Spray distance monitoring and control for directed energy deposition additive manufacturing systems

Abstract

An additive manufacturing system with spray distance monitoring and control that can be responsive, dynamic, and real-time. The techniques can use a spray distance measurement system to monitor, read, or interrogate a workpiece or a substrate on which the workpiece is positioned in real-time as the workpiece moves past a directed energy source, or vice versa. The techniques can use a feedback controller to responsively and dynamically control the spray distance in real-time based on data from the spray distance measurement system.

Description

background Technical Field

[0002] The present disclosure relates generally to directed energy deposition additive manufacturing systems and more particularly to spray distance monitoring and control. Background Art

[0004] Rapid plasma deposition (RPD) TM ) The additive manufacturing system may contain an inert gas environment (e.g., a noble gas) containing a wire (e.g., a metal) and a plasma torch. RPD TM The additive manufacturing system additively manufactures a workpiece (e.g., an aircraft structure) based on a plasma torch controllably directing a plasma arc toward a wire and the plasma arc melting the wire to form the workpiece layer by layer as the workpiece controllably moves past the plasma torch or vice versa within an inert gas environment.

[0005] During such operation, a spray distance is maintained between the plasma torch and the workpiece (e.g., along a vertical axis). The spray distance determines the plasma arc resistance and, thus, the plasma arc power and characteristics (e.g., a constant plasma arc current provided by a constant current power supply). Although a greater spray distance produces a higher arc voltage, at least some of the energy transferred to the workpiece is reduced due to radiation and convection heat transfer along the plasma arc. The spray distance is statically varied between a lower limit given by equipment settings (e.g., physical equipment constraints) and an upper limit given by reduced power input to the workpiece (e.g., inadequate wire melting).

[0006] There are various factors that may cause the spray distance to deviate. Some of such factors include substrate distortion, uneven deposition surface (e.g., due to wire movement), uneven workpiece height steps, workpiece features (e.g., joints, ends, intersections), and other complex process variations. Although the spray distance can be indirectly controlled based on voltage measurement by maintaining a constant voltage, this technology is technically disadvantageous due to various factors. Some of such factors include voltage measurements that are very noisy and highly sensitive to changes (e.g., gas flow, electrode mechanical or material configuration, equipment changes, or workpiece geometry changes). As a result, indirectly controlling the spray distance based on voltage measurement introduces spray distance errors that accumulate cumulatively over the workpiece layer, thereby negatively affecting workpiece quality. Summary of the invention

[0007] Thus, disclosed herein are methods for directed energy deposition (e.g., RPD TM) various techniques for additive manufacturing systems that enable spray distance monitoring and control that can be responsive, dynamic, and / or real-time. These techniques can use a spray distance measurement system, such as a laser triangulation system or a laser line scanner (LLS), to monitor, read, or interrogate a workpiece (e.g., a bead profile, a workpiece shape) or a substrate on which the workpiece is positioned in real time as the workpiece (e.g., a bead profile, a workpiece shape) moves (e.g., via a substrate) past a directed energy source (e.g., a plasma torch), or vice versa. It should be noted that other optical measurement techniques, such as time of flight, confocal, chromatic confocal, interferometry, shadow shape, depth of focus / defocus, LiDAR, alone or in combination with illumination, such as fringe projection, pattern projection of different wavelengths (e.g., lines, multiple lines, multiple points), such as infrared, visible light, UV, X-ray, and non-optical methods, such as sonar, ultrasonic readers or interrogators, can be used in addition or alternatively to monitor, read, or interrogate the workpiece (e.g., melt bead profile, workpiece shape) or a substrate on which the workpiece is positioned in real time as the workpiece (e.g., melt bead profile, workpiece shape) moves (e.g., via a substrate) past a directed energy source (e.g., a plasma torch), or vice versa. These techniques may use a feedback controller to responsively and dynamically control the spray distance in real time (e.g., raising or lowering the directed energy source relative to the workpiece, or vice versa) based on data from a spray distance measurement system such as a laser triangulation system or a laser line scanner, but may additionally or alternatively use other optical measurement techniques such as time of flight, confocal, chromatic confocal, interferometry, shadow shape, depth of focus / defocus, LiDAR, alone or in combination with illumination, such as fringe projection, pattern projection of different wavelengths (e.g., lines, multiple lines, multiple points), such as infrared, visible light, UV, X-ray, and non-optical methods such as sonar, ultrasonic readers or interrogators. Thus, these techniques eliminate at least some of the technical limitations associated with the industry standard of using voltage-based measurements. In addition, these techniques may enable the use of plasma arcs (e.g., RPDs) to measure the spray distance in real time. TM ) or other forms of directed energy via metal (e.g., titanium, aluminum) or metal alloy (e.g., Ti6Al4V, Inconel variants, etc.) additive manufacturing of workpieces (e.g., aircraft structures, maritime structures, vehicle parts, medical devices, firearms, cutting tools, etc.) to automatically measure, evaluate, respond to, and dynamically control spray distance in real time.

[0008] The advantage of these techniques is that they have an objective online / field automatic system for real-time spray distance response and dynamic control, which provides at least some consistent plasma arc (or other forms of directed energy) characteristics, such as power, pressure, shape, and energy distribution on the machine, and reduces scrap rates over time, enabling early detection of unacceptable deviations, shortening part development cycles, etc. Moreover, these techniques enable spray distance control that is more robust, faster, and more objective than subjective manual adjustments by human operators, where such adjustments can be based on visual feedback. Similarly, due to automatic spray distance control based on the movement (e.g., vertical) of the directed energy source relative to the substrate, these techniques enable spray distance control that is generally more accurate and faster than robotic arm welding, or vice versa. It should be noted that these techniques can be used with any type of motion system (e.g., computer numerical control, robotic manipulator).

[0009] Additional features and advantages of these technologies will be set forth in the detailed description that follows, and in part will be apparent from the following detailed description, or may be learned by practicing the present disclosure. Various objectives and other advantages of the present disclosure will be realized and obtained through the structures particularly pointed out in the detailed description and its claims and a set of drawings.

[0010] To achieve these and other advantages and in accordance with the purposes of the present disclosure, a directed energy deposition additive manufacturing system, as embodied and broadly described, includes: logic, a spray distance measurement unit, a substrate, a torch, a supply unit, a material, and a mover, wherein the logic causes the supply unit to output material and the torch to output plasma, so that the plasma melts the material onto the substrate, and thereby additively manufactures a workpiece on the substrate, wherein the workpiece has a geometric profile, wherein the torch is vertically spaced from the workpiece so that a spray distance is defined, wherein the logic causes the spray distance measurement unit to monitor the geometric profile when additively manufacturing the workpiece, and the logic causes the mover to move at least one of the torch relative to the substrate and the substrate relative to the torch so as to maintain the spray distance.

[0011] To achieve these and other advantages and in accordance with the purposes of the present disclosure, as embodied and broadly described, a method for additive manufacturing includes: outputting a material; outputting a plasma via a torch; melting the material via the plasma so as to additively manufacture a workpiece on a substrate, wherein the workpiece has a geometric profile, wherein the torch is vertically spaced from the workpiece so as to define a spray distance; monitoring the geometric profile while additively manufacturing the workpiece so that a mover can move at least one of the torch relative to the substrate and the substrate relative to the torch so as to maintain the spray distance.

[0012] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the claims, as further recited below. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] A set of accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the detailed description serve to explain various principles of the disclosure.

[0014] In this set of drawings:

[0015] Figure 1 An embodiment of a directed energy deposition additive manufacturing system according to the present disclosure is shown, the system including a laser line scanner that reads a geometric profile of a workpiece on a substrate and the substrate.

[0016] Figure 2 An embodiment of a directed energy deposition process flow according to the present disclosure is shown.

[0017] Figure 3 An embodiment of a directed energy deposition process flow according to the present disclosure is shown.

[0018] Figure 4 An embodiment of a substrate supporting a workpiece according to the present disclosure is shown.

[0019] Figure 5 An embodiment of a block diagram of a directed energy deposition additive manufacturing system according to the present disclosure is shown, the system including a laser line scanner that reads a geometric profile of a workpiece on a substrate.

[0020] Figure 6 An embodiment of a diagram of a laser line scanner system according to the present disclosure is shown.

[0021] Figure 7 An embodiment of a diagram of a laser line scanner system according to the present disclosure is shown.

[0022] Figure 8 An embodiment of a substrate supporting a workpiece and a set of information related to data verification and grid spacing according to the present disclosure is shown.

[0023] Fig. 9 An embodiment of a diagram of a control block according to the present disclosure is shown.

[0024] Fig.10 An embodiment of a diagram of a control block according to the present disclosure is shown.

[0025] Fig.11Implementations of multiple scenarios for spray distance monitoring and control according to the present disclosure are shown.

[0026] Fig.12 An embodiment of a border around multiple edges of a substrate according to the present disclosure is shown wherein the risk of collision with a tool head is increased.

[0027] Fig.13 An embodiment of a technique for minimizing the risk of or avoiding collision with a clamp holding a substrate in accordance with the present disclosure is shown. DETAILED DESCRIPTION

[0028] The present disclosure is now described more fully with reference to this set of drawings, in which some embodiments of the present disclosure are shown. However, the present disclosure can be implemented in many different forms and should not be interpreted as necessarily being limited to the embodiments disclosed herein. On the contrary, these embodiments are provided to make the present disclosure thorough and complete, and to fully convey the various concepts of the present disclosure to the technician. Reference will now be made in detail to embodiments of the present disclosure, and examples thereof are shown in this set of drawings.

[0029] Figure 1 An embodiment of a directed energy deposition additive manufacturing system according to the present disclosure is shown, the system including a laser line scanner for reading the geometric profile of a workpiece on a substrate and the substrate. In particular, directed energy deposition (e.g., RPD TM ) The additive manufacturing system 100 includes a workpiece 118 and a substrate 102 supporting the workpiece 118. It should be noted that the workpiece 118 may not be mounted or positioned on or resting on the substrate 102 (e.g., another workpiece used as the substrate 102). For example, the workpiece 118 does not have to be a plate (substrate 102) and can be, for example, a forged part, a printed part, or a part made using any other technology (e.g., additive manufacturing, subtractive manufacturing). For example, starting deposition on a plate (substrate 102) is not necessary, but optional. For example, another workpiece or part can be used as the substrate 102.

[0030] The directed energy deposition additive manufacturing system 100 includes a controller 119, a wire source 104 (connected to a wire supply system) controlled by the controller 119 (e.g., wired, wireless, waveguide), a directed energy source 106 controlled by the controller 119 (e.g., wired, wireless, waveguide), a directed energy source 110 (e.g., a plasma torch) controlled by the controller (e.g., wired, wireless, waveguide), and a laser line scanner (LLS) 112 (or another form of spray distance measurement system) controlled by the controller 119 (e.g., wired, wireless, waveguide).

[0031] Controller 119 may be a programmable logic controller (PLC), an industrial PC (IPC), etc. For example, the PLC may be a master PLC. Directed energy source 106 may be a primary directed energy source, and directed energy source 110 may be a secondary directed energy source. LLS 112 may include a laser source that generates a laser beam and an optical camera that reads multiple reflections from the laser beam. Directed energy source 106 houses electrode 108. LLS 112, which may be pre-calibrated, projects a laser pattern 114 onto workpiece 118 and substrate 102. Laser pattern 114 may be projected via a laser source. Substrate 102 moves in 3-dimensional space.

[0032] Various components of the directed energy deposition additive manufacturing system 100 may be omitted, replaced, or supplemented. For example, the LLS 112 may be supplemented or replaced by other optical measurement techniques, such as time of flight, confocal, color confocal, interferometry, shadow shape, focus depth / defocus, lidar, alone or in combination with illumination (e.g., fringe projection, pattern projection (e.g., lines, multiple lines, multiple points, random points, random patterns, gradient patterns) of different wavelengths (e.g., infrared, visible light, UV, X-ray)) and non-optical methods (e.g., sonar, ultrasonic reader or other interrogator). Similarly, the directed energy source 110 or the directed energy source 106 containing the electrode 108 may be supplemented or replaced by other energy output devices (e.g., flame torches) or forms of directed energy (e.g., thermal, acoustic, electrical). Similarly, the directed energy source 110 may be omitted (may be optionally included). In addition, the wire source 104 may be supplemented or replaced by other material feeders (e.g., nozzles).

[0033] The directed energy source 106 housing the electrode 108 may be the primary energy source for generating directed energy (e.g., plasma arc) toward the substrate 102 at a location operationally proximate to the wire source 104. The directed energy may be transferred from the electrode 108 to the wire from the wire source 104, or the directed energy may be optionally transferred from the electrode 108 to the substrate 102, or to both simultaneously (e.g., using multiple plasma arcs). The directed energy source 106 may be stationary or movable (e.g., horizontally, vertically) relative to the wire source 104, or vice versa. The wire source 104 may be stationary or movable (e.g., horizontally, vertically) relative to the directed energy source 106, or vice versa. The substrate 102 may be stationary or movable (e.g., horizontally, vertically) relative to the wire source 104 or the directed energy source 106, or vice versa. For example, the substrate 102 may be movable in a direction along the horizontal axis relative to the wire source 104 and the directed energy source 106. When included, the directed energy source 110 may include an electrode (or another energy output support device) that may be a preheater electrode (or another energy output support device) that preheats the substrate 102, which may be relatively cool, before additive manufacturing of the workpiece 118 begins via the directed energy source 106 and the wire source 104. When included, the directed energy source 110 may be positioned between the LLS 112 and the directed energy source 106 along the horizontal axis.

[0034] The substrate 102 moves in 3-dimensional space relative to the wire source 104, the directed energy source 106, the directed energy source 110, and the LLS 112. The wire source 104 supplies a wire (e.g., metal, titanium, aluminum, steel, etc., metal alloy, Ti6Al4V, Inconel variant) on the substrate 102, so that the directed energy source 106 containing the electrode 108 generates a plasma arc, which melts the wire on the substrate 102, while the substrate 102 moves in 3-dimensional space, so that a plurality of droplets are formed from the wire melted via the directed energy (e.g., plasma arc), so that the droplets are deposited, positioned, layered, cascaded, or dropped on the substrate 102 or the preloaded workpiece 118, so as to additively form or additively extend the workpiece 118 layer by layer. For example, the workpiece 118 does not have to be a plate (substrate 102), and can be, for example, a forged part, a printed part, or a part made with any other technology (e.g., additive manufacturing, subtractive manufacturing). For example, starting the deposition on a plate (substrate 102 ) is not necessary but optional. For example, another workpiece or part may be used as substrate 102 .

[0035] Since the workpiece 118 has a geometric profile that can vary vertically or horizontally or be geometrically shaped or vertically or horizontally shaped, the LLS 112 projects the laser pattern 114 onto the geometric profile of the workpiece 118, which may or may not be supported by the substrate 102, so that the LLS 112 optically illuminates the geometric profile of the workpiece 118 and / or the substrate 102, which may be in at least some underlying layers of the substrate 102. The LLS 112 can then read the reflection from the laser pattern 114 using a camera. At a certain point in time, when the substrate 102 is used as a base for the workpiece 118 (e.g., printing on a forging), the substrate 102 may become part of the workpiece 118. For example, the workpiece 118 does not have to be a plate (substrate 102), and can be, for example, a forged part, a printed part, or a part made with any other technology (e.g., additive manufacturing, subtractive manufacturing). For example, starting deposition on a plate (substrate 102) is not necessary, but optional. For example, another workpiece or part can be used as the substrate 102.

[0036] More than one LLS 112 may be used (e.g., to optically read the geometric profile of the workpiece 118 and / or the substrate 102 from another view or angle). For example, the laser patterns 114 may be perpendicular to each other, parallel to each other, or L-shaped, or U-shaped, or O-shaped, and the pattern may be a single line, multiple lines, a single point, multiple points, random points, random patterns, pulses, non-pulses, etc. For example, more than one LLS 112 may be used depending on the scenario, and when measuring the spray distance, it may be necessary to read different offsets from the front end of the electrode 108 along the X and Y directions (see also Fig.11 ). In addition, when the directed energy deposition additive manufacturing system 100 involves a plasma arc, since the plasma arc may affect the quality of the measurements of the LLS 112, at least some measurements or corrections of the LLS 112 may be performed when the plasma arc is turned off to avoid measurement inaccuracies.

[0037] In the directed energy deposition additive manufacturing system 100, the spray standoff may be measured along a vertical axis between the tool center point and a point on the workpiece 118. The tool center point (TCP) may be statically defined based on a tool structure (e.g., the tip of the electrode 108, or a point at the end of the origin of a directed energy source (e.g., a plasma arc)) or dynamically offset (e.g., calculated in real time based on process variables such as wire speed, arc angle, deflection, shape in scenarios where the point of interest must be offset to the portion where the droplet encounters the workpiece 118 rather than the portion below the tip of the electrode). Without loss of generality, this point is interchangeably referred to herein as TCP or DTCP.

[0038] For example, the spray distance can be measured to include less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 10 mm, and including any value therebetween (e.g., approximately every 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, or 9 mm), but may include values ​​greater than 100 mm (e.g., approximately 125 mm, 150 mm, 200 mm, 225 mm, 250 mm, 300 mm, or more), including various larger orders of magnitude (e.g., centimeters, decimeters, meters). The workpiece 118 and / or substrate 102 can be moved in 3D space using an X-axis (e.g., length), a Y-axis (e.g., depth), a Z-axis (e.g., height), a C-axis (e.g., rotating an XY plane), a B-axis (e.g., an XZ or YZ plane), and without loss of generality, the vertical axis may be referred to as the Z-axis. The geometric profile of the workpiece 118 may change gradually or abruptly along the X-axis, Y-axis, or Z-axis. When the directed energy deposition additive manufacturing system 100 avoids the electrode 108 or the electrode 108 supplemented with another energy output device (e.g., a flame torch), the spray distance may be measured along a vertical axis between the DTCP (e.g., the center portion) of the energy output device and the workpiece 118. For example, the DTCP may be vertically above the electrode tip or other energy support device above the point where at least some droplets land and vertically in the same Z plane as the electrode tip or other energy support device.

[0039] The spray distance can be dynamically maintained within various defined limits to achieve consistent plasma arc conditions (e.g., voltage, power, temperature distribution) from the electrode 108. Thus, the directed energy deposition additive manufacturing system 100 includes a spray distance monitoring and control system, described further below, that enables the spray distance to be automatically measured and responded to and dynamically controlled in real time via vertical movement of the electrode 108 relative to a point extracted from a segment on the substrate 102 below the TCP / DTCP or a point extracted from a segment on the geometric contour of the workpiece 118 below the TCP / DTCP (e.g., up, down, toward the workpiece 118 or substrate 102, away from the workpiece 118 or substrate 102). For example, as the substrate 102 moves the workpiece 118 in 3D space, the directed energy source 106 together with the electrode 108 can move vertically relative to the point extracted from the segment on the substrate 102 below the TCP / DTCP or the point extracted from the segment on the geometric contour of the workpiece 118 below the TCP / DTCP. It should be noted that vice versa configurations are possible (eg, substrate 102 moves vertically upward or downward relative to directed energy source 106 or electrode 108).

[0040] Directed Energy Deposition Additive Manufacturing System 100 running RPD TMprogram (e.g., executable code, numerical control (NC) value list, markup code, delimited text, populated spreadsheet), the RPD TM The program particularly sets various parameters of the spray distance monitoring and control system, such as spray distance set points, set value trajectory, control mode, control enable, measurement offset, reading offset, etc. In a specific area centered on various specified reading offsets, the spray distance monitoring and control system responsively and dynamically maintains the spray distance between TCP / DTCP and the highest point on the workpiece 118 below TCP / DTCP in real time based on the geometric contour of the workpiece 118; or maintains the spray distance between TCP / DTCP and the lowest point of the workpiece 118 based on the geometric contour of the workpiece 118; or maintains the spray distance between TCP / DTCP and the average of the highest point and the lowest point of the workpiece 118 based on the geometric contour of the workpiece 118. Based on LLS 112 optically reads (e.g., a camera reads laser beam reflections) the substrate 102 and the workpiece 118 via a laser pattern 114 extending laterally along or across the substrate 102 and the workpiece 118, and then dynamically moves the electrode 108 vertically relative to the geometric contour of the workpiece 118 or the substrate 102 in response to the geometric contour of the workpiece 118, meeting or not meeting the spray distance (e.g., including less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 10 mm, and including them) The distance monitoring and control system may be configured to dynamically and responsively maintain or dynamically and responsively adjust the distance in real time. It should be noted that configurations vice versa are possible (e.g., substrate 102 moves vertically relative to directed energy source 106). For example, laser pattern 114 may be perpendicular to the cross-section of the bead forming workpiece 118, and the center portion of laser pattern 114 may be the point of interest for height measurement. It should be noted that laser pattern 114 may be dynamically projected below TCP / DTCP at the point of interest for distance measurement, at a fixed position in front of TCP, or at a fixed position behind TCP. In scenarios where the laser pattern 114 is not directly below the TCP / DTCP, the extracted spray distance data needs to be accompanied by the workpiece position information and stored (e.g., in a grid buffer) so that when the TCP / DTCP is located at the point of interest, the spray distance control system can retrieve at least some values ​​from a storage device (e.g., memory) to maintain the spray distance.

[0041] The spray distance monitoring and control system uses LLS 112 (or another laser-based triangulation system) mounted so that the directed energy source 110 is positioned along the horizontal axis between LLS 112 and directed energy source 106 to optically measure the spray distance and, if necessary, responsively and dynamically in real time, a positioning system or mover (e.g., motor, engine, actuator, mechanical linkage, gear mechanism, pulley mechanism, hydraulic mechanism, pneumatic mechanism) moves the electrode 108 vertically along the Z axis (e.g., up, down) relative to the substrate 102 or workpiece 118. This functionality enables the mover to dynamically and responsively maintain, maintain or adjust the spray distance in real time via control functions running on a controller (e.g., PLC, IPC) of the directed energy deposition additive manufacturing system 100. For example, the PLC can be a master PLC. It should be noted that a configuration vice versa is possible (e.g., the substrate 102 is moved vertically relative to the directed energy source 106 by the mover).

[0042] It should be noted that the directed energy deposition additive manufacturing system 100 may be implemented as disclosed in U.S. Patent Application 15 / 206,163 and U.S. Patents 7,301,120, 7,326,377, 9,346,116, and 9,481,931, all of which are fully incorporated herein by reference for all purposes. For example, the directed energy deposition additive manufacturing system 100 may receive a design file (e.g., a computer-aided design (CAD) file, etc.) of a workpiece 118 and a spool of wire (e.g., including titanium or other wire) via a wire source 104, and produce the workpiece 118 based on a specific workpiece geometry extracted from the design file of the workpiece 118, which may be aerospace grade, etc. For example, the directed energy deposition additive manufacturing system 100 may include a chamber filled with an inert gas, such as argon, helium, xenon, krypton, or a combination thereof. As such, substrate 102 , wire source 104 , directed energy source 106 , electrode 108 , directed energy source 110 , laser line scanner 112 , laser pattern 114 , and workpiece 118 may be positioned within a chamber.

[0043] In one mode of operation, the standoff distance may be the distance from the DTCP to the workpiece 118 in the vertical direction. The standoff distance is maintained within defined limits to achieve consistent arc discharge conditions. The standoff distance monitoring and control system can automatically measure and control the standoff distance. It should be noted that the RPD TMThe program defines various parameters of the directed energy deposition additive manufacturing system 100 (e.g., spray distance set points, control modes, control enable, measurement offsets, read offsets). The directed energy deposition additive manufacturing system 100 then maintains the spray distance between the DTCP and the highest or lowest point on the workpiece 118 within a specific area centered around some specified read offsets. The directed energy deposition additive manufacturing system 100 uses the LLS 112 mounted in front of the electrode 108 to measure the spray distance, and uses a mover to maintain the spray distance with the help of control functions running on the main logic controller of the directed energy deposition additive manufacturing system 100.

[0044] In one mode of operation, the directed energy deposition additive manufacturing system 100 may be configured for spray distance monitoring and control in layer 0 (measurements will be made on the substrate) and based on a small average distance (approximately 0-10 mm long) at the beginning of the string before deposition. The directed energy deposition additive manufacturing system 100 may be configured for spray distance monitoring and control over the entire deposition length of the string, where the arc is turned on or scanned to deposit the next string when returning (without significantly affecting the part deposition progress or process). The directed energy deposition additive manufacturing system 100 may be configured for line shape monitoring and spray distance estimation. This may be done based on a model of the bead / string including overlap and laser measurements, while providing a user interface to monitor and discover deviations from the model and record the overall shape of the deposited string.

[0045] Figure 2 2 shows an embodiment of a directed energy deposition process flow according to the present disclosure. In particular, the directed energy deposition process 200 includes inputting a directed energy deposition (e.g., RPD) TM ) multiple inputs 202 (e.g., wire, substrate, inert gas) into an additive manufacturing machine 204, which responsively outputs multiple outputs 206 including a workpiece 224 and a process machine-readable record 226 (e.g., data structure, file). In addition, the directed energy deposition additive manufacturing machine 204 receives the RPD from the graphic conversion software application 212 TM A program 214 (e.g., NC commands, executable code, list of values, markup code, delimited text, populated spreadsheet) that converts a computer-aided design (CAD) file 210 (e.g., a multi-dimensional representation of an object to be additively manufactured) into an RPD TM Program 214. The graphic conversion software application 212 is connected or communicates with a data source 208 (e.g., database, data structure, software application, function, API) that converts a set of directed energy deposition (e.g., RPD TM) Additive manufacturing process knowledge data (e.g., machine settings, deposition parameters) is provided to the graphics conversion software application 212 to assist the graphics conversion software application 212 in converting the CAD file 210 into the RPD TM Procedure 214.

[0046] In the directed energy deposition additive manufacturing machine 204, the RPD TM Program 214 is input into a logic controller 216 (eg, a PLC) which controls directed energy deposition (eg, RPD) TM ) an additive manufacturing process 218, the directed energy deposition additive manufacturing machine producing a workpiece 224. It should be noted that the directed energy deposition additive manufacturing machine 204 houses a logic controller 216. During the directed energy deposition additive manufacturing process 218, the logic controller 216 executes a parameter monitoring process 220 and a parameter control process 222, which assists the directed energy deposition additive manufacturing process 218 in manufacturing the workpiece 224.

[0047] One of the several ways in which the parameter monitoring process 220 and the parameter control process 222 assist the directed energy deposition additive manufacturing process 218 may be by employing a spray distance monitoring and control system that responsively and dynamically maintains or controls in real time the spray distance between the DTCP of the electrode 108 and the highest point of the workpiece 118 based on the geometric profile of the workpiece 118 within a specific area centered at various specified read offsets; or maintains or controls the spray distance between the DTCT of the electrode 108 and the lowest point of the workpiece 118 based on the geometric profile of the workpiece 118. LLS-based 112 optically reads substrate 102 and workpiece 118 via laser pattern 114 extending laterally along or across substrate 102 and workpiece 118, and then dynamically moves electrode 108 vertically (e.g., up, down) relative to the geometric profile of substrate 102 or workpiece 118 in response to the geometric profile of workpiece 118, meeting or not meeting the spray distance (e.g., including less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 10 mm, and including therein) Any value of (e.g., approximately every 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, or 9 mm), but values ​​greater than 100 mm (e.g., approximately 125 mm, 150 mm, 200 mm, 225 mm, 250 mm, 300 mm, or greater) are possible, including various larger orders of magnitude (e.g., centimeters, decimeters, meters)) associated with a predetermined threshold (e.g., a numerical value), the spray distance monitoring and control system is able to dynamically and responsively maintain or dynamically and responsively adjust the spray distance in real time. In this way, the logic controller 216 dynamically and responsively maintains, maintains, or adjusts the spray distance (e.g., feedback iteration processing) based on the parameter monitoring process 220 and the parameter control process 222.

[0048] Figure 3 An embodiment of a directed energy deposition process flow according to the present disclosure is shown. In particular, the directed energy deposition process 200 shows how a process monitoring technology 230 is fed to a process control technology 228, and in turn to a logic controller 216. The process monitoring technology 230 monitors a directed energy deposition additive manufacturing process 218 based on a spray distance monitoring and control system. For example, the process monitoring technology 230 may include the LLS 112 optically reading changes in the profile of the substrate 102 or the workpiece 118 via a laser pattern 114 extending laterally along or across the substrate 102 and the workpiece 118.

[0049] If the process monitoring technology 230 determines that dynamic, responsive, and real-time spray distance adjustment, control, maintenance, or regulation is not feasible (e.g., large spray distance deviation, cannot be corrected or timely corrected spray distance deviation), the process monitoring technology 230 records the error in the process machine readable record 226 and does not additively manufacture the workpiece 118. Otherwise, if the process monitoring technology 230 determines that dynamic, responsive, and real-time spray distance maintenance or regulation is feasible, the process monitoring technology 230 communicates with the process control technology 228 and promptly informs the process control technology of various parameters or characteristics of the directed energy deposition additive manufacturing machine 204 that can be adjusted in a timely manner (e.g., spray distance control, mover motion parameters, wire control in the arc). The process control technology 228 then communicates with the logic controller 216 so that the logic controller 216 can act in a timely manner based on the various parameters or characteristics of the directed energy deposition additive manufacturing machine 204 that can be adjusted in a timely manner. For example, the logic controller 216 can communicate with a mover (e.g., a motor, a motor, an actuator, a mechanical linkage, a gear mechanism, a pulley mechanism, a hydraulic mechanism, a pneumatic mechanism) coupled to the electrode 108 so that the mover moves (e.g., vertically) the electrode 108 in time along the Z axis (e.g., up, down) relative to the geometric contours of the workpiece 118 or substrate 102. For example, the mover can move (e.g., vertically) the electrode in time in a smooth manner while avoiding sudden or jerky movements that may not be desired. This functionality enables the mover to dynamically and responsively maintain the spray distance in real time via the control functions running on the logic controller 216.

[0050] Figure 4An embodiment of a substrate supporting a workpiece according to the present disclosure is shown. In particular, the substrate 102 or the workpiece 118 can be configured in various ways to ensure control of the spray distance between the electrode 108 and the workpiece 118, whether longitudinally or laterally. For example, the workpiece 118 can have distortions, especially for double-sided parts, uneven string surfaces, uneven height steps, features (e.g., starting features, ending features, joints). Similarly, the substrate 102 can be avoided to be flat (e.g., longitudinally, laterally), and its opposite ends can be bent upward toward each other (e.g., longitudinally, laterally). For example, the substrate 102 may not be flat (e.g., a sloped end) or the workpiece 118 may have an increasing or decreasing slope (e.g., a feature), and the LLS 112 may optically read the substrate 102 that is not flat or has an increasing or decreasing slope, and gradually move (e.g., vertically upward away from the substrate 102 or workpiece 118 or vertically downward toward the substrate 102 or workpiece 118) the electrode 108 to dynamically and smoothly maintain the spray distance as preset in advance. This timely and gradual movement may occur in advance or long before the electrode 108 is positioned on the substrate 102 or workpiece 118 at the point (e.g., above which wire melting occurs), otherwise, by the time the substrate 102 or workpiece 118 is positioned below the electrode 108 to gradually maintain the spray distance (e.g., may include sudden or jerky movements that may not be desired) it may be too late or not at all. Similar processing would apply when the substrate 102 (eg, an end portion with a reduced slope) or the workpiece 118 may have a reduced slope (eg, a feature).

[0051] Figure 5 An embodiment of a block diagram of a directed energy deposition additive manufacturing system according to the present disclosure is shown, the system including a laser line scanner that reads the geometric profile of a workpiece on a substrate. In particular, directed energy deposition (e.g., RPD TM ) Additive manufacturing system 500 includes LLC 112, data validation logic 502, grid spacing logic 504, RPD TM Program 506, operator human machine interface (HMI) 508, control logic 510, Z-axis drive logic 512, integrated position sensor 514 (e.g., Bosch Integrated Measurement System (IMS) version), workpiece coordinate system (WCS) logic 516, and processor 518 (e.g., single core, multi-core, PLC, circuit, printed circuit board).

[0052] RPD TMProgram 506 (e.g., executable code, list of numerical control (NC) values, markup code, delimited text, populated spreadsheet) contains various directed energy deposition additive manufacturing system settings (e.g., maintaining a specified spray distance), and operator HMI 508 is programmed to provide a user interface (e.g., analog, digital) that can be used in the RPD TM Program 506 rewrites the RPD if necessary when executed on the logic controller 214 TM Procedure 506 . This rewriting may be in real time while the workpiece 118 is being additively manufactured via the directed energy deposition additive manufacturing system 500 .

[0053] Once the directed energy deposition additive manufacturing system 500 reads the RPD TM Program 506 and the operator HMI 508 has not overwritten the RPD TM At step 506, the directed energy deposition additive manufacturing system 500 additively manufactures a workpiece 118 on the substrate 102 by directing a plasma arc via the electrode 106 at a wire from the wire source 104 while the substrate 102 moves in 3-dimensional space relative to the wire source 104, the directed energy source 106, the directed energy source 110, and the LLS 112. The wire source 104 provides (e.g., unwinds, supplies) a wire (e.g., metal, alloy, titanium, aluminum, steel) on the substrate 102, causing the electrode 108 to generate a plasma arc that melts the wire on the substrate 102 while the substrate 102 moves in 3-dimensional space, causing droplets to form from the wire melted via the plasma arc (or any other related energy source), and causing the droplets to be deposited, positioned, layered, cascaded, or dropped onto the substrate 102 to additively form the workpiece 118 layer by layer. Since the workpiece 118 has a geometric profile, the LLS 112 outputs the laser pattern 114 on the geometric profiles of the substrate 102 and the workpiece 118, so that the LLS 112 optically reads the geometric profiles of the substrate 102 and the workpiece 118 and generates a set of readings (e.g., workpiece profile, workpiece height, workpiece width) accordingly. As further explained below, the set of readings may be filtered, saturated, and smoothed.

[0054] The LLS 112 supplies the set of readings to data validation logic 502 (e.g., hardware circuitry, software function, API), which compares the set of readings from the LLS 112 to a set of expected values ​​for the workpiece 118 (e.g., serially, concurrently) to validate the set of readings. The set of expected values ​​may be derived from a data structure (e.g., an array) populated based on user input from the operator HMI 508. For example, the set of readings from the LLS 112 is compared to the set of expected values ​​for the workpiece 118 to filter the set of readings, which may include a set of expected parameters, standards, ranges, or thresholds based on the workpiece 118 or a geometric profile of the substrate 102. If the data validation logic 502 is able to validate the set of readings from the LLS 112, the data validation logic 502 inputs the set of readings to grid spacing logic 504 (e.g., hardware circuitry, software function, API), which converts the set of readings into an array or grid (e.g., two-dimensional, three-dimensional) that corresponds to (e.g., is dimensionally shaped to) the workpiece 118. Grid spacing logic 504 supplies the array or grid to control logic 510 (eg, hardware circuitry, software function, API).

[0055] The Z-axis drive logic 512 is coupled (e.g., wired, wireless, electrically, mechanically) to a mover (e.g., a motor, an engine, an actuator, a mechanical linkage, a gear mechanism, a pulley mechanism, a hydraulic mechanism, a pneumatic mechanism). In this way, the control logic 510 reads this set of readings while considering how the mover is currently positioned relative to the substrate 102 or the workpiece 118 based on the IMS 514. For example, the directed energy source 106 and the IMS 514 can be track mounted. For example, the IMS 514 can include a linear position sensor, a linear encoder, a distance sensor, or another sensor, interrogator, or reader that determines its position. It should be noted that when the directed energy source 106 is track mounted, the mover can be track mounted. The control logic 510 then converts this position information (e.g., Cartesian X / Y coordinates) into a set of workpiece coordinate system (WCS) coordinates (e.g., two-dimensional, three-dimensional) for the workpiece 118. Because the mover is (e.g., mechanically, electrically) connected to the electrode 108, the set of WCS coordinates is supplied (e.g., serially, concurrently) to the processor 518, which then requests the mover to move (e.g., vertically) the electrode 108 based on the set of WCS coordinates so as to maintain the spray distance between the workpiece 118 or substrate (layer 0) and the electrode 108 (or vice versa) when the substrate 102 with the workpiece 118 moves relative to the LLS 112.

[0056] In one mode of operation, the laser line scanner 112 measures the geometric profile of the workpiece 118 and the substrate 102 and forms a set of data based on such measurements. This set of data is computationally verified and stored in an X, Y array or grid in the WCS system, which then calculates the distance control deviation value using the following terms: TM The routine 506 takes the set point, the operator override for the operator HMI 508 , and the result of the drive position to enable the mover to move (eg, vertically) and thereby adjust the electrode 108 relative to the geometrical contours of the workpiece 118 and the substrate 102 .

[0057] like Figure 4 As shown, in one operating mode, there are multiple factors that cause the spray distance to deviate, including substrate distortion, uneven string surface, uneven height steps, joints, features, and other complex process variations. Figure 5 As shown, the spray distance monitoring and control system uses a laser distance measurement scanner and control system to automate monitoring and control. The LLS112 system block is responsible for capturing, filtering and extracting the distance of the workpiece 118 in the laser coordinate system, and the data verification block verifies the data from the laser, converts it into the workpiece coordinate system, resamples it and stores it in the data array (in workpiece coordinates). The control block uses this data, the set point from the program, and feedback from the drive position sensor (such as IMS) to control the Z axis to keep the spray distance at the set point.

[0058] Figure 6 An embodiment of a diagram of a laser line scanner system according to the present disclosure is shown. Figure 7 An embodiment of a diagram of a laser line scanner system according to the present disclosure is shown. In particular, LLS 112 performs, enables, or causes a set of operations 600 to be performed. The set of operations 600, as illustrated in diagram 700, includes set 602, set 604, set 606, and set 608.

[0059] Group 602 involves ensuring that the data from the LLS 112 is correct, as illustrated in diagram 700. For example, if the wire source 104 provides a source for a wire having a reflective metal or metal alloy, the LLS 112 may have at least some optical readings that may be distorted due to at least some undesirable or unforeseen reflections from the metal or metal alloy, particularly when the electrode 106 directs the plasma arc to the wire and causes or introduces other optical distortions. Thus, group 602 involves control of the frames read per second, camera-level filters, high dynamic range (HDR) image processing, image saturation processing, image smoothing, and other related image processing or data preprocessing operations. It should be noted that the substrate 102 may be preprocessed to reduce gloss or shine so as to reduce optical distortion or deviations at the substrate plane (e.g., in layers 0, 1, and 2).

[0060] Likewise, group 604, as illustrated in diagram 700, involves determining various measurements of the geometric profile of the substrate 102 and the workpiece 118 relative to the substrate 102 (e.g., satisfying expected data, minimizing outliers) based on data from group 602. For example, these measurements may include laser pattern width, timing values, the lowest point of the geometric profile of the workpiece 118 relative to the substrate 102 (e.g., extracted valleys), the highest point of the geometric profile of the workpiece 118 relative to the substrate 102 (e.g., extracted peaks), etc.

[0061] Similarly, group 606, as illustrated in diagram 700, involves determining multiple peak-to-valley average height workpiece gaps, workpiece profile slopes, and other related height, width, and length determinations based on data from group 604. For example, group 606 may include determining gap 1 based on finding the height difference between each of the following and the height at the center point of the laser pattern 114 (e.g., Figure 7 80 to 84): (a) a peak of the workpiece 118 relative to the substrate 102 at the time point (e.g., the highest peak), (b) a valley of the workpiece 118 relative to the substrate 102 at the time point (e.g., the lowest valley), or (c) an average height of the workpiece 118 relative to the substrate 102 at the time point. For example, group 606 may include determining gap 2 (e.g., based on finding a height difference between a peak and a valley within the time point (e.g., a search window). Figure 7 80 to 81). For example, group 606 may include fitting a line segment through a peak and a valley to determine the slope of the line segment. It should be noted that these are example functions and that this software may perform more data and image processing.

[0062] Additionally, group 608, as illustrated in diagram 700, involves verifying the data from group 606 and communicating with the logic controller 216 based on the success or failure of the verification. For example, based on the laser pattern 114 from the LLS 112, the distance between the LLS 112 and the substrate 102 or workpiece 118 may be determined (e.g., based on a conversion), and then the distance may be converted to a spray distance value based on a set of correction parameters (this may be done by the data verification logic 502). For example, group 608 may include verifying the height of the workpiece 118 relative to the substrate 102 (e.g., distance of peaks, distance of valleys, distance of average points), gap 1, gap 2, and the slope of the bead of the workpiece 118, and based on this height being verified, a set of data is then sent to the logic controller 216. For example, this may be enabled by observing the first deposited layer in the top layer, the substrate may or may not be relevant, but the distance relative to the previous deposited layer may be measured. For example, this set of data may include an X parameter (e.g., length), a Y parameter (e.g., depth), a Z parameter (e.g., height), gap 1, gap 2, and an error code. In this way, the logic controller 216 can cause the mover to move the electrode 108. Otherwise, if the height data is invalid, an appropriate error message and code is sent to the logic controller 216, based on which the logic controller 216 acts or refrains from acting.

[0063] Diagram 700 shows that a string formed by melting of the wire from the wire source 104 can be measured (e.g., between 1 frame per second to 10,000 frames per second (fps) or more), and depending on the traversal speed, this will translate into a number of samples per millimeter along the deposit (e.g., at a traversal speed of 10 mm / s and a frame rate of 100 fps, the samples will be 10 per millimeter). Likewise, HDR and filters are used to suppress noise and stray light to the greatest extent possible. The LLS system 112 is developed to be flexible to return the highest (e.g., peak), lowest (e.g., valley), or average spray distance of approximately + / - 10 mm around or contained within the center portion of the laser pattern 114. This can be particularly useful for features, blocks, and other structural portions of the workpiece 118.

[0064] Figure 8 800 is a diagram illustrating an embodiment of a substrate supporting a workpiece and a set of information related to data verification and grid spacing according to the present disclosure. In particular, diagram 800 relates to data verification logic 502 and grid spacing logic 504 originating from LLS 112. Thus, data obtained from LLS 112 may be downsampled and based on the following example: Figure 8The positions in the workpiece coordinates of the workpiece 118 deposited as shown are stored. In addition, at least some, many, most, or all of the measurements can be verified to exclude outliers (e.g., based on expected values). Moreover, at least some, many, most, or all of the data are further verified in several layers and stored in an array or grid having a resolution of less than about 10 mm, 9 mm, 8 mm, 7 mm, 6 mm, 5 mm, 4 mm, 3 mm, 2 mm, 1 mm, or less than 1 mm along the X-axis and the Y-axis. Figure 8 As shown, tolerances are defined based on a low-pass filter applied to (e.g., a moving average filter) to remove outliers. Moreover, at least some, many, most, or all measurements are verified against at least some, many, most, or all measurements from a previous layer. In the event that data is lost in a previous layer for any reason for more than a defined time period (e.g., less than approximately 10 seconds, 9 seconds, 8 seconds, 7 seconds, 6 seconds, 5 seconds, 4 seconds, 3 seconds, 2 seconds, 1 second, 0.5 seconds, 0.3 seconds inclusive), the directed energy deposition additive manufacturing system 500 may use the previous layer maximum value to verify the data. For example, methods or mechanisms may be used to handle missing data and outliers, noise in measurements, damaged measurements, and the like. These forms of processing enable the removal of outliers and avoidance of collisions (e.g., objects on substrate 102, workpiece 118, fixtures on substrate 102). It should be noted that the operator-entered average substrate or workpiece height (which may be obtained based on accurate substrate height measurements prior to loading) may be used as an initial condition for data validation while also helping to avoid or minimize unnecessary corrections at the end portions of the string (e.g., molten material, molten wire) that forms the workpiece 118.

[0065] Fig. 9 An embodiment of a diagram of a control block according to the present disclosure is shown. Fig.10 1000 shows an embodiment of a diagram of a control block according to the present disclosure. In particular, diagram 900 represents control logic 510 implemented via logic controller 216 as illustrated by diagram 1000. Diagram 900 has input 902, input 904, input 906, and input 908. Input 902 originates from RPD TM Program 506. Input 904 originates from LLS 112. Input 906 originates from operator HMI 508. Input 908 originates from IMS 514. Input 902 is fed into saturation logic 910 for use from RPD TM A plurality of additive manufacturing values ​​are selected from a set of preset values ​​in program 506 to ensure that at least some of the commanded spray distance values ​​are within at least some process specification limits. This result is then fed into comparison rule block 940 to calculate the spray distance control deviation of control rule block 926.

[0066] Input 904 (e.g., representing the expected string height accumulation based on the RPD program) is fed into the decision logic to determine whether the input 904 is valid based on a set of expected values. The expected values ​​are based on the RPD TM 108 . The process control specification of the embodiment of the present invention provides a method for determining the height of the directed energy source 108 by the operator during the process control process. The method of determining the height of the directed energy source 108 by the operator during the process control process is described in detail in conjunction with FIG. 9B . The process control specification of the embodiment of the present invention provides a method for determining the height of the directed energy source 108 by the operator during the process control process. The method of determining the height of the directed energy source 108 by the operator during the process control process is described in detail in conjunction with FIG. 9B . The process control specification of the embodiment of the present invention provides a method for determining the height of the directed energy source 108 by the operator during the process control process. The method of determining the height of the directed energy source 108 by the operator during the process control process is described in detail in conjunction with FIG. 9B . The process control specification of the embodiment of the present invention provides a method for determining the height of the directed energy source 108 by the operator during the process control process. The method of determining the height of the directed energy source 108 by the operator during the process control process is described in detail in conjunction with FIG. 9B .

[0067] Comparison rules 940 receive data from saturation logic 910 and logic bus OR gate 918 and generate a spray distance deviation value based on this data. Processor 940 then executes, causes or enables execution of initial condition check 922 (e.g., verification) regarding the spray distance deviation value, control gain selection 924 regarding the output of initial condition check 922, spray distance control rule logic 926 regarding the output of control gain selection 924, and then executes including sudden motion avoidance 928, correction limit for each part 930, correction limit for each deposition string 932, low pass filter 934, RPD TM Program reset check 936 and a set of condition checks that drive dynamic ramp control 938. Thus, these operations enable a flexible set of control modes (e.g., no control start, string-based start, or full control of the spray pitch set point (per string)), a set of dynamic adjustments (e.g., slow for small errors, fast for sharp or large errors), a set of correction limits (e.g., to prevent overall collision or excessive correction per string and per part), dynamic ramp control (e.g., to enable smooth corrections, avoid vibrations, sudden movements), and operator overrides (e.g., the operator has control to override the system at any time to prevent machine damage).

[0068] Fig.11An implementation of multiple scenarios for spray distance monitoring and control according to the present disclosure is shown. In particular, diagram 1100 shows different scenarios in which the definition of spray distance varies, whether on the substrate profile or on the melt bead profile (e.g., the highest or lowest or average distance around the center point of the laser pattern). It should be noted that for accurate or consistent through-pass temperature measurement, the spray distance can be set to a first preset distance for T1, regardless of what the cross-spray distance may be, and to a second preset distance for T3, wherein the first predetermined distance is less than the second predetermined distance (although greater than or equal to is possible since this is not required), and wherein the spray distance is maintained at the set point during directed energy deposition. In addition, it should be noted that the DTCP is calculated based on the wire speed to move the spray distance control to the point where the droplet meets the workpiece 118, rather than under the front end of the electrode 108. In addition, it is fully recorded to a record database in which all original measurements, layer heights, corrections, control deviations, and drive actions are recorded. In addition, configuration management is designed in which the directed energy deposition additive manufacturing system is able to be based on RPD TM The preset requested by the program to load the control settings.

[0069] Fig.12 Embodiments of boundaries around multiple edges of a substrate according to the present disclosure are shown where the risk of collision with a tool head is increased. In particular, diagram 1200 shows an electrode center point position boundary around an edge of a substrate where the risk of tool head collision is high (e.g., clearance includes less than about 10 mm, 9 mm, 8 mm, 7 mm, 6 mm, 5 mm, 4 mm, 3 mm, 2 mm, 1 mm, undamaged fixture without spatter).

[0070] Fig.13 An embodiment of a technique for minimizing or avoiding collisions with a fixture holding a substrate according to the present disclosure is shown. In particular, diagram 1300 shows important geometries that need to be considered to avoid collisions during active control. The actual gap (correction lower limit) will actually be smaller due to string height variations. In addition, diagram 1300 shows consideration of the substrate fixture during spray distance control (e.g., different geometries define the correction lower limit to avoid collisions based on the spray distance set point). For example, when some measurements make it so that the spray distance control will risk a collision between the tool head and the fixture, the logic controller 214 system can limit downward control movement to avoid collisions.

[0071] In one mode of operation, directed energy deposition (eg, RPD TM) The additive manufacturing system can be configured for: frame rate and filtering (e.g., measuring at 1-10,000 frames per second, using HDR capabilities and pre-filtering to reduce reflections and stray light from the plasma arc or energy source), flexible measurement modes (e.g., highest, lowest, average spray distance around the center of the laser pattern 114 or less than approximately (+ / -10mm), measurement verification (e.g., difference between highest and lowest z, and slope used to verify measurement), flexible control modes (e.g., no control start, string-based start, or full control of spray distance set point (per string)), dynamic adjustment (e.g., slow for small errors, fast for sharp or large errors), dynamic correction limits (e.g., dynamically calculate and apply correction limits, which are used to prevent collisions and avoid overall over-calibration of each string and each part positive), dynamic ramp control (e.g., dynamic ramp is used to enable smooth corrections to avoid vibrations, sudden movements), operator overrides (e.g., the operator has control to override the system at any time to prevent machine damage), accurate or consistent inter-pass temperature measurement (e.g., the spray distance can be set to a first preset distance for T1 regardless of what the cross-spray distance may be, and to a second preset distance for T3 while maintaining the spray distance at the set point during deposition), DTCP (e.g., based on wire speed calculations to move the spray distance control to the point where the droplet meets the workpiece, rather than under the electrode tip), adequate logging to a logging database (e.g., logging some, most, or all raw measurements, layer heights, corrections, and drive actions), or configuration management (e.g., preset load control settings based on program requests).

[0072] In one mode of operation, the directed energy deposition additive manufacturing system 100 includes a controller 119, an LLS 112, a substrate 102, a directed energy source 106, an additive manufacturing material (e.g., a wire source 104), and a mover. The controller 119 is coupled to the LLS 112, the directed energy source 106, and the mover. The substrate 102 is movable relative to the LLS 112 in 3-dimensional space. The directed energy source 106 is movable along a vertical axis relative to the substrate 102. The mover is coupled to the directed energy source 106. The mover moves the directed energy source 106 along a vertical axis. The directed energy source 106 generates energy, and the energy melts the additive manufacturing material onto the substrate 102, so that when the substrate 102 moves toward the LLS 112 relative to the directed energy source 106 and the LLS 112 in 3-dimensional space, a workpiece 118 is additively manufactured on the substrate 102. The workpiece 118 has a geometric profile, and the directed energy source 106 is vertically spaced from the workpiece 118 so that a spray distance is defined. The LLS 112 monitors the geometric profile of the workpiece 118 while the substrate 102 moves in 3-dimensional space, so that the controller 119 controls the mover to move the directed energy source 106 along the vertical axis so as to maintain the spray distance. The controller 119 can control the mover to move the directed energy source 108 along the vertical axis based on how fast the substrate 102 moves in 3-dimensional space so as to maintain the spray distance. The controller 119 can control the mover to move the directed energy source 106 along the vertical axis based on how fast the additive manufacturing material is melted via the plasma arc generated by the directed energy source 106 so as to maintain the spray distance. The directed energy source 106 includes a central end portion, and the controller can control the mover to move the directed energy source 106 along the vertical axis based on how fast the additive manufacturing material is supplied (e.g., via the wire source 104) so ​​as to maintain a spray distance so that droplets generated by the melting of the additive manufacturing material encounter the workpiece 118 before the droplets are positioned under the central end portion of the electrode 108. The controller 119 can be programmed to request the mover to smoothly move the directed energy source 106 along the vertical axis so as to minimize vibrations of the directed energy source 106 while the directed energy source 106 moves along the vertical axis. The controller 119 can be programmed to request the mover to smoothly move the directed energy source 106 along the vertical axis so as to minimize sudden movements of the directed energy source 106 while the directed energy source 106 moves along the vertical axis. The controller 119 can be programmed to request the mover to move the directed energy source 106 along the vertical axis so as to avoid collisions with an object that engages the substrate other than the workpiece 118. The object can be a fixture that clamps the substrate. The controller 119 can be programmed to limit the movement of the directed energy source 106 along the vertical axis on a per bead basis. The controller 119 can be programmed to limit the movement of the directed energy source 106 along the vertical axis on a per workpiece basis. The controller 119 can be programmed to dynamically adjust the movement of the directed energy source 106 along the vertical axis based on the error type.The LLS 112 generates a plurality of readings, and the controller 119 is programmable to receive the readings from the LLS 112 and verify the readings before the controller requests the mover to move the directed energy source 106 along the vertical axis. The directed energy source 106 may generate a plasma arc to melt the additive manufacturing material. The LLS 112 may generate a plurality of readings. The workpiece 118 may generate reflections, and the controller may be programmable to apply at least one of HDR and pre-filtering techniques to the readings from the LLS 112 to reduce at least one of reflections and stray light generated by at least one of the workpiece 118 and the plasma arc. The directed energy source 106 may be a first directed energy source, and the directed energy source 110 may preheat the substrate 102, wherein the directed energy source 110 is positioned between the LLS 112 and the directed energy source 106 along the horizontal axis. The controller 119 may control the mover to move the directed energy source 106 along the vertical axis based on the substrate 102 being twisted, warped, or deformed along at least one of the horizontal axis and the vertical axis in a longitudinal manner and a lateral manner, so as to maintain the spray distance. The controller 119 may control the mover to move the directed energy source 106 along the vertical axis to maintain the spray distance based on at least one of a feature of the workpiece 118, a joint of the workpiece 118, an intersection of the workpiece 118, an uneven height step, an uneven string surface, and a twist of the substrate 102. A sensor (e.g., IMS 514) may monitor the mover. The controller may be coupled to the sensor, and the controller controls the mover to move the directed energy source 106 along the vertical axis to maintain the spray distance based on the sensor.

[0073] Various embodiments of the present disclosure may be implemented in a data processing system suitable for storing and / or executing program code, the data processing system comprising at least one processor coupled directly or indirectly to a memory element via a system bus. The memory element comprises, for example, a local memory, a mass storage device, and a cache memory used during the actual execution of the program code, the cache memory providing temporary storage of at least some program code in order to reduce the number of times the code must be retrieved from the mass storage device during execution.

[0074] I / O devices (including but not limited to keyboards, displays, pointing devices, DASD, tapes, CDs, DVDs, thumb drives and other storage media) may be coupled to the system either directly or through intervening I / O controllers. Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the available types of network adapters.

[0075] The present disclosure may be implemented in a system, method and / or computer program product. A computer program product may include a computer-readable storage medium (or medium) having computer-readable program instructions thereon, which are used to cause a processor to perform various aspects of the present disclosure. A computer-readable storage medium may be a tangible device capable of retaining and storing instructions for use by an instruction execution device. A computer-readable storage medium may be, for example, but not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the above. A non-exhaustive list of more specific examples of computer-readable storage media includes the following devices: a portable computer disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanical encoding device such as a punch card or a raised structure in a groove on which instructions are recorded, and any suitable combination of the above.

[0076] The computer-readable program instructions described herein may be downloaded from a computer-readable storage medium to a corresponding computing / processing device, or downloaded to an external computer or external storage device via a network (e.g., the Internet, a local area network, a wide area network, and / or a wireless network). The network may include copper transmission cables, optical transmission fibers, wireless transmissions, routers, firewalls, switches, gateway computers, and / or edge servers. The network adapter card or network interface in each computing / processing device receives the computer-readable program instructions from the network, and forwards the computer-readable program instructions to be stored in a computer-readable storage medium in the corresponding computing / processing device.

[0077] The computer-readable program instructions for performing the operation of the present disclosure may be source code or object code written in any combination of assembly instructions, instruction set architecture (ISA) instructions, machine instructions, machine-related instructions, microcode, firmware instructions, state setting data, or one or more programming languages, including object-oriented programming languages ​​(e.g., Smalltalk, C++, etc.) and conventional procedural programming languages ​​(e.g., "C" programming language or similar programming languages). Code segments or machine-executable instructions may represent any combination of procedures, functions, subroutines, programs, routines, subroutines, modules, software packages, classes, or instructions, data structures, or program statements. A code segment may be connected to another code segment or hardware circuit by transmitting and / or receiving information, data, independent variables, parameters, or memory contents. Information, independent variables, parameters, data, etc. may be transmitted, forwarded, or transmitted via any suitable means, including memory sharing, message passing, token passing, network transmission, etc. Computer-readable program instructions may be executed completely on a user's computer, partially on a user's computer, as an independent software package, partially on a user's computer and partially on a remote computer, or completely on a remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer via any type of network, including a LAN or WAN, or may be connected to an external computer (e.g., via the Internet using an Internet service provider). In some embodiments, electronic circuits including, for example, programmable logic circuits, field programmable gate arrays (FPGAs), or programmable logic arrays (PLAs) may execute computer-readable program instructions to personalize the electronic circuits by utilizing state information of the computer-readable program instructions so as to perform aspects of the present disclosure.

[0078] Various aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of methods, devices (systems) and computer program products according to embodiments of the present disclosure. It will be understood that each frame of the flowchart and / or block diagram and the combination of frames in the flowchart and / or block diagram can be implemented by computer-readable program instructions. Various illustrative logic blocks, modules, circuits and algorithm steps described in conjunction with the embodiments disclosed herein can be implemented as electronic hardware, computer software or a combination of the two. In order to clearly illustrate this interchangeability of hardware and software, various illustrative components, frames, modules, circuits and steps have been generally described above in terms of their functionality. Whether this functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the entire system. The technician can implement the described functionality in different ways for each specific application, but this implementation decision should not be interpreted as making it depart from the scope of the present disclosure.

[0079] The flow charts and block diagrams in the accompanying drawings illustrate the architecture, functions and operations of possible implementations of the systems, methods and computer program products according to various embodiments of the present disclosure. In this regard, each frame in the flow chart or block diagram may represent a module, segment or part of an instruction, which includes one or more executable instructions for implementing a specified logical function. In some alternative implementations, the functions mentioned in the frame may not occur in the order mentioned in the accompanying drawings. For example, the two frames shown in succession may actually be performed substantially simultaneously, or these frames may sometimes be performed in reverse order, depending on the functions involved. It will also be noted that each frame of the block diagram and / or flow chart and the combination of frames in the block diagram and / or flow chart may be implemented by a dedicated hardware-based system that performs a specified function or action or performs a combination of dedicated hardware and computer instructions.

[0080] Words such as "then," "next," and the like are not intended to limit the order of the steps; these words are merely used to guide the reader through the description of the method. Although a process flow diagram may describe the operations as a sequential process, many of the operations may be performed in parallel or simultaneously. In addition, the order of the operations may be rearranged. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.

[0081] Features or functions described with respect to certain embodiments may be combined and sub-combined in various other embodiments and / or with various other embodiments. Moreover, as disclosed herein, different aspects and / or elements of the embodiments may also be combined and sub-combined in a similar manner. In addition, some embodiments, either individually or collectively, may be components of a larger system, wherein other processes may take precedence over their application and / or otherwise modify their application. In addition, as disclosed herein, multiple steps may be required before, after, and / or simultaneously with the embodiments. It should be noted that, at least as disclosed herein, any and / or all methods and / or processes may be at least partially performed in any manner via at least one entity or actor.

[0082] The terms used herein may imply an action or inaction, direct or indirect, full or partial, temporary or permanent. For example, when an element is referred to as being "on," "connected," or "coupled" to another element, the element may be directly on, directly connected or coupled to the other element and / or there may be intervening elements, including indirect and / or direct variations. Conversely, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements.

[0083] Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not necessarily be limited by such terms. These terms are used to distinguish one element, component, region, layer, or segment from another element, component, region, layer, or segment. Therefore, without departing from the teachings of the present disclosure, the first element, component, region, layer, or segment discussed below may be referred to as a second element, component, region, layer, or segment.

[0084] The terms used herein are used to describe specific embodiments and are not intended to necessarily limit the present disclosure. As used herein, the singular forms "one", "an" and "the" are intended to also include plural forms, unless the context clearly indicates otherwise. Moreover, as used herein, the terms "one" and / or "one" should mean "one or more", even if the phrase "one or more" is also used in this article. The terms "include", "comprise" and / or "include", "comprise" when used in this specification specify the presence of the features, wholes, steps, operations, elements and / or parts, but do not exclude the presence and / or addition of one or more other features, wholes, steps, operations, elements, parts and / or their groups. In addition, when the present disclosure states that something is "based on" something else in this article, this statement refers to the basis that may also be based on one or more other things. In other words, unless otherwise clearly stated, as used herein, "based on" inclusively refers to "based at least in part on" or "based at least in part on".

[0085] As used herein, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or." That is, unless specified otherwise or clear from the context, "X employs A or B" is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then "X employs A or B" is satisfied under any of the foregoing instances.

[0086] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology and should not be interpreted in an idealized and / or overly formal sense unless explicitly defined as such herein.

[0087] As used herein, the terms "about" and / or "substantially" refer to a variation of + / - 10% relative to the nominal value / term. Such variations are always included in any given range.

[0088] If any disclosure is incorporated herein by reference, and such disclosure conflicts with the present disclosure in part and / or in its entirety, the present disclosure shall prevail to the extent of the conflict, and / or the broader disclosure, and / or the broader definition of terms. If such disclosures conflict with each other in part and / or in its entirety, the later disclosure shall prevail to the extent of the conflict.

[0089] For the skilled person, various modifications and changes can be made to the present disclosure without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure is intended to cover its modifications and changes, as long as such modifications and changes fall within the scope of the claims described below and their equivalents.

Claims

1. A directed energy deposition additive manufacturing system, comprising: The controller, including the logic; Spray distance measuring unit; substrate; Plasma torch; Supply unit; Material; as well as A mover, wherein the logic causes the supply unit to output the material and the plasma torch to output plasma, so that the plasma melts the material onto the substrate and thereby additively manufactures a workpiece on the substrate, wherein the workpiece has a geometric profile, wherein the plasma torch is vertically spaced apart from the workpiece, so that a distance between the plasma torch and the workpiece is defined as a spray distance, wherein the logic causes the spray distance measurement unit to monitor the geometric profile when additively manufacturing the workpiece, and based on the geometric profile measured by the spray distance measurement unit, the logic causes the mover to at least one of move the plasma torch relative to the substrate or move the substrate relative to the plasma torch so as to maintain the spray distance in real time.

2. The directed energy deposition additive manufacturing system according to claim 1, wherein: The spray distance measurement unit includes a laser source and a camera, wherein the logic causes the laser source to output a laser pattern onto the geometric profile, thereby generating a plurality of reflections, wherein the logic causes the camera to read the reflections, and wherein the spray distance measurement unit monitors the geometric profile based on the reflections.

3. The directed energy deposition additive manufacturing system according to claim 1, wherein: The mover is configured to move the plasma torch relative to the substrate so as to maintain the spray distance.

4. The directed energy deposition additive manufacturing system according to claim 3, wherein: The substrate moves at least one of longitudinally and laterally relative to the plasma torch.

5. The directed energy deposition additive manufacturing system according to claim 1, wherein: The mover moves the substrate relative to the plasma torch based on the spray distance measurement unit monitoring the geometric profile so as to maintain the spray distance.

6. The directed energy deposition additive manufacturing system according to claim 1, wherein: The workpiece is a first workpiece, wherein the substrate is a second workpiece, and the first workpiece is additively manufactured on the second workpiece.

7. The directed energy deposition additive manufacturing system according to claim 1, wherein: The substrate is not a workpiece.

8. The directed energy deposition additive manufacturing system according to claim 1, wherein: The geometric profile has a maximum height and a minimum height, wherein the spray distance measurement unit monitors the geometric profile based on the maximum height and the minimum height.

9. The directed energy deposition additive manufacturing system according to claim 1, wherein: The directed energy deposition additive manufacturing system is configured to maintain the spray distance based on a spray distance set point accessed via the logic.

10. The directed energy deposition additive manufacturing system of claim 1, further comprising a user interface that enables rewriting of the logic regarding control of at least one of the spray distance measurement unit, the substrate, the plasma torch, the supply unit, and the mover.

11. The directed energy deposition additive manufacturing system according to claim 1, wherein: The directed energy deposition additive manufacturing system maintains the spray distance based on the spray distance for temperature measurement.

12. The directed energy deposition additive manufacturing system of claim 1, wherein: The logic reads control inputs from a deposition specification and inputs from a user interface, wherein the deposition specification and the inputs are associated with the workpiece.

13. The directed energy deposition additive manufacturing system of claim 1, wherein: The logic controls the mover to enable deposition and measurement scans, wherein the deposition and the measurement scans are associated with the workpiece.

14. The directed energy deposition additive manufacturing system of claim 1, wherein: The logic obtains a set of measurements from the spray distance measurement unit, wherein the set of measurements is associated with the workpiece.

15. The directed energy deposition additive manufacturing system of claim 1, wherein: The spray distance measurement unit scans at least one of the workpiece and the substrate to determine the spray distance and inputs the spray distance to the logic as needed.

16. The directed energy deposition additive manufacturing system of claim 15, wherein: The distance measurement unit scans at least one of the workpiece and the substrate based on at least one of a time interval, a position, a resolution, and a filter.

17. The directed energy deposition additive manufacturing system of claim 1, wherein: The spray distance measurement unit determines a feature of the workpiece, wherein the spray distance is determined based on the feature.

18. The directed energy deposition additive manufacturing system of claim 17, wherein: The feature is at least one of a shape of the workpiece, a gap in the workpiece, and an angle of the workpiece.

19. The directed energy deposition additive manufacturing system of claim 1, wherein: The spray distance measurement unit is at least one of calibrated and programmed to eliminate at least one of optical aberrations and stray light interference.

20. The directed energy deposition additive manufacturing system of claim 1, wherein: The logic performs validation of a set of measurements, samples the set of measurements to obtain a preset spatial resolution based on the validation, and provides the set of measurements to a workpiece coordinate system based on a grid spacing.

21. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller operates feedback control logic to maintain the spray distance.

22. The directed energy deposition additive manufacturing system according to claim 1, further comprising a positioning unit, wherein: The logic is programmed to avoid at least one of vibration and jerky motion of the positioning unit.

23. The directed energy deposition additive manufacturing system of claim 1, wherein: The feed unit is a wire feed unit having a feed speed, wherein the logic maintains the feed speed to calculate a real-time tool center point (DTCP) position.

24. The directed energy deposition additive manufacturing system of claim 1, wherein: The logic is programmed to control at least one of an inert gas flow, a welding current, a temperature, a loading of the work piece, an unloading of the work piece, a loading of a wire spool, and an unloading of the wire spool.

25. The directed energy deposition additive manufacturing system of claim 1, wherein: The mover is at least one of a motor, a engine, an actuator, a mechanical linkage, a gear mechanism, a pulley mechanism, a hydraulic mechanism, and a pneumatic mechanism.

26. The directed energy deposition additive manufacturing system of claim 1, further comprising a sensor, wherein: The controller controls the mover to vertically move the plasma torch based at least in part on data from the sensor and based on how fast the substrate is moving so as to maintain the spray standoff.

27. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller controls the mover to vertically move the plasma torch based on how fast the material is melted via the plasma so as to maintain the spray distance.

28. The directed energy deposition additive manufacturing system of claim 1, wherein: The plasma torch includes a central end portion, wherein the controller controls the mover to vertically move the plasma torch based on how fast the material is fed by a wire source so as to maintain the spray distance so that droplets generated by the material being melted meet the workpiece before the droplets are positioned below the central end portion.

29. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller is programmed to request the mover to vertically move the plasma torch smoothly so as to minimize vibration of the plasma torch while the plasma torch is vertically moved.

30. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller is programmed to request the mover to smoothly move the plasma torch vertically to minimize abrupt movements of the plasma torch while the plasma torch is moved along a vertical axis.

31. The directed energy deposition additive manufacturing system of claim 1 , further comprising an object other than a workpiece joined to the substrate, wherein: The controller is programmed to request the mover to vertically move the plasma torch to avoid collision with the object.

32. The directed energy deposition additive manufacturing system of claim 31, wherein: The object is a fixture that holds the substrate.

33. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller is programmed to limit vertical movement of the plasma torch based on a melt bead profile.

34. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller is programmed to limit vertical movement of the plasma torch based on a workpiece contour.

35. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller is programmed to dynamically adjust vertical movement of the plasma torch based on an error from the verification of a spray pitch deviation value.

36. The directed energy deposition additive manufacturing system of claim 1, wherein: The distance measurement unit generates a plurality of readings, wherein the controller is programmed to receive the readings from the distance measurement unit and to verify the readings before the controller requests the mover to vertically move the plasma torch.

37. The directed energy deposition additive manufacturing system of claim 1, wherein: The spray distance measurement unit generates a plurality of readings, wherein the workpiece generates reflections from the plasma, wherein the controller is programmed to apply at least one of a high dynamic range (HDR) and a pre-filtering technique to the readings to reduce at least one of the reflections and stray light generated by at least one of the workpiece and the plasma.

38. The directed energy deposition additive manufacturing system of claim 1, wherein: The plasma torch is a first plasma torch, and the directed energy deposition additive manufacturing system further includes a second plasma torch for preheating the substrate, wherein the second plasma torch is positioned between the spray distance measurement unit and the first plasma torch.

39. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller controls the mover to vertically move the plasma torch so as to maintain the spray distance based on at least one of twisting, warping, and deforming the substrate in at least one of a longitudinal manner and a lateral manner.

40. The directed energy deposition additive manufacturing system of claim 1, wherein: The controller controls the mover to vertically move the plasma torch so as to maintain the spray distance based on at least one of features of the workpiece, joints of the workpiece, intersections of the workpiece, uneven height steps, uneven string surfaces, and at least one of twisting, warping, and deformation of the substrate.

41. The directed energy deposition additive manufacturing system of claim 1 , further comprising a sensor to monitor the mover, wherein: The logic is coupled to the sensor, wherein the logic controls the mover to vertically move the plasma torch based on the sensor so as to maintain the spray distance.

42. A method for additive manufacturing, the method comprising: Output materials; outputting plasma via a plasma torch; Melting the material via the plasma to additively manufacture a workpiece on a substrate, wherein the workpiece has a geometric contour, wherein the plasma torch is vertically spaced apart from the workpiece to define a spray distance between the plasma torch and the workpiece; The geometric profile is monitored while additively manufacturing the workpiece, and based on the geometric profile measured by the spray distance measurement unit, a mover moves at least one of the plasma melting torch relative to the substrate or the substrate relative to the plasma melting torch so as to maintain the spray distance in real time.

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