Energy Beam Position Verification in Additive Manufacturing
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Solution Overview
Problem
Current methods for verifying the position, size, and deflection speed of energy beams in freeform fabrication or additive manufacturing are complex and inefficient, requiring knowledge of the work table's lateral position and angle, which complicates the calibration and verification processes.
Innovation Solution
A method involving providing an energy beam with two different focuses at multiple positions on a work table, detecting these positions, and comparing them to verify the beam's position and deflection speed, allowing for position stability verification without requiring knowledge of the work table's orientation or lateral position, using cameras like IR, CCD, or CMOS for detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional methods are used to verify energy beam position and deflection speed, then verification can be performed, but the process becomes complex and requires knowledge of work table lateral position and angle
Solution Approach 1:
The invention extracts the verification process from the complex coordinate system transformations and work table parameter dependencies. By using a camera to directly image the energy beam spot and compare its position with the digital model, the method eliminates the need to know work table lateral position and angle, simplifying the verification process while maintaining measurement precision
Solution Approach 2:
The invention introduces a camera as an intermediary device to capture images of the energy beam spot on the work table. This intermediary allows direct visual measurement and comparison with the digital model, bypassing the need for complex coordinate transformations and work table parameter knowledge
2Manufacturing precision
If traditional calibration methods are used, then beam position can be verified, but the calibration process becomes time-consuming and complex
Solution Approach 1:
The invention performs preliminary action by creating a digital model of the work table surface with embedded coordinate information before the actual manufacturing process. This pre-established digital reference allows for immediate verification during manufacturing without requiring time-consuming calibration procedures at each step
Solution Approach 2:
The invention creates a digital copy or model of the work table surface and energy beam path. This digital model serves as a reference for verification, allowing rapid comparison with actual beam positions captured by the camera, thereby eliminating repeated physical calibration while maintaining manufacturing precision
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 simplifies the verification of energy beam position and deflection speed, improving the accuracy of three-dimensional article formation by eliminating the need for complex calibration and allowing verification on both cold and hot surfaces, with the ability to send warning signals for deviations and switch off the beam if necessary.
Implementation Method 1
an energy beam source for delivering an energy beam spot to the powder whereby fusion of the powder takes place
Implementation Method 2
detecting the at least two positions of the energy beam spot on the work table
Data Source
AI summary
A method for verifying a position of an energy beam spot, said method comprising the steps of: providing a calibrated energy beam having a first focus in a at least two positions at a work table, detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said first focus, providing said calibrated energy beam having a second focus in said at least two positions at a work table, detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said second focus, comparing said at least two positions created with said first and second focus, wherein said position of the energy beam is verified if said positions created with said first focus are deviating less than a predetermined distance from said positions created with said second focus.