Calorimeter Head Tangential Inlet for Thermal Measurement
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Solution Overview
Problem
Current methods for monitoring energy transfer in solidification manufacturing processes, such as additive manufacturing and welding, lack precision and real-time feedback, leading to variability and limited control over thermal characteristics, which affects the quality of the final product.
Innovation Solution
A calorimeter system with a calorimeter head and control unit that measures net energy input by directing a coolant flow through a cavity with tangentially arranged inlet ports, allowing for precise calculation of net power transferred to the substrate, enabling real-time adjustments and improved process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If melt pool monitoring is used to measure thermal characteristics, then some positive results are achieved, but measurement precision and real-time feedback capability are insufficient
Solution Approach 1:
The invention extracts the measurement function from complex optical systems (infrared cameras and sensors) and implements it through a simplified calorimeter that directly measures net energy input. The calorimeter head separates the measurement function from the manufacturing process, providing precise thermal characteristic data without requiring complex optical measurement componentry.
Solution Approach 2:
The calorimeter acts as an intermediary device between the directed energy source and the workpiece. It measures the net energy input through coolant temperature changes in a controlled cavity, providing real-time thermal characteristic data without directly observing the melt pool. This intermediary approach simplifies the measurement system while maintaining high precision.
2Measurement precision
If infrared cameras and sensors are used to monitor melt pool size, then thermal characteristics can be measured, but the system becomes complex and expensive
Solution Approach 1:
The invention replaces complex optical measurement systems (infrared cameras and sensors) with a thermal-based calorimetric system. Instead of optically measuring melt pool size, the calorimeter uses coolant temperature changes to directly determine net energy input, substituting mechanical/thermal measurement for optical measurement and significantly reducing system complexity.
Solution Approach 2:
The calorimeter uses a disposable or easily replaceable calorimeter head with coolant flow paths. Rather than investing in expensive, complex optical measurement systems, the invention employs a simpler, more affordable thermal measurement approach that can be easily maintained or replaced, reducing overall system cost and complexity.
3Productivity
If net energy input is not directly measured, then manufacturing variability increases and process control is limited
Solution Approach 1:
The calorimeter provides real-time feedback on net energy input by continuously monitoring coolant temperature changes. This feedback mechanism enables dynamic adjustment of manufacturing parameters during the solidification process, improving both process control precision and manufacturing efficiency. The control system uses calorimeter data to maintain optimal thermal characteristics throughout production.
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 system provides accurate and precise control over solidification manufacturing processes, reducing manufacturing variability and validating modeling assumptions, thereby enhancing the quality and consistency of the final product.
Implementation Method 1
a plurality of inlet ports equally spaced and tangentially arranged relative to a cavity of the calorimeter head are arranged to receive a coolant flow
Implementation Method 2
The plurality of inlet ports are arranged to receive a coolant flow via a coolant flow loop from the control unit
Data Source
AI summary
A calorimeter head and an associated system are provided. The calorimeter head provides symmetric circumferential laminar flow parallel to the bottom plane of a substrate plate of the calorimeter head. The calorimeter head defines a cavity which employs multiple tangentially arranged inlets for receipt of a flow of coolant from a control unit of the system.