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浙江大学学报(工学版)
Journal of ZheJiang University (Engineering Science)  2021, Vol. 55 Issue (3): 548-554    DOI: 10.3785/j.issn.1008-973X.2021.03.015
    
Dynamic monitoring and identification of wire feeder in FDM-based additive manufacturing
Xiao-wei LIU1(),Yun CHEN1,2,*(),Si ZHANG1,Kang CHEN1
1. School of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang 212003, China
2. Jiangsu Key Laboratory of Advance Manufacturing of Ship and Ocean Machinery Equipment, Zhenjiang 212003, China
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Abstract  

An acceleration vibration sensor was used to monitor the working state of the motor in the wire feeder, in order to study the effect of abnormal flow ratio (the ratio between the printing speed of the printer and the extrusion speed of the wire material) on nozzle blocking or lamination of printed products in the additive manufacturing process. The vibration signal of the wire feeder motor in different motion state during the printing process were collected, and the Fourier transform method was used to convert the time domain signal into frequency domain signal. Based on a frequency domain data, the characteristic value that characterizes the difference between each group of signals was extracted, KNN classification algorithm and K-fold cross-validation were introduced, the characteristic quantity was studied to clarity the relationship between the failure mode and the signal, to identify the different motion states of the wire feeder. Experimental results show that the proposed monitoring method has an accuracy of 92.73% for the identification of abnormal flow ratio, by using the signal frequency domain data difference as the characteristic quantity.

Key words： additive manufacturing      fused deposition modeling (FDM)      filament feeding      flow ratio      process monitoring     
Received: 16 January 2020      Published: 25 April 2021
CLC:  TP 181  
Fund:  国家自然科学基金资助项目（51705214，51875003）；江苏省自然科学基金资助项目（BK20170582）
Corresponding Authors: Yun CHEN     E-mail: issue_ge@foxmail.com;yunchen.just@foxmail.com
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Xiao-wei LIU
Yun CHEN
Si ZHANG
Kang CHEN
Cite this article:

Xiao-wei LIU,Yun CHEN,Si ZHANG,Kang CHEN. Dynamic monitoring and identification of wire feeder in FDM-based additive manufacturing. Journal of ZheJiang University (Engineering Science), 2021, 55(3): 548-554.

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http://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2021.03.015     OR     http://www.zjujournals.com/eng/Y2021/V55/I3/548


FDM型增材制造中送丝机构动态监测与识别

为了研究在增材制造过程中，流量比（打印机打印速度与丝材挤出速度之间的比值）的异常状态对喷头阻塞或打印产品分层现象的影响情况，采用加速度振动传感器监测送丝机构中电机的工作状态. 采集打印过程中送丝机构电机不同运动状态的振动信号，利用傅里叶变换方法将时域信号转换成频域信号. 基于频域数据提取表征每组信号间差异的特征值，通过KNN分类算法并引入K折交叉验证，研究特征量以明确故障模式与信号的关系，识别送丝机构的不同运动状态. 实验结果表明，以信号频域数据差异为特征量提出的监测方法对异常流量比的识别准确率达到92.73%.


关键词： 增材制造,  熔融沉积成型（FDM）,  送丝机构,  流量比,  过程监测 
Fig.1 Structure of 3D Printer
Fig.2 Monitoring platform of wire feeding mechanism
Fig.3 KNN Classification algorithm schematic
Fig.4 The diagram of K-fold cross-validation
真实值 预测值
正例 负例
正例 A B
负例 C D
Tab.1 Confusion matrix of binary classification
真实类 预测类
1 2 $ \cdots $ n
1 ${a_{11}}$ ${a_{12}}$ $ \cdots $ ${a_{1n}}$
2 ${a_{21}}$ ${a_{22}}$ $ \cdots $ ${a_{2n}}$
$ \vdots $ $ \vdots $ $ \vdots $ $\vdots$ $ \vdots $
n ${a_{n1}}$ ${a_{n2}}$ $ \cdots $ ${a_{nn}}$
Tab.2 Confusion matrix of multi-classification
Fig.5 Time-domain diagram of vibration signals in different motion states of wire feeding mechanism
Fig.6 Amplitude-frequency diagram of vibration signal in different motion states of wire feeding mechanism
Fig.7 Accuracy of different Ҡ
Fig.8 Average results of 10 times 5-fold training
Fig.9 Classification results of different motion states signals of wire feeding mechanism
真实值 预测值
类1 类2 类3
类1 54 3 3
类2 2 95 3
类3 0 5 55
Tab.3 Confusion matrix of tri-classification of different motion states of wire feeding mechanism
类别 SE/% SP/% AN/%
类1 90.00 98.75 92.73
类2 95.00 93.33 92.73
类3 91.76 96.25 92.73
Tab.4 Numerical statistics of tri-classification
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