Multi-Machine Adaptation of High-Voltage Power Supply for Electron Beam Additive Manufacturing
The differences in electron beam additive equipment models (such as printing size, electron gun type, process requirements) lead to different parameter requirements for high-voltage power supplies. Traditional power supplies need to be customized for specific models, resulting in poor compatibility and high R&D costs. Multi-machine adaptation technology needs to achieve compatibility with various models such as small and medium-sized desktop machines, large industrial machines, and special medical machines through modular design, wide parameter adjustment, and multi-protocol communication.
Modular design is the basis of adaptation: the power supply is divided into three independent modules: power module, control module, and sampling module. The power module adopts a standardized interface and supports parallel connection of 1-5 modules to realize adjustable output power of 1-10kW, meeting the power needs of desktop machines (1-3kW) and industrial machines (5-10kW); the control module has built-in configurable logic, and adapts to the control logic of different models by replacing different control chips (such as STM32F4, DSP TMS320). For example, desktop machines need simplified control (only voltage/current adjustment), and industrial machines need complex process linkage (coordination with scanning systems and vacuum systems); the sampling module supports access to multiple types of sensors (voltage sensors, current sensors, temperature sensors), and the sampling range can be adjusted through hardware DIP switches (voltage 0-50kV, current 0-100mA) to adapt to the sampling needs of different models.
Wide parameter adjustment covers model differences: the output voltage is designed to be continuously adjustable from 10-40kV, meeting the voltage needs of desktop machines (10-20kV), industrial machines (20-35kV), and medical machines (35-40kV, for bioceramic printing); the output current is adjustable from 0-80mA, adapting to different electron gun types (thermal emission electron guns require 10-30mA, field emission electron guns require 30-80mA); the ripple coefficient is controlled below 0.3% to ensure the printing accuracy requirements of different models. For example, medical machines have high accuracy requirements (ripple ≤ 0.2%), and industrial machines can be appropriately relaxed (ripple ≤ 0.3%).
Multi-protocol communication realizes machine collaboration: the control interface supports three mainstream industrial communication protocols: RS485, EtherCAT, and Profinet. The communication method of the adapted model is selected through the protocol switch. For example, RS485 is commonly used for desktop machines, and EtherCAT is commonly used for industrial machines; at the same time, a general communication protocol conversion module is developed, which can convert the power supply communication protocol into the protocol required by the machine control system, avoiding adaptation problems caused by protocol incompatibility; in addition, a unified upper computer control software is designed to support the setting and monitoring of power supply parameters of different models, and the interface can be customized according to the model requirements (such as industrial machines display process linkage parameters, medical machines display accuracy monitoring parameters).
Adaptation verification is carried out through multi-machine testing: on the desktop machine (printing size 200×200×200mm), the power supply stably outputs 15kV/20mA, and the printing accuracy of titanium alloy samples reaches ±0.1mm; on the industrial machine (printing size 1000×1000×800mm), it outputs 28kV/50mA, and prints continuously for 8 hours without parameter drift; on the medical machine (bioceramic printing), it outputs 38kV/15mA, with a ripple coefficient of 0.15%, meeting the printing accuracy requirements of biological materials. Multi-machine adaptation technology reduces power supply R&D costs (reducing 60% of customized development), shortens the machine adaptation cycle (from 3 months to 1 week), and promotes the standardized development of electron beam additive equipment.
