Additive Manufacturing Height Feedback for Bead Accuracy
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Solution Overview
Problem
The existing additive manufacturing apparatuses face challenges in maintaining shape accuracy due to arc discharges between the wire and workpiece, leading to inconsistent droplet separation and bead height, which affects the overall object shape.
Innovation Solution
An additive manufacturing apparatus equipped with a height measurement unit to measure the object's height and a control unit to adjust machining conditions based on these measurements, ensuring precise control of the machining process and preventing arc discharges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current is supplied to the wire to melt and separate droplets, then droplet separation is achieved, but arc discharge may occur between the wire and workpiece
Solution Approach 1:
The system measures the height of the object formed at the machining position and uses this measurement feedback to control the machining conditions for adding machining material. This closed-loop control ensures consistent bead height and prevents arc discharge by maintaining proper wire-to-workpiece distance.
Solution Approach 2:
The system dynamically adjusts machining parameters (current supply, wire feed rate, laser power) based on measured object height to maintain optimal droplet separation while preventing arc discharge. This involves changing electrical and mechanical parameters in response to real-time measurements.
2Reliability
If current supply is precisely controlled to prevent arc discharge, then workpiece destruction is avoided, but droplet separation may become insufficient
Solution Approach 1:
Height measurement feedback enables the system to maintain current supply levels that ensure adequate droplet separation while preventing arc discharge. The control unit adjusts parameters based on measured height to achieve both workpiece integrity and consistent bead formation.
Solution Approach 2:
The system dynamically adjusts current supply and wire feed rate based on real-time height measurements, allowing droplet separation to be maintained at optimal levels without causing arc discharge. This dynamic parameter adjustment resolves the contradiction between reliability and manufacturing precision.
3Manufacturing precision
If height measurement and control are implemented, then shape accuracy is improved, but device complexity increases
Solution Approach 1:
The control unit performs multiple functions: it controls wire feed rate, laser power, and current supply, while also processing height measurement data and adjusting all these parameters based on a single measurement feedback loop. This multi-functionality reduces the need for separate control systems.
Solution Approach 2:
A single height measurement feedback loop controls multiple machining parameters (wire feed rate, laser power, current supply), consolidating the control system rather than requiring separate feedback mechanisms for each parameter. This approach improves shape accuracy while limiting the increase in device complexity.
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
This solution improves the shape accuracy of the objects produced by maintaining consistent bead height and preventing arc discharges, resulting in higher precision and quality of the manufactured objects.
Implementation Method 1
a height measurement unit to measure a height of the object formed at a machining position
Implementation Method 2
A current is supplied to the wire which is the machining material, whereby a molten droplet is formed at the end of the wire
Implementation Method 3
melts and deposits the machining material with a laser, an electron beam, or the like to form an object having a desired shape
Implementation Method 4
melts and deposits the machining material with a laser, an electron beam, or the like to form an object having a desired shape
Implementation Method 5
the workpiece may be destroyed upon occurrence of an arc discharge between the wire and the workpiece
Data Source
AI summary
An additive manufacturing apparatus that forms an object by repeating additive machining of melting a machining material and adding, onto a workpiece, the machining material solidified includes: a height measurement unit that measures a height of the object formed at a machining position; and a control unit that controls a machining condition for adding the machining material to the machining position on the basis of a measurement result provided by the height measurement unit.