Build Plate Preheating via Spatial Power Control
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Solution Overview
Problem
In energy beam additive manufacturing, preheating build plates for processing brittle alloys is challenging due to the difficulty in determining the required beam power, which is sensitive to base plate material, surface emissivity, and environmental conditions, leading to inhomogeneous temperature distribution and potential local melting.
Innovation Solution
A method that automatically controls the power distribution over the build plate dimensions using thermocouples to measure center and edge temperatures, with a limiting function to prevent local melting, and a separate control loop for homogeneous temperature distribution, allowing for precise control of temperature differences and power allocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If beam power is increased to reach target temperature, then preheating speed is improved, but local melting of the base plate occurs
Solution Approach 1:
The patent applies local quality by differentiating the heating approach for different regions of the base plate. The control method adjusts beam power distribution based on spatial location, applying higher power to edge regions that lose heat faster and lower power to center regions. This prevents local melting while achieving uniform temperature distribution across the entire base plate surface.
Solution Approach 2:
The patent implements dynamics by using real-time temperature feedback from thermocouples to dynamically adjust beam power. The system continuously monitors temperature at multiple locations and modifies the heating power accordingly, transitioning from static power application to dynamic control that adapts to changing thermal conditions, preventing local melting while maintaining preheating speed.
2Device complexity
If uniform power distribution is applied across the build plate, then device complexity is reduced, but temperature distribution becomes inhomogeneous
Solution Approach 1:
The patent applies parameter changes by modifying the beam power parameter based on spatial location and thermal feedback. Instead of using a single uniform power level, the system varies power parameters across different regions of the base plate and adjusts them dynamically based on temperature measurements, achieving homogeneous temperature distribution without excessive device complexity.
Solution Approach 2:
The patent implements feedback control by using thermocouples to monitor temperature at multiple locations on the base plate and using this information to adjust beam power distribution. The system continuously compares actual temperature with target temperature and modifies heating parameters accordingly, maintaining homogeneous temperature distribution while keeping the control system manageable.
3Stability of the object's composition
If beam power is increased to compensate for heat loss at edges, then temperature uniformity is improved, but local melting occurs
Solution Approach 1:
The patent resolves this contradiction by applying local quality through region-specific power control. The system identifies edge regions as having higher heat loss and applies targeted power compensation only to those areas, while maintaining lower power in the center region. This localized approach achieves temperature uniformity without causing local melting at any specific location.
Solution Approach 2:
The patent uses dynamics to resolve the contradiction by implementing real-time feedback control that adjusts power distribution based on actual temperature conditions. The system continuously monitors temperature at edge and center regions, dynamically adjusting power to edge areas only when temperature drop is detected, preventing both temperature non-uniformity and local melting through adaptive control.
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
Enables fast, automatic, and homogeneous preheating of build plates, improving microstructure control and productivity by maintaining consistent temperatures across the plate, preventing damage from excessive power and ensuring even heating.
Implementation Method 1
preheating a build plate (10) for additive manufacturing with at least one energy beam (50) emitting a power P
Implementation Method 2
determining a temperature distribution ΔT in the build plate (10)
Data Source
AI summary
In summary the invention concerns a method for preheating a build plate (10) for additive manufacturing with at least one energy beam (50) emitting a power (P), wherein the method comprises controlling a power distribution (PXY) of the power (P) over dimensions (X, Y) of the build plate (10) comprising: - determining the power (P) of the beam (50) based on a target temperature (TSET) for the base plate (10) and - determining the allocation of the power (P) to the dimensions (X, Y) based on a temperature distribution (ΔΤ) in the base plate (10). The invention further concerns a method for manufacturing an object and an additive manufacturing apparatus.