Integrated Additive-Removal Stage With Optical Position Sensing
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Solution Overview
Problem
Existing processing systems face challenges in efficiently performing additive manufacturing and removal processing on a workpiece without requiring multiple stages and separate measurement areas, leading to reduced throughput and increased operational complexity.
Innovation Solution
A processing system that integrates a single stage for both additive manufacturing and removal processing, with a movable stage and measurement head, allowing for simultaneous or sequential processing and measurement across multiple areas, enhancing operational efficiency and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate stages are used for additive manufacturing and removal processing, then processing reliability is improved, but device complexity and loss of time increase
Solution Approach 1:
The patent combines additive manufacturing and removal processing into a single integrated processing system. The processing head includes both additive manufacturing units (laser source, powder supply) and removal processing units (laser source) that can operate on the same workpiece platform, eliminating the need for separate stages while maintaining processing reliability through unified control
Solution Approach 2:
The processing head is designed as a universal device that can perform multiple functions: additive manufacturing through powder bed fusion, removal processing through laser ablation, and measurement through integrated sensors. This multi-functional design reduces device complexity by consolidating what would otherwise require separate specialized equipment
2Reliability
If separate stages are used for additive manufacturing and removal processing, then processing reliability is improved, but loss of time increases
Solution Approach 1:
The integrated system enables continuous processing by eliminating the need to transfer workpieces between separate additive manufacturing and removal processing stages. The workpiece remains on the same platform throughout the entire manufacturing cycle, allowing uninterrupted sequential or parallel execution of additive and removal operations
Solution Approach 2:
The system performs measurement and inspection operations during the processing sequence rather than requiring separate post-processing measurement stages. The integrated sensors and measurement capabilities allow for real-time monitoring and verification throughout manufacturing, eliminating time loss from separate measurement cycles
3Productivity
If a single stage is used for both additive manufacturing and removal processing, then productivity is improved, but measurement precision may worsen
Solution Approach 1:
The patent introduces dedicated measurement sensors and detection devices as intermediary components within the integrated processing head. These specialized measurement units (optical sensors, cameras, displacement sensors) are positioned to independently monitor workpiece geometry and processing quality without being affected by the additive or removal processing activities, thereby maintaining high measurement precision despite the integrated design
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 integrated approach improves processing throughput by enabling parallel execution of additive manufacturing, removal processing, and measurement without the need for separate stages, thus optimizing the processing system's efficiency and flexibility.
Implementation Method 1
a first light receiving unit that is configured to optically receive at least one of the first energy beam and the second energy beam, the second light receiving apparatus includes a second light receiving unit that is configured to optically receive at least one of the first energy beam and the second energy beam
Data Source
AI summary
A processing system includes: a first processing apparatus that performs an additive manufacturing in a first processing area by emitting a first energy beam; a second processing apparatus that performs a removal processing in a second processing area by emitting a second energy beam; first and second placing apparatuses on which the additive manufacturing and the removal processing are performed; a positional change apparatus that relatively moves the first and second placing apparatuses between the first and second processing areas; and first and second light receiving apparatuses respectively disposed on the first and second placing apparatuses, wherein each of the first and second light receiving apparatuses may optically receive at least one of the first and second energy beams, and information related to a position of the first placing apparatus is acquired by an optical received result by the first light receiving apparatus, and information related to a position of the second placing apparatus is acquired by an optical received result by the second light receiving apparatus.