Additive Manufacturing Feed Control During Head Acceleration
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Solution Overview
Problem
In additive manufacturing, errors in material supply and beam velocity can lead to inaccuracies due to response performance issues, affecting machining accuracy even when conventional techniques are used to set constant velocity paths.
Innovation Solution
A numerical control device that analyzes the transition of machining head velocity and material supply rate, calculates specific movement distances for acceleration and deceleration phases, and adjusts material supply commands to maintain a constant relation between velocity and supply rate, ensuring accurate machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machining head is accelerated and decelerated during movement, then the productivity is improved, but the machining precision deteriorates due to errors between commanded and actual velocity
Solution Approach 1:
The invention applies preliminary action by pre-calculating and compensating for velocity errors before they occur. The numerical control device calculates the difference between commanded velocity and actual velocity in advance, and adjusts the material supply amount accordingly to maintain constant relation during acceleration and deceleration phases.
Solution Approach 2:
The invention changes the parameter of material supply amount dynamically based on velocity transitions. By adjusting the material supply amount in response to velocity changes, the system maintains a constant relation between beam velocity and material supply rate, thereby preserving machining accuracy during speed changes.
2Manufacturing precision
If the material supply amount is increased during acceleration phase, then the machining precision is improved, but the device complexity increases
Solution Approach 1:
The invention implements feedback by continuously monitoring the relation between beam velocity and material supply amount, and adjusting the material supply command based on detected deviations. The system calculates velocity errors and uses this feedback to dynamically adjust material supply, maintaining constant relation despite velocity changes.
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
The solution enables high machining accuracy by precisely controlling the additive manufacturing process, addressing errors in material supply and beam velocity transitions.
Implementation Method 1
a machining head emitting a beam and produces a modeled object by adding a material molten by irradiation of the beam to a workpiece
Data Source
AI summary
A numerical control device includes: a program analyzing unit analyzing a transition of a moving velocity of a machining head and a transition of a supply amount of a material supplied to a beam-irradiation position based on a machining program; a movement distance calculating unit calculating a first distance based on a result of analysis performed by the program analyzing unit, the first distance being a length of a first movement section to a first position at which addition of the material to the workpiece is started, the first movement section being a section through which the machining head is moved while the head is accelerated; and a condition command generating unit generating a supply command to increase the supply amount of the material per hour from zero to a command value according to a machining condition while the machining head is moved through the first movement section.