OpenLMD, Open Laser Metal Deposition

Open Laser Metal Deposition(OpenLMD)

Jorge Rodríguez-AraújoAIMEN Technology Center, Porriño, Spain

Porriño, 7-12-2016

openlmd.github.io | [email protected] 2

Index

1. Motivation and Innovative Character

2. OpenLMD, modular architecture

3. ROS-based LMD cell integration

4. 3D geometrical monitoring

5. Multimodal monitoring

6. Off-line robot path planning

7. Real-time power control

8. Adaptive LMD path planning

9. Big data registration and analysis

10.Conclusions and future work

Index


Motivation and Innovative Character



Promising additive manufacturing technique. Parts are built up layer by layer directly from a 3D CAD model.

For repair and direct fabrication of pieces.

Near-net-shape (close to the final shape).

Manufacturing of large metallic parts. The material is directly deposited on the previous surface.

Complex setup and adjustment of parameters. Thermal heating accumulation produces geometrical distortions. Distortions rise in poor dimensional accuracy and defects. Traditional off-line process (with constant parameters)

becomes unsuccessful.

Laser Metal Deposition (LMD)

LMD Issues



There are a lot of industrial robotized laser cells. Empower robotized laser cells for effective AM.

Retrofit current industrial facilities. Apply state of the art robotic

software solutions.

Motivation

Robotized Cladding Cell

MotionController

Main Controller

Off-line Path Planning

6-AxisRobot Laser Powder

Feeder

PowerController

FlowController

Innovation


Multiprocessing architecture based on message publishing Multi-node and multi-machine Synchronized multimodal data acquisition

Multiple high speed image sensors Process equipment (e.g. robot, laser) and data

RT-control, cloud storage, data analysis, and visualization Common timestamp

High bandwidth multimodal data storage and analysis Thinked for deep learning algorithms

Open Laser Metal Deposition

ROS-based architecture


OpenLMD Modular Architecture


OpenLMD, modular architecure

CONCEPT

Open-source solution for on-line multimodal monitoring and control of LMD

Modular set of software components. Built on ROS (Robot Operating System)

Interoperability and standardization

Robotics, machine vision, embedded control, machine learning

ROS-based LMD cell integrationIntegration of ABB LMD robotized cell based on ROS.

3D Geometrical Monitoring3D on-line monitoring (point cloud) for LMD robotized cells.

Multimodal monitoringImage-based multimodal monitoring for Laser applications.

Off-line Robot Path PlanningOff-line path planning for robotized LMD automation.

Real-Time Process ControlImage-based asynchronous RT close-loop control for LMD systems.

Adaptive LMD Process PlanningAdaptive path planning for an automatic repair of large and complex metal parts.

Big Data Registration and analysisBig data registration for LMD adaptive parametric control (for Cloud Computing and Deep Learning)


ROS-based modular laser cell integration

The PC integrates the interface and modules to command the robot (ROS)

The robot controls all the cell elements

ROS components:

Robot state publisher

Robot command server

ROS-based LMD cell integration

PowderFeeder

Fiber Laser

6-Axis Industrial Robot

PC Controller

Cladding Head

ROS-Driver(ABB Rapid)

Geometrical Cell Description

(URDF)

STATEPUBLISHER

Laser Source(slave)

Powder Feeder(slave)

COMMANDSERVER

PowerSpeed

Powder flow

Motion path

States

Commands

ROBOT

Process parameters


On-line 3D scanning

Real –time point cloud registration

Actual metric measurements (mm)

Direct acquisition in robot coordinates

3D geometrical monitoring

Industrial Robotic Laser Cell

ROBOTROS-DRIVER

CAMERAIDS-DRIVER

State Publisher Peak Finder

Robot PoseTool-Camera

Laser TriangulationCalibration

3D ProfileCamera Pose

3D Point CloudWorking Cell Coordinate

Point Cloud Reconstruction


Multimodal monitoring

Multimodal Cladding Head

3D System

TachyonMWIR

NIR

Multimodal monitoring approach

Coaxial SWIR/MWIR images (thermal monitoring): NIT microcore (1000fps) [1-3um]

Coaxial NIR images (surface monitoring): CMOS camera (100fps) [830-880nm]

Off-axis 3D system: on-line 3D point cloud scanning (50fps)

MWIR+NIRMultispectral

Imaging

LMD Cell Virtualization


Off-line robot path planning

Robot Routine(ABB rapid)

Intuitive robot programming

Automatic generation of robot trajectories

User friendly interface with high level of abstraction

CAD-based off-line programming (no robot programming skills needed)

3D Part Visualization


Melt poolgeometry

PI controller(Kp, Ki)

CLADDINGprocess

width

powereSP

PVMicroCore

Close-Loop Control

Real-Time power control

Without control With control

On-line asynchronous laser power control

Closed-loop control

Embedded vision

RT Control Interface


Adapts the path to the real geometry

Automatic repair of large parts

On-line geometrical monitoring

Adaptive path planning

Geometrical control

Adaptive LMD path planning

Robotized Laser Cell

Track MeasurementPath Planning

3D Model

Layer Planning Layer Measurement

STL Generation

On-

line

3D Filtering

Initialization(setup)

Scan layer

Depth mapTarget

Depth map Disparity

Data

Layer pathplanning

Layer Path Planning(geometrical control)

Laser Cellsupervisor

Robotized Cell

0 Finished

Repair Job

Adaptive path planning


Cyber Physical registration

High throughput (28MB/s) (NIR + MWIR + 3D point cloud+ Robot)

Deep learning capabilities

Data management and analysis (DataFrames)

Feature extraction

Integration of temporal data

Iterative adjustment

Quality diagnosis and

reconfiguration

Process parameters

LMD

Big data registration and analysis

60 GB/h

Cyber Physical Sytem


Conclusions


Data acquisition Spatial reference sistem and temporaly synchronized

Annalysis Deep learning: features extration

Actuation Real-time laser power control Adaptive path planning

Embedded vision and control systems

Robot

Pose Process speed

3D geometry

Point cloud (<0.5mm)

Multimodal: SWIR/MWIR-NIR

2D melt pool geometry Thermal distribution

and texture

Reconfigurable

Conclusions

Conclusions

Current lines

Modular and reconfigurable

Interoperability

Large parts

Low-cost solution

Scalability

AIMEN – Central y Laboratoriosc/ Relva 27 A

36410 – O PORRIÑO (Pontevedra)Telf.+34 986 344 000 – Fax. +34 986 337 302

Thank you for your attention

Jorge Rodríguez-Araújo | Research EngineerPh +34 986 344 000 | [email protected]

www.aimen.es | [email protected]

mailto:[email protected]

OpenLMD, Open Laser Metal Deposition

Technology

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