Energy Beam Calibration Using Source and Optics Sensors
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Solution Overview
Problem
Calibration procedures for energy beam systems in additive manufacturing machines are often manual, time-intensive, and affect the operating performance and quality of three-dimensional components, necessitating improved apparatuses and methods for automatic calibration.
Innovation Solution
An additive manufacturing system with integrated sensors and control systems that automatically calibrate energy beam systems by determining beam source and optical assembly parameters, using beam source and optics sensors to generate calibration factors and curves, allowing for independent adjustment of beam parameters and synchronization across multiple irradiation devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration procedures are used by service technicians, then calibration can be performed, but the process is time-intensive and cumbersome
Solution Approach 1:
The energy beam system performs self-calibration using integrated sensors (beam source sensor and optics sensor) that automatically measure beam parameters and adjust system settings without requiring external service technicians. The control system processes sensor data and generates calibration commands autonomously, eliminating manual intervention while maintaining calibration accuracy.
Solution Approach 2:
The system implements feedback loops where beam source sensors and optics sensors continuously monitor beam parameters, compare measurements against target values, and automatically adjust beam source power and optical assembly settings. This closed-loop feedback mechanism enables rapid iterative calibration that is both accurate and time-efficient.
2Manufacturing precision
If manual calibration is performed, then calibration can be completed, but the quality of calibration impacts operating performance and component quality
Solution Approach 1:
The patent replaces manual mechanical calibration procedures with an automated optical measurement and control system. Beam source sensors and optics sensors optically measure beam parameters, and the control system electronically adjusts beam source power and optical assembly settings, substituting human operators and manual adjustments with automated sensing and control mechanisms.
Solution Approach 2:
The control system acts as an intermediary between the sensors and the beam source/optical assembly. It receives raw sensor measurements, processes the data to determine calibration deviations, generates appropriate calibration commands, and executes adjustments, thereby mediating the calibration process to achieve high precision while simplifying operation.
3Productivity
If sensors and control systems are integrated for automatic calibration, then calibration efficiency improves, but device complexity increases
Solution Approach 1:
The control system serves multiple functions: it controls beam source power, manages optical assembly settings, processes sensor data from both beam source and optics sensors, generates calibration commands, and monitors system performance. This multi-functional integration consolidates what would otherwise be separate systems into a unified control platform, improving efficiency while managing complexity through functional consolidation.
Solution Approach 2:
The patent merges the beam source sensor system, optics sensor system, and control system into an integrated calibration apparatus. The sensors and control system are combined with the energy beam system to form a unified automated calibration capability, reducing the need for external equipment and manual procedures while enhancing calibration productivity.
Data Source
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AI summary
An additive manufacturing system may include an additive manufacturing machine and a control system. The additive manufacturing machine may include one or more irradiation devices respectively including a beam source configured to emit an energy beam, an optical assembly that has one or more optical elements configured to focus the energy beam emitted by the beam source, a beam source sensor configured to determine a beam source sensor value from a source measurement beam representative of the energy beam prior to the energy beam passing through one or more optical elements of the optical assembly, and an optics sensor configured to determine an optics sensor value from an optics measurement beam representative of the energy beam downstream from the one or more optical elements of the optical assembly. The control system may include an irradiation control module configured to provide one or more control commands to the additive manufacturing machine based at least in part on the beam source sensor value and/or based at least in part on the optics sensor value.