CN112453428A - Binary channels laser vibration material disk numerical control system - Google Patents
Binary channels laser vibration material disk numerical control system Download PDFInfo
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- CN112453428A CN112453428A CN202011247159.5A CN202011247159A CN112453428A CN 112453428 A CN112453428 A CN 112453428A CN 202011247159 A CN202011247159 A CN 202011247159A CN 112453428 A CN112453428 A CN 112453428A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention discloses a double-channel laser additive manufacturing numerical control system, which comprises a control system, a data acquisition system, an online monitoring system and an HMI unit, wherein: the control system adopts a bus-based multifunctional module design and comprises a core control unit, an axis control unit, a position feedback unit and a digital input/output control unit; the data acquisition system is integrated with an analog acquisition card and a digital I/O acquisition card; the online monitoring system comprises an industrial personal computer, a CCD high-speed camera and an infrared imager; the HMI unit is connected with the control system, comprises a liquid crystal screen, a full-function keyboard and a lower operation panel and is used for realizing the input of process parameters, the editing of processing programs and the display of position coordinates of a deposition axis/a movement axis and alarm information. The system can improve the analysis capability of the double-channel processing technology combined data in the additive manufacturing process, monitor the processing state in real time and improve the processing quality.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a dual-channel laser additive manufacturing numerical control system.
Background
At present, additive manufacturing is also called 3D printing technology, which is a manufacturing technology that integrates computer aided design, material processing and molding technology, and based on a digital model file, a dedicated metal material, a non-metal material and a medical biomaterial are stacked layer by layer through software and a numerical control system in modes of extrusion, sintering, melting, photocuring, spraying and the like to manufacture a solid object. Compared with the traditional manufacturing mode of reducing materials by removing, cutting and assembling raw materials, the method is a manufacturing method through material accumulation from bottom to top, and the manufacture of complex structural parts which cannot be realized due to the constraint of the traditional manufacturing mode is possible from the beginning.
However, in the prior art, the defects of low processing efficiency and long construction period for processing large structural parts exist in the laser additive manufacturing process, and the development of the additive manufacturing technology is restricted because double channels cannot be simultaneously controlled during self-adaptive control.
Disclosure of Invention
The invention aims to provide a double-channel laser additive manufacturing numerical control system which can improve the analysis capability of the double-channel processing technology combined data in the additive manufacturing process, monitor the processing state in real time and improve the processing quality.
The purpose of the invention is realized by the following technical scheme:
a dual channel laser additive manufacturing numerical control system, the system comprising a control system, a data acquisition system, an online monitoring system, and an HMI unit, wherein:
the control system adopts a bus-based multifunctional module design and comprises a core control unit, an axis control unit, a position feedback unit and a digital input/output control unit; the core control unit is used for designing a two-channel multi-deposition-axis synchronous control algorithm and an anti-interference and anti-collision algorithm; the shaft control unit is used for controlling the servo driving unit and the motor; the position feedback unit is used for real-time detection and feedback of the motion position of the laser head; the digital input/output control unit is used for realizing control over the two-channel multi-deposition-axis limit switch, the valve and the scram input/output signal;
the data acquisition system is integrated with an analog acquisition card and a digital I/O acquisition card and is used for realizing the real-time acquisition of laser power, laser water temperature, laser head water flow, water cooler water pressure, water cooler water flow, gas source air pressure, box body air pressure, head gas flow and oxygen content parameter of the oxygen content meter and transmitting the acquired data to the control system through Ethernet;
the online monitoring system comprises an industrial personal computer, a CCD high-speed camera and an infrared imager, and is used for realizing online monitoring of the longitudinal section morphology, the thickness of a single-layer deposition layer and the side morphology of the molten pool of the additive manufacturing molten pool, monitoring the temperature field and the highest temperature distribution near the local area of the molten pool and in the whole range of the formed part, and transmitting the monitored data to the control system through the industrial personal computer;
the HMI unit is connected with the control system, comprises a liquid crystal screen, a full-function keyboard and a lower operation panel and is used for realizing the input of process parameters, the editing of processing programs and the display of position coordinates of a deposition axis/a movement axis and alarm information.
According to the technical scheme provided by the invention, the system can improve the analysis capability of the double-channel processing technology combined data in the additive manufacturing process, monitor the processing state in real time and improve the processing quality.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on the drawings without creative efforts.
Fig. 1 is a schematic overall structure diagram of a dual-channel laser additive manufacturing numerical control system according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating an exemplary dual channel synchronous control G code execution process;
FIG. 3 is a schematic diagram of the distribution of local coordinate systems according to an embodiment of the present invention;
fig. 4 is a schematic diagram of a system hardware architecture according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention are 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 embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention.
The embodiment of the present invention will be further described in detail with reference to the accompanying drawings, and as shown in fig. 1, is an overall structural schematic diagram of a dual-channel laser additive manufacturing numerical control system provided by the embodiment of the present invention, the system includes a control system, a data acquisition system, an online monitoring system and an HMI unit, wherein:
the control system adopts a bus-based multifunctional module design and comprises a core control unit, an axis control unit, a position feedback unit and a digital input/output control unit; the core control unit is used for designing a two-channel multi-deposition-axis synchronous control algorithm and an anti-interference and anti-collision algorithm; the shaft control unit is used for controlling the servo driving unit and the motor; the position feedback unit is used for real-time detection and feedback of the motion position of the laser head; the digital input/output control unit is used for realizing control over the two-channel multi-deposition-axis limit switch, the valve and the scram input/output signal;
in the specific implementation, the two channels controlled by the control system can execute two numerical control programs to run in parallel or coordinate and synchronize without mutual influence, wherein the two channels are required to independently execute own G codes without mutual influence in the two-channel parallel control, and the two channels are respectively responsible for finishing own processing procedures without mutual interference in the actual processing process.
For example, when one channel runs a machining program, the intelligent manufacturing dedicated numerical control system simultaneously allows the other channel to run a designated program by using an INIT () instruction and a START () instruction, and then, the two channels respectively run numerical control programs without mutual influence, and assuming that there is a two-channel machine tool, the channel 1 allows the channel 2 to simultaneously load and execute the program 0001 in the process of running the programs.
N1 INIT (2, "0001"); the loaded program name is 0001
N2 START (2); channel 2 running program
.......
M30
When channel 1 finishes executing line N3, channel 2 starts running program 0001, which is a program in which two channels execute respective G codes in parallel.
The movable beam type gantry guide rail is characterized in that two lasers of two channels are controlled to move along the direction of a cross beam through saddles arranged on the cross beam, if the two lasers work simultaneously, interference is easy to generate, the two lasers are controlled in a time-sharing mode under a common condition, namely, the other channel waits when one channel works, the channel enters a waiting state after the machining procedure of the channel is completed, the other channel executes a machining program, correspondingly, an X axis is also switched to the other channel, and the two channels are synchronously controlled and work cooperatively. The control system special for additive manufacturing realizes synchronization between the two channels through instructions M60\ M61\ M70\ M71. When the active channel executes the instruction, a signal is sent; when the inactive channel executes the instruction, a waiting state is entered, and when the waiting signal value arrives, the inactive channel is switched to the active channel. As shown in fig. 2, which is a schematic diagram of an execution process of a dual-channel synchronous control G code according to an embodiment of the present invention, a numerical control program in a channel 0 and a channel 1 is executed in a time-sharing manner, the channel 1 waits when the channel 0 executes the program, and the channel 0 waits when the channel 1 executes the program, and the execution sequence is as follows: → → ② → ③ → fourthly → fifthly → → the procedure is finished.
The example of switching the X-axis of the movable beam type gantry guide rail between two channels is used to illustrate how the core control unit realizes the synchronous control between the channels, and it is assumed that the X-axis of the common axis of the two channels is configured in the channel 0 by default.
TABLE 1 Dual-channel numerical control program
As shown in table 1, the loop starts after channel 1 and channel 2 are loaded with their respective programs, and the operation process is as follows:
1. channel 1 goes to N3, sends synchronization signal, and is in waiting state, waits for channel 2 to go to N3;
2. channel 2 performs N3, channel 1 may continue to execute down in response to the channel 1 sync signal;
3. channel 2 executes to N5, sends a synchronization signal, and is in a waiting state, waiting for channel 1 to execute to N5;
4. lane 1 performs N5, and in response to the lane 2 sync signal, lane 2 may continue to execute down, as does lane 1.
In addition, the double channels controlled by the control system use a machine tool zero coordinate system as a world coordinate system WCS, the laser head coordinate system of the first channel 1 and the laser head coordinate system of the second channel 2 are both local coordinate systems UCS, as shown in fig. 3, the laser head coordinate system and the laser head coordinate system of the second channel 2 are schematic diagrams distributed in the embodiment of the invention, and the anti-interference and anti-collision algorithm aims to prevent the laser head of the first channel 1 and the laser head of the second channel 2 from generating position interference to cause collision, so the control system adopts an operation of triggering emergency stop when the distance between the laser heads of the two channels is smaller than 15 mm.
Specifically, the operation process for triggering the emergency stop operation is as follows:
1. and determining the coordinate values of the laser head of the channel 1 and the laser head of the channel 2 in a laser coordinate system.
a) Laser head of channel 1:
and the coordinate is set in an X-axis local coordinate system and is X, and the coordinate is set in a global coordinate system and is X.
Since the x-axis coordinate system origin is spaced from the global coordinate system origin by Offset _ x1, and is located in the negative direction of the global coordinate system. Therefore, the method comprises the following steps:
X＝(x+Offset_x1)；
b) laser head of channel 2:
let the laser head of channel 2 be P in the local coordinate system, P in the global coordinate system:
since the laser head coordinate system origin of the channel 2 is spaced from the global coordinate system origin by Offset _ x2, and is located in the positive direction of the global coordinate system. Therefore, the method comprises the following steps:
P＝(Offset_x2+p)；
2. the relative position M between the global coordinate system of both the laser head of machine channel 1 and the laser head of channel 2 is determined.
a) When X < P, M-P-X-Offset _ X2+ P-X-Offset _ X1 (Offset _ X2-Offset)
_x1)+p–x；
b) When X is not less than P, M is X-P X-P- (Offset _ X2-Offset _ X1).
In summary, M ═ X-P |.
3. And determining the limit relation between the two shafts.
When M is required to be less than or equal to 10, an alarm emergency stop occurs. Then there are:
|x–p–(Offset_x2-Offset_x1)|≤15
the emergency stop triggering conditions can be deduced as follows:
(Offset_x2-Offset_x1)–15≤x–p≤(Offset_x2-Offset_x1)+15
x is con _ x [0]. actual position of laser head of work _ coordinate channel 1;
p is the actual position of the laser head for con _ x _ ii [0] work _ coordinate _ ii channel 2.
The data acquisition system is integrated with an analog acquisition card and a digital I/O acquisition card and is used for realizing the real-time acquisition of laser power, laser water temperature, laser head water flow, water cooler water pressure, water cooler water flow, gas source air pressure, box body air pressure, head gas flow and oxygen content parameter of the oxygen content meter and transmitting the acquired data to the control system through Ethernet;
the online monitoring system comprises an industrial personal computer, a CCD high-speed camera and an infrared imager, and is used for realizing online monitoring of the longitudinal section morphology, the thickness of a single-layer deposition layer and the side morphology of the molten pool of the additive manufacturing molten pool, monitoring the temperature field and the highest temperature distribution near the local area of the molten pool and in the whole range of the formed part, and transmitting the monitored data to the control system through the industrial personal computer;
the HMI unit is connected with the control system, comprises a liquid crystal screen, a full-function keyboard and a lower operation panel and is used for realizing the input of process parameters, the editing of processing programs and the display of position coordinates of a deposition axis/a movement axis and alarm information.
In the specific implementation process, the control system is further connected with a communication module, the control system communicates with an external laser processing track planning system through the communication module, dynamic planning is carried out on the motion track according to the actual processing condition, and processing parameters are corrected.
In addition, the whole system can adopt a hardware architecture based on the combination of a DSP, an FPGA and an ARM, as shown in fig. 4, the hardware architecture of the system according to the embodiment of the present invention is schematically illustrated, and the adopted DSP has a strong operation capability; the FPGA has high flexible configurability and logic sequential control capability; the ARM as an embedded core industrial control platform can effectively meet the design requirements of the system.
The specific process flow of the double-channel laser additive manufacturing numerical control system is as follows:
in the process of machining the part, a three-dimensional CAD model of the part is designed by adopting three-dimensional modeling software, the three-dimensional CAD model is stored as an STL file after being processed by slicing software, and data information of the STL file is transmitted to laser additive manufacturing rapid prototyping equipment through FTP.
The current sliced layer is processed by adopting a powder feeding type laser melting method, and path planning is carried out for preventing a double-channel stroke shaft from mechanical collision and preventing the bending deformation or fracture of parts caused by internal stress in the cold and hot forming process through a system analysis sliced model. Due to the special structure of the double-channel laser processing equipment, the laser heads of the two channels process the same slicing file and plan the path to ensure the integrity of the processed parts. And then, issuing the execution parameters to a main control system according to the processing parameters, wherein the main control system starts to process a layer of metal powder with the thickness of about 0.02mm and the particle size of lO mu m according to the processing parameters, and the laser output power is automatically set according to the actually processed material and the running speed according to an equipment processing technology library in a database.
In the processing process, the temperature and humidity sensor, the oxygen instrument, the water temperature meter, the flowmeter and other devices in the data acquisition system are used for monitoring the processing process, and whether the current processing state is in accordance with the normal state or not is judged through a program. By monitoring the state, the abnormal state can be quickly responded, and the irreversible result is avoided.
Meanwhile, the longitudinal section morphology of the molten pool is monitored in real time through a CCD high-speed camera and an infrared imager in the online monitoring system, the thickness of a single-layer deposition layer and the side morphology of the molten pool are tracked and captured, and the short-time powder flow and the interaction behavior of the molten pool are captured. Through obtaining the processing temperature of processing laser head position on the picture layer in the infrared thermal imager, through changing equipment powder feeding flow and laser head machining power, guarantee in the course of working, part surface temperature keeps invariable to flow through adjusting air supply arrangement guarantees at whole operation in-process, and the equipment surface thickness of processing keeps unanimous basically.
After the machining operation is finished, the system self-checks the state, the two laser channels return to the initial positions, the loading and unloading device moves the parts out of the machining bin, and the machining is finished through the system prompt.
It is noted that those skilled in the art will recognize that embodiments of the present invention are not described in detail herein.
In conclusion, the system provided by the embodiment of the invention can be used for automatically processing and manufacturing single-channel parts, the problems of low efficiency and long working time in the laser material increase manufacturing process are solved, and the processing quality can be improved by combining the environmental data analysis and adjusting the processing parameters such as flow and moving speed in the processing process, so that the welding quality is ensured, and the yield is increased.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (5)
1. A dual channel laser additive manufacturing numerical control system, the system comprising a control system, a data acquisition system, an online monitoring system, and an HMI unit, wherein:
the control system adopts a bus-based multifunctional module design and comprises a core control unit, an axis control unit, a position feedback unit and a digital input/output control unit; the core control unit is used for designing a two-channel multi-deposition-axis synchronous control algorithm and an anti-interference and anti-collision algorithm; the shaft control unit is used for controlling the servo driving unit and the motor; the position feedback unit is used for real-time detection and feedback of the motion position of the laser head; the digital input/output control unit is used for realizing control over the two-channel multi-deposition-axis limit switch, the valve and the scram input/output signal;
the data acquisition system is integrated with an analog acquisition card and a digital I/O acquisition card and is used for realizing the real-time acquisition of laser power, laser water temperature, laser head water flow, water cooler water pressure, water cooler water flow, gas source air pressure, box body air pressure, head gas flow and oxygen content parameter of the oxygen content meter and transmitting the acquired data to the control system through Ethernet;
the online monitoring system comprises an industrial personal computer, a CCD high-speed camera and an infrared imager, and is used for realizing online monitoring of the longitudinal section morphology, the thickness of a single-layer deposition layer and the side morphology of the molten pool of the additive manufacturing molten pool, monitoring the temperature field and the highest temperature distribution near the local area of the molten pool and in the whole range of the formed part, and transmitting the monitored data to the control system through the industrial personal computer;
the HMI unit is connected with the control system, comprises a liquid crystal screen, a full-function keyboard and a lower operation panel and is used for realizing the input of process parameters, the editing of processing programs and the display of position coordinates of a deposition axis/a movement axis and alarm information.
2. The dual-channel laser additive manufacturing numerical control system according to claim 1, wherein the control system is further connected with a communication module, the control system communicates with an external laser processing trajectory planning system by using the communication module, dynamically plans a motion trajectory according to an actual processing condition, and corrects processing parameters.
3. The dual channel laser additive manufacturing numerical control system of claim 1 wherein the dual channels controlled by the control system are capable of executing two numerical control programs either in parallel or in coordinated synchronous operation without affecting each other;
the two-channel parallel control requires that the two channels independently execute own G codes without mutual influence, which is shown in the practical processing process that the two channels are respectively responsible for finishing own processing procedures without mutual interference.
4. The dual-channel laser additive manufacturing numerical control system according to claim 1, wherein the dual channels controlled by the control system have a machine zero coordinate system of a world coordinate system WCS, and the laser head coordinate system of the first channel and the laser head coordinate system of the second channel are both local coordinate systems UCS;
the anti-interference and anti-collision algorithm is used for preventing the laser head of the first channel from interfering with the laser head of the second channel to cause collision, so that the control system is used for triggering emergency stop when the distance between the laser heads of the two channels is smaller than 15 mm.
5. The dual-channel laser additive manufacturing numerical control system of claim 1, wherein the system as a whole adopts a hardware architecture based on a combination of a DSP, an FPGA and an ARM, wherein:
the DSP has stronger computing capability; the FPGA has high flexible configurability and logic sequential control capability; the ARM as an embedded core industrial control platform can effectively meet the design requirements of the system.
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| CN114226757A (en) * | 2021-12-14 | 2022-03-25 | 上海交通大学 | Laser DED manufacturing control system and method fusing temperature and image information |
| CN115383140A (en) * | 2022-08-24 | 2022-11-25 | 上海交通大学 | System and method for monitoring deposition state of blue laser melting deposition aluminum alloy material |
| CN115383140B (en) * | 2022-08-24 | 2024-02-23 | 上海交通大学 | System and method for monitoring deposition state of blue laser melting deposition aluminum alloy material |
| CN116275114A (en) * | 2023-05-12 | 2023-06-23 | 山东海纳智能装备科技股份有限公司 | Process monitoring control system based on laser additive manufacturing |
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