DE102019215960A1 - Manufacturing facility for the additive manufacturing of a component from a powder material - Google Patents

Abstract

The invention relates to a manufacturing device (1) for the generative manufacture of a component from a powder material, with a building level (3) which is set up to form a component layer of the component to be manufactured in the building level (3) and an optical recording device (7) for making optical recordings of the construction plane (3), a central axis (M) of the construction plane (3) and an optical axis (O) of the recording device (7) being offset from one another, the recording device (7) having an image recording plane (11) and an imaging optics (9), and wherein an optical axis (O) of the imaging optics (9) can be arranged or arranged offset to an image center axis (B) of the image acquisition plane (11).

Description

The invention relates to a manufacturing device for the additive manufacturing of a component from a powder material.

Such a manufacturing device has a building level which is set up to form a component layer of the component to be manufactured in the building level. In particular, a powder layer of the powder material, which is also referred to as a powder bed, is repeatedly provided in the building plane, the component layer then being produced by locally solidifying the powder material, in particular by adding powder grains of the powder material in certain areas, i.e. at predetermined locations in the building plane. connected to one another, in particular> fused to one another. The finished component layer is then shifted out of the building level, in particular shifted geodetically downwards, and a new powder layer is generated in the building level. This procedure is continued sequentially in order to finally obtain the additively manufactured, in particular three-dimensional component. In this way, a plurality of component layers are sequentially formed in the building plane, and the component is built up in layers.

In order to monitor the progress of the additive manufacturing of the component and, if necessary, to intervene in a controlling manner, in particular to discover defects in the powder layer that is generated in the building plane, or to control the formation of the component layer, the manufacturing device has an optical recording device that is set up is to make optical recordings of the building level. For the purpose of easily evaluating, distortion-free recordings, it would be advantageous if the optical recording device could be attached axially above the construction plane so that a central axis of the construction plane is aligned with an optical axis of the optical recording device. However, this is not possible due to the geometric boundary conditions of the manufacturing facility, in particular since the corresponding central area is usually occupied by a beam guidance of a working beam, in particular a laser beam, which is provided in order to solidify the powder material in the construction plane in certain areas. The central axis of the construction plane and the optical axis of the receiving device are therefore arranged offset from one another. This leads to an unfavorable mapping of the building level. In particular, it is typically provided in conventional production facilities that the optical recording direction looks obliquely from the side onto the building plane. This leads to geometrical boundary conditions that only have to be met with additional effort on the optical recording device and on protective glasses and holders for the same, all of which have to be installed in an inclined position. An image of the building plane recorded in this way is not free from projection errors, and additional blurring occurs. In principle, it is possible to mathematically rectify such a recording. However, this leads to a reduction in the pixel resolution and / or an inhomogeneous pixel enlargement. In order to obtain a resolution in the rectified recording that corresponds to the actual resolution of a recording with a certain recording device, a higher-quality recording device with increased resolution must actually be used. The rectification also makes it more difficult to process the recorded images in terms of measurement technology.

The invention is based on the object of creating a production facility in which the disadvantages mentioned are at least reduced, preferably avoided.

The object is achieved in that the present technical teaching is provided, in particular the teaching of the independent claims and the embodiments disclosed in the dependent claims and the description.

The object is achieved in particular by creating a manufacturing device in which the optical recording device has an image acquisition plane and imaging optics, an optical axis of the imaging optics being displaceable or offset from an image center axis of the image acquisition plane. This advantageously provides a displacement of the image section relative to the image acquisition plane, so that - in particular without changing the projection - the construction plane can be mapped in the image acquisition plane. The corresponding arrangement corresponds in particular to the use of a shift lens or, in the large format area, to a parallel displacement of the standards, for example a view camera, relative to one another, the optical axis being displaced parallel to the image plane. In this case, the image center of the image generated by the imaging optics in the image capture plane is no longer effectively used, but rather image areas further out are captured.

Generative manufacturing is understood here to mean, in particular, additive manufacturing of a component. In particular, this is understood to mean building up a component in layers from powder material, in particular a manufacturing method that is selected from a group consisting of: a selective laser sintering; a laser metal fusion (LMF); Direct Metal Laser Melting (DMLM); a laser net shaping Manufacturing (LNSM); and a Laser Engineered Net Shaping (LENS). The generative manufacturing device is accordingly set up in particular to carry out at least one of the aforementioned generative manufacturing processes.

For additive manufacturing, in particular for local solidification of the powder material, an optical working beam is used in particular. An optical working beam is to be understood in particular as directed electromagnetic radiation, continuous or pulsed, which, with regard to its wavelength or a wavelength range, is suitable for the generative manufacture of a component from powder material, in particular for sintering or melting the powder material. In particular, an optical working beam is understood to mean a laser beam which can be generated continuously or in a pulsed manner. The optical working beam preferably has a wavelength or a wavelength range in the visible electromagnetic spectrum or in the infrared electromagnetic spectrum, or in the overlap area between the infrared range and the visible range of the electromagnetic spectrum.

A central axis of the building plane is understood here in particular to be an imaginary axis that is perpendicular to the building plane and runs through the center or center of gravity of the building plane.

The optical axis of the recording device is in particular the optical axis of the imaging optics. Alternatively, the optical axis of the recording device is the image center axis of the image acquisition plane. Both the optical axis of the imaging optics and the image center axis of the image capturing plane are preferably offset from the center axis of the construction plane, so that it is irrelevant whether the optical axis of the imaging device is viewed as the optical axis of the imaging optics or the image center axis of the image capturing plane.

The fact that the central axis of the construction plane and the optical axis of the receiving device are offset from one another means in particular that these axes are spaced from one another. In particular, these axes are measured at a distance from one another perpendicular to the central axis of the building plane. In particular, the optical axis of the imaging optics, in particular at the location of an entrance pupil of the imaging optics, is at a distance from the central axis of the building plane - measured perpendicular to the central axis of the building plane.

The image acquisition plane is in particular the image plane of the optical recording device, in particular the image plane of the imaging optics, in particular a sensor plane or film plane in which a light-sensitive sensor or a light-sensitive film of the optical recording device is arranged. In particular, the optical recording device and the imaging optics are arranged and set up to image the construction plane onto the image acquisition plane.

The optical recording device preferably has, on the one hand, the imaging optics and, on the other hand, a camera, the image recording plane being arranged in the camera. The camera is preferably designed as a digital camera, the image acquisition plane being a sensor plane of a light-sensitive sensor. In particular, the camera preferably has a CCD or CMOS sensor as the light-sensitive sensor, which then in turn has the image acquisition plane.

The imaging optics are preferably designed as an objective. It is possible for the camera of the optical recording device to have additional optical elements which are then spatially arranged between the imaging optics, in particular the objective, and the image recording plane. However, the camera particularly preferably has no such additional optical elements.

The image center axis of the image acquisition plane is in particular an imaginary axis that is perpendicular to the image acquisition plane and preferably extends through a center point or focal point of the image acquisition plane.

The fact that the image central axis and the optical axis of the imaging optics are offset from one another means in particular that they are at a distance from one another, measured perpendicular to the image central axis.

According to a further development of the invention, it is provided that the central axis of the construction plane and the optical axis of the receiving device are oriented parallel to one another. The offset between the optical axis of the imaging optics and the image central axis advantageously enables the central axis of the construction plane and the optical axis of the recording device to be arranged parallel to one another, while at the same time a distortion-free image with homogeneous sharpness can be obtained. The image section can therefore be selected advantageously with a view to capturing the construction plane as cheaply as possible, while at the same time avoiding perspective artifacts and distortions that would be expected if the optical recording device were positioned at an angle.

In particular, the central axis of the image acquisition plane is preferably oriented parallel to the central axis of the building plane. Preferably the Camera of the optical recording device aligned perpendicular to the building plane.

According to a further development of the invention it is provided that the optical axis of the imaging optics is fixed relative to the image acquisition plane. In this case, the associated optical imaging properties can advantageously not be disadvantageously changed subsequently by a user of the production facility. Rather, it is possible to determine an optimal position of the optical axis relative to the image acquisition plane, taking into account the arrangement of the optical recording device in the manufacturing device, and to hold the corresponding arrangement in place. The optical axis of the imaging optics is thus statically arranged at an optimal location relative to the image acquisition plane. In particular, this arrangement can be optimized numerically or in some other way beforehand and then mechanically implemented during the construction or design of the production facility.

Alternatively, it is also possible for the optical axis of the imaging optics to be adjustable relative to the image acquisition plane. In this case, the imaging optics are preferably designed as a shift objective, so that the optical axis can be shifted relative to the image acquisition plane by a user of the production facility, in particular offset parallel to the image acquisition plane. In particular, the distance between the optical axis of the imaging optics and the image center axis of the image acquisition plane can be changed in this way. This allows a particularly flexible use of the optical recording device also by a user of the production device.

According to a further development of the invention, it is provided that the optical axis of the imaging optics is oriented parallel to the central axis of the image. This in particular enables a distortion-free recording of the building plane, in particular when the central axis of the building plane is oriented parallel to the optical axis, the optical axis being oriented parallel to the image central axis at the same time. Thus, a focal plane of the optical recording device is then also advantageously oriented parallel to the construction plane.

Alternatively, however, it is also possible that the optical axis of the imaging optics is oriented obliquely to the image central axis, that is to say in particular encloses an angle with the image central axis which is different from 0 °, 90 ° and 180 °.

In particular, it is also possible for the optical axis of the imaging optics to be pivotable relative to the central axis of the image. This then corresponds to the use of a tilt lens. In particular, it is provided that the imaging optics are pivotably mounted at least in some areas. An angle of the optical axis relative to the central axis of the image can thus then be set so that the optical recording device can be used particularly flexibly by a user of the production device.

According to one embodiment, it is therefore possible for the imaging optics to be designed as a shift objective. According to another embodiment, it is also possible for the imaging optics to be designed as a tilt lens. According to yet another embodiment, it is also possible for the imaging optics to be designed as a tilt-shift lens.

According to another aspect of the invention, it is also possible that the optical axis of the imaging optics cannot be arranged or arranged offset to the image central axis of the image acquisition plane, but is only oriented obliquely to the image central axis, i.e. in particular includes an angle with the image central axis that is from 0 °, 90 ° and 180 ° is different. The arrangement can be static, or the optical axis of the imaging optics can be pivotable relative to the central axis of the image. The oblique arrangement of the optical axis to the image center axis enables homogeneous sharpness over the construction plane even with an oblique viewing direction.

According to a further development of the invention, it is provided that the manufacturing device, in particular the optical recording device, has an optics holder, the optics holder having a holding receptacle which is set up for fastening the imaging optics to the optics holder. The optics holder has a positioning device arranged radially offset from the holding receptacle, the positioning device being set up to position the camera on the optics holder. In this way, the optics holder enables the imaging optics to be easily positioned relative to the camera. In particular, the optics holder can define the offset between the optical axis of the imaging optics and the image center axis of the image acquisition plane in a simple and inexpensive manner and ensure it is permanent - in particular constant - the offset of the optical axis to the image center axis in particular due to the relative arrangement of the holding receptacle the positioning device is defined on the optics holder.

The holding receptacle is preferably designed as a bore, in particular a through bore, with an internal thread, into which a corresponding, complementary external thread of the imaging optics, in particular of the objective, can be screwed.

The fact that the positioning device is arranged radially offset from the holding receptacle means in particular that the positioning device is arranged eccentrically or eccentrically with respect to the holding receptacle. A radial direction extends in particular perpendicular to the optical axis of the imaging optics, in particular perpendicular to a central axis or axis of symmetry of the holding receptacle.

According to a development of the invention it is provided that the positioning device has a positioning projection or a positioning recess, or is designed as a positioning projection or as a positioning recess. The positioning recess is preferably designed as a positioning groove, in particular an annular groove. The positioning projection is preferably designed as a positioning ring, which is designed in particular to engage in a front opening or recess of the camera in order to position it on the optics holder. In this way, the positioning device can be produced simply and inexpensively and can also be easily connected to the camera. In particular, the positioning device is arranged eccentrically to the internal thread of the holding receptacle.

According to a development of the invention it is provided that the optics holder has a cylinder and a cover that can be arranged on the cylinder. In particular, the optics holder is designed as a cylinder with a cover that can be arranged on the cylinder. In particular, the optics holder consists of a cylinder with a cover that can be arranged on the cylinder. The fact that the cover can be arranged on the cylinder means in particular that the cover can be fastened to the cylinder. Preferably the lid is attached to the cylinder. In a preferred embodiment, the cover can be screwed to a cylinder wall of the cylinder, in particular by means of fastening screws which extend through the cover into the cylinder wall.

An axis of symmetry of the cylinder preferably extends in the assembled state coaxially to the optical axis of the imaging optics arranged on the optics holder. The cylinder wall is preferably designed to be closed all around - viewed in the circumferential direction. As a result, the optical recording device is advantageously protected from stray light.

The cylinder is preferably designed as a circular cylinder. In particular, the cylinder is designed as a cylinder sleeve, in particular as a circular cylinder sleeve.

The cover can be arranged, in particular arranged, preferably fastened, in particular on an end face of the cylinder or the cylinder sleeve. The cylinder or the cylinder sleeve is preferably open on an end face opposite the cover along the axis of symmetry. In the assembled state, the imaging optics then look through this open end face onto the construction level of the production facility.

The holding device and the positioning device are arranged on the cover, preferably on opposite sides of the cover. In a preferred embodiment, the holding receptacle is designed as a through hole with an internal thread in the cover.

According to a development of the invention, it is provided that the optics holder has a fixing device which is set up to position, in particular to fix, the optics holder on a housing of the manufacturing device. In this way, the optics holder and thus also the entire optical receiving device can be positioned and arranged in a defined manner on the housing of the manufacturing device. The fixing device is set up in particular to fix the optics holder on the housing of the manufacturing device at least in two directions - in particular in two Cartesian directions, both of which are perpendicular to the optical axis of the imaging optics and perpendicular to one another. The two directions are preferably perpendicular to the central axis of the building plane.

The fixing device preferably has a fixing projection or is designed as a fixing projection. In a preferred embodiment, the fixing projection is a fixing ring, in particular a centering ring. The fixing projection is preferably designed to engage in a recess on the housing of the manufacturing device and thus to position the optical recording device on the housing in a defined manner.

The optics holder preferably additionally has an axial stop, in particular a stop ring, which extends, preferably radially on the outside, in the circumferential direction - around the axis of symmetry of the optics holder - around the fixing projection. This axial stop is designed to hit the housing of the fixing device in the axial direction, i.e. in particular in the direction of the axis of symmetry of the optics holder or in the direction of the optical axis of the imaging optics, preferably also in the direction of the central axis of the construction plane, and thus ultimately the optics holder and thus also fix the optical recording device in a third Cartesian direction perpendicular to the two directions mentioned above. The fixing device and the axial stop then place the optics holder and thus at the same time also the optical recording device in all three Cartesian directions on the housing of the manufacturing facility.

With the manufacturing device proposed here, a sharp image of the building plane can advantageously be obtained over the entire building plane without the need for masking. In particular, a distortion-free image is obtained. In particular, the result is an improved installation situation, in particular without tilting the optical recording device, in particular without tilting the camera. Furthermore, a cost saving can advantageously be achieved in that a camera with a lower resolution can be used, in particular since it is possible to dispense with computational rectification of the recorded images.

• 1 eine Darstellung eines Ausführungsbeispiels einer Fertigungseinrichtung, und
• 2 eine Darstellung eines Ausführungsbeispiels eines Optikhalters mit einer optischen Aufnahmeeinrichtung der Fertigungseinrichtung gemäß 1.

The invention is explained in more detail below with reference to the drawing. Show:

• 1 a representation of an embodiment of a manufacturing facility, and
• 2 a representation of an embodiment of an optics holder with an optical recording device of the manufacturing device according to FIG 1 .

1 shows an illustration of an exemplary embodiment of a production facility 1 which is set up for the generative production of a component from a powder material. The manufacturing facility 1 has a building level 3 which is set up to form a component layer of the component to be manufactured in the building plane 3 . In 1 is an opening 5 shown, which is used to pass a working beam that is on the building level 3 can be directed to the powder material in areas in the building plane 3 to solidify, in particular to melt or sinter. The working beam is in particular an optical working beam, in particular a laser beam. A device for generating and deflecting the working beam is not shown here for the sake of simplicity.

The manufacturing facility 1 has an optical recording device 7th on, which is set up to take optical recordings, in particular images, of the building level 3 to prepare, in particular to record. Due to the arrangement of the opening 5 at the manufacturing facility 1 can the optical recording device 7th not coaxial with the building plane 3 , especially not axially above the building level 3 to be ordered. Therefore, a central axis M is the building plane 3 and an optical axis of the pickup device 7th , here in particular an optical axis O of an imaging optics 9 the optical recording device 7th , arranged offset to one another. The optical recording device 7th shows the imaging optics 9 and an image capture plane 11 on. The image capture plane 11 is particularly in a camera 13th arranged or part of the camera 13th the optical recording device 7th , in particular an image plane, in particular a sensor plane or film plane of the camera 13th .

The optical axis O of the imaging optics 9 is to an image center axis B of the image capture plane 11 staggered. This enables a sharp, distortion-free image of the building plane 3 with an improved installation situation of the optical recording device at the same time 7th , this in particular perpendicular to the building plane 3 can be mounted without tilting. The camera can also be advantageous 13th with the same resolution of the recorded images have a lower sensor resolution than would be necessary if the camera 13th at an angle to the building level 3 would look. This in turn allows the use of a cheaper camera 13th .

The imaging optics 9 is preferably designed as a lens.

The central axis M of the building level 3 and the optical axis O are advantageously oriented parallel to one another. In particular, the camera is 13th perpendicular to the building plane 3 aligned.

The optical axis O is preferably the imaging optics 9 relative to the image capture plane 11 , in particular set relative to the image center axis B.

The optical axis O is preferably the imaging optics 9 oriented parallel to the image center axis B, in particular offset parallel to this.

2 shows a detailed representation of the optical recording device 7th . Identical and functionally identical elements are provided with the same reference symbols in all figures, so that reference is made to the preceding description in each case.

The optical recording device 7th has an optics holder 15th on that a holding shot 17th having, the holding receptacle 17th is set up to attach the imaging optics 9 on the optics holder 15th . The holding shot 17th is preferably designed as a bore, in particular a through bore, preferably with an internal thread. The imaging optics, which are preferably designed as an objective 9 can then be inserted into the holding fixture with a corresponding external thread 17th be screwed in.

The optics holder 15th also has one to the holding receptacle 17th Radially, that is perpendicular to the optical axis O, arranged offset positioning device 19th on. The positioning device 19th is in particular eccentric to the holding receptacle 17th arranged. The positioning device 19th is set up to position the camera 13th on the optics holder 15th .

The positioning device 19th is preferred as a positioning projection, here in particular as a positioning ring 21 formed, which is in particular eccentric to the internal thread of the holding receptacle 17th is arranged. The positioning ring 21 preferably engages in a forehead opening 23 the camera 13th a.

The optics holder 15th here in particular has a cylinder 25th , in particular a cylinder sleeve, and one on the cylinder 25th attachable lid 27 . The lid 27 is particular with screws 29 to the cylinder 25th or the cylinder sleeve can be screwed on. In particular are the screws 29 preferably in a cylinder wall 31 of the cylinder 25th screwable.

The cylinder 25th is designed in particular as a circular cylinder. An axis of symmetry of the cylinder 25th is preferably aligned coaxially to the optical axis O or coincides with it. The cylinder wall 31 is preferably in the circumferential direction around the axis of symmetry of the cylinder 25th and thus at the same time also designed to run around the optical axis O and to be opaque or opaque along the entire circumference.

The holding shot 17th as well as the positioning device 19th are both on the lid 27 arranged.

The optics holder 15th preferably also has a fixing device 33 that is set up to hold the optics holder 15th at an in 1 housing shown 35 the manufacturing facility 1 to be determined. The fixing device 33 is preferred as a fixing projection, here in particular as a fixing ring 34 formed, the fixing ring 34 - again with reference to 1 - In the assembled state in a recess 37 of the housing 35 engages to the optics holder 15th on the housing 35 to be determined.

In addition, the optics holder 15th an axial stop 39 , in particular in the form of a stop ring with which the optics holder 15th - again with reference to 1 - in the assembled state on the housing 35 strikes in the direction of the optical axis O. The attack 39 encompasses the fixing ring 34 preferably in the circumferential direction and is radially outside of the fixing ring 34 arranged.

Claims (8)

Manufacturing device (1) for the generative manufacturing of a component from a powder material, with - A construction level (3) which is set up to form a component layer of the component to be manufactured in the construction level (3) and - An optical recording device (7), set up for making optical recordings of the building level (3), wherein - A central axis (M) of the building plane (3) and an optical axis (O) of the receiving device (7) are arranged offset from one another, wherein - The recording device (7) has an image acquisition plane (11) and imaging optics (9), and wherein - An optical axis (O) of the imaging optics (9) can be or is offset from an image center axis (B) of the image acquisition plane (11). Production facility (1) according to Claim 1 , characterized in that the central axis (M) of the building plane (3) and the optical axis (O) of the receiving device (7) are oriented parallel to one another. Manufacturing device (1) according to one of the preceding claims, characterized in that the optical axis (O) of the imaging optics (9) is fixed relative to the image acquisition plane (11). Manufacturing device (1) according to one of the preceding claims, characterized in that the optical axis (O) of the imaging optics (9) is oriented parallel to the image center axis (B), or that the optical axis (O) of the imaging optics (9) is inclined to the image central axis (B) and / or is pivotable relative to the image central axis. Manufacturing device (1) according to one of the preceding claims, characterized by an optics holder (15) which has a holding receptacle (17) for fastening the imaging optics (9) to the optics holder (15), the optics holder (15) having a holding receptacle ( 17) has a radially offset positioning device (19) which is set up to position a camera (13) on the optics holder (15). Manufacturing device (1) according to one of the preceding claims, characterized in that the positioning device (19) is designed as a positioning projection or as a positioning recess, in particular as a positioning ring (21). Manufacturing device (1) according to one of the preceding claims, characterized in that the optics holder (15) has a cylinder (25) with a cover (27) which can be arranged on the cylinder (25), the holding receptacle (17) and the Positioning device (19) are arranged on the cover (27). Manufacturing device (1) according to one of the preceding claims, characterized in that the optics holder (15) has a securing device (33) for securing the optics holder (15) on a housing (35) of the manufacturing device (1).

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