Energy Beam Calibration Using Complementary Pattern Units
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Solution Overview
Problem
Existing determination devices for energy beams, particularly in additive manufacturing, are cumbersome and time-consuming due to the need for thin wires that heat up and deform under irradiation, requiring skilled operators and extensive safety precautions.
Innovation Solution
A determination device comprising two determination units with complementary pattern elements arranged in succession in the energy beam path, generating a superordinate pattern that allows for the calibration of the energy beam by identifying misalignments and deviations from a nominal position without the need for thin wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin wires are used as determination units, then the energy beam alignment can be properly identified, but the wires heat up quickly and deform or melt under irradiation
Solution Approach 1:
The patent changes the material parameter of the determination unit from thin wire to thick plate. This parameter change increases the mass and heat capacity of the determination unit, allowing it to withstand the energy beam irradiation without rapid heating and deformation, while still maintaining the ability to identify alignment issues through the generated pattern.
2Measurement precision
If thin wires are used to identify misalignments, then alignment precision is improved, but the determination process must be performed quickly before wires deform, increasing operator skill dependency
Solution Approach 1:
By changing the determination unit from thin wire to thick plate, the time window for safe operation is extended. The thick plate can withstand irradiation for longer periods without deforming, allowing operators more time to perform the determination process and reducing the need for highly skilled operators to complete the task rapidly.
3Device complexity
If thin wires are used, then the determination device is compact, but safety precautions are extensive and time-consuming to implement
Solution Approach 1:
The patent changes the determination unit from thin wire to thick plate, which can withstand direct irradiation. This allows the determination device to be positioned closer to the energy beam source without requiring extensive safety precautions, reducing the time needed to implement safety measures while maintaining device compactness.
4Device complexity
If wires are used as determination units, then the device structure is simple, but the impact on intensity distribution is small, reducing measurement sensitivity
Solution Approach 1:
The patent changes the determination unit from thin wire to thick plate with specific geometric features. This parameter change increases the impact on the energy beam intensity distribution, creating more pronounced patterns that improve the precision of lateral position deviation detection while maintaining relatively simple device structure.
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 solution significantly reduces the dependence on operator skill and safety precautions, as the determination process can be performed with more robust and less sensitive determination units, increasing the accuracy and efficiency of energy beam calibration.
Implementation Method 1
the resulting pattern, e.g. the shadow generated by illuminating the two wires with the energy beam, can be viewed on a screen
Data Source
AI summary
Determination device for determining at least one parameter of an energy beam, in particular an energy beam generated via an irradiation device of an apparatus for additively manufacturing three-dimensional objects, which determination device comprises two determination units arrangeable or arranged in succession in a beam path of the energy beam, characterized in that each determination unit builds or comprises at least one complementary pattern element, wherein at least two pattern elements of the two determination units complement each other to a superordinate pattern.