Additive Manufacturing Path Planning for Multi-Tool Process Sequencing
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Solution Overview
Problem
Conventional additive manufacturing systems require manual operator intervention to determine the path and processes for manufacturing parts, which can be inefficient and prone to errors due to the need to select appropriate additive manufacturing processes and parameters for various features of a part.
Innovation Solution
A system and method that utilize a processing circuit and machine-readable instructions to receive a three-dimensional model of a part, determine a sequence of additive manufacturing processes based on the model, available tools, and motion capabilities, and control the tools to manufacture the part automatically, incorporating sensor data and various welding-type processes such as arc welding and laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operator intervention is used to determine manufacturing paths and processes, then flexibility in handling complex part features is maintained, but efficiency and accuracy deteriorate due to time-consuming manual planning and potential human errors
Solution Approach 1:
The additive manufacturing system performs automated path planning and process selection for itself by analyzing the three-dimensional model of the part and automatically determining the manufacturing sequence, eliminating the need for manual operator intervention and significantly improving manufacturing efficiency
Solution Approach 2:
The patent replaces manual mechanical planning operations with an automated computational system that uses algorithms to analyze part geometry and generate manufacturing paths, substituting human cognitive processes with automated software-based solutions
2Manufacturing precision
If automated path planning is implemented, then manufacturing efficiency and precision are improved, but the complexity of the control system increases
Solution Approach 1:
The system incorporates feedback mechanisms where the automated path planning algorithm continuously analyzes the three-dimensional model, evaluates manufacturing capabilities, and adjusts the manufacturing sequence based on real-time system status and sensor data, ensuring high precision while managing control complexity through iterative optimization
Solution Approach 2:
The system performs preliminary analysis of the part's three-dimensional model before manufacturing begins, automatically determining all path planning parameters and process sequences in advance, which ensures manufacturing precision while reducing the complexity of real-time control decisions
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 approach enables efficient and precise planning and execution of additive manufacturing processes, reducing human error and optimizing the use of resources by determining the best sequence of processes and tools for each feature of the part, thereby improving manufacturing efficiency and quality.
Implementation Method 1
Additive manufacturing is a process that deposits material in a layered fashion to build up a part into a particular geometry
Implementation Method 2
incorporating sensor data and various welding-type processes such as arc welding and laser welding
Implementation Method 3
incorporating sensor data and various welding-type processes such as arc welding and laser welding
Data Source
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AI summary
Disclosed are systems and methods to plan a path to form a part using an additive manufacturing system. The additive manufacturing system may include one or more additive manufacturing tools. The additive manufacturing tools may include arc welding tools and non-arc welding tools. The system may also manufacture the part based on the planned path.