Additive Manufacturing Alignment Using Multi-Scale Optical Sensing
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in achieving precise alignment of additively manufactured areas relative to conventionally manufactured preforms, particularly for hybrid components, due to difficulties in optimizing positioning at various length scales with high accuracy and efficiency.
Innovation Solution
A measuring device is provided with a first sensor for detecting a large area with low accuracy and a second sensor for detecting areas of interest with high accuracy, allowing for multi-scale sensor fusion to align the blueprint coordinate system with the build plane coordinate system, ensuring precise alignment of additively manufactured areas onto preforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single sensor device is used to detect the entire working area, then the device complexity is reduced, but the measurement precision cannot be sufficiently high for precise alignment
Solution Approach 1:
The patent divides the detection system into multiple sensor devices: a first sensor device for detecting the overall working area and a second sensor device for detecting specific areas of interest with higher precision. This segmentation allows each sensor to be optimized for its specific function, achieving high measurement precision without requiring a single overly complex device.
Solution Approach 2:
The patent introduces a multi-scale detection approach by combining coarse-grained detection from the first sensor with fine-grained detection from the second sensor. This dimensional transition from overall to local detection enables precise alignment while managing device complexity through functional differentiation.
2Measurement precision
If multiple sensor devices with different measurement accuracies are used, then the measurement precision for alignment is improved, but the device complexity increases
Solution Approach 1:
The measuring device is segmented into functional modules: a first sensor device for coarse detection, a second sensor device for fine detection, and an alignment module that integrates both measurements. This modular segmentation achieves high precision alignment while keeping individual components relatively simple.
Solution Approach 2:
The patent merges the detection results from multiple sensor devices with different precision characteristics through the alignment module. By combining coarse and fine measurement data, the system achieves high overall measurement precision while distributing complexity across multiple simpler components rather than one complex device.
3Measurement precision
If high measurement accuracy is achieved through optimized sensing, then the alignment precision is improved, but the operating time and computational effort increase
Solution Approach 1:
The alignment process is segmented into two stages: first, the first sensor device performs rapid coarse detection to identify the working area; second, the second sensor device performs targeted fine detection only in areas of interest. This segmentation dramatically reduces alignment time compared to high-precision detection across the entire area, while maintaining high measurement precision where needed.
Solution Approach 2:
Instead of applying high-precision measurement across the entire working area (excessive action), the system applies high precision only to the necessary areas of interest (partial action). This selective approach achieves sufficient alignment precision while significantly reducing computational effort and time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of high-quality hybrid components by accurately aligning the design and build plane coordinate systems, enhancing the precision and efficiency of additive manufacturing processes.
Implementation Method 1
a first sensor device (19) configured to detect a first detection area (21) of the work area (13)
Implementation Method 2
a second sensor device (29) configured to detect the at least one selected area of interest (25)
Data Source
Figure 1~2
AI summary
The invention relates to a measuring device (5) for aligning a build-plan coordinate system with respect to a build-plane coordinate system of a working region (13) of an additive manufacturing device (1), the working region being located in a build plane (11). The measuring device comprises: - a first sensor apparatus (19) which is designed to sense a first sensing region (21) of the working region (13) with a first measurement accuracy; - a selection module (23) which is designed to select at least one region of interest (25) within the first sensing region (21); - a second sensor apparatus (29) which is designed to sense the at least one selected region of interest (25) with a second measurement accuracy, the second measurement accuracy being higher than the first measurement accuracy; and - an alignment module (31) which is designed to determine, on the basis of the sensed region of interest (25), at least one alignment of the build-plan coordinate system relative to the build-plane coordinate system, selected from an angular alignment and a translational alignment.