Additive Processing Device Height Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive processing devices face accuracy issues due to errors in layer formation, leading to a shift in the focal position of the laser beam, which decreases modeling accuracy as errors accumulate over multiple layers.
Innovation Solution
An additive processing device that includes a laser head, a drive unit, a recognition unit to measure the workpiece height during layer formation, a generation unit to create a drive path for the next layer based on the recognized height, and a control unit to adjust the drive unit accordingly, ensuring consistent focal position and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser head moves by a fixed amount corresponding to layer thickness, then the processing speed is maintained, but the focal position shifts away from the workpiece surface causing decreased modeling accuracy
Solution Approach 1:
The patent implements a feedback mechanism where a sensor detects the actual height of the workpiece surface after each layer formation. This detected height information is fed back to the control unit, which then adjusts the laser head's movement amount for the next layer based on the actual layer height rather than using a fixed predetermined value. This closed-loop feedback system ensures the focal position remains accurately positioned on the workpiece surface while maintaining processing speed.
Solution Approach 2:
The patent transitions from a static, fixed movement approach to a dynamic adjustment approach. The laser head's movement amount is no longer a constant value but varies dynamically based on the actual height of each formed layer. This dynamic adjustment allows the system to adapt to variations in layer formation, maintaining both high processing speed and accurate focal positioning throughout the additive manufacturing process.
2Manufacturing precision
If error correction is performed for each layer, then modeling accuracy is improved, but processing time increases
Solution Approach 1:
The patent maintains continuous processing by performing height detection and error correction operations during layer formation rather than stopping the process. The sensor detects workpiece height continuously or at appropriate intervals during the additive manufacturing process, and the control unit adjusts subsequent layer parameters without interrupting the overall workflow. This continuous operation minimizes idle time while ensuring accurate error correction for each layer.
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 enhances modeling accuracy by maintaining a constant focal position of the laser beam, resulting in higher precision and efficiency in forming layers, as demonstrated by experimental results showing improved modeling efficiency and accuracy compared to conventional techniques.
Implementation Method 1
a laser head configured to supply the powder material to the workpiece and irradiate the workpiece with a laser beam
Implementation Method 2
melting a supplied powder material and forming layers of the melted powder material
Data Source
AI summary
There is provided an additive processing device that models a workpiece by melting a supplied powder material and forming layers of the melted powder material. The additive processing device is provided with a laser head configured to supply the powder material to the workpiece and irradiate the workpiece with a laser beam, a drive unit configured to drive the laser head, a recognition unit configured to recognize a height of the workpiece in a laminating direction while the laser head is forming an N-th layer (N being a natural number) of the workpiece, a generation unit configured to generate a drive path for the laser head for formation of an N+1-th layer of the workpiece, based on the recognized height, and a control unit configured to control the drive unit based on the drive path.