Abstract:
A processing machine includes a plurality of radiating modules disposed in a row, and a process chamber module configured to releasably attach to the plurality of radiating modules. The process chamber module includes a process chamber defining a processing field, a construction platform, a powder coater, and a powder reservoir. The powder coater is configured to apply a powder material layer-by-layer in a direction of the construction platform within the processing field. The powder reservoir is configured to infeed the powder material to the powder coater. Each radiating module includes a respective energy beam source configured to generate an energy beam, and a respective beam guide configured to guide the energy beam in a direction of the construction platform within a portion of the processing field. The portions of the processing field of two adjacent radiating modules partially overlap.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of and claims priority under 35 U.S.C. §120 to PCT Application No. PCT/EP2015/080072 filed on Dec. 16, 2015, which claims priority to German Application No. 10 2015 200 134.2, filed on Jan. 8, 2015. The entire contents of these priority applications are incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to a processing machine for producing components by way of a layer-by-layer construction from material powder and of a layer-by-layer solidification of the material powder by at least one energy beam, and to a modular system for assembling such a processing machine. 
       BACKGROUND 
       [0003]    A processing machine for selectively laser sintering or selectively laser melting a material powder (e.g., prototyping/adaptive laser manufacturing equipment) is described in WO 2010/026397 A1. 
         [0004]    Selective laser sintering (SLS) and selective laser melting (SLM) are generative layer-by-layer construction methods in which a component is constructed layer-by-layer by sintering or melting a material powder by means of a laser beam. The material powder is applied all-over to a construction platform, and the layers are sintered or melted step-by-step into the powder bed by actuating the laser beam according to the layered contour of the component. The construction platform is subsequently lowered by the amount of a layer thickness, and powder is applied from anew. This cycle is repeated until all layers of the component have been sintered or applied by melting, respectively. 
         [0005]    The selective laser melting (SLM) or selective laser sintering (SLS) laser processing machine described in WO 2010/026397 A1 includes an optical module which has the beam guide for a laser beam, and a molding part which has the powder-conducting elements such as the process chamber. 
         [0006]    Furthermore, an SLM or SLS laser processing machine having a plurality of lasers, the laser beams of the latter covering different processing part-fields on the construction platform that by way of the field boundaries thereof mutually overlap, is described in DE 10 2005 014 483 A1. However, this laser processing machine does not permit a rapid changeover in terms of the material powder, for example from plastics-material powder to metal or ceramics powder; to this end, prior thereto all powder-conducting elements have to be cleaned in a complex manner. 
       SUMMARY 
       [0007]    It is the object of the present disclosure to increase the flexibility in terms of the processing field of said processing machine. 
         [0008]    This object can be achieved by a processing machine having the features of claim  1 . 
         [0009]    According to the subject matter of the present disclosure, SLM or SLS processing machines of different sizes can be flexibly produced by way of a few process chamber and radiating modules. The processing machine can be scaled in a very simple manner by way of such a modular machine concept. The process chamber can jointly with the powder-conducting elements (coater/powder management) be constructed in various sizes, while the radiating modules have a standard size and can be lined up beside one another with other radiating modules, so as to be able to receive a process chamber module having a larger process chamber. The controller of one of the radiating modules herein becomes the master controller in terms of the controllers of the other radiating modules. 
         [0010]    The width of the construction platform of the process chamber module preferably corresponds to approximately the width of the processing fields of the plurality of radiating modules. 
         [0011]    One of the plurality of radiating modules is preferably operated as a master module, and each of the other radiating modules is operated as a slave module that is controlled by the master module. The radiating modules that are lined up beside one another, in terms of control technology, are interconnected in the manner of a master/slave concept and are optically inter-referenced in order for the processing field to be distributed among the individual processing part-fields. Each radiating module herein advantageously has a controller interface for connecting to a controller interface of another radiating module that is lined up. This controller interface can be a wireless interface or an electronic machine interface which is disposed on either side on a radiating module, so as to connect to the machine interface of an adjacent radiating module. 
         [0012]    One or some of the radiating modules, in particular all radiating modules, advantageously have at least one optical sensor, in particular a camera, the detection range of said optical sensor being configured for detecting at least part of a processing field of an adjacent radiating module. For example, the master module by means of the energy beam thereof can carry out a processing procedure or illuminate fixed calibration points which in turn are detected by the camera of the adjacent first slave module, the latter thus calibrating its own positioning in relation to the master module. The next slave module can thus be calibrated in relation to an already calibrated slave module and so forth until all slave modules have been calibrated in relation to the master module. 
         [0013]    One or some of the radiating modules, in the case of a plurality of radiating modules, in particular the outer radiating modules, or the process chamber module, particularly preferably have referencing aids, in particular side plates or referencing bolts, for assembling the processing machine. For example, in the case of a single radiating module, the process chamber module can be disposed between two locating aids of the radiating module, or in the case of a plurality of radiating modules that are disposed beside one another, the process chamber module can be disposed between two referencing aids of the two outer radiating modules, said referencing aids being provided on the end sides. Each radiating module on either side advantageously has an interface for releasably fastening the side plates. Alternatively, the process chamber module can also have side plates between which the one radiating module or the plurality of radiating modules is/are disposed. 
         [0014]    In the case of particularly preferred embodiments, the process chamber module during the production of the component is connected to supply sources (power, water, gas, data) and to the controller of the (master) radiating module exclusively by way of the at least one radiating module. The complete supply to the process chamber module is ensured by way of the radiating module or modules, and the (master) radiating module not only controls/regulates the energy beam source(s) and the beam guide(s) but also the coater and the powder management of the process chamber. Once the production of the components has been terminated, the process chamber module can also be connected to external supply stations which deliver power/water, for example, so as to permit slow/regulated cooling or to deliver gas so as to generate a positive protective gas pressure in the retrieval of the component, said positive protective gas pressure permitting retrieval without the powder being exposed to a significant concentration of atmospheric gases. It is possible for controlling/regulating of these processes to be performed by a controller of the process chamber module, but the external supply stations preferably have a controller for such tasks. 
         [0015]    The process chamber of the process chamber module is advantageously embodied as a self-contained chamber having a process chamber window, in particular as a chamber which is evacuatable or is substantially relievable of reactive gases by purging with an inert gas, the at least one energy beam being capable of being coupled into the process chamber through said process chamber window. 
         [0016]    The process chamber module and/or the at least one radiating module can be mounted so as to be mobile, for example on rollers, in order for said modules to be able to be moved together to form the laser processing machine in an easy and simple manner. 
         [0017]    The energy beam source is particularly preferably configured as a laser for generating a laser beam, and the beam guide is configured as a deflection unit for deflecting the laser beam in a two-dimensional manner. Alternatively, the energy beam source can also be embodied as an electron beam source, the electron beam of which being deflected onto the powder bed. 
         [0018]    In the assembly (docking) of the powder chamber module, the radiating module is informed by a management system as to which component is to be produced. The radiating module disposes of a controller which controls the energy beam (output, orientation, focus, etc.) and at least the powder coating and the lowering of the construction platform. The radiating module when being docked optionally recognizes the process chamber module by way of a unique identifier (via an exchange of data, input of an operator, scanning of a barcode/QR code on the process chamber module), said radiating module demanding the production job envisaged for the process chamber module from the management system. The controller of the radiating module can optionally also control a powder pre-heater/component cooler, the powder preparation and/or conveyance, etc. 
         [0019]    The process chamber of the process chamber module is preferably embodied so as to be gas-tight and to have a gas inlet and a gas outlet so as to be able to evacuate the process chamber or to purge the latter with an inert gas. 
         [0020]    The process chamber module preferably has at least one screen that is inclined at an angle in relation to the horizontal, and at least one collection container that is disposed below the at least one screen in such a manner that material powder that is not capable of being screened moves in a manner aided by gravity along the at least one screen and is collectable in the at least one collection container. The at least one screen is advantageously mounted so as to be mechanically movable and by way of a drive driven so as to move in an oscillating manner. 
         [0021]    The process chamber module furthermore preferably has a self-contained powder circuit which includes the at least one screen and at least one conveying section for infeeding the material powder that has been screened by the at least one screen into the powder reservoir. 
         [0022]    The process chamber module can furthermore have detection means, in particular a balance, for detecting the powder quantity in the powder reservoir, and at least one closable powder inlet for infeeding powder in a metered manner into the powder reservoir or into the powder circuit. For example, a cartridge with powder can be connected to the powder inlet. In particular, the detection means weighs the powder remaining in the powder reservoir/powder circuit following the production of a component, and opens the powder inlet on demand. 
         [0023]    The construction platform is particularly preferably embodied so as to be separable in a gas-tight manner from other elements of the powder circuit. 
         [0024]    The subject matter of the present disclosure also relates to a modular system for assembling a processing machine as is configured above, having a plurality of process chamber modules of different widths, and having a plurality of radiating modules, wherein the width of the process chamber modules in each case corresponds to the overall width of at least some radiating modules that are disposed in a row beside one another. The radiating modules are preferably of identical construction, that is to say embodied so as to be of identical width. 
         [0025]    Further advantages can be derived from the claims, from the description, and from the drawing. Likewise, the features mentioned above and hereunder can be used individually or in any arbitrary combination with one another. The embodiments shown and described are not to be understood as an exhaustive enumeration but rather have an exemplary character in order for the invention to be narrated. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0026]      FIG. 1  is a schematic illustrating an example of an SLS or SLM laser processing machine; 
           [0027]      FIG. 2  is a schematic illustrating an example of a process chamber module and a radiating module from which the laser processing machine of  FIG. 1  is releasably assembled; 
           [0028]      FIGS. 3A and 3B  are schematics illustrating the process chamber module ( FIG. 3A ) and the radiating module ( FIG. 3B ) of the laser processing machine of  FIG. 1 ; 
           [0029]      FIG. 4  is a schematic illustrating an example of a SLS or SLM laser processing machine; 
           [0030]      FIG. 5  is schematic illustrating an example of a process chamber module and two radiating modules from which the laser processing machine in  FIG. 4  is releasably assembled; 
           [0031]      FIGS. 6A and 6B  are schematics illustrating examples of the process chamber module ( FIG. 6A ) and the radiating modules ( FIG. 6B ) of the laser processing machine of  FIG. 4 ; 
           [0032]      FIG. 7  is a schematic illustrating an example of a modular system for assembling laser processing machines; and 
           [0033]      FIG. 8  is a schematic illustrating an example of a process chamber and of a powder recovery/preparation of the process chamber module. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    In the description of the figures hereunder, the same reference signs are used for the same or functionally equivalent components, respectively. 
         [0035]    The SLS or SLM laser processing machine  1  shown in  FIG. 1  serves for producing components by way of a layer-by-layer construction from a material powder  2  and for the layer-by-layer sintering or melting of the material powder  2  by means of at least one laser beam  3 . 
         [0036]    The laser processing machine  1  in a manner known includes powder-conducting elements such as, for example, a process chamber  4  having a construction platform  5  and having a powder coater  6  for the layer-by-layer application of a material powder  2  to the construction platform  5 , and a powder reservoir  7  for the material powder  2  that is to be infed to the powder coater, and a powder recovery/preparation  8 , as well as non-powder-conducting elements such as, for example, a laser  9  for generating the one laser beam  3 , and a deflection unit  10  for aligning the laser beam  3  in a two-dimensional manner to the material powder  2  that is applied to the construction platform  5 . The laser  9  and the deflection unit  10  are disposed above the process chamber  4 . 
         [0037]    In the laser processing machine  1 , a component is constructed layer-by-layer by sintering or melting the material powder  2  by means of the laser beam  3 . The material powder  2  is applied all-over to the construction platform  5  by the powder coater  6 , and the layers are sintered or melted step-by-step into the powder bed by actuating the laser beam  3  according to the layered contour of the component. The construction platform  5  is subsequently lowered by the amount of a layer thickness, and the material powder  2  is applied from anew. This cycle is repeated until all layers of the component have been sintered or applied by melting, respectively. 
         [0038]    As is shown in  FIG. 2 , the laser processing machine  1  is releasably assembled from a process chamber module  11   1  and from a radiating module  12 , wherein the process chamber module  11   1  shown in  FIG. 3A  includes all powder-conducting elements, that is to say presently the process chamber  4 , the construction platform  5 , the powder coater  6 , the powder reservoir  7 , and the powder recovery/preparation  8 , and the radiating module  12  shown in  FIG. 3B  includes the non-powder-conducting elements, that is to say presently the laser  9  and the beam guide  10 . The radiating module  12  is preferably embodied so as to be stationary, while the process chamber module  11   1  is mounted so as to be displaceable on rollers  13 . Two side plates  14  between which the process chamber module  11   1  can be plug-fitted to an exact fit are fastened to either side on the radiating module  12 . The laser beam  3  that exits in a downward manner from the radiating module  12  is coupled into the process chamber  4  by way of a process chamber window  15  on the upper side. The supply of the process chamber module  11   1  with power, water, controller data, etc., is performed exclusively by way of the radiating module  12 , wherein the connectors and interfaces required to this end on the process chamber module  11   1  and on the radiating module  12  are not shown. The process chamber module  11   1  per se does not have any dedicated controller for the production of components but is connected to the controller  16  of the radiating module  12 . The radiating module  12  thus controls/regulates not only the laser  9  and the deflection unit  10  but also the powder management in the process chamber  4 . Furthermore, an external display/operator panel  17  is attached to the radiation module  12 . 
         [0039]    Another laser processing machine  1  which is releasably assembled from a process chamber module  11   2  and two radiating modules  12  is shown in  FIG. 4 . The radiating modules  12  are of identical construction to the radiating module  12  of  FIGS. 1 to 3A and 3B , while the process chamber module  11   2  is embodied so as to be double the width of the process chamber module  11   1  of  FIGS. 1 to 3A and 3B . The two radiating modules  12  are fastened to one another in a side-by-side manner, and on the end side each have two side plates  14  between which the process chamber module  11   2  is plug-fitted to an exact fit. The two radiating modules  12 , in terms of control technology, are connected in the manner of a master/slave concept and are optically inter-referenced in order for the processing field of the process chamber  4  to be distributed among mutually overlapping processing part-fields  18  of the two laser beams  3  of the radiating modules  12 . 
         [0040]    Each radiating module  12  has a controller interface (not shown) for connecting to the controller interface of the other radiating module, so as to interconnect the controllers  16  of the two radiating modules  12 . For example, the controller interface can be a wireless interface or an electronic machine interface which is disposed on either side on a radiating module  12 , so as to connect to the machine interface of an adjacent radiating module  12 . The one radiating module  12  is operated as the master module, and the other radiating module  12  is operated as a slave module that is controlled by the master module. 
         [0041]    The two radiating modules  12  each have one optical sensor  19  (for example a camera), the detection range of said optical sensor  19  being configured for detecting at least part of the processing part-field  18  of the respective other radiating module. For example, the master radiating module  12  by means of the laser beam  3  thereof can thus carry out a processing procedure or illuminate fixed calibration points which in turn are detected by the sensor  19  of the adjacent slave radiating module  12 , the latter thus calibrating its own positioning in relation to the master radiating module. In the case of further radiation modules that are lined up beside one another, the next slave radiating module can then be calibrated in relation to an already calibrated slave radiating module and so forth until all slave radiating modules have been calibrated in relation to the master radiating module. 
         [0042]    The supply of the process chamber module  11   2  with power, water, controller data, etc., is performed exclusively by way of the radiating modules  12 , wherein the connectors and interfaces required to this end on the process chamber module  11   2  and on the radiating modules  12  are not shown in the drawing. The process chamber module  11   2  per se does not have any dedicated controller but is connected to the master controller  16  of the master radiating module  12 . The master controller  16  thus controls/regulates not only the laser  9  and the deflection units  10  of the two radiating modules  12  but also the powder management in the process chamber  4 . Furthermore, the external display/operator panel  17  which is used for both radiating modules  12  is attached to the radiating modules  12 . 
         [0043]      FIG. 7  shows a modular system  20  for assembling laser processing machines  1 , said modular system  20  being composed of a plurality of process chamber modules  11   1 ,  11   2 ,  11   3  of different widths, and from a plurality of radiating modules  12  of identical construction. The width of the process chamber module  11   1  herein corresponds to the width of a radiating module  12 , the width of the process chamber module  11   2  corresponds to the width of two radiating modules  12 , and the width of the process chamber module  11   3  corresponds to the width of n (n≧3) radiating modules  12 . Moreover, the modular system  20  also has at least two side plates  14  and at least one external display/operator panel  17 . Depending on the desired size of the process chamber, the respective process chamber module  11   1 ,  11   2 ,  11   3  is selected, and the respective number of radiating modules  12  are lined up beside one another. In the lining up of the radiating modules  12 , the controller  16  of each further connected radiating module  12  follows the controller  16  of the first radiating module  12 , the latter thus defining the master module. 
         [0044]    As is shown in  FIG. 8 , the process chamber  4  of the process chamber modules  11   1  to  11   3 , with the exception of a gas inlet  31  and a gas outlet  32 , can be embodied so as to be gas-tight, so as to be able to evacuate the process chamber  4  or to purge the process chamber  4  with an inert gas. 
         [0045]    Furthermore, a screen  33  is provided that is inclined at an angle in relation to the horizontal and a collection container  34  is provided that is disposed below the at least one screen  33  in such a manner that material powder  2  that is not capable of being screened moves in a manner aided by gravity along the one screen  33  and is collectable in the collection container  34 . The screen  33  is advantageously driven by a drive  35  so as to move in an oscillating manner. The material powder  2  in the process chamber module is conducted in a self-contained powder circuit which includes the at least one screen  33  and at least one conveying section (not shown) for infeeding the material powder  2  that has been screened by the at least one screen  33  into the powder reservoir  7 . The construction platform  5  is preferably embodied so as to be separable in a gas-tight manner from other elements of the powder circuit. 
         [0046]    The powder reservoir  7  furthermore includes detection means  36 , for example a balance, for detecting the quantity of powder, and a closable powder inlet  37  for infeeding powder in a metered manner into the powder reservoir  7  or into the powder circuit. For example, a cartridge with a material powder  2  can be connected to the powder inlet  37 . The detection means  36  weighs the material powder  2  remaining in the powder reservoir  7  or powder circuit, respectively, following the production of a component, and opens the powder inlet  37  on demand. 
         [0047]    Moreover, supply stations (not shown) to which the process chamber module  11   1  to  11   3  can be connected and which, like the radiating module  12 , have a power, water, gas, and/or data connector, can be provided. Powder preheating/component cooling can be carried out with power in a regulated manner by the process chamber  4 ; water can likewise be used for the cooling of components or for cooling other elements of the process chamber. This function can be performed either by a simple controller in the process chamber  4  or by controlling the supply station via a data connector. The gas connector can provide a protective gas atmosphere in the process chamber  4 , for example when the component is to be retrieved. 
         [0048]    Whether controllers required for the process chamber modules are accommodated in this module or in the radiating modules and supply stations depends in particular on whether the radiating modules are rather used in a docked manner as a master and slave, or rather used individually. However, there will usually be more process chamber modules than radiating modules, since the process chamber modules are preferably always used for only one material, and only those process chamber modules are used with the materials required at any given time. There will furthermore be process chamber modules in which the component is being cooled or powder is being preheated. It can thus be more favorable for only the radiating stations to be equipped with a controller for the application of powder in the process chamber module than for all process chamber modules to be thus equipped. The same applies in an analogous manner to controllers for other functions of the powder circuit/heaters, etc. In the case of very wide process chamber modules, in which a plurality of radiating modules are always required, it would however be more favorable for only the process chamber modules to be equipped with controllers for the process chamber module rather than for each radiating module to be thus equipped. It can also be advantageous for the controller to be embodied so as to be modular, and for the radiating modules or the process chamber modules to be equipped with controllers, depending on production. 
         [0049]    A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.