Abstract
A composite forging device includes a connecting component, a heating module and a forging module. The heating module is connected to the connector and includes a heater. The forging module is connected to the connector and includes a forger. The heater and the forger are disposed opposite each other.
Claims
1. A composite forging device, comprising: a connecting component; a heating module connected to the connecting component and comprising a heater; and a forging module connected to the connecting component and comprising a forger; wherein the heater is disposed opposite to the forger.
2. The composite forging device as claimed in claim 1, wherein the heating module further comprises: a first force sensor connected to the heater; and a spacer connecting the first force sensor with the heater and separated the first force sensor from the heater.
3. The composite forging device as claimed in claim 1, wherein the heating module further comprising: a displacement driver connecting the connecting component with the heater and configured to drive the heater to move.
4. The composite forging device as claimed in claim 3, wherein the displacement driver is further configured to: drive the heater to move along an axial direction; wherein a connection line between an end portion of the heater and an end portion of the forger is substantially parallel to an axial direction.
5. The composite forging device as claimed in claim 4, wherein the end portion of the forger has an inclined surface, and the forger presses against the lamination layer with the inclined surface.
6. The composite forging device as claimed in claim 1, wherein the forging module further comprises: a second force sensor connected to the forger and configured to sense a reaction force of the forger exerting on the lamination layer.
7. A metal lamination equipment, comprising: a driving device; and a composite forging device connected to the driving device and comprising: a connecting component; a heating module connected to the connecting component and comprising a heater; and a forging module connected to the connecting component and comprising a forger; wherein the heater is disposed opposite to the forger.
8. The metal lamination equipment as claimed in claim 7, wherein the heating module further comprises: a first force sensor connected to the heater; and a spacer connecting the first force sensor with the heater and separated the first force sensor from the heater.
9. The metal lamination equipment as claimed in claim 7, wherein the heating module further comprises: a displacement driver connecting the connecting component with the heater and configured to drive the heater to move.
10. The metal lamination equipment as claimed in claim 9, wherein the displacement driver is further configured to: drive the heater to move along an axial direction; wherein a connection line between an end portion of the heater and an end portion of the forger is substantially parallel to an axial direction.
11. The metal lamination equipment as claimed in claim 10, wherein the end portion of the forger has an inclined surface, and the forger presses against the lamination layer with the inclined surface.
12. The metal lamination equipment as claimed in claim 7, wherein the forging module further comprises: a second force sensor connected to the forger and configured to sense a reaction force of the forger exerting on the lamination layer.
13. The metal lamination equipment as claimed in claim 7, wherein the driving device is a robot arm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a functional block diagram of a metal lamination equipment according to an embodiment of the present invention;
[0009] FIG. 2 shows a schematic diagram of the metal lamination equipment in FIG. 1;
[0010] FIG. 3 shows a functional block diagram of a metal lamination equipment according to another embodiment of the present disclosure;
[0011] FIG. 4 shows a schematic diagram of the metal lamination equipment in FIG. 3;
[0012] FIGS. 5A and 5B show a further structural diagram of the composite forging device in FIG. 4; and
[0013] FIG. 6 shows a schematic diagram of a control block of the composite forging device in FIG. 3.
DETAILED DESCRIPTION
[0014] Referring to FIGS. 1 and 2, FIG. 1 shows a functional block diagram of a metal lamination equipment 10 according to an embodiment of the present invention, and FIG. 2 shows a schematic diagram of the metal lamination equipment 10 in FIG. 1.
[0015] As shown in FIGS. 1 and 2, the metal lamination equipment 10 includes a composite forging device 100 and a driving device 200. The composite forging device 100 is connected to the driving device 200. The composite forging device 100 includes a connecting component 105, a heating module 110 and a forging module 120. The heating module 110 is connected to the connecting component 105 and includes a heater 111. The forging die set 120 is connected to the connecting component 105 and includes a forger 121. The heater 111 and the forger 121 may be disposed oppositely. As a result, the heater 111 and the forger 121 may be respectively located at or press against two opposite sides of a lamination layer 20, so as to simultaneously heat the lamination layer 20 and forge the lamination layer 20. In other words, during the formation process of the lamination layer, the composite forging device 100 heats the lamination layer 20 to reduce a temperature drop gradient of the lamination layer 20 (which may improve the problem of the crack of the lamination layer 20 caused by excessive temperature drop gradient (too fast cooling rate)), and at the same time forge the lamination layer 20 to improve the grain structure of the lamination layer 20 (which may increase the strength of the lamination layer). The driving device 200 is, for example, a robot arm or a machine platform with a slide rail. The connecting component 105 of the composite forging device 100 may be connected to the driving device 200 so as to be driven by the driving device 200. The driving device 200 may drive the heater 111 of the composite forging device 100 and the forger 121 of the forging module 120 to move, so as to process at least one position of the lamination layer 20.
[0016] The temperature drop gradient in this article is, for example, a temperature variation rate over time, or a temperature variation rate over the position of the lamination layer. In terms of the temperature variation rate over time, it means that the temperature variation rate at a fixed position of the lamination layer over time. In terms of the temperature variation rate over position, it means that the variation rate of multiple temperatures at different positions of the lamination layer overtime.
[0017] Referring to FIGS. 3 and 4, FIG. 3 shows a functional block diagram of a metal lamination equipment 10 according to another embodiment of the present disclosure, and FIG. 4 shows a schematic diagram of the metal lamination equipment 10 in FIG. 3. The metal lamination equipment 10 includes a composite forging device 100, a driving device 200, a metal deposition device 300 and a control device 400.
[0018] As shown in FIGS. 3 and 4, the composite forging device 100 includes a connecting component 105, a heating module 110 and a forging module 120. The heating module 110 is connected to the connecting component 105 and includes a heater 111, a first force sensor 112, a displacement driver 113, a temperature sensor 114 and at least one spacer 115 (the spacer 115 is shown in FIG. 5A). The forging module 120 is connected to the connecting component 105 and includes a forger 121 and a second force sensor 122. The heater 111 and the forger 121 are disposed oppositely. In an embodiment, the heater 111 and the forger 121 may be respectively located at or press against two opposite sides of the lamination layer 20 to simultaneously heat the lamination layer 20 and forge the lamination layer 20. In other words, during the formation process of the lamination layer 20, the composite forging device 100 heats the lamination layer 20 to reduce the temperature drop gradient of the lamination layer 20 (which may improve the problem of the crack of the lamination layer 20 caused by excessive temperature drop gradient) and at the same time forge the lamination layer 20 to improve the grain structure of the lamination layer 20 (which may increase the strength of the lamination layer).
[0019] As shown in FIGS. 4 and 5, in the present embodiment, the driving device 200 is, for example, a robot arm. For example, the driving device 200 includes at least one driving mechanism 210 and a controller 220. The driving mechanism 210 includes, for example, a plurality of linkages 211, and the linkages 211 are pivotally connected to each other. Although not shown, the driving device 210 further includes at least one driver (for example, motor) which is pivotally connected to the two linkages 211 to drive the two linkages 211 to move relatively (for example, relative rotation). The controller 220 may control the driver to control the movement of the drive mechanism 210. The controller 220 may be electrically connected to the control device 400, and the control device 400 may transmit control instructions to the controller 220, so that the controller 220 controls the movement of the driving mechanism 210 accordingly. The connecting component 105 of the aforementioned composite forging device 100 may be connected to (for example, fixed to) the linkage 211 at the end of the driving device 200. Through the movement of the driving mechanism 210 of the driving device 200, the composite forging device 100 may be driven at six freedoms: at least one of the translation along the X-axis, the translation along the Y-axis, the translation along the Z-axis, the rotation around the X-axis, the rotation around the Y-axis and the rotation around the Z-axis. As a result, the heater 111 and the forger 121 may move with the formation trajectory of the lamination layer 20. In a type of control, through the movement of the driving mechanism 210 of the driving device 200, the heater 111 and the forger 121 of the composite forging device 100 may be constantly located on the opposite two sides of the lamination layer 20, and/or constantly press against (for example, keep pressing against) on opposite two sides of the lamination layer 20.
[0020] In another embodiment, although not shown, the driving device 200 is, for example, a machine platform, wherein the machine platform includes a carrier that may translate along at least one axis (for example, three axes which are perpendicular to each other). The connecting component 105 of the composite forging device 100 may be fixed to the carrier. Through at least one axial translational movement of the carrier, the lamination layer 20 may still be constantly pressed or clamped between the heating module 110 and the forging module 120 of the composite forging device 100.
[0021] As shown in FIGS. 3 and 4, the metal deposition device 300 includes a driving mechanism 310, a controller 315, a metal deposition tool 320 and a camera 330. The driving mechanism 310 is, for example, a robot arm. The driving mechanism 310 includes at least one linkage 311, and the linkages 311 are pivotally connected to each other and controlled by the controller 315. Although not shown, the driving mechanism 310 further includes at least one driver (for example, a motor) which is pivotally connected to the two linkages 311 to drive the two linkages 311 to move relatively (for example, relative rotation). The controller 315 may control the driver to drive the driving mechanism 310 to move. The controller 315 may be electrically connected to the control device 400, and the control device 400 may transmit the control instruction to the controller 315, so that the controller 315 controls the movement of the driving mechanism 310. Through the movement of the linkage 311 of the driving mechanism 310, the metal deposition tool 320 may be driven to move along a movement trajectory P1, so as to form the lamination layer 20 along the movement trajectory P1. The metal deposition tool 320 and the camera 330 may be disposed on (or fixed to) the linkage 311 at the end of the driving mechanism 310. The metal deposition tool 320 melts the alloy powder (not shown) into a high-temperature liquid metal by high temperature (for example, laser), and sprays the high-temperature liquid metal on a base material (not shown) to form the lamination layer 20. The camera 330 may capture an image M of the lamination layer 20. The camera 330 is, for example, a thermal imaging camera. The controller 315 may be electrically connected to the metal deposition tool 320 and the camera 330 to control the operation of these components. The controller 315 or the control device 400 may perform thermal image analysis on the image M to analyze the thermal information of the lamination layer 20 (for example, temperature value, temperature drop gradient, etc.).
[0022] As shown in FIGS. 3 and 4, the control device 400 is, for example, a server, which may include at least one controller 410. The controller 410 is electrically connected to the controller 220 to control the composite forging device 100 and/or the driving device 200 through the controller 220. For example, the controller 410 may receive a signal from the composite forging device 100 and analyzes and/or processes the signal to obtain information of the force of the composite forging device 100 pressing against the lamination layer 20. The controller 410 is further configured to transmit a movement instruction CM to the controller 220, and the controller 220 controls the movement of the driving mechanism 210 and/or the movement of the heating module 110, so that the heater 111 and the forger 121 press against the opposite two sides of the lamination layer 20. The controller 410 is further configured to transmit a heating instruction CH (the heating instruction CH is shown in FIG. 5A) to the controller 220, and the controller 220 controls a heating component 1112 to accordingly generate heat. The controller 410 is further configured to transmit a forging instruction CF (the forging instruction CF is shown in FIG. 5A) to the controller 220, and the controller 220 controls the forging module 120 to accordingly forge the lamination layer 20. In addition, the controller 410 is further electrically connected to the controller 315 to control the metal deposition device 300 through the controller 315. For example, the controller 410 may transmit the instructions to the controller 315, and accordingly the controller 315 controls the movement of the driving mechanism 310 and/or the metal deposition tool 320 to perform the spraying operation. The controller 410 may receive the image M of the lamination layer 20 captured by the camera 330 and analyze the image M to obtain the thermal information of the lamination layer 20.
[0023] Referring to FIGS. 5A and 5B, FIGS. 5A and 5B show a further structural diagram of the composite forging device 100 in FIG. 4.
[0024] As shown in FIGS. 5A and 5B, the connecting component 105 is, for example, a plate, which may be fixed to the linkage 211 of the driving device 200. The linkage 211 of the driving device 200 may drive the connecting component 105 to translate along at least one of the X-axis, the X-axis and the Z-axis and/or rotate around at least one of the X-axis, the X-axis and the Z-axis. The displacement driver 113 of the heating module 110 may connect the connecting component 105 and the heater 111. For example, the displacement driver 113 may be fixed on the connecting component 105 to move together with the connecting component 105. The displacement driver 113 is configured to drive the heater 111 to move, for example, to translate along the X-axis. For example, the displacement driver 113 includes a slide rail 1131 and a slide block 1132, wherein the slide rail 1131 may extend along an axial direction P2, wherein the axial direction P2 may be parallel to the X-axis or intersect with the X-axis (that is, non-parallel). The slide block 1132 is slidably connected to the slide rail 1131. Although not shown, the displacement driver 113 further includes a driver that may be electrically connected to the slide block 1132 and may drive the slide block 1132 to move relative to the slide rail 1131.
[0025] As shown in FIGS. 5A and 5B, the first force sensor 112 may be connected to (or fixed on) the slide block 1132 to move along the axial direction P2 with the slide block 1132. The first force sensor 112 is connected to the heater 111. For example, the first force sensor 112 is connected to the heater 111 through the spacer 115. The first force sensor 112 may sense the force of the heater 111 along the axial direction P2. The first force sensor 112 may be electrically connected to the control device 400, and the first force sensor 112 may transmit the sensed force signal to the control device 400, so that the controller 410 of the control device 400 obtains a measured pressing force F1,.sub.f (measured pressing force F1,.sub.f is shown in FIGS. 4 and 5) on the lamination layer 20, and determine whether the measured pressing force F1,.sub.f reaches a required pressing force F1,.sub.f (described later).
[0026] As shown in FIGS. 5A and 5B, the spacer 115 connects the first force sensor 112 and the heater 111 and separates the first force sensor 112 from the heater 111 to form a thermal resistance between the first force sensor 112 and the heater 111. As a result, the negative impact of the heat of the heater 111 on the first force sensor 112 may be reduced. In an embodiment, the spacers 115 are, for example, bolts. In another embodiment, the composite forging device 100 further includes a covering component covering at least one of the heater 111, the first force sensor 112 and the spacer 115. The covering component has an opening that exposes the heater 111 for contact with the lamination layer 20. The covering component, for example, has thermal insulation properties (for example, a heat-insulating covering component), which may reduce or even avoid the heat loss from the heater 111, and may also prevent the heating module 110 (or the heater 111) from being exposed and causing the burn incident.
[0027] As shown in FIGS. 5A and 5B, the heater 111 includes a heating body 1111 and a heating component 1112. The heating body 1111 is formed of, for example, a material with good thermal conductivity, for example, metal, such as copper, aluminum, iron, etc. The heating body 1111 has an end portion 1111A, and the heating component 1112 may be embedded in an end portion 1111A to heat the end portion 1111A. The heating body 1111 is connected to the lamination layer 20 with the end portion 1111A. The heating component 1112 may be electrically connected to the controller 220, and the controller 220 may provide current to the heating component 1112 to cause the heating component 1112 to generate heat. In an embodiment, the heating component 1112 is, for example, an electro-thermal rod.
[0028] As shown in FIGS. 3, 5A and 5B, the temperature sensor 114 may be embedded in the end portion 1111A and exposed or protruded from the end portion 1111A to sense the temperature of the lamination layer 20 which is in contact with the end portion 1111A. The temperature sensor 114 is, for example, a thermocouple. In addition, the temperature sensor 114 may be electrically connected to the controller 220, the temperature sensor 114 may transmit the sensed temperature signal (for example, a voltage signal) to the controller 220, and accordingly the controller 220 obtains the measured temperature value of the lamination layer 20 (for example, a lamination initial temperature value T.sub.i and a lamination final temperature value T.sub.f), and obtains the required pressing force F1,.sub.f (to be described later) according to the measured temperature value.
[0029] As shown in FIGS. 3, 5A and 5B, the forger 121 includes an oscillation unit 1211 and a vibration rod 1212. The oscillation unit 1211 is connected to the vibration rod 1212. The oscillation unit 1211 is configured to generate an oscillation (or a vibration) V1, wherein the oscillation V1 may be transferred to the end 1212A of the vibration rod 1212. An oscillation direction P3 of the oscillation V1 is, for example, substantially parallel to an extending direction of a long axis of the vibrating rod 1212. The end 1212A of the vibration rod 1212 is in contact with the lamination layer 20, so the vibration V1 may be transferred to the lamination layer 20 through the end 1212A to forge the lamination layer 20. The oscillation V1 may generate a required forging force F2,.sub.f on the lamination layer 20. The oscillation V1 has a frequency, which is, for example, an ultrasonic frequency, for example, equal to or greater than 20 kHz. The amplitude of the oscillation V1 is small, for example, micron-level amplitude, and thus the forging may be called micro forging. In addition to producing a forging effect on the laminated layer 20, the oscillation V1 may also increase the temperature of the laminated layer 20 and slow down the temperature drop gradient of the laminated layer 20. Through controlling the frequency and/or amplitude of the oscillation V1, the forging force exerted by the forger 121 on the lamination layer 20 may be controlled.
[0030] As shown in FIG. 5B, the end 1212A of the vibrating rod 1212 has an inclined surface 1212A1, and the inclined surface 1212A1 may abut against the lamination layer 20. The vibration rod 1212 exerts the required forging force F2,.sub.f on the lamination layer 20 along the oscillation direction P3. The required forging force F2,.sub.f may be divided into a sliding component force F2,.sub.fS and a normal component force F2,.sub.fP, wherein the sliding component force F2,.sub.fS may scrape off an oxide layer on the lamination layer 20 (an oxide layer will be produced after the lamination layer 20 is cooled), and the normal component force F2,.sub.fP may be generate a forging effect on the lamination layer 20. In an embodiment, an angle may be included between the oscillation direction P3 (or the extension direction of the long axis of the vibrating rod 1212) and a normal direction of the inclined surface 1212A1. Such angle may be ranges between 30 degrees and 60 degrees. For example, it is 45 degrees, but it may be greater or less.
[0031] As shown in FIGS. 5A and 5B, a connection line L1 between the end 1212A of the forger 121 and the end 1111A of the heating body 1111 may be substantially parallel to the aforementioned axial direction P2, so that the heater 111 may move along the axial direction P2 to press the lamination layer 20 against the forger 121 (that is, the lamination layer 20 is clamped or pressed between the heater 111 and forger 121).
[0032] As shown in FIGS. 5A and 5B, the second force sensor 122 of the forging module 120 may be connected to (or fixed on) the connecting component 105. The second force sensor 122 may sense an exerted-force (the reaction force of the force exerted on the lamination layer 20) of the forger 121. The forger 121 is connected to the second force sensor 122. When the forger 121 applies a force to the lamination layer 20, an equal reaction force is transferred to the second force sensor 122 through the forger 121. The second force sensor The device 122 thereby senses the force exerted by the forging device 121 on the lamination layer 20 to obtain the measured forging force F2,.sub.f.
[0033] For example, according to the following formula (1), the thermal stress .sub.t of the lamination layer 20 may be determined (or obtained) by the Young's modulus E of the laminate material, a thermal expansion coefficient of the material of the lamination layer, a lamination initial temperature value T.sub.i and a lamination final temperature value T.sub.f. In an embodiment, the lamination initial temperature value T.sub.i is, for example, the measured temperature value sensed when the temperature sensor 114 contacts a first position of the lamination layer 20, such as 120 degrees Celsius, and the lamination final temperature value T.sub.f is, for example, the measured temperature value sensed when the temperature sensor 114 contacts a second position of the lamination layer 20. T is a temperature difference between the lamination initial temperature value T.sub.i and the lamination final temperature value T.sub.f. The thermal stress .sub.t is a tensile stress for the lamination layer 20, and the forging stress .sub.t may produce a compressive stress (F.sub.2,f/A.sub.c) for the lamination layer 20. If the compressive stress and the tensile stress offset (or cancel) each other (formula (2A)), so the required forging force F2,.sub.f needs to satisfy formula (2B). A.sub.c in the formula (2B) represents the forging area (for example, a contact area between the forging tool 121 and the lamination layer 20), and is Poisson's ratio.
[0034] The first position and the second position of the lamination layer 20 may be two different positions or the same position of the lamination layer 20. For example, when the temperature drop gradient refers to the temperature variation rate over time, the first position and the second position may be the same position of the lamination layer 20. In other words, the composite forging device 100 may stay at the same position point of the lamination layer 20 for a period of time (for example, several seconds or less than one second), and measure the lamination initial temperature value T.sub.i and the lamination final temperature value T.sub.f. For another example, when temperature drop gradient refers to the temperature variation rate over position, the first position and the second position may be two different positions of the lamination layer 20. In other words, the composite forging device 100 may measure the lamination initial temperature value T.sub.i and the lamination final temperature value T.sub.f at two different positions of the lamination layer 20 respectively.
[00001]
[0035] Poisson's ratio , Young's modulus E, and thermal expansion coefficient are material properties. Poisson's ratio , Young's modulus E, and thermal expansion coefficient may be obtained by looking up the table according to the material type of the lamination layer 20. The lamination initial temperature value T.sub.i and the lamination final temperature value T.sub.f may be sensed by the temperature sensor 114. After the control device 400 obtains the required forging force F2,.sub.f through the above formulas (1), (2A) and (2B), the control device 400 may control the forging module 120 to generate the required forging force F2,.sub.f, and control the forging module 120 to apply the required forging force F2,.sub.f on the lamination layer 20.
[0036] Referring to FIG. 6, FIG. 6 shows a schematic diagram of a control block of the composite forging device 100 in FIG. 3. F1,.sub.f represents the required pressing force exerted by the heating module 110 on the lamination layer 20, F1,.sub.f represents the measured pressing force actually exerted by the heating module 110 on the lamination layer 20, F2,.sub.f represents the required forging force exerted by the forging module 120 on the lamination layer 20, and F2,.sub.f represents the measured forging force actually exerted by the heating module 110 on the lamination layer 20 The measured pressing force F1,.sub.f may be measured by the first force sensor 112, and the measured forging force F2,.sub.f may be measured by the second force sensor 122. The required forging force F2,.sub.f may be obtained by the controller 410 through the above formulas (1), (2A) to (2B). Since the heater 111 and the forger 121 press respectively against opposite two sides of the lamination layer 20, so the measured pressing force F1,.sub.f may be roughly or substantial equal to the measured forging force F2,.sub.f. The controller 410 may be disposed on the control device 400 in FIG. 3, and is configured to: obtain a difference f1 between the measured pressing force F1,.sub.f and the required forging force F2,.sub.f; obtain a difference f2 between the measured forging force F2,.sub.f and the required forging force F2,.sub.f; obtain a compensation displacement instruction x1 for the heating module 110 compensating the difference f1; and obtain a compensation displacement instruction x2 for the forging Module 120 compensating the difference f2. The aforementioned compensation displacement instruction x1 is, for example, an instruction for the translation of the slide block 1132 along the axial direction P2, and the compensation displacement instruction x2 is, for example, at least one of the instructions for the translations of the linkage 211 (or the connecting component 105) along X-axis, along Y-axis, along Z-axis, the rotations of the linkage 211 (or the connecting component 105) around X axis, around Y axis, and around the Z axis.
[0037] As shown in FIG. 6, the controller 220 is further configured to: generate a corresponding control instruction x1,.sub.cmd, according to the compensation displacement instruction x1, to control the movement of the slide block 1132 of the heating module 110 to drive the heater 111 of the heating module 110 to press against on a side of the lamination layer 20; and generate a corresponding control instruction x2,.sub.cmd, according to the compensation displacement instruction x2, to control the movement of the linkage 211 (or connecting component 105) to drive the forging tool 121 of the forging module 120 to press against the opposite side of the lamination layer 20.
[0038] Through the above control, the heater 111 of the heating module 110 and the forger 121 of the forging module 120 may press against the opposite sides of the lamination layer 20 respectively. For example, through the aforementioned control, the heating module 110 and the forging module 120 may move with the formation path of the lamination layer 20, and during the movement, the heater 111 of the heating module 110 and the forger 121 of the forging module 120 may respectively constantly (or usually) press against (for example, kept in abutment) the two opposite sides of the lamination layer 20.
[0039] In summary, embodiments of the present invention provide a composite forging device including a connecting component, a heating module and a forging module. The heating module is connected to the connecting component and includes a heater. The forging module is connected to the connector and includes a forger. The heater and the forger are disposed opposite each other. As a result, the heater and the forger may be respectively located at or press against two opposite sides of a lamination layer, so as to simultaneously heat and forge the lamination layer.
[0040] It will be apparent to those skilled in the art that various modifications and variations could be made to the disclosed embodiments. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
