用红外相机实时调速,让机器人焊接铝件时每层高度更准。
Robotic Wire Arc Additive Manufacturing with Variable Height Layers
- 通过红外相机监测焊焰,闭环反馈调节机械臂速度。
- 使铝材多层打印高度误差显著降低,优于开环控制。
- 适合需要高精度复杂结构的金属增材制造场景。
机器人丝弧增材制造因沉积速率高、成形体积大而广泛应用。对于复杂结构,采用层内变高度打印可避免支撑结构或几何分解。此前钢材料已通过预设机器人速度曲线实现良好几何质量。但铝材的熔池形状与前一层温度紧密相关,导致不同位置沉积高度变化明显。本文提出一种闭环修正方法:利用安装在独立机械臂上的红外相机追踪焊焰,估算实际沉积高度;根据前一层误差和预定高度曲线动态调整机器人速度,同时考虑工艺与系统约束。实验表明该方法显著优于开环方案,并对模型参数偏差具有强鲁棒性。
原文摘要 · Abstract (English)
Robotic wire arc additive manufacturing has been widely adopted due to its high deposition rates and large print volume relative to other metal additive manufacturing processes. For complex geometries, printing with variable height within layers offer the advantage of producing overhangs without the need for support material or geometric decomposition. This approach has been demonstrated for steel using precomputed robot speed profiles to achieve consistent geometric quality. In contrast, aluminum exhibits a bead geometry that is tightly coupled to the temperature of the previous layer, resulting in significant changes to the height of the deposited material at different points in the part. This paper presents a closed-loop approach to correcting for variations in the height of the deposited material between layers. We use an IR camera mounted on a separate robot to track the welding flame and estimate the height of deposited material. The robot velocity profile is then updated to account for the error in the previous layer and the nominal planned height profile while factoring in process and system constraints. Implementation of this framework showed significant improvement over the open-loop case and demonstrated robustness to inaccurate model parameters.
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