Bead Additive Manufacturing Feedback Control for Void Prevention

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Solution Overview

Problem

Bead-type additive manufacturing faces challenges with surface variations such as notches or gaps between beads, leading to voids that compromise the structural integrity of finished articles, requiring iterative adjustment of bead forming parameters, which is time-consuming and costly.

Innovation Solution

A manufacturing system incorporating a printhead, profilometer, and control system that measures in-work cross-sectional profiles during bead formation, compares data to reference profiles, and adjusts bead forming parameters in real-time to reduce or prevent nonconformities like voids, gaps, and mislocations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If iterative adjustment of bead forming parameters is used to reduce nonconformities, then manufacturing precision improves, but loss of time and productivity deteriorate

Engineering Contradiction:

Improvebead forming precisionVSAvoidevaluation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by performing real-time measurement and evaluation of bead profiles during the manufacturing process itself, rather than waiting until completion. The profilometer continuously monitors bead formation and provides immediate feedback, allowing parameter adjustments to be made proactively before defects propagate through the entire article.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by using the profilometer to continuously measure bead cross-sectional profiles and comparing them against target specifications. This measurement feedback is fed back to the control system, which automatically adjusts bead forming parameters in real-time to maintain precision without requiring manual iterative evaluation after manufacturing.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If iterative adjustment of bead forming parameters is used to reduce nonconformities, then manufacturing precision improves, but productivity deteriorates

Engineering Contradiction:

Improvebead forming precisionVSAvoidmanufacturing throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies self-service by enabling the manufacturing system to automatically monitor and adjust its own parameters without external intervention. The control system receives profilometer data, compares it to specifications, and autonomously modifies bead forming parameters, allowing the system to self-correct precision issues while maintaining continuous production flow.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If real-time profile measurement and parameter adjustment is implemented, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improvebead profile accuracyVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies mechanics substitution by replacing manual measurement and parameter adjustment operations with automated optical/electronic systems. The profilometer uses optical scanning to measure bead profiles, and the control system uses computational algorithms to determine parameter adjustments, substituting mechanical/manual processes with automated sensing and control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies copying by creating a digital representation of the bead profile through profilometer measurement. This digital copy of the physical bead geometry is then compared against target specifications in the control system, allowing virtual analysis and parameter optimization without physically manipulating the bead.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS11225026B2Bead-type additive manufacturing system and method

Publication Date: 2022.01.18 THE BOEING CO

AI summary

A manufacturing system includes a printhead, at least one profilometer, and a control system. The printhead extrudes a material onto a substrate and forms a new bead during additive manufacturing of an in-work article. The profilometer moves with the printhead and measures an in-work cross-sectional profile of existing beads of the in-work article. The control system generates in-work profile data including the in-work cross-sectional profile at a plurality of in-work profile locations, and continuously compares the in-work profile data to reference profile data of a reference article. The reference profile data includes a reference cross-sectional profile at a plurality of reference profile locations. The control system adjusts, based on the profile comparison, one or more bead forming parameters and causes the printhead to form the new bead according to the bead forming parameters to reduce or prevent nonconformities associated with forming the new bead.