Contained Laser Power Metering for Sealed Metal AM Chambers
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Solution Overview
Problem
Traditional power meter systems for laser-based powder bed fusion additive manufacturing are cumbersome, require external power sources and cooling lines, violating the inert integrity of metal sintering systems and contaminating feedstock with oxygen exposure.
Innovation Solution
A contained radiation power metering system with a base that fits within the additive manufacturing machine, featuring a radiation sensor, wireless module, and optional liquid cooling, allowing for sealed and wireless power measurement without external connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional power meters are used to measure laser power, then power measurement capability is achieved, but the inert integrity of the metal sintering system is violated and feedstock is contaminated by oxygen exposure
Solution Approach 1:
A transparent window is introduced as an intermediary component that allows laser radiation to pass through while maintaining the seal of the inert atmosphere chamber. The window is positioned such that it transmits the laser beam to an external power meter without requiring opening of the chamber, thus preventing oxygen contamination while enabling accurate power measurement.
Solution Approach 2:
The measurement system is segmented into two separate zones: an internal zone within the inert atmosphere chamber containing the transparent window and laser source, and an external zone containing the power meter. This segmentation allows the measurement function to be performed without mixing the inert and external atmospheres, preventing contamination while maintaining measurement capability.
2Measurement precision
If traditional power meters with external connections are used, then power measurement is enabled, but device complexity increases due to external power sources and cooling lines
Solution Approach 1:
The power meter is extracted from the inert atmosphere chamber and positioned externally, with only the necessary transparent window remaining inside the chamber. This extraction eliminates the need for complex internal mounting structures, external power cables, and cooling line connections within the sealed chamber, thereby reducing device complexity while maintaining measurement functionality.
Solution Approach 2:
The transparent window serves multiple functions: it acts as a seal for the inert atmosphere chamber, a transmission medium for the laser beam, and a mounting interface for the power meter. This multi-functionality reduces the number of separate components needed, simplifying the overall system while enabling power measurement.
3Measurement precision
If frequent power verification is performed using traditional meters, then laser power precision is maintained, but loss of time occurs due to setup and recovery procedures
Solution Approach 1:
The transparent window is pre-installed in the chamber during initial setup, and the power meter is pre-positioned externally in the optimal measurement location. This preliminary arrangement eliminates the need for repeated setup and recovery procedures during frequent power verification, reducing time loss while maintaining measurement precision.
Solution Approach 2:
The system is designed to be self-contained with the transparent window permanently integrated into the chamber structure and the power meter automatically positioned for optimal measurement. This self-service design allows operators to perform power verification without manual setup or recovery actions, minimizing time loss and maintaining precision through automated or semi-automated measurement processes.
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
Streamlines power testing by reducing setup and recovery time, maintaining inert atmosphere integrity, and ensuring operator safety with automated positioning and wireless data transfer, significantly reducing measurement time to under 5 minutes.
Implementation Method 1
a radiation sensor connected to the base and configured to receive radiation from the radiation source and output a radiation power signal
Implementation Method 2
The cooling system can include a coolant tank mounted to the base... The radiation sensor can be fluidly connected to the coolant tank via one or more coolant lines
Data Source
AI summary
A contained radiation power metering system for measuring power of a radiation source of an additive manufacturing machine includes a base configured to fit within the additive manufacturing machine, a radiation sensor connected to the base and configured to receive radiation from the radiation source and output a radiation power signal, and a wireless module disposed on the base configured to receive the radiation power signal and transmit the radiation power signal from the system to a separate wireless receiver.