Removable Calibration Plate for Precise AM Beam Alignment
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Solution Overview
Problem
Existing calibration systems for additive manufacturing devices are limited by the need for image acquisition within the device, leading to dependency on the calibration plate and poor precision in detecting contours and surfaces, as well as issues with radiation beam reflections during etching.
Innovation Solution
A removable calibration plate with an opaque etching layer that can be locally destroyed by the radiation beam to form test markings, featuring a frosted underside for improved image capture and reduced reflections, along with a transportable calibration kit for separate image capture and correction calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image acquisition is performed within the additive manufacturing device using the control equipment, then the calibration process can be completed, but the measurement precision and image quality are insufficient
Solution Approach 1:
The patent extracts the image acquisition function from the additive manufacturing device by using a separate backlight unit and camera system. The calibration plate is removed from the manufacturing device and placed on a standalone calibration station with its own illumination and imaging equipment, eliminating dependency on the manufacturing device's control equipment and improving image quality through dedicated imaging hardware.
Solution Approach 2:
The patent introduces a backlight unit as an intermediary component that provides controlled illumination from below the calibration plate. This intermediary lighting system enables high-contrast image capture of the etched markings by illuminating them from the opposite direction of the camera, significantly improving measurement precision compared to the manufacturing device's top-down illumination.
2Manufacturing precision
If the radiation beam is used to etch test markings on the calibration plate, then calibration data can be obtained, but reflections from the plate surface interfere with the etching process
Solution Approach 1:
The patent inverts the traditional etching setup by positioning the calibration plate on a backlight unit that illuminates from below, rather than illuminating from above. This inversion changes the angle of incidence for the radiation beam, causing reflections to diverge away from the etching zone and reducing interference with the etching process, thereby improving etching accuracy.
Solution Approach 2:
The patent converts the harmful reflections into a beneficial effect by using the reflected light to illuminate the etched markings from the side, enhancing their visibility to the camera. The reflections that would normally interfere with etching now provide additional lighting for the imaging system, improving both etching accuracy and image quality simultaneously.
3Measurement precision
If a transparent plate is used for calibration, then visibility of etched markings is improved, but reflections from the plate surface interfere with the radiation beam
Solution Approach 1:
The patent inverts the illumination direction by placing a backlight unit beneath the transparent calibration plate, causing light to pass upward through the plate. This inversion allows the transparent plate to maintain its visibility advantage while the backlight configuration minimizes reflections that would interfere with the radiation beam, as the light source is now from the opposite direction of the beam's approach.
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
Enhances measurement precision and reduces radiation beam reflections, allowing for better image quality and independent calibration outside the additive manufacturing device, improving the accuracy of contour and surface detection.
Implementation Method 1
the at least one power incident radiation beam etching layer being capable of being destroyed locally by the power incident radiation beam to form the at least one test marking
Implementation Method 2
the plate being transparent to visible light, the underside of the plate being frosted
Data Source
Figure 1
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AI summary
The present invention relates to a removable calibration plate (10), comprising a pane (20) having an upper face (21), intended to be turned toward the incident beam of radiant power and bearing a reference marking (30) and being intended to receive a test marking (40), and a lower face (23). According to the invention, the plate (10) comprises a layer (22) for etching by the incident beam (F) of radiant power, which layer is securely fastened to the upper face (21) of the pane (20) and opaque to visible light, and able to be destroyed locally by the incident beam (F) of radiant power in order to form the at least one test marking (40), the pane (20) being transparent to visible light, the lower face (23) of the pane (20) being ground.