Camera-Guided Molten Pool Control for Precise 3D Deposition
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Solution Overview
Problem
Existing processing systems face challenges in accurately controlling the size and position of molten pools formed during the processing of objects, particularly in laser metal deposition methods, which affect the quality and precision of the resulting molding objects.
Innovation Solution
A processing system incorporating irradiation optics, a material supply unit, a measuring device, a storage device, and a controller that works together to accurately control the size and position of molten pools by acquiring and storing information about their size and position, and adjusting the processing beam to match the desired dimensions and trajectory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a processing beam is radiated to form a molten pool for molding, then the molding object can be created, but the size and position of the molten pool cannot be accurately controlled
Solution Approach 1:
The patent implements a feedback control system where a measuring device (camera) captures images of the molten pool, the controller calculates its size and position, and compares these measurements with target values. The system then adjusts the processing beam parameters to correct deviations, forming a closed-loop feedback control that continuously maintains accurate molten pool control throughout the molding process.
Solution Approach 2:
The patent replaces traditional mechanical measurement and control methods with an optical-based measurement system (camera imaging) and automated digital control. Instead of mechanical probes or contact-based measurement, the system uses optical fields to detect molten pool characteristics and electronically processes the data to achieve precise control, eliminating mechanical interference and improving measurement accuracy.
2Manufacturing precision
If the processing system uses traditional control methods, then the system structure remains simple, but the molding accuracy and quality deteriorate
Solution Approach 1:
The patent makes the measuring device (camera) serve multiple functions: it captures images for molten pool measurement, provides visual monitoring of the processing area, and supplies data for quality control. This multi-functionality reduces the need for separate dedicated measurement devices, thereby limiting the increase in system complexity while achieving accurate molten pool control.
Solution Approach 2:
The system uses the processing beam's own light emission and the natural optical properties of the molten pool to enable self-measurement. The molten pool's characteristics (size, position, temperature-related optical properties) inherently provide measurement signals that the camera can detect, allowing the system to self-diagnose and self-correct without external complex measurement equipment.
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 ensures precise control over molten pool formation, leading to improved accuracy and quality in molding objects, enhancing the precision of three-dimensional structures produced by laser metal deposition.
Implementation Method 1
irradiation optics capable of radiating a processing beam
Implementation Method 2
a portion where a molten pool is formed by radiating the processing beam
Data Source
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AI summary
A processing system includes a processing device including irradiation optics and a material supply unit and configured to mold a molding object, a measuring device configured to acquire information about a size of the molten pool formed by radiating a processing beam, a storage device configured to store information about the size of the molten pool in association with information about a position of the molten pool, and a controller. The controller controls the processing device so that the size of the molten pool formed by radiating the processing beam coincides with a size of the molten pool read from the storage device.