CN112296336A - 一种柔性增减材制造方法 - Google Patents
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Abstract
本发明公布了一种柔性增减材制造方法及系统组成,建立了该制造方法的工艺流程,明确了各模块的作用和相互关系,在确立系统中的核心设备—材料沉积设备的集成条件的基础上,建立了柔性增减材制造系统的过程控制模型,规划了系统各组成设备的总体布局。这种制造方法将扩大现有增减材制造设备的适应范围,更加灵活匹配实际需求。
Description
技术领域
本发明涉及一种增减材制造方法,特别是涉及一种柔性增减材制造方法。
背景技术
增减材制造是继快速原形制造(RP)之后出现的另一种快速制造零件的方法。该方法的基本思想是把材料添加(增材)过程与机械切削(减材)过程进行结合,以充分发挥出两种制造方法的优点。增材制造可根据零件的材料不同而采用不同的方法,其每层材料的沉积厚度是根据零件的三维几何分层来确定,其优点是可采用较大厚度的材料层来提高零件的制造速度,减材制造则可消除常规的快速原形制造方法制造的带有倾斜表面的零件中常见的阶梯型效应而得到光滑的零件表面。
从目前增减材研究现状来看,增减材系统都是集成在一台数控设备上,或者是在原有的数控机床主轴上叠加沉积装置,这种简单集成的增减材制造系统所加工的零件种类、尺寸范围很窄,并且由于增材制造的沉积时间长,其加工效率低。
发明内容
本发明的目的在于提供一种人机交互式、衣物自动存取的衣柜,以解决人工收纳耗时费力问题。
基于上述背景,本发明的目的在于提出一种柔性增减材制造方法,将增减材制造与柔性制造技术相结合,以期扩展增减材制造技术的应用范围。
为实现上述目的,本发明采用如下技术解决方案。
本发明所述的柔性增减材制造方法主要包括材料沉积,材料去除,净化,应力消除四个工序,其其工艺过程是:根据指令,托盘库中一托盘出库,进入一沉积设备单元中进行增材制造;沉积好一层后,托盘送入数控去除设备单元中进行铣削;该层铣削减材完成后,托盘进入到净化设备单元,净化铣削加工时残留的杂物;净化完成后,如果零件是金属材料,托盘则进入去应力设备单元,消除沉积过程中产生的残余应力,为后续沉积作业做准备,如果零件是非金属材料,则不需要去应力环节,直接进入沉积设备单元,继续进行下一次的沉积;经过多次重复上述增减材加工步骤后,零件完成,完成的零件进入托盘零件分离单元,将零件与托盘分离,托盘进入托盘库备用,零件进入后处理环节,至此,一个完整的零件就被制造出来;在控制系统的协调下,这个制造过程中不限于一个零件的加工,它可以同时加工多个零件,即有的零件在沉积,有的零件在铣削,有的在去应力,有效提高增减材制造的效率。
本方法所述的托盘库中包含有不同尺寸、不同自由度的托盘,但所有托盘都有统一的定位、夹紧、电源及数据接口,以便能与AGV小车、沉积设备、数控去除设备、净化设备、应力消除设备的工作台对接。
本方法所述的沉积设备应该具备以下条件:1)沉积材料应该是丝材、粉末、颗粒;2)沉积方式要简单,要适应零件的频繁进出沉积仓,要易于实现自动化;3)沉积设备的结构必须满足柔性增减材制造系统的接口标准,包括工作台自动托料装置;4)沉积设备要具备一套完整的沉积装置及驱动控制装置。本发明中所述的制造方法是一个开放的集成系统,所有成熟的沉积工艺,其结构能够适合柔性增减材制造系统的,都可以根据实际需要,柔性的添加或移除沉积设备。
本发明所述的净化方法应该采用压缩空气进行吹、吸的方式实现。
本发明所述的应力消除采用激光温喷丸,也就是激光表面强化。
下面结合附图和具体实施例对本发明作进一步的说明。
图1柔性增减材制造的工艺流程图。
图2柔性增减材制造系统的过程控制模型。
图3柔性增减材制造系统的总体布局示意图。
具体实施方式
参照图1所示,所述的柔性增减材制造的工艺流程是:根据指令,托盘库中一托盘出库,进入一沉积设备单元中进行增材制造;沉积好一层后,托盘送入数控去除设备单元中进行铣削,从而提高沉积层的尺寸及表面精度;该层铣削减材完成后,托盘进入到净化设备单元,净化铣削加工时残留的杂物;净化完成后,如果零件是金属材料,托盘则进入去应力设备单元,消除沉积过程中产生的残余应力,为后续沉积作业做准备,如果零件是非金属材料,则不需要去应力环节,直接进入沉积设备单元,继续进行下一次的沉积;经过多次重复上述增减材加工步骤后,零件完成,完成的零件进入托盘零件分离单元,将零件与托盘分离,托盘进入托盘库备用,零件进入后处理环节。至此,一个完整的零件就被制造出来。在该系统的协调控制下,这个制造过程中不限于一个零件的加工,它可以同时加工多个零件,比如有的零件在沉积,有的零件在铣削,有的在去应力,有效提高增减材制造的效率。
参照图1所示,所述的柔性增减材制造系统的托盘库中包含有不同尺寸、不同自由度的托盘,但所有托盘都有统一的定位、夹紧、电源及数据接口,以便能与AGV小车、沉积设备、数控去除设备、净化设备、应力消除设备的工作台对接。这样的托盘库及托盘将能适应不同尺寸、形状的零件增减材制造需求,极大提高了原有增减材制造的加工范围,是柔性增减材制造系统中“柔性”的具体体现。比如托盘的平台可以任意角度倾斜一定角度,这样就可以沉积弯曲零件而不用支撑。
参照图1所示,所述的柔性增减材制造系统的的沉积设备应该具备以下条件:1)沉积材料应该是丝材、粉末、颗粒。这些材料适于材料在沉积过程中托盘的移动,如果是液体材料,则不方便托盘移动及数控去除。目前常用的沉积材料中,金属部分是碳钢、不锈钢、铜、铝及其合金等;非金属材料部分可以采用石蜡、塑料、陶瓷等;2)沉积方式要简单,要适应零件的频繁进出沉积仓,还要易于实现自动化。就目前的沉积方式而言,激光沉积、电弧沉积、热熔沉积最适合,而电子束沉积由于需要制造真空环境,而增减材所加工的零件需要频繁进出沉积仓,所以难以实现;3)沉积设备的结构必须满足柔性增减材制造系统的接口标准,包括工作台自动托料装置;4)沉积设备要具备一套完整的沉积装置及驱动控制装置。
本系统是一个开放的集成系统,所有成熟的沉积工艺,其结构能够适合柔性增减材制造系统的,都可以根据实际需要,柔性的添加或移除沉积设备。
参照图1所示,所述的柔性增减材制造系统的数控去除设备也是本系统的重要组成部分,在本系统中,沉积工件的材料去除是按层进行的,是一个间歇式,反复多次的切削过程,对工件定位、去除加工的要求高,因此根据根据零件形状的和分层的不同,去除材料的所用的机床可采用可以采用3轴或5轴的CNC机床,可根据实际需求配置。机床的运行需要与整个制造系统统一,需要与其他设备,尤其是与材料沉积设备相互协调配合,因此CNC机床的运行受总控制台控制,接收来自总控制台的控制指令及加工程序,通过自身的数控驱动装置来进行沉积工件的材料去除。
参照图1所示,所述的柔性增减材制造系统的净化设备的作用是将零件在去除过程中产生的切屑等杂物去除,其净化方法应该采用压缩空气进行吹、吸的方式实现。这是因为其切屑都是固态,粘附在零件上,采用一定压力的空气将杂物除开,然后用吸尘装置将悬浮状态的杂物吸入。实现沉积零件的净化,为后续的继续沉积做准备。
参照图1所示,所述的柔性增减材制造系统的应力消除设备主要是消除在零件沉积过程产生的参与应力,对于金属零件而言,沉积过程中,层间会形成残余应力,如果不消除的话会使零件变形,不利于后续沉积作业。应力消除采用激光温喷丸,也就是激光表面强化。由于所采用的是激光作为动力源,结构简单,效率高,很适合集成到自动化系统中。
参照图2所示,所述的柔性增减材制造系统包含三个子系统,即增减材加工子系统,物流子系统,信息子系统。增减材加工子系统各设备承担本系统中各工序的加工任务,主要包括各种沉积设备、CNC数控切削机床,吹吸气净化设备,激光温喷丸设备。物流子系统主要承担加工过程中的零件在各工序之间的流通,包括各种型号托盘,AGV物流小车。信息子系统主要承担各种数据处理、数据通讯及工艺智能推荐等,具体包括主控计算机,通讯网络,监控与报警系统,专家系统,物流控制系统,增减材加工控制系统。主控计算机主要进行数据处理,通讯网络主要是各硬件设备之间的数据传输,专家系统主要是用于工艺智能推荐,物流控制系统则为加工中的各托盘提供最短且互不干涉的运动路径,增减材加工控制主要是数控程序与指令的处理。
参照图2所示,针柔性增减材制造系统包含三个子系统,本系统从五个方面来进行控制管理,即作业计划、数控加工、物流调度、过程监控、信息管理。根据作业计划及图纸,安排作业计划,这一环节可以用专家系统来进行工艺方案智能推荐,选择最合适、最经济、最高效的托盘及沉积方式。作业计划确定好后,生成CAD/CAM制造数据输送至数控加工及动态调度环节,由相应的增减材加工控制系统生成适合各种加工设备的NC程序及指令,由相应的物流控制系统向托盘及AGV小车发运行与调度指令,这里还涉及到增减材加工子系统各设备的开关门仓及与托盘对接接口的开闭。过程监控环节主要有监控与报警系统来适时监控增减材加工过程及物流调度。信息管理环节主要是对整个系统的数据指令进行处理与管理。
参照图3所示,柔性增减材制造系统的工艺设备采用一字直线型布局,AGV小车主干道采用直线型,与每个设备之间采用弧形转弯设计,左右都有弧形转弯轨道,方便工件进出各设备,同时也方便各AGV小车运行之间的避让。采用直线型则非常有利于系统根据实际需要来增减配备沉积设备、CNC数控切削机床,实现设备级的柔性化。
以上所述,仅为本发明较佳实施例而已,故不能以此限定本发明实施的范围,即依本发明申请专利范围及说明书内容所作的等效变化与修饰,皆应仍属本发明专利涵盖的范围内。
Claims (6)
1.权利要求1 一种柔性增减材制造方法主要包括材料沉积,材料去除,净化,应力消除四个工序,其其工艺过程是:根据指令,托盘库中一托盘出库,进入一沉积设备单元中进行增材制造;沉积好一层后,托盘送入数控去除设备单元中进行铣削;该层铣削减材完成后,托盘进入到净化设备单元,净化铣削加工时残留的杂物;净化完成后,如果零件是金属材料,托盘则进入去应力设备单元,消除沉积过程中产生的残余应力,为后续沉积作业做准备,如果零件是非金属材料,则不需要去应力环节,直接进入沉积设备单元,继续进行下一次的沉积;经过多次重复上述增减材加工步骤后,零件完成,完成的零件进入托盘零件分离单元,将零件与托盘分离,托盘进入托盘库备用,零件进入后处理环节,至此,一个完整的零件就被制造出来;在控制系统的协调下,这个制造过程中不限于一个零件的加工,它可以同时加工多个零件,即有的零件在沉积,有的零件在铣削,有的在去应力,有效提高增减材制造的效率。
2.权利要求2 依据权利要求1,本方法所述的托盘库中包含有不同尺寸、不同自由度的托盘,但所有托盘都有统一的定位、夹紧、电源及数据接口,以便能与AGV小车、沉积设备、数控去除设备、净化设备、应力消除设备的工作台对接。
3.权利要求3 依据权利要求1,本方法所述的沉积设备应该具备以下条件:1)沉积材料应该是丝材、粉末、颗粒;2)沉积方式要简单,要适应零件的频繁进出沉积仓,要易于实现自动化;3)沉积设备的结构必须满足柔性增减材制造系统的接口标准,包括工作台自动托料装置;4)沉积设备要具备一套完整的沉积装置及驱动控制装置;本发明中所述的制造方法是一个开放的集成系统,所有成熟的沉积工艺,其结构能够适合柔性增减材制造系统的,都可以根据实际需要,柔性的添加或移除沉积设备。
4.权利要求4 依据权利要求1,本发明所述的净化方法应该采用压缩空气进行吹、吸的方式实现。
5.权利要求5 依据权利要求1,本发明所述的应力消除采用激光温喷丸,也就是激光表面强化。
6.权利要求6 依据权利要求1,本发明所述柔性增减材制造系统的工艺设备采用一字直线型布局,AGV小车主干道采用直线型,与每个设备之间采用弧形转弯设计,左右都有弧形转弯轨道。
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