Additive Manufacturing Scan Speed Detection via Optical Brightness
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Solution Overview
Problem
Existing methods for determining the scanning speed of high-energy beams in additive manufacturing, particularly for turbomachine components, are inefficient and lack precision, affecting component quality and manufacturing tolerances.
Innovation Solution
A method that uses a detection device to record brightness values over a predetermined period, calculating scanning speed without requiring complex control of the radiation source or precise distance measurements, allowing for precise and cost-effective determination of the beam's speed across various surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex control of the radiation source is used to determine scanning speed, then measurement precision can be improved, but device complexity increases
Solution Approach 1:
Instead of controlling the radiation source (laser) to create measurable patterns, the invention inverts the approach by controlling the detection device (camera) to record the moving laser beam. The laser continuously illuminates the surface while the camera captures its position over time, reversing who is active and who is measured, thereby simplifying the control requirements while maintaining measurement precision
Solution Approach 2:
The invention replaces complex mechanical control of the radiation source with an optical detection system. Instead of using mechanical pulse generators and precise timing controls to mark positions, the system uses optical recording of the laser's natural movement, substituting mechanical control complexity with optical field measurement
2Measurement precision
If precise distance measurements are used to calculate scan speed, then measurement precision improves, but device complexity and cost increase
Solution Approach 1:
The invention creates an optical copy of the laser beam's position by recording it on the camera sensor. Instead of directly measuring physical distances with complex instrumentation, the system captures a visual copy of the beam's location at different times, which can then be processed to determine speed without requiring direct physical measurement tools
Solution Approach 2:
The camera sensor acts as an intermediary between the moving laser beam and the speed calculation. Rather than directly measuring the beam's position with complex distance measurement devices, the camera provides an intermediate optical record that simplifies the measurement process while maintaining accuracy
3Measurement precision
If the radiation source is pulsed to create dashed lines for measurement, then scan speed can be determined, but device complexity and operation difficulty increase
Solution Approach 1:
The laser beam serves itself as both the processing tool and the measurement marker. Instead of requiring external pulse generation and dashed line creation, the continuous laser beam naturally leaves a visible trace that the camera can record, allowing the system to determine its own speed without external intervention or complex operational procedures
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 method ensures high component quality and manufacturing accuracy by providing a reliable and inexpensive means to determine scanning speed, reducing errors and environmental influences, and enabling continuous process monitoring.
Implementation Method 1
a section of surface illuminated by a high-energy beam for a predetermined duration is measured by recording the surface brightness values using a detection device
Data Source
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AI summary
The invention relates to a method for determining the scan speed of a high-energy beam (14) of a manufacturing device (10) for the additive manufacturing of a component, in particular a component of a turbomachine, comprising the steps of: - guiding the high-energy beam (14) generated by a radiation source (12) of the manufacturing device (10) over a surface (20); - detecting the area (34) illuminated by the high-energy beam (14) on the surface (20) during a predetermined time period by recording the respective brightness values of the surface (30) using a detection device (50) during the predetermined time period; - calculating the scan speed as a function of the predetermined time period and the detected illuminated area (34) using an evaluation device (42).Furthermore, the invention relates to a method for operating a manufacturing device (10) and a manufacturing device (10) for additively manufacturing a component, in particular a component of a turbomachine.