Additive Repair Tool Path Reuse for Accurate Component Filling
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Solution Overview
Problem
Existing methods for repairing components using additive manufacturing require high computing effort and data conversion steps, leading to inefficiencies and susceptibility to errors due to the need for multiple data processing steps from measurement to manufacturing.
Innovation Solution
An automated method where the tool path in the measurement cycle is used directly for the filling cycle, with data values from the measurement cycle compared to a threshold value to activate or deactivate the additive manufacturing system, reducing the need for further data conversion and enabling automatic repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple data conversion steps and processing steps are used to create a structure from measurement data, then the repair accuracy can be improved, but the computing effort and data amount increase significantly
Solution Approach 1:
The patent extracts only the essential measurement data directly from the component surface that is needed for repair, eliminating unnecessary intermediate data conversion steps. The measuring device captures depth information at specific measurement points along the tool path, and this raw data is directly used to control filler application, removing the need for complex data processing pipelines while maintaining repair accuracy.
Solution Approach 2:
The patent performs preliminary measurement of the component surface geometry before repair, storing the depth values at predetermined measurement points. This preliminary data collection enables direct control of the filler application process without requiring real-time data conversion during the repair operation, reducing computing effort while ensuring accurate restoration of the original surface.
2Manufacturing precision
If multiple data conversion steps are performed from measurement to manufacturing data, then the repair precision can be improved, but the susceptibility to errors increases
Solution Approach 1:
The patent extracts and uses only the critical depth measurement data directly from the component surface, bypassing multiple intermediate data conversion steps that introduce errors. By eliminating these conversion processes and using the raw measurement data to directly control filler application, the system maintains high repair precision while significantly reducing error susceptibility.
3Loss of information
If elaborate data conversions of point clouds are performed, then the complete repair information can be obtained, but the process complexity and fault susceptibility increase
Solution Approach 1:
The patent extracts only the essential depth information at specific measurement points along the tool path, eliminating the need for elaborate point cloud data conversions. This selective data extraction approach obtains all necessary repair information while dramatically simplifying the processing workflow and reducing fault susceptibility.
Solution Approach 2:
The patent applies local quality measurement by determining depth values at specific measurement points along the tool path rather than processing the entire point cloud. This localized approach captures all necessary repair information for each position while avoiding the complexity of global data conversions, thereby reducing process complexity and error potential.
4Manufacturing precision
If manual intervention is required for data processing and conversion, then the repair accuracy can be maintained, but the automation level and efficiency decrease
Solution Approach 1:
The patent implements self-service automation where the measuring device automatically captures depth data at predetermined measurement points along the tool path, and this data directly controls the filler application process without requiring manual intervention. The system serves itself by using its own measurement data to guide the repair operation, maintaining high accuracy while achieving full automation and improved efficiency.
Data Source
AI summary
The invention relates to a device and a method for repairing components by means of additive manufacturing. The deviation of the surface of the component from a predetermined dimensions within a repair region is determined along a specified tool path. In a subsequent filling cycle, a selective application of a filler along the specified tool path is carried out.