CN110954542A - Defect detection device, defect detection system and defect detection method for additive manufacturing - Google Patents
Defect detection device, defect detection system and defect detection method for additive manufacturing Download PDFInfo
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Abstract
The defect detection device comprises a laser generation mechanism, a laser detection mechanism and a control mechanism, wherein the control mechanism is respectively connected with the laser generation mechanism and the laser detection mechanism and is used for controlling the laser generation mechanism to emit first laser to an additive manufacturing piece in the additive manufacturing process, controlling the laser detection mechanism to emit second laser to the additive manufacturing piece so as to detect a radiation signal generated by the first laser and receiving a detection signal fed back by the laser detection mechanism. The invention can realize the defect detection of the additive manufactured parts, has simple structure, good detection real-time performance and high precision, can avoid the problem of surface blind areas of the additive manufactured parts, and is beneficial to improving the quality of finished products of the additive manufactured parts.
Description
Technical Field
The invention relates to the field of additive manufacturing, in particular to a defect detection device, a defect detection system and a defect detection method for additive manufacturing.
Background
The additive manufacturing technology is a technology for manufacturing a solid part by designing data through a Computer Aided Design (CAD) and adopting a material layer-by-layer accumulation method, and the additive manufacturing technology thoroughly subverts a top-down research strategy adopted by a traditional material removal (namely, cutting processing) technology, and is a bottom-up material accumulation manufacturing method.
The internal quality of the additive product is one of the bottleneck problems restricting the development of the laser additive manufacturing process. Based on the technical principles of point-by-point scanning melting, line-by-line scanning lapping and layer-by-layer accumulation forming in laser additive manufacturing, a metal material is subjected to complex thermodynamic behaviors under the action of laser, and is influenced by various conditions such as laser parameters, scanning parameters, powder materials, temperature and the like in the cyclic reciprocating process of heating melting, molten pool flowing and cooling solidification.
The inventors of the present application have found, through long-term research and development, that the defect detection in the conventional additive manufacturing adopts common inspection means such as ultrasonic flaw detection and X-ray detection, and the defect detection has low precision, and cannot detect pores of 0.1mm or less and non-fusion defects. In addition, the existing detection method mainly carries out off-line detection on the formed additive parts, so that the detection real-time performance is poor, a large number of unqualified products are easy to generate, and the additive manufacturing cost is increased. Meanwhile, compared with the traditional manufacturing method, the additive manufacturing method has the advantages that the machining allowance of the surface of the part is small, and surface blind areas exist in more detection methods, so that partial areas cannot be detected, and the quality hidden danger exists.
Disclosure of Invention
The invention provides a defect detection device, a defect detection system and a defect detection method for additive manufacturing, and aims to solve the technical problems that in the prior art, the defect detection range of an additive product is small and the precision is low.
In order to solve the technical problem, one technical scheme adopted by the invention is to provide a defect detection device for additive manufacturing, which comprises a laser generation mechanism, a laser detection mechanism and a control mechanism, wherein the control mechanism is respectively connected with the laser generation mechanism and the laser detection mechanism and is used for controlling the laser generation mechanism to emit first laser to an additive manufactured piece in the additive manufacturing process, controlling the laser detection mechanism to emit second laser to the additive manufactured piece so as to detect a radiation signal generated by the first laser and receiving a detection signal fed back by the laser detection mechanism.
In a specific embodiment, the defect detecting apparatus further includes a robot, the robot is connected to the control mechanism, the laser generating mechanism is a pulse laser, and the pulse laser is configured to generate the first laser and emit the first laser through a first lens disposed on the robot.
In a specific embodiment, the laser detection mechanism is a laser interference detector for generating the second laser light and emitting the second laser light through a second lens disposed on the robot.
In a specific embodiment, control mechanism includes host computer management mechanism, AD acquisition mechanism, signal conditioning mechanism and robot control mechanism, host computer management mechanism respectively with AD acquisition mechanism with robot control mechanism connects, AD acquisition mechanism respectively with pulse laser with the laser interference detector is connected, signal conditioning mechanism respectively with AD acquisition mechanism with the laser interference detector is connected, robot control mechanism with the robot is connected.
In order to solve the technical problem, another technical solution of the present invention is to provide a defect detection system for additive manufacturing, including an additive manufacturing apparatus and the defect detection apparatus, where the defect detection apparatus is configured to perform defect detection on an additive manufactured part prepared by the additive manufacturing apparatus.
In a specific embodiment, the additive manufacturing apparatus includes a workbench, a material supply mechanism disposed corresponding to the workbench, and an additive manufacturing laser disposed corresponding to the material supply mechanism, and the additive manufacturing laser is connected to the control mechanism to act on the material supply mechanism under the control of the control mechanism, so as to prepare the additive manufactured part on the workbench and adjust a manufacturing process according to the detection signal.
In order to solve the above technical problem, another technical solution adopted by the present invention is to provide a method for detecting defects in additive manufacturing, including:
the control mechanism controls the laser generating mechanism to emit first laser to the additive manufacturing part so as to generate a radiation signal;
the control mechanism controls the laser detection mechanism to emit second laser to the additive manufacturing part so as to detect the radiation signal;
and the control mechanism receives a detection signal fed back by the laser detection mechanism.
In a specific embodiment, the controlling mechanism controls the laser generating mechanism to emit the first laser to the additive manufactured part, and the controlling mechanism controls the laser detecting mechanism to emit the second laser to the additive manufactured part specifically includes:
the upper computer management mechanism sends a first control signal and a second control signal to the A/D acquisition mechanism;
the A/D acquisition mechanism controls a pulse laser to generate the first laser according to the first control signal and transmits the first laser to the additive manufacturing piece through a first lens;
and the A/D acquisition mechanism controls the laser interference detector to generate second laser according to the second control signal, and the second laser is emitted to the additive manufacturing piece through a second lens.
In a specific embodiment, the receiving the detection signal fed back by the laser detection mechanism specifically includes:
and the laser interference detector sends the detection signal to an upper computer management mechanism through a signal conditioning mechanism and an A/D acquisition mechanism in sequence.
In a specific embodiment, after receiving the detection signal fed back by the laser detection mechanism, the method further includes:
the upper computer management mechanism processes the detection signal to generate a third control signal;
sending the third control signal to an additive manufacturing device to adjust a manufacturing process of the additive manufacturing device.
According to the invention, by arranging the control mechanism respectively connected with the laser generating mechanism and the laser detecting mechanism, the laser generating mechanism can emit first laser to the additive manufactured part in the additive manufacturing process, the laser detecting mechanism emits second laser to the additive manufactured part to detect a radiation signal generated by the first laser and receives a detection signal fed back by the laser detecting mechanism, so that the defect detection of the additive manufactured part is realized, the structure is simple and easy to realize, the detection real-time performance is good, the precision is high, the problem of a surface blind area of the additive manufactured part can be avoided, and the improvement of the finished product quality of the additive manufactured part is facilitated.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without inventive efforts, wherein:
FIG. 1 is a schematic structural diagram of an embodiment of a defect detection apparatus for additive manufacturing according to the present invention;
FIG. 2 is a schematic diagram of a robot in an embodiment of an additive manufacturing defect detection apparatus of the present invention;
FIG. 3 is a schematic diagram of a defect detection system for additive manufacturing according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of an additive manufacturing apparatus in an embodiment of a defect detection system for additive manufacturing according to the present invention;
FIG. 5 is a schematic flow chart diagram illustrating a defect detection method for additive manufacturing according to an embodiment of the present invention;
FIG. 6 is a schematic flow chart diagram illustrating a defect detection method for additive manufacturing according to another embodiment of the present invention;
fig. 7 is a schematic diagram of laser scanning on an additive manufactured part in another embodiment of a defect detection method for additive manufacturing according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
The terms "first" and "second" in this application are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. In the description of the present application, "plurality" means at least two, e.g., two, three, etc., unless explicitly specifically limited otherwise. Furthermore, the terms "include" and "have," as well as any variations thereof, are intended to cover non-exclusive inclusions. For example, a process, method, system, article, or apparatus that comprises a list of steps or elements is not limited to only those steps or elements listed, but may alternatively include other steps or elements not listed, or inherent to such process, method, article, or apparatus. While the term "and/or" is merely one type of association that describes an associated object, it means that there may be three types of relationships, e.g., a and/or B, which may mean: a exists alone, A and B exist simultaneously, and B exists alone. In addition, the character "/" herein generally indicates that the former and latter related objects are in an "or" relationship.
Referring to fig. 1, an embodiment of a defect detection apparatus 10 for additive manufacturing according to the present invention includes a laser generating mechanism, a laser detecting mechanism, and a control mechanism 300, where the control mechanism 300 is connected to the laser generating mechanism and the laser detecting mechanism, respectively, and is configured to control the laser generating mechanism to emit first laser to an additive manufactured part in an additive manufacturing process, control the laser detecting mechanism to emit second laser to the additive manufactured part to detect a radiation signal generated by the first laser, and receive a detection signal fed back by the laser detecting mechanism.
According to the embodiment of the invention, the control mechanism 300 respectively connected with the laser generating mechanism and the laser detecting mechanism is arranged, so that the laser generating mechanism can emit the first laser to the additive manufacturing part in the additive manufacturing process, the laser detecting mechanism emits the second laser to the additive manufacturing part to detect the radiation signal generated by the first laser and receives the detection signal fed back by the laser detecting mechanism, the defect detection of the additive manufacturing part is realized, the structure is simple and easy to realize, the detection real-time performance is good, the precision is high, the problem of surface blind area of the additive manufacturing part can be avoided, and the improvement of the finished product quality of the additive manufacturing part is facilitated.
Referring to fig. 2, in the present embodiment, the defect detecting apparatus 10 further includes a robot 400, the robot 400 is connected to the control mechanism 300, the laser generating mechanism is a pulse laser 100, and the pulse laser 100 is configured to generate a first laser and emit the first laser through a first lens 410 disposed on the robot 400.
In this embodiment, the pulsed laser 100 may be a Nd: YAG (Neodymium-doped yttrium aluminum Garnet) pulsed laser.
In the present embodiment, the laser detection mechanism is a laser interference detector 200, and the laser interference detector 200 is configured to generate the second laser light and emit the second laser light through a second lens 420 disposed on the robot 400.
In this embodiment, the first laser light generated by the pulse laser 100 may be emitted to the first lens 410 through an optical fiber, and the second laser light generated by the laser interference detector 200 may be emitted to the second lens 420 through an optical fiber.
In this embodiment, the control mechanism 300 includes an upper computer management mechanism 310, an Analog/Digital (a/D) acquisition mechanism 320, a signal conditioning mechanism 330, and a robot control mechanism 340, where the upper computer management mechanism 310 is connected to the a/D acquisition mechanism 320 and the robot control mechanism 340, the a/D acquisition mechanism 320 is connected to the pulse laser 100 and the laser interference detector 200, the signal conditioning mechanism 330 is connected to the a/D acquisition mechanism 320 and the laser interference detector 200, and the robot control mechanism 340 is connected to the robot 400.
Referring to fig. 3, a defect detection system for additive manufacturing according to an embodiment of the present invention includes an additive manufacturing apparatus 500 and a defect detection apparatus 10, where the defect detection apparatus 10 is configured to perform defect detection on an additive manufactured article 600 prepared by the additive manufacturing apparatus 500. The specific structure of the defect detection apparatus 10 is described in the above embodiment of the defect detection apparatus 10, and is not described herein again.
Referring to fig. 4 together, in this embodiment, an additive manufacturing apparatus 500 includes a table 510, a material supply mechanism 520 disposed corresponding to the table 510, and an additive manufacturing laser 530 disposed corresponding to the material supply mechanism 520, where the additive manufacturing laser 530 is connected to the control mechanism 300 to act on the material supply mechanism 520 under the control of the control mechanism 300, so as to prepare an additive manufactured article 600 on the table 510, and adjust a manufacturing process according to a detection signal.
In this embodiment, the material supply mechanism 520 includes a powder feeder 521, a powder feeding nozzle 522, a focusing mirror 523, and a lens 524, where the powder feeder 521 is connected to the powder feeding nozzle 522 and is configured to provide a powder material to the powder feeding nozzle 522, the powder feeding nozzle 522 is configured to correspond to the workbench 510 and is configured to spray the powder material, the lens 524 is respectively configured to correspond to the additive manufacturing laser 530 and the powder feeding nozzle 522, the focusing mirror 523 is configured between the lens 524 and the powder feeding nozzle 522, and the lens 524 is configured to receive additive manufacturing laser light emitted by the additive manufacturing laser 530 and emit the additive manufacturing laser light to the powder feeding nozzle 522 after being focused by the focusing mirror 523 to act on the powder material, so as to form the additive manufactured part 600 on the workbench 510.
Referring to fig. 3 and 5, an embodiment of a defect detection method for additive manufacturing according to the present invention includes:
s710, the control mechanism 300 controls the laser generating mechanism to emit the first laser to the additive manufactured article 600 during the additive manufacturing process to generate the radiation signal.
S720, the control mechanism 300 controls the laser detection mechanism to emit the second laser to the additive manufacturing element 600, so as to detect the radiation signal.
S730, the control mechanism 300 receives the detection signal fed back by the laser detection mechanism.
According to the embodiment of the invention, the control mechanism 300 respectively connected with the laser generating mechanism and the laser detecting mechanism is arranged, so that the laser generating mechanism can emit the first laser to the additive manufacturing part in the additive manufacturing process, the laser detecting mechanism emits the second laser to the additive manufacturing part to detect the radiation signal generated by the first laser and receives the detection signal fed back by the laser detecting mechanism, the defect detection of the additive manufacturing part is realized, the structure is simple and easy to realize, the detection real-time performance is good, the precision is high, the problem of surface blind area of the additive manufacturing part can be avoided, and the improvement of the finished product quality of the additive manufacturing part is facilitated.
Referring to fig. 2, 3 and 6, another embodiment of the defect detection method of additive manufacturing of the present invention comprises:
s810, the upper computer management mechanism 310 sends an additive manufacturing signal to the additive manufacturing apparatus 500 to prepare the additive manufactured article 600.
S820, the upper computer management mechanism 310 sends a first control signal and a second control signal to the A/D acquisition mechanism 320.
In this embodiment, when the thickness of the additive manufactured article 600 is greater than or equal to the thickness threshold, the upper computer management mechanism 310 sends the first control signal and the second control signal. The upper computer management mechanism 310 may calculate a time required for the thickness of the additive manufacturing apparatus 600 to reach a thickness threshold according to the manufacturing efficiency of the additive manufacturing apparatus 500, and send the first control signal and the second control signal when the time is reached. The upper computer management mechanism 310 may also be connected to a height detection device (not shown in the figure), and send the first control signal and the second control signal when the height detection device detects that the thickness of the additive manufactured part 600 reaches the thickness threshold, which is not limited herein.
In this embodiment, the upper computer management mechanism 310 also sends a control signal to the robot 400 through the robot control mechanism 340 at the same time, so as to control the arm position of the robot 400 according to the position of the additive material 600 and adjust the positions of the first lens 410 and the second lens 420.
S830, the a/D collecting mechanism 320 controls the pulse laser 100 to generate a first laser according to the first control signal, and transmits the first laser to the additive manufacturing device 600 through the first lens 410.
And S840, the A/D acquisition mechanism 320 controls the laser interference detector 200 to generate second laser according to the second control signal, and the second laser is emitted to the additive manufacturing element 600 through the second lens 420.
In this embodiment, the upper computer management mechanism 310 may adjust the laser energy of the pulse laser 100 and the laser interference detector 200 according to the appearance roughness of the additive manufactured article 600.
Referring to fig. 7, the emitting point of the first laser is the excitation point M1、M2…MnAnd the emission point of the second laser is a detection point, wherein the distance between the excitation point and the detection point is less than L, so that the detection point can detect laser irradiation generated by the excitation point on the surface of the additive manufactured part 600.
Specifically, the excitation point generates laser irradiation due to a laser thermo-elastic effect to generate a transverse wave signal, a surface wave signal and a longitudinal wave signal, and when the surface and the inside of the additive manufactured piece have air holes 610 and are not fused, deformed or cracked, the longitudinal wave signal generates an echo signal when encountering a defect, and can be detected by the detection point.
In this embodiment, the distance between the excitation point and the detection point may be preset, and the upper computer management mechanism 310 sends a control signal to the robot control mechanism 340 to control the robot 400 according to the preset distance information between the excitation point and the detection point, so as to adjust the distance between the first lens 410 and the second lens 420, so that the distance between the excitation point and the detection point is smaller than L.
In other embodiments, the upper computer management mechanism 310 may also adjust the distance between the first lens 410 and the second lens 420 in real time during the detection process, which is not limited herein.
And S850, the laser interference detector 200 sends the detection signal to the upper computer management mechanism 310 through the signal conditioning mechanism 330 and the A/D acquisition mechanism 320 in sequence.
And S860, the upper computer management mechanism 310 processes the detection signal to generate a third control signal.
In this embodiment, the upper computer management mechanism 310 may store the defect information of the additive manufactured part 600 according to the detection signal, establish an additive manufacturing defect database for analysis and management, establish a defect prediction model, and further optimize the manufacturing process parameters of the additive manufactured part 600 to generate a third control signal.
S870, sending a third control signal to the additive manufacturing apparatus 500 to adjust the manufacturing process of the additive manufacturing apparatus 500, so as to reduce or remove the defect of the additive manufacturing apparatus 600 during the manufacturing process.
According to the embodiment of the invention, the control mechanism 300 respectively connected with the laser generating mechanism and the laser detecting mechanism is arranged, so that the laser generating mechanism can emit the first laser to the additive manufacturing part in the additive manufacturing process, the laser detecting mechanism emits the second laser to the additive manufacturing part to detect the radiation signal generated by the first laser and receives the detection signal fed back by the laser detecting mechanism, the defect detection of the additive manufacturing part is realized, the structure is simple and easy to realize, the detection real-time performance is good, the precision is high, the problem of surface blind area of the additive manufacturing part can be avoided, and the improvement of the finished product quality of the additive manufacturing part is facilitated.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes performed by the present specification and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. The defect detection device for additive manufacturing is characterized by comprising a laser generation mechanism, a laser detection mechanism and a control mechanism, wherein the control mechanism is respectively connected with the laser generation mechanism and the laser detection mechanism and used for controlling the laser generation mechanism to emit first laser to an additive manufactured piece in the additive manufacturing process, controlling the laser detection mechanism to emit second laser to the additive manufactured piece so as to detect a radiation signal generated by the first laser and receiving a detection signal fed back by the laser detection mechanism.
2. The apparatus of claim 1, further comprising a robot, the robot being connected to the control mechanism, the laser generating mechanism being a pulsed laser, the pulsed laser being configured to generate the first laser light and emit the first laser light through a first lens disposed on the robot.
3. The apparatus according to claim 2, wherein the laser detection mechanism is a laser interference detector for generating the second laser light and emitting the second laser light through a second lens provided on the robot.
4. The defect detecting device according to claim 3, wherein the control mechanism comprises an upper computer management mechanism, an A/D acquisition mechanism, a signal conditioning mechanism and a robot control mechanism, the upper computer management mechanism is respectively connected with the A/D acquisition mechanism and the robot control mechanism, the A/D acquisition mechanism is respectively connected with the pulse laser and the laser interference detector, the signal conditioning mechanism is respectively connected with the A/D acquisition mechanism and the laser interference detector, and the robot control mechanism is connected with the robot.
5. A defect detection system for additive manufacturing, comprising an additive manufacturing apparatus and the defect detection apparatus of any one of claims 1 to 4, wherein the defect detection apparatus is configured to perform defect detection on the additive manufactured part prepared by the additive manufacturing apparatus.
6. The system of claim 5, wherein the additive manufacturing apparatus comprises a worktable, a material supply mechanism disposed corresponding to the worktable, and an additive manufacturing laser disposed corresponding to the material supply mechanism, and the additive manufacturing laser is connected to the control mechanism to act on the material supply mechanism under the control of the control mechanism, so as to prepare the additive part on the worktable and adjust a manufacturing process according to the detection signal.
7. A method of defect detection for additive manufacturing, comprising:
the control mechanism controls the laser generation mechanism to emit first laser to the additive manufacturing part in the additive manufacturing process so as to generate a radiation signal;
the control mechanism controls the laser detection mechanism to emit second laser to the additive manufacturing part so as to detect the radiation signal;
and the control mechanism receives a detection signal fed back by the laser detection mechanism.
8. The method of claim 7, wherein the controlling mechanism controls the laser generating mechanism to emit the first laser to the additive manufactured part, and the controlling mechanism controls the laser detecting mechanism to emit the second laser to the additive manufactured part specifically includes:
the upper computer management mechanism sends a first control signal and a second control signal to the A/D acquisition mechanism;
the A/D acquisition mechanism controls a pulse laser to generate the first laser according to the first control signal and transmits the first laser to the additive manufacturing piece through a first lens;
and the A/D acquisition mechanism controls the laser interference detector to generate second laser according to the second control signal, and the second laser is emitted to the additive manufacturing piece through a second lens.
9. The method according to claim 7, wherein the receiving the detection signal fed back by the laser detection mechanism specifically comprises:
and the laser interference detector sends the detection signal to an upper computer management mechanism through a signal conditioning mechanism and an A/D acquisition mechanism in sequence.
10. The method of claim 7, wherein the receiving the detection signal fed back by the laser detection mechanism further comprises:
the upper computer management mechanism processes the detection signal to generate a third control signal;
sending the third control signal to an additive manufacturing device to adjust a manufacturing process of the additive manufacturing device.
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