Dynamic Sensor Positioning for Additive Manufacturing Quality Control
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Solution Overview
Problem
Existing additive manufacturing devices for three-dimensional objects require dedicated, spatially fixed sensors for test bodies, which are underutilized and inefficient, as they are only used for quality control and not for regular component production, leading to wasted space and reduced flexibility.
Innovation Solution
A method utilizing two or more beam sources and scanning units with sensor units that can be dynamically positioned to monitor both test bodies and regular components, allowing for precise process control and data collection without the need for separate test body area sensors, enabling efficient use of production facility space and flexible monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dedicated spatially fixed sensors are used for test bodies, then quality control precision is improved, but device complexity and space utilization deteriorate
Solution Approach 1:
The sensor unit originally designed for monitoring test bodies is made universal by enabling it to monitor both test bodies and regular components. The scan unit dynamically repositions the sensor's detection area between a test body area and a component area, allowing the same sensor to serve dual purposes: quality control of test bodies and process monitoring of regular components, thereby eliminating the need for separate dedicated sensors.
Solution Approach 2:
The sensor system transitions from a static, fixed-position configuration to a dynamic, repositionable configuration. The scan unit enables the sensor's detection area to be moved between different spatial locations (test body area and component area) during operation, allowing flexible adaptation to different monitoring needs without requiring multiple fixed sensors.
2Measurement precision
If dedicated sensors for test bodies are implemented, then measurement capability for test bodies is improved, but productivity and space efficiency deteriorate
Solution Approach 1:
The sensor unit performs multiple functions by monitoring both test bodies and regular components. During production of regular components, the sensor monitors process parameters to enable real-time quality control. During test body production, it provides detailed quality assurance data. This multi-functionality eliminates idle time and maximizes the utilization of monitoring resources, improving overall productivity.
Solution Approach 2:
The sensor unit maintains continuous useful action by alternating between monitoring test bodies and regular components without interruption. The scan unit dynamically switches the detection area between different areas, ensuring the sensor is always engaged in a productive monitoring task, thereby eliminating downtime and maximizing measurement utility throughout the production cycle.
3Measurement precision
If separate test body area sensors are used, then monitoring precision for test bodies is improved, but adaptability and flexibility deteriorate
Solution Approach 1:
The monitoring system becomes dynamic and adaptable through the scan unit, which enables the sensor's detection area to be repositioned between test body areas and component areas. This dynamic capability allows the system to adapt to different production needs, switch between monitoring modes, and flexibly allocate monitoring resources based on current priorities, thereby greatly enhancing system versatility.
Solution Approach 2:
The build area is segmented into distinct functional zones (test body area and component area), and the scan unit enables selective directing of the sensor's detection area to specific segments. This segmentation allows independent monitoring of different areas while using a single sensor, providing both precision for test bodies and flexibility to monitor components when needed.
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
This approach allows for more efficient use of production facilities, increased flexibility in constructing test bodies, and improved precision in monitoring processes, enabling better quality control and data collection for both test bodies and regular components.
Implementation Method 1
irradiated in the build chamber with electromagnetic radiation from the aforementioned beam sources, particularly laser light
Implementation Method 2
processes known as 'Selective Laser Sintering' (SLS) or 'Selective Laser Melting' (SLM)
Implementation Method 3
each layer is sintered or melted to create the object
Implementation Method 4
At least the first scan unit is assigned a first sensor unit. The detection range of the first sensor unit is directed via the first scan unit to the target point of the first scan unit
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method for operating a manufacturing device (10) for the additive manufacture of a three-dimensional object by the layered application and selective solidification of a particularly powdery building material (20) in a building area (16) lying in a working surface (14), the method comprising irradiation of at least a part of a test body region (34).