Energy Beam Calibration Pattern for Additive Manufacturing Alignment
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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 thin wires that quickly deform and necessitate extensive safety precautions, making the calibration process operator-dependent and inefficient.
Innovation Solution
A determination device with two units in the beam path, each comprising complementary pattern elements that generate a superordinate pattern, allowing for the use of solid units and reduced safety precautions, enabling accurate calibration by analyzing deviations from a nominal pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin wires are used as determination units, then misalignment of the energy beam can be properly identified, but the wires heat up quickly and deform or melt causing determination errors
Solution Approach 1:
The determination device is divided into two separate determination units (first and second determination units) arranged in succession in the beam path. Each unit contains pattern elements that can be independently designed and positioned, allowing the system to achieve high measurement precision while using more robust materials than thin wires.
Solution Approach 2:
Instead of directly observing the energy beam's effect on thin wires, the patent creates a visual copy or representation of the beam's position and alignment by projecting patterns through the determination units onto a screen. This allows indirect measurement that avoids the thermal deformation problems of direct wire-based methods.
2Measurement precision
If thin wires are used for determination, then alignment can be detected, but the determination process must be performed quickly before wires deform, making it operator-dependent
Solution Approach 1:
The determination units with their pattern elements automatically indicate beam alignment status through the projected patterns on the screen. The system self-calibrates and provides visual feedback without requiring operator intervention or interpretation, reducing skill dependency and enabling more consistent operation.
Solution Approach 2:
The patent uses visual pattern changes (analogous to color changes) on the screen to indicate alignment status. When the energy beam is properly aligned, specific patterns are visible; when misaligned, the patterns change. This provides intuitive visual feedback that reduces operator skill requirements.
3Measurement precision
If wires are used as determination units, then beam alignment can be assessed, but it is difficult to determine deviation from lateral position with respect to optical axis
Solution Approach 1:
The patent transitions from one-dimensional wire-based detection to two-dimensional pattern element detection. The pattern elements have specific geometries (lines, crosses, or other shapes) that create distinctive projection patterns, enabling detection of lateral position deviations in multiple directions simultaneously.
Solution Approach 2:
The determination units employ asymmetric pattern elements with specific orientations and geometries. These asymmetric patterns produce characteristic projection patterns that reveal lateral position deviations. For example, a cross-shaped pattern element with arms of different lengths or orientations can indicate deviation in specific lateral directions.
4Ease of operation
If operators view the pattern on a screen directly, then calibration can be performed, but safety precautions are mandatory to protect from direct energy beam contact
Solution Approach 1:
The patent introduces a screen as an intermediary between the energy beam and the operator. The screen intercepts the energy beam and converts it into a visible projection pattern that the operator can safely observe. This intermediary protects the operator from direct beam exposure while still allowing calibration to be performed.
Solution Approach 2:
Instead of observing the energy beam directly, the operator views a visual copy or projection of the beam's effects on the determination units, displayed on the screen. This indirect observation method eliminates the need for protective glasses and safety housings while maintaining calibration accuracy.
5Object-affected harmful factors
If safety precautions are installed for each apparatus in a plant with multiple apparatuses, then personnel are protected from radiation, but the calibration process becomes cumbersome and time-consuming
Solution Approach 1:
The screen serves as a universal intermediary that allows safe observation without requiring protective housings or curtains around each apparatus. Operators can safely view calibration patterns from a distance or through open areas, eliminating the need to install and configure safety infrastructure for each calibration operation.
Solution Approach 2:
By projecting the calibration patterns onto a screen rather than requiring direct beam observation, the system eliminates the need for extensive safety precautions. This allows rapid calibration setup and execution across multiple apparatuses without the time-consuming installation of protective housings, curtains, or enforcement of protective glass wear.
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 significantly reduces errors from thermal effects and increases operator safety by allowing for automatic calibration analysis, enhancing the efficiency and accuracy of energy beam alignment without the need for thin wires.
Implementation Method 1
the resulting pattern, e.g. the shadow generated by illuminating the two wires with the energy beam
Data Source
Figure 1
Figure 2~3
Figure 4~5
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).