具有可变层高的机器人电弧增材制造
Robotic Wire Arc Additive Manufacturing with Variable Height Layers
AI总结：
针对铝电弧增材制造中层间沉积高度因温度耦合易变化的问题，提出基于红外相机高度估算的闭环速度剖面更新方法，显著提升打印质量并增强对模型参数误差的鲁棒性。
摘要：
机器人电弧增材制造因其相对于其他金属增材制造工艺的高沉积速率和大打印体积而被广泛采用。对于复杂几何形状，在层内采用可变高度打印的方式，无需支撑材料或几何分解即可制造悬垂结构，这一优势十分显著。此前，该方法已在钢材上得到验证，通过预先计算的机器人速度剖面实现了一致的几何质量。相比之下，铝的熔池几何形状与前一层的温度紧密耦合，导致零件不同位置沉积材料的高度发生显著变化。本文提出一种闭环方法，用于校正层间沉积材料高度的变化。我们使用安装在另一台机器人上的红外（IR）相机跟踪焊接火焰，并估算沉积材料的高度。随后，在考虑工艺和系统约束的前提下，更新机器人速度剖面，以补偿前一层的误差和标称规划高度剖面。该框架的实施显示出相对于开环情况的显著改进，并证明了对不准确模型参数的鲁棒性。
英文摘要：
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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