Energy Beam Alignment Measurement with Complementary Pattern Elements
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Solution Overview
Problem
Existing determination devices for energy beams in additive manufacturing are cumbersome and time-consuming due to their sensitivity to irradiation, requiring extensive safety precautions and relying on fragile wires that can deform or melt under the energy beam, making operator skill-dependent and inefficient.
Innovation Solution
A determination device with two units in the energy beam path, each comprising complementary pattern elements that generate a superordinate pattern, allowing for improved calibration and misalignment detection without the need for thin wires, enabling safer and faster calibration processes by analyzing the superordinate pattern generated on a screen or via camera.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin wires are used as determination units, then misalignment detection capability is improved, but wire stability deteriorates due to rapid heating and deformation
Solution Approach 1:
The determination device is divided into multiple independent determination units (at least two), each comprising multiple pattern elements (e.g., lines, crosses, annular structures). This segmentation allows the system to use thicker, more stable pattern elements while maintaining high misalignment detection precision through the collective arrangement of multiple elements that form a superordinate pattern.
Solution Approach 2:
Instead of using fragile wire objects directly in the beam path, the invention uses pattern elements that create optical copies or shadow patterns on a screen. The pattern elements (lines, crosses, annular structures) are arranged to generate characteristic shadow patterns that indicate beam alignment, replacing the need for thin wires while improving stability.
2Ease of manufacture
If wires are used as determination units, then calibration can be performed, but the process becomes time-consuming due to operator skill dependency and rapid wire heating
Solution Approach 1:
The determination device is designed to be self-indicating through the superordinate pattern formed by multiple pattern elements. The pattern automatically shows beam misalignment characteristics without requiring operator interpretation or skill. The superordinate pattern provides clear, objective visual feedback that eliminates dependency on operator experience and reduces calibration time.
Solution Approach 2:
The pattern elements are pre-arranged in specific configurations (lines, crosses, annular structures) that are optimized for detecting various types of beam misalignment. This preliminary arrangement of pattern elements ensures that the determination device is ready for immediate use and provides consistent, reliable results without requiring time-consuming operator setup or adjustment.
3Measurement precision
If wires are used in the beam path, then beam parameter determination is possible, but extensive safety precautions are required due to direct beam exposure
Solution Approach 1:
The invention introduces a screen as an intermediary element between the energy beam and the operator. The pattern elements are arranged on or near the screen, and the beam creates shadow patterns or illumination patterns on the screen that can be observed without direct beam exposure. This intermediary screen allows operators to view beam parameters safely without wearing protective glasses or requiring extensive safety precautions.
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
The device reduces errors from thermal effects and allows for more accurate and efficient calibration of energy beams, minimizing safety precautions and operator dependency, while enabling the use of solid pattern elements that are less susceptible to deformation, thus improving the overall calibration process.
Implementation Method 1
the resulting pattern, e.g. the shadow generated by illuminating the two wires with the energy beam, can be viewed on a screen
Data Source
AI summary
Determination device (2) for determining at least one parameter of an energy beam (4), in particular an energy beam (4) generated via an irradiation device of an apparatus (1) for additively manufacturing three-dimensional objects, which determination device (2) comprises two determination units (5, 6) arrangeable or arranged in succession in a beam path (3) of the energy beam (4), characterized in that each determination unit (5, 6) builds or comprises at least one complementary pattern element (15, 18, 21, 23, 24, 27, 30), wherein at least two pattern elements (15, 18, 21, 23, 24, 27, 30) of the two determination units (5, 6) complement each other to a superordinate pattern (32, 35).