Additive Processing Alignment Using Fiducial Build Objects
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Solution Overview
Problem
Existing additive processing systems face challenges in accurately positioning energy beams for precise processing due to changes in the relationship between the build head and stage coordinate systems, leading to potential inaccuracies in forming three-dimensional structural objects.
Innovation Solution
A processing system that includes a support apparatus, a processing apparatus for irradiating an energy beam, a position change apparatus, and a control apparatus that uses fiducial build objects to measure and adjust the positional relationship between the support apparatus and the energy beam, ensuring accurate alignment and positioning for additive processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive processing is performed without correcting coordinate system relationship changes, then processing speed is maintained, but manufacturing precision deteriorates due to positional inaccuracies
Solution Approach 1:
The system performs preliminary measurement of fiducial marks on the support apparatus and processing target before additive processing begins. This preliminary action establishes the initial coordinate system relationship and enables subsequent correction of positional deviations, thereby improving manufacturing precision without requiring continuous complex adjustments during processing
Solution Approach 2:
The control apparatus continuously monitors the positional relationship between the support apparatus and processing target during additive processing using measured fiducial mark positions. This feedback mechanism enables real-time correction of coordinate system drift, maintaining positioning accuracy while managing system complexity through automated control algorithms
2Manufacturing precision
If fiducial marks are measured and coordinate corrections are applied, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
Fiducial marks are measured and coordinate transformations are calculated before additive processing begins. This preliminary measurement and correction setup establishes accurate positioning for the entire processing run, improving shape accuracy while minimizing time loss by avoiding continuous measurements during processing
Solution Approach 2:
The system changes the parameter set used for positioning by switching from theoretical coordinate values to empirically measured fiducial mark positions. This parameter change enables accurate positioning that accounts for actual physical variations in the apparatus, improving manufacturing precision with a single measurement step
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 enables precise and accurate formation of three-dimensional structural objects by correcting for changes in the coordinate system relationship, thereby improving the shape accuracy and consistency of the additive processing results.
Implementation Method 1
A processing apparatus that performs additive processing by melting a powdery material with an energy beam and then solidifying the molten material again
Data Source
AI summary
A processing system is provided with: a support apparatus that is configured to support a processing target; a processing apparatus that performs an additive processing by irradiating a processed area on the processing target with an energy beam and by supplying materials to an area that is irradiated with the energy beam; and a position change apparatus that changes a positional relationship between the support apparatus and an irradiation area of the energy beam from the processing apparatus, wherein the processing system forms a fiducial build object by performing the additive processing on at least one of a first area that is a part of the support apparatus and a second area that is a part of the processing target, and the processing system controls at least one of the processing apparatus and the position change apparatus by using an information relating to the fiducial build object.