Digital Twin Stack Visualization for Real-Time DED Shape Prediction
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Solution Overview
Problem
In the Directed Energy Deposition process, it is difficult to check the shape and state of the stack in real time due to the controlled environment and high energy heat source, and existing simulation methods are time-consuming.
Innovation Solution
A stack visualization method and apparatus using a digital twin model to visualize the stack movement and shape in real time, incorporating a deposition head, laser power information, and thermal image monitoring, with a processor to select and visualize virtual stacks based on collected data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If computational analysis software and thermo/hydrodynamic physics engine are used for stack shape simulation, then analysis accuracy is improved, but analysis time increases significantly
Solution Approach 1:
The patent pre-calculates and stores virtual stack data for various process conditions before actual manufacturing. This preliminary action creates a lookup database that can be quickly queried during production, eliminating the need for time-consuming real-time computational analysis while maintaining accurate stack shape prediction.
Solution Approach 2:
The patent creates virtual copies of stack data through digital twin models that replicate the physical manufacturing process. These virtual models are pre-simulated and stored, allowing rapid retrieval and comparison without performing full computational analysis during actual production, thus reducing analysis time while preserving accuracy.
2Reliability
If real-time monitoring of stack shape is implemented during Directed Energy Deposition, then process control is improved, but system complexity increases due to controlled environment requirements
Solution Approach 1:
The patent introduces a digital twin as an intermediary between the physical manufacturing process and the monitoring system. The digital twin receives process parameters and outputs predicted stack shapes, serving as a mediator that simplifies the monitoring architecture while enabling real-time process control without direct complex sensing in the controlled environment.
Solution Approach 2:
The patent replaces direct physical measurement systems with computational modeling and virtual simulation. Instead of installing complex physical sensors and measurement equipment in the controlled environment, the system uses software-based digital twins to predict and monitor stack shape, reducing hardware complexity while maintaining monitoring capability.
3Speed
If virtual stack data is pre-stored for multiple process conditions, then real-time visualization speed is improved, but memory requirements increase
Solution Approach 1:
The patent segments the virtual stack data into distinct categories based on process conditions (e.g., different laser powers, deposition speeds). This segmentation allows the system to store data in an organized manner and retrieve only the relevant segment during visualization, reducing the amount of data that needs to be actively managed while maintaining fast retrieval speed for specific conditions.
Data Source
AI summary
There is a stack visualization method using a stack visualization apparatus including a deposition head. The method comprises collecting a moving speed of the deposition head; collecting laser power information of the deposition head by which a laser is irradiated to a stack; selecting a virtual stack corresponding to the moving speed of the deposition head and the laser power information among a plurality of previously stored virtual stacks based on the moving speed of the deposition head and the laser power information; and visualizing the selected virtual stack through a digital twin model.