, it is necessary to understand that the terms "opening", "upper", "lower", "thickness", "top", "middle", "length", "inside", "all around" and the like indicating orientation or positional relationship are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the components or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.
请参阅图1所示，本发明第一方面提供一种技术方案：一种基于数据分析的智能增材制造流程控制方法，包括通过云端获取增材材料的工艺参数，并将增材制造流程划分为增材材料沉积阶段和支撑结构生成阶段。Please refer to Figure 1. The first aspect of the present invention provides a technical solution: an intelligent additive manufacturing process control method based on data analysis, including obtaining process parameters of additive materials through the cloud, and dividing the additive manufacturing process into an additive material deposition stage and a support structure generation stage.
对增材材料沉积阶段进行监测分析，得到增材材料的沉积质量表征值，匹配得到激光器的输出功率。The deposition stage of the additive material is monitored and analyzed to obtain the deposition quality characterization value of the additive material and match it to obtain the output power of the laser.
对支撑结构生成阶段进行监测分析，并根据激光器的输出功率，得到增材材料的支撑结构稳定表征值，并执行控制预警提示。The support structure generation stage is monitored and analyzed, and based on the output power of the laser, the stability characterization value of the support structure of the additive material is obtained, and control early warning prompts are executed.
具体地，对增材材料沉积阶段进行监测分析，具体分析过程为：设置监测周期，在监测周期中设置若干监测时间段，在各监测时间段中统计增材材料在各监测时间段开始时间和结束时间点的沉积体积，提取监测时间段的时长，得到各监测时间段中增材材料的沉积速率，并提取工艺参数中增材材料的参照沉积速率，经处理得到增材材料的沉积速率均匀值。Specifically, the deposition stage of the additive material is monitored and analyzed, and the specific analysis process is: setting a monitoring cycle, setting a number of monitoring time periods in the monitoring cycle, counting the deposition volume of the additive material at the start time and end time point of each monitoring time period in each monitoring time period, extracting the duration of the monitoring time period, obtaining the deposition rate of the additive material in each monitoring time period, and extracting the reference deposition rate of the additive material in the process parameters, and obtaining the uniform value of the deposition rate of the additive material after processing.
需要说明的是，各监测时间段中增材材料的沉积速率表示对各监测时间段开始时间和结束时间点的沉积体积进行数据分析，得到的用于分析增材制造过程中增材材料的沉积速率的稳定程度的量化结果，在实施例中，不仅可以通过称重传感器测量增材材料的质量变化，间接推断出增材材料的沉积速率，还可以通过以下分析方法获得，具体的分析条件如下：It should be noted that the deposition rate of the additive material in each monitoring time period represents a quantitative result obtained by analyzing the deposition volume at the start time and the end time point of each monitoring time period for analyzing the stability of the deposition rate of the additive material in the additive manufacturing process. In the embodiment, not only can the mass change of the additive material be measured by a weighing sensor to indirectly infer the deposition rate of the additive material, but it can also be obtained by the following analysis method. The specific analysis conditions are as follows:
； ;
式中，表示第个监测时间段中增材材料的沉积速率，表示第个监测时间段开始时间点时增材材料的沉积体积，表示第个监测时间段结束时间点时增材材料的沉积体积，表示监测时间段的时长，表示各监测时间段的编号，，表示监测时间段的总数。In the formula, Indicates The deposition rate of the additive material in the monitoring time period, Indicates The deposition volume of the additive material at the start time of the monitoring period, Indicates The deposition volume of the additive material at the end of the monitoring period, Indicates the duration of the monitoring period. Indicates the number of each monitoring time period, , Indicates the total number of monitoring time periods.
需要说明的时，各监测时间段的时长一致。Where necessary, the duration of each monitoring period is the same.
需要说明的是，增材材料的沉积速率均匀值表示通过对增材材料在各监测时间段中的增材材料的沉积体积进行分析，得到的用于分析增材制造过程中增材材料的沉积体积变化程度的量化结果，有助于评估增材材料在不同温度下的沉积速率，并作为增材材料的沉积质量表征值的分析依据，在实施例中，增材材料的沉积速率与增材材料表面的温度变化密切相关，不仅可以利用红外热像仪或热像摄像头等设备，监测增材材料表面的温度分布情况，进而通过热成像来评估沉积速率的均匀值，还可以通过以下分析方法获得，具体的分析条件如下：It should be noted that the uniform value of the deposition rate of the additive material represents a quantitative result obtained by analyzing the deposition volume of the additive material in each monitoring time period, which is used to analyze the degree of change in the deposition volume of the additive material in the additive manufacturing process. It is helpful to evaluate the deposition rate of the additive material at different temperatures and serve as an analysis basis for the deposition quality characterization value of the additive material. In the embodiment, the deposition rate of the additive material is closely related to the temperature change on the surface of the additive material. Not only can the temperature distribution on the surface of the additive material be monitored by using equipment such as an infrared thermal imager or a thermal imaging camera, and then the uniform value of the deposition rate can be evaluated by thermal imaging, but it can also be obtained by the following analysis method. The specific analysis conditions are as follows:
； ;
式中，表示增材材料的沉积速率均匀值，表示参照沉积速率，表示设定的沉积速率对应的修正因子，表示表示第个监测时间段中增材材料的沉积速率。In the formula, represents the average value of the deposition rate of the additive material, represents the reference deposition rate, Indicates the correction factor corresponding to the set deposition rate, Indicates the The deposition rate of the additive material during the monitoring period.
需要说明的是，增材材料的沉积速率表示单位时间内增材材料在增材制造过程中沉积的体积，表1为不同增材材料的沉积速率以及沉积速率对应的修正因子。It should be noted that the deposition rate of the additive material represents the volume of the additive material deposited in the additive manufacturing process per unit time. Table 1 shows the deposition rates of different additive materials and the correction factors corresponding to the deposition rates.
表1 不同增材材料的沉积速率以及沉积速率对应的修正因子Table 1 Deposition rates of different additive materials and the corresponding correction factors of deposition rates
本实施方案中，了解沉积速率的均匀性可以帮助识别制造过程中的变化和不稳定性，为后续的智能增材制造流程控制提供了数据支持，进而发现增材材料沉积阶段可能存在的质量问题，保证增材材料的尺寸精度和表面质量。In this embodiment, understanding the uniformity of the deposition rate can help identify changes and instabilities in the manufacturing process, provide data support for subsequent intelligent additive manufacturing process control, and further discover possible quality problems in the additive material deposition stage to ensure the dimensional accuracy and surface quality of the additive material.
本实施方案中，通过光学扫描设备监测获取材料在各监测时间段的沉积体积，分析得到增材材料的沉积速率均匀值。In this embodiment, the deposition volume of the material in each monitoring time period is monitored and acquired by an optical scanning device, and the uniform value of the deposition rate of the additive material is obtained by analysis.
在各监测时间段中监测统计增材材料的加热源的平均温度和平均功率，并提取工艺参数中的加热源的参照平均温度和参照平均功率，经处理得到增材材料的加热源的运行稳定指数。The average temperature and average power of the heating source of the additive material are monitored and counted in each monitoring time period, and the reference average temperature and reference average power of the heating source in the process parameters are extracted, and the operation stability index of the heating source of the additive material is obtained after processing.
本实施方案中，加热源是用于熔化或烧结增材材料以便构建所需三维形状的激光束。In this embodiment, the heating source is a laser beam that is used to melt or sinter the additive material to build the desired three-dimensional shape.
需要说明的是，增材材料的加热源的运行稳定指数表示通过对各监测时间段中监测统计增材材料的加热源的平均温度和平均功率进行数据分析处理，得到的用于分析加热源运行稳定性的量化结果，并作为增材材料的沉积质量表征值的分析依据，在实施例中，不仅可以通过分析加热源向增材材料传递能量的效率的均匀性和稳定性，得到增材材料的加热源的运行稳定指数，还可以通过以下分析方法获得，具体的分析条件如下：It should be noted that the operation stability index of the heating source of the additive material represents a quantitative result for analyzing the operation stability of the heating source obtained by performing data analysis and processing on the average temperature and average power of the heating source of the additive material monitored and counted in each monitoring time period, and serves as an analysis basis for the deposition quality characterization value of the additive material. In the embodiment, the operation stability index of the heating source of the additive material can be obtained not only by analyzing the uniformity and stability of the efficiency of energy transfer from the heating source to the additive material, but also by the following analysis method. The specific analysis conditions are as follows:
； ;
式中，表示增材材料的加热源的运行稳定指数，表示第个监测时间段中加热源的平均温度，表示参照平均温度，表示设定的加热源的平均温度对应的修正因子，表示第个监测时间段中加热源的平均功率，表示参照平均功率，表示设定的加热源的平均功率对应的修正因子。In the formula, Indicates the operational stability index of the heating source of the additive material, Indicates The average temperature of the heating source during the monitoring period, Indicates the reference average temperature, Indicates the correction factor corresponding to the average temperature of the set heating source, Indicates The average power of the heating source in the monitoring period, represents the reference average power, Indicates the correction factor corresponding to the average power of the set heating source.
在一个具体的实施例中，加热源的平均温度对应的修正因子，收集历史加热源的平均温度，计算出每个监测时间段中加热源的平均温度相对于上一个监测时间段中加热源的平均温度的偏差，经过统计分析，探究出加热源的平均温度与加热源的运行稳定指数的相关性，经假设分析，得出加热源的平均温度偏差每增加1%，加热源的运行稳定指数减少0.001，则加热源的平均温度对应的修正因子=0.001，同理，经假设分析，得出加热源的平均功率偏差每增加1%，加热源的运行稳定指数减少0.02，则加热源的平均功率对应的修正因子=0.02。In a specific embodiment, the correction factor corresponding to the average temperature of the heating source is collected by collecting the historical average temperatures of the heating sources, and the deviation of the average temperature of the heating source in each monitoring time period relative to the average temperature of the heating source in the previous monitoring time period is calculated. After statistical analysis, the correlation between the average temperature of the heating source and the operating stability index of the heating source is explored. After hypothesis analysis, it is concluded that for every 1% increase in the average temperature deviation of the heating source, the operating stability index of the heating source decreases by 0.001, and the correction factor corresponding to the average temperature of the heating source = 0.001. Similarly, after hypothesis analysis, it is concluded that for every 1% increase in the average power deviation of the heating source, the operating stability index of the heating source decreases by 0.02, and the correction factor corresponding to the average power of the heating source = 0.02.
本实施方案中，通过温度传感器和功率传感器分别监测加热源的温度和功率，可以得到加热源的温度和功率在各监测时间段的具体数据，最终分析得到增材材料的加热源的运行稳定指数。In this embodiment, the temperature and power of the heating source are monitored respectively by a temperature sensor and a power sensor, and specific data of the temperature and power of the heating source in each monitoring time period can be obtained, and finally the operation stability index of the heating source of the additive material is analyzed.
本实施方案中，监测增材材料加热源的平均温度和平均功率，综合分析得到增材材料加热源的运行稳定指数，有助于保持增材材料沉积阶段增材材料的温度稳定，减少增材材料的表面产生的缺陷。In this embodiment, the average temperature and average power of the additive material heating source are monitored, and a comprehensive analysis is performed to obtain an operation stability index of the additive material heating source, which helps to maintain the temperature stability of the additive material during the additive material deposition stage and reduce defects on the surface of the additive material.
在各监测时间段中采集提取增材材料的表面扫描图像，与工艺参数中的增材材料标准表面扫描图像进行比对，由此统计识别增材材料表面裂纹、凹陷和气泡的总数量，并提取材料分析数据库中存储的单位裂纹数量对应的质量影响因子、界定凹陷数量和界定气泡数量，经处理得到增材材料的表面质量符合计量值。Surface scanning images of the additive material are collected and extracted in each monitoring time period, and compared with the standard surface scanning images of the additive material in the process parameters, so as to statistically identify the total number of cracks, depressions and bubbles on the surface of the additive material, and extract the quality influencing factors, defined depression numbers and defined bubble numbers corresponding to the unit crack number stored in the material analysis database. After processing, the surface quality of the additive material is obtained to meet the measurement value.
需要说明的是，增材材料的表面质量符合计量值表示通过对各监测时间段中增材材料表面裂纹、凹陷和气泡的总数量进行数据分析处理，得到的用于分析增材材料表面质量的量化结果，并作为增材材料的沉积质量表征值的分析依据，在实施例中，不仅可以通过色差计或光谱仪等设备对增材材料表面的颜色差异进行测量和分析，根据颜色差异的大小和范围，分析得到增材材料的表面质量符合计量值，还可以通过以下分析方法获得，具体的分析条件如下：It should be noted that the surface quality of the additive material conforming to the metered value indicates that the quantitative result for analyzing the surface quality of the additive material is obtained by performing data analysis and processing on the total number of cracks, depressions and bubbles on the surface of the additive material in each monitoring time period, and is used as the analysis basis for the deposition quality characterization value of the additive material. In the embodiment, not only can the color difference on the surface of the additive material be measured and analyzed by a colorimeter or a spectrometer and other equipment, but also the surface quality of the additive material conforming to the metered value can be obtained by analyzing the size and range of the color difference. The following analysis method can also be used to obtain the surface quality of the additive material. The specific analysis conditions are as follows:
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式中，表示增材材料的表面质量符合计量值，表示第个监测时间段中增材材料表面单位裂纹数量，表示增材材料表面单位裂纹数量对应的质量影响因子，表示第个监测时间段中凹陷的总数量，表示界定凹陷数量，表示设定的凹陷数量对应的补偿因子，表示第个监测时间段中气泡的总数量，表示界定气泡数量，表示设定的气泡数量对应的补偿因子，表示自然常数。In the formula, Indicates that the surface quality of the additive material meets the measured value, Indicates The number of unit cracks on the surface of the additive material in the monitoring time period, Represents the quality impact factor corresponding to the number of unit cracks on the surface of the additive material, Indicates The total number of depressions in the monitoring period, Indicates the number of defined depressions, Indicates the compensation factor corresponding to the set number of depressions, Indicates The total number of bubbles in the monitoring time period, Indicates the number of defined bubbles, Indicates the compensation factor corresponding to the set number of bubbles, Represents a natural constant.
在一个具体的实施例中，增材材料表面单位裂纹数量对应的质量影响因子，收集历史增材材料表面单位裂纹数量，计算出每个监测时间段中增材材料表面单位裂纹数量相对于上一个监测时间段中增材材料表面单位裂纹数量的偏差，经过统计分析，探究出增材材料表面单位裂纹数量与增材材料的表面质量符合计量值的相关性，经假设分析，得出增材材料表面单位裂纹数量的偏差每减少1%，增材材料的表面质量符合计量值增加0.002，则增材材料表面单位裂纹数量对应的质量影响因子=0.002，同理，经假设分析，得出凹陷数量偏差减少5%，增材材料的表面质量符合计量值增加0.003，则凹陷数量对应的补偿因子=0.003，同理，经假设分析，得出气泡数量偏差减少1%，增材材料的表面质量符合计量值增加0.01，则气泡数量对应的补偿因子=0.01。In a specific embodiment, the quality influence factor corresponding to the number of unit cracks on the surface of the additive material is collected, and the historical number of unit cracks on the surface of the additive material is collected. The deviation of the number of unit cracks on the surface of the additive material in each monitoring time period relative to the number of unit cracks on the surface of the additive material in the previous monitoring time period is calculated. After statistical analysis, the correlation between the number of unit cracks on the surface of the additive material and the surface quality of the additive material is found to meet the measurement value. After hypothesis analysis, it is concluded that for every 1% decrease in the deviation of the number of unit cracks on the surface of the additive material, the surface quality of the additive material meets the measurement value by 0.002, then the quality influence factor corresponding to the number of unit cracks on the surface of the additive material = 0.002. Similarly, after hypothesis analysis, it is concluded that if the deviation of the number of depressions decreases by 5%, the surface quality of the additive material meets the measurement value by 0.003, then the compensation factor corresponding to the number of depressions = 0.003. Similarly, after hypothesis analysis, it is concluded that if the deviation of the number of bubbles decreases by 1%, the surface quality of the additive material meets the measurement value by 0.01, then the compensation factor corresponding to the number of bubbles = 0.01.
本实施方案中，通过激光扫描仪采集提取增材材料的表面扫描图像，进而分析增材材料表面裂纹、凹陷和气泡的总数量，得到增材材料的表面质量符合计量值。In this embodiment, a surface scanning image of the additive material is collected and extracted by a laser scanner, and then the total number of cracks, depressions and bubbles on the surface of the additive material is analyzed to obtain a surface quality of the additive material that meets the measurement value.
本实施方案中，通过监测分析增材材料表面裂纹、凹陷和气泡的总数量，分析得到增材材料的表面质量符合计量值，为增材制造过程中的操作方法进行调整和优化，有助于减少增材制造过程中因材料的应力集中产生的疲劳裂纹，提高最终增材材料的质量。In this embodiment, by monitoring and analyzing the total number of cracks, depressions and bubbles on the surface of the additive material, it is analyzed that the surface quality of the additive material meets the measured value, and the operating methods in the additive manufacturing process are adjusted and optimized, which helps to reduce fatigue cracks caused by stress concentration of the material during the additive manufacturing process and improve the quality of the final additive material.
具体地，得到增材材料的沉积质量表征值，具体分析过程为：根据增材材料的沉积速率均匀值、增材材料的加热源的运行稳定指数以及增材材料的表面质量符合计量值，综合分析得到增材材料的沉积质量表征值。Specifically, the deposition quality characterization value of the additive material is obtained, and the specific analysis process is: according to the uniform value of the deposition rate of the additive material, the operation stability index of the heating source of the additive material and the surface quality compliance measurement value of the additive material, the deposition quality characterization value of the additive material is obtained through comprehensive analysis.
本实施方案中，根据增材材料的沉积速率均匀值、增材材料的加热源的运行稳定指数以及增材材料的表面质量符合计量值，综合分析得到增材材料的沉积质量表征值，有助于提高增材材料沉积质量的稳定性，从而提高增材制造过程的制造效率。In this embodiment, based on the uniform value of the deposition rate of the additive material, the operating stability index of the heating source of the additive material, and the surface quality compliance value of the additive material, a comprehensive analysis is performed to obtain a deposition quality characterization value of the additive material, which helps to improve the stability of the deposition quality of the additive material, thereby improving the manufacturing efficiency of the additive manufacturing process.
匹配得到激光器的输出功率，具体匹配过程为：根据增材材料的沉积质量表征值，与设定的各增材材料的沉积质量表征值区间对应的激光器的输出功率进行比对，得到激光器的输出功率。The output power of the laser is obtained by matching. The specific matching process is: according to the deposition quality characterization value of the additive material, the output power of the laser corresponding to the set deposition quality characterization value interval of each additive material is compared to obtain the output power of the laser.
需要说明的是，激光器的输出功率表示根据增材材料根据增材材料的沉积质量表征值与设定的各增材材料的沉积质量表征值区间对应的激光器的输出功率进行比对，得到的用于分析激光器输出过程中功率稳定性的量化结果，并作为增材材料的支撑结构稳定表征值的分析依据，在实施例中，可以使用专业的激光功率计来直接测量激光器的输出功率，这种方法能够提供实时的、准确的输出功率数值。It should be noted that the output power of the laser is expressed by comparing the deposition quality characterization value of the additive material with the output power of the laser corresponding to the set deposition quality characterization value interval of each additive material, and the quantitative result obtained is used to analyze the power stability during the laser output process, and serves as the basis for analyzing the stability characterization value of the support structure of the additive material. In an embodiment, a professional laser power meter can be used to directly measure the output power of the laser. This method can provide real-time and accurate output power values.
本实施方案中，根据增材材料的沉积质量表征值，与设定的各增材材料的沉积质量表征值区间对应的激光器的输出功率进行比对，匹配得到激光器的输出功率。In this embodiment, the deposition quality characterization value of the additive material is compared with the output power of the laser corresponding to the set deposition quality characterization value interval of each additive material to match the output power of the laser.
具体地，增材材料的沉积质量表征值表示通过对增材材料沉积阶段进行监测分析，得到的用于分析增材制造过程中增材材料沉积的质量状况程度的量化结果，并作为激光器的输出功率的分析根据。Specifically, the deposition quality characterization value of the additive material represents a quantitative result obtained by monitoring and analyzing the deposition stage of the additive material, which is used to analyze the quality status of the additive material deposition in the additive manufacturing process, and serves as a basis for analyzing the output power of the laser.
具体地，得到增材材料的支撑结构稳定表征值，具体分析过程为：设置监测周期，在监测周期中对增材材料的支撑结构生成阶段进行监测分析，采集增材材料的三维图像，从增材材料的三维图像中提取增材材料的空隙率、支撑结构的数量和支撑结构的高度。Specifically, a stable characterization value of the support structure of the additive material is obtained, and the specific analysis process is: setting a monitoring period, monitoring and analyzing the support structure generation stage of the additive material during the monitoring period, collecting a three-dimensional image of the additive material, and extracting the porosity of the additive material, the number of support structures, and the height of the support structures from the three-dimensional image of the additive material.
需要说明的是，增材材料的空隙率表示增材材料的内部空隙的体积与增材材料总体积之比，增材材料的支撑结构的数量表示增材制造过程中为了支撑材料悬空部分而添加的支撑结构的数量，增材材料的支撑结构的高度表示支撑结构与支撑结构构件表面之间的高度。It should be noted that the porosity of the additive material refers to the ratio of the volume of the internal voids of the additive material to the total volume of the additive material, the number of support structures of the additive material refers to the number of support structures added during the additive manufacturing process to support the suspended parts of the material, and the height of the support structure of the additive material refers to the height between the support structure and the surface of the support structure component.
提取材料分析数据库中存储的参照空隙率、参照支撑结构的数量以及参照支撑结构的高度，经处理得到增材材料的支撑结构第一符合表征值。The reference porosity, the number of reference support structures, and the height of the reference support structures stored in the material analysis database are extracted and processed to obtain a first conforming characterization value of the support structure of the additive material.
需要说明的是，增材材料的支撑结构第一符合表征值表示通过对增材材料的空隙率、支撑结构的数量和支撑结构的高度进行数据分析处理，得到的用于分析增材材料稳定结构的量化结果，并作为增材材料的支撑结构稳定表征值的分析依据，在实施例中，不仅可以通过分析增材材料支撑结构的形状特征和表面的连接方式，得到增材材料的支撑结构第一符合表征值，还可以通过以下分析方法获得，具体的分析条件如下：It should be noted that the first conforming characterization value of the support structure of the additive material represents a quantitative result for analyzing the stable structure of the additive material obtained by performing data analysis and processing on the porosity of the additive material, the number of support structures, and the height of the support structures, and serves as an analysis basis for the stable characterization value of the support structure of the additive material. In the embodiment, the first conforming characterization value of the support structure of the additive material can be obtained not only by analyzing the shape characteristics and the surface connection mode of the support structure of the additive material, but also by the following analysis method. The specific analysis conditions are as follows:
； ;
式中，表示增材材料的支撑结构第一符合表征值，表示第个监测时间段中增材材料的空隙率，表示参照空隙率，表示设定的空隙率对应的补偿因子，表示第个监测时间段中增材材料的支撑结构的数量，表示参照支撑结构的数量，表示设定的支撑结构的数量对应的补偿因子，表示第个监测时间段中增材材料的支撑结构的高度，表示参照支撑结构的高度，表示设定的支撑结构的高度对应的修正因子。In the formula, Indicates the first compliance characterization value of the support structure of the additive material, Indicates The void fraction of the additive material during the monitoring period, represents the reference void ratio, Indicates the compensation factor corresponding to the set void ratio, Indicates The number of support structures of the additive material during the monitoring period, represents the number of reference support structures, Indicates the compensation factor corresponding to the set number of support structures, Indicates The height of the support structure of the additive material during the monitoring period, represents the height of the reference support structure, Indicates the correction factor corresponding to the set support structure height.
在一个具体的实施例中，空隙率对应的补偿因子，收集历史空隙率，计算出每个监测时间段中空隙率相对于上一个监测时间段中空隙率的偏差，经过统计分析，探究出空隙率与增材材料的支撑结构第一符合表征值的相关性，经假设分析，得出空隙率偏差每增加1%，支撑结构第一符合表征值减少0.001，则空隙率对应的补偿因子=0.001，同理，经假设分析，得出支撑结构的数量偏差每增加1%，支撑结构第一符合表征值减少0.02，则支撑结构的数量的补偿因子=0.02，同理，经假设分析，得出支撑结构的高度偏差每增加1%，支撑结构第一符合表征值减少0.003，则支撑结构的高度的补偿因子=0.003。In a specific embodiment, the compensation factor corresponding to the void ratio collects historical void ratios, calculates the deviation of the void ratio in each monitoring time period relative to the void ratio in the previous monitoring time period, and through statistical analysis, explores the correlation between the void ratio and the first compliance characterization value of the support structure of the additive material. After hypothesis analysis, it is found that for every 1% increase in the void ratio deviation, the first compliance characterization value of the support structure decreases by 0.001, then the compensation factor corresponding to the void ratio = 0.001. Similarly, after hypothesis analysis, it is found that for every 1% increase in the deviation of the number of support structures, the first compliance characterization value of the support structure decreases by 0.02, then the compensation factor for the number of support structures = 0.02. Similarly, after hypothesis analysis, it is found that for every 1% increase in the deviation of the height of the support structure, the first compliance characterization value of the support structure decreases by 0.003, then the compensation factor for the height of the support structure = 0.003.
本实施方案中，通过三维摄像机采集增材材料的三维图像，提取增材材料的空隙率、支撑结构的数量和支撑结构的高度，进而分析得到增材材料的支撑结构第一符合表征值。In this embodiment, a three-dimensional image of the additive material is captured by a three-dimensional camera, the porosity of the additive material, the number of support structures and the height of the support structures are extracted, and then the first conformity characterization value of the support structure of the additive material is obtained by analysis.
本实施方案中，分析增材材料的空隙率，可以制定合理的质量检测标准，优化增材制造流程，分析增材材料支撑结构的数量和高度，可以优化支撑结构的设计，减少不必要的材料消耗，有助于提高材料利用率，降低成本，并减少废料的产生。In this embodiment, the porosity of the additive material is analyzed to formulate reasonable quality inspection standards and optimize the additive manufacturing process. The number and height of the additive material support structure are analyzed to optimize the design of the support structure and reduce unnecessary material consumption, which helps to improve material utilization, reduce costs, and reduce waste generation.
从增材材料的三维图像中提取增材材料各支撑结构构件表面的直径和厚度，并提取材料分析数据库中存储的各支撑结构构件表面的参照直径和参照厚度，经处理得到增材材料的支撑结构第二符合表征值。The diameter and thickness of the surface of each supporting structure component of the additive material are extracted from the three-dimensional image of the additive material, and the reference diameter and reference thickness of the surface of each supporting structure component stored in the material analysis database are extracted, and the second conforming characterization value of the supporting structure of the additive material is obtained after processing.
需要说明的是，增材材料的支撑结构第二符合表征值表示通过对增材材料各支撑结构构件表面的直径和厚度进行数据分析处理，得到的用于评估增材材料各支撑结构的稳定性和承载能力的量化结果，并作为增材材料的支撑结构稳定表征值的分析依据，在实施例中，不仅可以通过分析支撑结构的形状、分支程度、交叉点的密度，得到增材材料的支撑结构第二符合表征值，还可以通过以下计算方法获得，具体的分析条件如下：It should be noted that the second conforming characterization value of the support structure of the additive material represents a quantitative result obtained by performing data analysis and processing on the diameter and thickness of the surface of each support structure component of the additive material, which is used to evaluate the stability and load-bearing capacity of each support structure of the additive material, and serves as an analysis basis for the stability characterization value of the support structure of the additive material. In the embodiment, the second conforming characterization value of the support structure of the additive material can be obtained not only by analyzing the shape, branching degree, and density of intersections of the support structure, but also by the following calculation method. The specific analysis conditions are as follows:
； ;
式中，表示增材材料的支撑结构第二符合表征值，表示第个监测时间段中增材材料第个支撑结构构件表面的直径，表示参照直径，表示设定的直径对应的补偿因子，表示第个监测时间段中增材材料第个支撑结构构件的厚度，表示参照厚度，表示设定的厚度对应的补偿因子，j表示各支撑结构构件的编号，，m表示支撑结构构件的总数。In the formula, Indicates the second most representative value of the support structure of the additive material, Indicates The additive material in the monitoring period The diameter of the surface of the supporting structural member, represents the reference diameter, Indicates the compensation factor corresponding to the set diameter, Indicates The additive material in the monitoring period The thickness of the supporting structural member, Indicates the reference thickness, represents the compensation factor corresponding to the set thickness,j represents the number of each supporting structure component, ,m represents the total number of supporting structure members.
需要说明的是，表2为不同增材材料支撑结构构件表面的直径、直径对应的补偿因子、支撑结构构件厚度及厚度对应的补偿因子。It should be noted that Table 2 shows the diameter of the surface of the supporting structure component of different additive materials, the compensation factor corresponding to the diameter, the thickness of the supporting structure component and the compensation factor corresponding to the thickness.
表2 不同增材材料支撑结构构件表面的直径、直径对应的补偿因子、支撑结构构件厚度及厚度对应的补偿因子Table 2 The diameter of the surface of the support structure components of different additive materials, the compensation factor corresponding to the diameter, the thickness of the support structure components and the compensation factor corresponding to the thickness
本实施方案中，通过光学扫描仪采集增材材料的三维图像，提取增材材料各支撑结构构件表面的直径和厚度，进而分析得到增材材料的支撑结构第二符合表征值。In this embodiment, an optical scanner is used to collect a three-dimensional image of the additive material, and the diameter and thickness of the surface of each supporting structure component of the additive material are extracted, and then the second conformity characterization value of the supporting structure of the additive material is obtained by analysis.
本实施方案中，通过对增材材料各支撑结构构件表面的直径和厚度进行数据分析处理，得到增材材料的支撑结构第二符合表征值，有助于评估增材材料支撑结构的稳定性，同时提高构建的表面质量和几何精度，减少对构建表面的影响，优化增材制造流程的效率和质量。In this embodiment, by performing data analysis and processing on the diameter and thickness of the surface of each supporting structure component of the additive material, a second conformity characterization value of the supporting structure of the additive material is obtained, which helps to evaluate the stability of the supporting structure of the additive material, while improving the surface quality and geometric accuracy of the build, reducing the impact on the build surface, and optimizing the efficiency and quality of the additive manufacturing process.
根据增材材料的支撑结构第一符合表征值和增材材料的支撑结构第二符合表征值，整合分析得到增材材料的支撑结构稳定表征值。According to the first conforming characterization value of the support structure of the additive material and the second conforming characterization value of the support structure of the additive material, a stable characterization value of the support structure of the additive material is obtained through integrated analysis.
具体地，增材材料的支撑结构稳定表征值表示通过对增材材料的支撑结构生成阶段，得到的用于分析增材材料在支撑结构生成阶段的质量稳定性的量化结果，并作为分析增材材料的质量反馈结果的依据。Specifically, the support structure stability characterization value of the additive material represents a quantitative result obtained through the support structure generation stage of the additive material, which is used to analyze the quality stability of the additive material during the support structure generation stage, and serves as a basis for analyzing the quality feedback results of the additive material.
具体地，执行控制预警提示，具体预警过程为：根据增材材料的支撑结构稳定表征值，与设定的增材材料的支撑结构稳定表征阈值进行对比，得到增材材料的质量反馈结果，增材材料的质量反馈结果为执行控制预警提示或不执行控制预警提示，若增材材料的支撑结构稳定表征值低于设定的增材材料的支撑结构稳定表征阈值，则执行控制预警提示，若增材材料的支撑结构稳定表征值不低于设定的增材材料的支撑结构稳定表征阈值，则不执行控制预警提示。Specifically, a control warning prompt is executed, and the specific warning process is: according to the support structure stability characterization value of the additive material, it is compared with the set support structure stability characterization threshold of the additive material to obtain the quality feedback result of the additive material. The quality feedback result of the additive material is to execute the control warning prompt or not to execute the control warning prompt. If the support structure stability characterization value of the additive material is lower than the set support structure stability characterization threshold of the additive material, the control warning prompt is executed; if the support structure stability characterization value of the additive material is not lower than the set support structure stability characterization threshold of the additive material, the control warning prompt is not executed.
需要说明的是，表3为不同支撑结构类型对应的支撑结构稳定表征阈值。It should be noted that Table 3 shows the support structure stability characterization thresholds corresponding to different support structure types.
表3 不同支撑结构类型对应的支撑结构稳定表征阈值Table 3 Support structure stability characterization thresholds corresponding to different support structure types
本实施方案中，通过对比分析增材材料的支撑结构稳定表征值与设定的增材材料的支撑结构稳定表征阈值，进一步能够及时对增材材料的质量进行反馈提示，进而对增材制造控制流程进行有效处理，提升产品的质量，提高增材材料的利用率。In this implementation, by comparing and analyzing the support structure stability characterization value of the additive material and the set support structure stability characterization threshold of the additive material, timely feedback on the quality of the additive material can be further provided, thereby effectively processing the additive manufacturing control process, improving product quality, and increasing the utilization rate of the additive material.
具体地，增材材料的沉积质量表征值，不仅可以使用历史数据进行模式识别和分析得到，还可以通过以下计算方法获得，具体分析条件为：Specifically, the deposition quality characterization value of the additive material can be obtained not only by pattern recognition and analysis using historical data, but also by the following calculation method. The specific analysis conditions are:
； ;
式中，表示增材材料的沉积质量表征值，表示增材材料的沉积速率均匀值，表示设定的增材材料的沉积速率均匀值对应的权重因子，表示增材材料的加热源的运行稳定指数，表示设定的增材材料的加热源的运行稳定指数对应的权重因子，表示增材材料的表面质量符合计量值，表示设定的增材材料的表面质量符合计量值对应的权重因子，表示自然常数。In the formula, represents the deposition quality characterization value of the additive material, represents the average value of the deposition rate of the additive material, Represents the weight factor corresponding to the average value of the deposition rate of the set additive material, Indicates the operational stability index of the heating source of the additive material, Indicates the weight factor corresponding to the operating stability index of the heating source of the set additive material, Indicates that the surface quality of the additive material meets the measured value, Indicates that the surface quality of the set additive material meets the weight factor corresponding to the measurement value, Represents a natural constant.
需要说明的是，增材材料的沉积速率均匀值对应的权重因子与增材材料的加热源的运行稳定指数对应的权重因子及增材材料的表面质量符合计量值对应的权重因子之和为1。It should be noted that the sum of the weight factor corresponding to the uniform value of the deposition rate of the additive material, the weight factor corresponding to the operation stability index of the heating source of the additive material, and the weight factor corresponding to the surface quality of the additive material conforming to the measurement value is 1.
需要说明的是，表4为不同增材材料的增材材料的沉积速率均匀值对应的权重因子与增材材料的加热源的运行稳定指数对应的权重因子及增材材料的表面质量符合计量值对应的权重因子。It should be noted that Table 4 shows the weight factors corresponding to the uniform values of the deposition rates of the additive materials of different additive materials, the weight factors corresponding to the operating stability indexes of the heating sources of the additive materials, and the weight factors corresponding to the surface quality compliance measurement values of the additive materials.
表4 不同增材材料的沉积速率均匀值与加热源的运行稳定指数及表面质量符合计量值分别对应的权重因子Table 4 Weight factors corresponding to the deposition rate uniformity of different additive materials, the operation stability index of the heating source, and the surface quality compliance measurement value
具体地，增材材料的支撑结构稳定表征值，不仅可以使用历史数据进行模式识别和分析得到，还可以通过以下计算方法获得，具体分析条件为：Specifically, the stability characterization value of the support structure of the additive material can be obtained not only by pattern recognition and analysis using historical data, but also by the following calculation method. The specific analysis conditions are:
； ;
式中，表示增材材料的支撑结构稳定表征值，表示增材材料的支撑结构第一符合表征值，表示设定的增材材料的支撑结构第一符合表征值对应的权重因子，表示增材材料的支撑结构第二符合表征值，表示设定的增材材料的支撑结构第二符合表征值对应的权重因子。In the formula, Indicates the stability characterization value of the support structure of the additive material, Indicates the first compliance characterization value of the support structure of the additive material, Indicates the weight factor corresponding to the first conformity characterization value of the support structure of the set additive material, Indicates the second most representative value of the support structure of the additive material, The weight factor corresponding to the second conformity characterization value of the support structure of the set additive material.
需要说明的是，增材材料的支撑结构第一符合表征值对应的权重因子与增材材料的支撑结构第二符合表征值对应的权重因子之和为1。It should be noted that the sum of the weight factor corresponding to the first conforming characterization value of the support structure of the additive material and the weight factor corresponding to the second conforming characterization value of the support structure of the additive material is 1.
需要说明的是，表5为不同增材材料的支撑结构第一符合表征值对应的权重因子和支撑结构第二符合表征值对应的权重因子。It should be noted that Table 5 shows the weight factors corresponding to the first conformity characterization values of the support structures of different additive materials and the weight factors corresponding to the second conformity characterization values of the support structures.
表5 不同增材材料的支撑结构第一符合表征值和支撑结构第二符合表征值分别对应的权重因子Table 5 Weight factors corresponding to the first and second compliant characterization values of the support structure of different additive materials
本发明第二方面还提供一种基于数据分析的智能增材制造流程控制系统，包括增材制造流程划分模块，用于通过云端获取增材材料的工艺参数，并将增材制造流程划分为增材材料沉积阶段和支撑结构生成阶段。The second aspect of the present invention also provides an intelligent additive manufacturing process control system based on data analysis, including an additive manufacturing process division module, which is used to obtain the process parameters of the additive material through the cloud and divide the additive manufacturing process into an additive material deposition stage and a support structure generation stage.
增材材料沉积阶段监测分析模块，用于对增材材料沉积阶段进行监测分析，得到增材材料的沉积质量表征值，匹配得到激光器的输出功率。The additive material deposition phase monitoring and analysis module is used to monitor and analyze the additive material deposition phase, obtain the deposition quality characterization value of the additive material, and match the output power of the laser.
支撑结构生成阶段监测分析模块，用于对支撑结构生成阶段进行监测分析，并根据激光器的输出功率，得到增材材料的支撑结构稳定表征值，并执行控制预警提示。The support structure generation phase monitoring and analysis module is used to monitor and analyze the support structure generation phase, and obtain the support structure stability characterization value of the additive material according to the output power of the laser, and execute control early warning prompts.
需要说明的是，一种基于基于数据分析的智能增材制造流程控制系统还包括材料分析数据库，用于存储的单位裂纹数量对应的质量影响因子、界定凹陷数量和界定气泡数量、参照空隙率、参照支撑结构的数量、参照支撑结构的高度及支撑结构构件表面的参照直径和参照厚度。It should be noted that an intelligent additive manufacturing process control system based on data analysis also includes a material analysis database, which is used to store the quality influencing factors corresponding to the number of unit cracks, the defined number of depressions and the defined number of bubbles, the reference porosity, the number of reference support structures, the height of the reference support structures, and the reference diameter and reference thickness of the surface of the support structure components.
需要说明的是，在本文中，诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.
以上公开的本发明优选实施例只是用于帮助阐述本发明。优选实施例并没有详尽叙述所有的细节，也不限制该发明仅为所述的具体实施方式。显然，根据本说明书的内容，可作很多的修改和变化。本说明书选取并具体描述这些实施例，是为了更好地解释本发明的原理和实际应用，从而使所属技术领域技术人员能很好地理解和利用本发明。本发明仅受权利要求书及其全部范围和等效物的限制。The preferred embodiments of the present invention disclosed above are only used to help illustrate the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to the specific implementation methods described. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.
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