Method and Device for Measuring a Powder Mass Flow for Powder Cladding

Abstract

The innovation relates to a device and a method for measuring a powder mass flow for powder cladding. Before the powder cladding, the powder mass flow is set by means of a powder mass determining device and a powder mass flow sensor is calibrated on the basis of the setting. Then a powder switch is used to begin the powder cladding without interrupting the delivery of the powder mass. During the powder cladding, the powder mass flow is monitored by means of the powder mass flow sensor.

Claims

1. A device (10) for measuring a powder mass flow for powder cladding, comprising: at least one powder metering device (11a, 11b), a control unit (20), characterized in that said device comprises a powder mass flow sensor (14), a powder mass determination device (18), and a powder switch (15), wherein said at least one powder metering device (11a, 11b) is configured to feed a powder mass via said powder mass flow sensor (14) to a powder mass determination device (18) and/or to a process head (16), depending on said powder switch (15), and wherein said control unit (20) is configured to calibrate said powder mass flow sensor (15) based on a powder mass flow measured by said powder mass determination device (18).

2. The device according to claim 1, wherein said control unit (20) is configured to adjust said powder metering device (11a, 11 b) based on the powder mass flow measured by said powder mass determination device (18) and a specified powder mass flow.

3. The device according to claim 1, wherein said control unit (20) is configured to adjust said powder metering device (11a, 11b) based on the powder mass flow detected by said powder mass flow sensor (14) and a specified powder mass flow.

4. The device according to claim 1, comprising a centrifugal separator, a gravity separator and/or an inertial separator (17) between said powder switch (15) and said powder mass determination device (18) for separating the powder mass from a gas or gas mixture.

5. The device according to claim 1, wherein said control unit (20) is configured to control the powder mass flow via one or more pinch valves (11a, 11b).

6. The device according to claim 1, wherein said powder mass determination device (18) is configured to measure the powder mass flow by measuring a mass of solids deposited in a time interval.

7. The device according to claim 1, wherein said control unit (20) is configured to carry out the following steps in a work preparation mode: adjusting a feeding amount of said at least one powder metering device (11a, 11b) per unit of time as a function of a specified powder mass flow and as a function of the powder mass flow measured by said powder mass determination device (18), and calibrating said powder mass flow sensor (14) as a function of the specified powder mass flow and/or the powder mass flow measured by said powder mass determination device (18).

8. The device according to claim 1, wherein said control unit (20) is configured to execute at least the following steps in order to carry out the powder cladding: actuating said powder switch (15) in order to feed the powder mass via said powder mass flow sensor (14) to said process head (16) in a working mode, and monitoring the powder mass flow using said powder mass flow sensor (14) in the working mode.

9. The device according to claim 8, wherein said control unit (20) is configured to switch from the work mode to the work preparation mode when a deviation between the powder mass flow detected by said powder mass flow sensor (14) and the specified powder mass flow exceeds a specified value.

10. A method for measuring a powder mass flow for powder cladding, comprising the steps of: feeding a powder mass, determining the powder mass flow of the fed powder mass, calibrating a powder mass flow sensor as a function of the determined powder mass flow, feeding the powder mass with a specified powder mass flow via said powder mass flow sensor to a process head, and monitoring the powder mass flow using said powder mass flow sensor.

11. The method according to claim 10, comprising the step of: separating the powder mass from a gas or a gas mixture before determining the powder mass flow.

12. The method according to claim 10, wherein the powder mass flow is measured using scales.

13. The method according to claim 10, comprising the steps of: actuating a powder switch to change the feeding direction from a powder mass flow determination unit to said process head.

14. The method according to claim 10, wherein the feeding amount per unit of time is controlled as a function of the determined powder mass flow of the fed powder mass and as a function of a specified powder mass flow.

15. The method according to claim 10, wherein the feeding amount per unit of time is adjusted as a function of the sensor values of said powder mass flow sensor and as a function of a specified powder mass flow.

16. The method according to claim 10, wherein said method is carried out again when a deviation of the powder mass flow detected by said powder mass flow sensor from a specified powder mass flow exceeds a specified value.

Description

DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 schematically shows a device for measuring a powder mass flow for powder cladding according to an embodiment of the invention.

[0030] FIG. 2 schematically shows a process flow chart of a method according to an embodiment of the invention.

[0031] FIG. 3 schematically shows a process flow chart of a method for measuring/determining the powder mass flow according to an embodiment of the invention.

[0032] FIG. 4 schematically shows a device for measuring a powder mass flow for powder cladding according to an embodiment of the invention.

[0033] In some embodiments, components may be combined, split into multiple components, and/or additional components may be added without affecting the functionality of the invention. In some embodiments, method steps can be switched in their order, carried out in parallel, combined or divided and/or further steps can be added without affecting the function of the method according to the invention.

[0034] FIG. 1 schematically shows a device 10 for measuring a powder mass flow for powder cladding according to an embodiment of the invention. In FIG. 1, the powder mass flow is shown schematically with solid arrows. Dashed lines show connections for signal and/or data exchange between different components. The connections for signal and/or data transmission may be wired and/or wireless.

[0035] In this embodiment, the powder mass is fed by means of two powder metering devices, the powder metering devices 11a and 11b. The powder metering devices are configured to generate a powder mass flow. The powder mass flows are combined in a Y connection 13 to form a common powder mass flow. In an embodiment with a powder metering device, the Y-connection may optionally be omitted. In some embodiments, particularly when the device comprises multiple powder metering devices, the device may comprise multiple Y-connections and/or alternatives such as mixers or n-fold Y-connections.

[0036] The common powder mass flow generated in this way is routed to a powder switch 15 via a powder mass flow sensor 14. Depending on the driving of the powder switch 15, the powder switch directs the powder mass flow to a process head 16 and/or scales 18. The powder switch is controlled by the control unit 20 in this embodiment.

[0037] In this embodiment, a powder separator 17 is mounted between powder switch 15 and scale 16. I may be configured to separate the powder from a gas or gas mixture, in particular a shielding gas.

[0038] In some embodiments, the control device 20 may consist of a plurality of partially independent control devices. In this embodiment, the control device is configured to control and/or regulate the powder metering devices 11a, 11 b as a function of sensor data from the powder mass flow sensor 14 and/or as a function of data/signals from the scales 18 and a specified powder mass flow.

[0039] In this embodiment, the control unit 20 is further configured to calibrate the powder mass flow sensor 14 as a function of data/signals from the scales 18 and/or a specified powder mass flow. The scales 18 may be configured, for example, to measure a powder mass flow by measuring a powder mass deposited on the scales 18 in a time interval. The powder mass flow is then obtained by dividing the measured powder mass by the length of the time interval.

[0040] In this embodiment, the control unit is configured to control the process head. The process head may be configured to be moved in one, two or three directions. In some embodiments, the process head may comprise a laser unit configured to introduce a predetermined energy into a laser processing area during powder cladding.

[0041] In some embodiments, the control unit is configured to direct the powder mass flow from the at least one powder metering device 11a, 11 b via the powder mass flow sensors 14 to the scales by means of the powder switch in a work preparation mode. The powder mass is separated from gases and gas mixtures in the optional powder mass separator mounted upstream of the scale. In this embodiment, the control unit is configured to regulate and control the at least one powder metering device 11a, 11 b in such a way that a specified powder mass flow is measured by means of the scale 18. If the at least one powder metering device is adjusted accordingly, the powder mass flow sensor 14 can be calibrated. The powder mass flow sensor can, for example, be configured optically, by means of radiation or by contact to detect a powder mass flow. In some embodiments, the sensor data of the powder mass flow sensor are simply adjusted according to a calibration.

[0042] After the calibration of the powder mass flow sensor, powder cladding may be carried out in this embodiment. In this embodiment, in order to switch to the work mode, i.e. powder cladding, the powder switch 15 is actuated via a control signal so that the powder mass flow is fed to the process head 16 instead of to the scales. This makes it possible to switch from a work preparation mode to the work mode without interrupting the powder mass feed.

[0043] During powder cladding, the powder mass flow is monitored using the powder mass flow sensor. This ensures a constant powder mass flow.

[0044] In some embodiments, the control unit may be configured to interrupt or abort the powder cladding when a deviation of the powder mass flow detected by the powder mass flow sensor from a specified powder mass flow exceeds a specified limit value. For this purpose, the powder switch 15 may be actuated by the control unit 20 so that the powder mass flow is fed from the powder switch 15 to the scales 18. Then the powder mass flow may be adjusted again using the scales and the powder mass flow sensor may be calibrated if necessary.

[0045] In some embodiments, the control unit may be configured to interrupt or abort the powder cladding based on an external signal, for example a sensor signal from a sensor for checking the powder mass deposition. In some versions, this may mean that there is a change from the work mode to the work preparation mode or that the powder cladding is aborted.

[0046] FIG. 2 schematically shows a process flow chart of a method according to an embodiment of the invention. In a first step S11, a powder mass is fed. The powder mass is preferably suitable as a powder for powder cladding. In a second step S12, a powder mass flow of the fed powder mass is determined. In a next step S13, depending on the determined powder mass flow, it is checked whether the powder mass flow deviates from a specified powder mass flow by more than a specified tolerance. If the deviation is greater than the tolerance, the feed of the powder mass is adjusted via step S14 and the powder mass flow is determined again in step S12. If the deviation is less than the tolerance, a powder mass flow sensor is calibrated in step S15 using the determined powder mass flow.

[0047] On the basis of the preparations for the powder cladding in steps S11 to S15, the powder cladding can be carried out in a step S16. In order to switch from the steps of preparation to carrying out the powder cladding S16, for example, a powder switch may be actuated to change the feeding direction to a process head of a powder cladding unit instead of to a determination unit for determining the powder mass flow, see step S12.

[0048] During powder cladding S16, the powder mass flow is monitored using the powder mass flow sensor in steps S16a, S17-S19. In step S16a the powder mass flow is detected by means of the powder mass flow sensor. In step S17, it is checked whether a deviation of the powder mass flow detected by means of the powder mass flow sensor from a specified powder mass flow is greater than a specified tolerance value. If the deviation is greater, the powder cladding is interrupted and the process continues with step S12 of determining the powder mass flow. Depending on the embodiment, when steps S12 to S16 are carried out again, step S15 of calibrating the powder mass flow sensor may be skipped.

[0049] If the deviation of the detected powder mass flow from the specified powder mass flow is within the tolerance range, it is checked in step S18 whether the detected powder mass flow corresponds to the specified value. If the detected powder mass flow corresponds to the specified powder mass flow, the execution of the powder cladding is continued with step S16. If the values do not match, the feed of the powder mass is adjusted in step S19 and the procedure also continues with step S16 of carrying out the powder cladding.

[0050] In some embodiments, step S16 of carrying out the powder cladding can be continued after step S18 if a deviation of the detected powder mass flow from the specified powder mass flow is below a further tolerance value. Otherwise, the procedure continues with step S19 of adjusting the feed of the powder mass. In some embodiments, the tolerance values of step S17 and step S18 may have the same value.

[0051] In some embodiments, steps S16, S16a, S17-S19, which include monitoring the powder mass flow during powder cladding with the powder mass flow sensor, among others, may be performed in a different order, with additional steps, may at least be partially combined, etc.

[0052] FIG. 3 schematically shows a process flow chart of a method for measuring/determining the powder mass flow according to an embodiment of the invention. Upon the start S21 of the method, a powder mass flow list is generated in a step S22 by means of a conveyor disk speed n. In this embodiment, the powder metering device is a conveyor disk. In this embodiment, a specified powder mass flow i.sub.soll is transferred in parallel. After the start of the method, the measurement cycle S24 begins.

[0053] Depending on whether the cycle has just started, including the powder switch to the scale being actuated, step S26 or step S25 is performed. If the cycle has started from a standstill, the settling of the powder conveyor/powder metering device, in this exemplary embodiment 60 seconds, is waited for in step S26. When the powder switch to the scales is actuated, the passage of a settling time of the powder switch, 30 seconds in this exemplary embodiment, is waited for in step S25.

[0054] Steps S25 and S26 may be skipped when neither the powder switch has been actuated nor the powder feeder has been activated from standstill.

[0055] In a next step S27, a first measurement of a powder mass m0 is carried out on scales. In a further step S28, the passage of a time interval/measurement duration T, 30 seconds in this exemplary embodiment, is waited for. During the time interval/measuring period T, the powder mass flow is fed onto the scale. A second measurement of the powder mass m1 is then carried out in step S29. In the next step S30, the powder mass flow is determined using the equation i.sub.ist=(m1−m0)/T.

[0056] In a further step S31, a deviation of the powder mass flow i.sub.soll from the specified powder mass flow is determined. In this exemplary embodiment, the deviation is determined using the formula |i.sub.soll−i.sub.ist|/i.sub.soll. If the deviation is below a specified tolerance, 1% in this exemplary embodiment, the conveyor disk speed n.sub.erf for feeding the specified powder mass flow i.sub.soll is specified with the conveyor disk speed n and the measurement/determination of the powder mass flow i can be completed in step S33.

[0057] If the deviation is greater than the specified tolerance, the speed of the conveyor disk n is adjusted in step S34. Depending on the embodiment, the passage of a reaction time of the powder metering device, in this exemplary embodiment 20 seconds, may be waited for in a step S35 before the cycle starts again with step S24.

[0058] FIG. 4 schematically shows a device for measuring a powder mass flow for powder cladding according to an embodiment of the invention. In this embodiment, pinch valves 11a, 11 b meter the powder fed by powder conveyors 41a, 41b. The resulting powder streams are combined into one stream by means of the Y-connection 13. In this exemplary embodiment, the pinch valves are controlled via the directional valve for driving one or more metering devices. The powder mass flow is fed from the Y-connection 13 to the powder switch 15 via the powder mass flow sensor 14

[0059] As shown in this embodiment, the powder switch 15 may be controlled by means of the directional valve for driving the powder switch 43. A possible position is that the powder mass flow is fed to the process head 16 via the powder transport 16a. In a further possible position, the powder mass flow is fed onto a scale 18. A powder separator 17 may be arranged on the feeding path between the scales 18 and the powder switch 15. In some embodiments, the directional valve for driving one or more metering devices 42, the directional valve for controlling the powder switch, the scale 18, the mass flow sensor 14, the powder separator and/or the process head may be connected to one another, for example, via one or more control units.

[0060] The control unit may be configured, for example, to control/regulate the powder mass flow using the directional valve for driving one or more metering devices 42 based on data/signals provided by the powder mass flow sensor 14 and/or the scales 18. In some embodiments, the control unit may be configured to control the powder switch by means of the directional valve for driving the powder switch and thus to switch between a work preparation mode and a work mode of powder cladding.

[0061] In the work preparation mode, a predetermined powder mass flow may be adjusted by means of the scales 18, the directional valve for driving one or more metering devices 42 and one or more metering devices 11a, 11b. The powder mass flow sensor 14 may preferably be calibrated after the powder mass flow has been adjusted. In order to then switch to the work mode without interruption, the powder mass flow can be fed to the process head 16 by actuating the directional valve for driving the powder switch 43. While the powder is being fed to the process head 16, the powder mass flow that is being fed may be monitored by means of the powder mass flow sensor 14.

[0062] In some embodiments, the control unit may be configured to automatically switch to the work preparation mode and adjust the powder mass flow again when the powder mass flow sensor 14 detects an excessive deviation from a specified value. This has the advantage that when, for example, powder from a first batch runs out during powder cladding and powder from a second batch is fed, it is ensured that the powder mass flow corresponds to a target value.

LIST OF REFERENCE SYMBOLS

[0063] 11a, 11b powder metering device [0064] 13 Y-connection [0065] 14 powder mass flow sensor [0066] 15 powder switch [0067] 16 process head [0068] 16a powder transport to the process head 16 [0069] 17 powder separator [0070] 18 scales [0071] 20 control unit [0072] 41a, 41b powder conveyor [0073] 42 directional valve for driving one or more metering devices [0074] 43 directional valve for driving the powder switch [0075] i.sub.ist measured/detected powder mass flow [0076] i.sub.soll specified powder mass flow [0077] T time interval/measurement duration [0078] m0 first weight measurement [0079] m1 second weight measurement [0080] n speed of the conveyor disc [0081] n.sub.erf conveyor disk speed for feeding i.sub.soll