Energy Beam Spot Tracking Using X-Ray Signal Feedback
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in accurately controlling the position and velocity of energy beams over time due to component failures, leading to deviations that result in parts out of specification.
Innovation Solution
A method involving mapping intensity modulated x-ray signals with a plurality of locations on an energy beam target to generate a model of background x-ray intensity, forming an x-ray signal time series by scanning the energy beam in various directions and speeds, and determining its position based on received x-ray signal strength using a computing device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration methods are used to determine energy beam position, then initial positioning accuracy is achieved, but the method cannot be used during operation and does not account for dynamic deviations
Solution Approach 1:
The patent implements real-time feedback by continuously monitoring x-ray signal intensity during energy beam operation. The system dynamically adjusts beam positioning based on detected deviations from the expected signal pattern, enabling corrective action during the manufacturing process rather than relying solely on pre-operation calibration
Solution Approach 2:
The patent replaces mechanical calibration methods with an x-ray based detection system. Instead of using physical reference targets and manual calibration procedures, the system uses x-ray imaging to optically detect energy beam position and velocity deviations in real-time during operation
2Productivity
If energy beam velocity and position are assumed known, then operation proceeds without interruption, but component failures cause undetected deviations leading to out-of-specification parts
Solution Approach 1:
The system continuously monitors energy beam position and velocity during manufacturing by analyzing x-ray signal characteristics. When deviations exceed predetermined thresholds, the system provides feedback to adjust beam parameters or alert operators, ensuring part quality without interrupting the manufacturing process
Solution Approach 2:
The patent introduces an x-ray detection system as an intermediary between the energy beam and the workpiece. This intermediary enables indirect measurement of beam position and velocity by detecting x-ray signals generated when the beam interacts with the workpiece or target material, providing monitoring capability without direct mechanical interference
3Manufacturing precision
If dynamic velocity of energy beam occurs due to component failure, then parts become out of specification, but no detection method exists to identify the deviation
Solution Approach 1:
The patent replaces direct mechanical measurement of beam position with x-ray based detection. By measuring x-ray signal intensity and timing, the system can calculate beam velocity and position deviations without mechanical contact or interference with the beam path
Solution Approach 2:
The system detects beam deviations by monitoring changes in x-ray signal parameters such as intensity, timing, and spectral characteristics. These parameter changes correlate with beam position and velocity deviations, enabling indirect measurement of dynamic beam behavior through signal analysis
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 method enables accurate tracking and correction of the energy beam's position, ensuring consistent part quality by identifying deviations and adjusting beam parameters, thereby improving manufacturing efficiency and reducing waste.
Implementation Method 1
mapping a first intensity modulated x-ray signal with a plurality of locations on an energy beam target
Data Source
AI summary
A method for detecting a position of an energy beam comprises mapping a first density modulated x-ray signal with a plurality of locations on an energy beam target, thereby generating a model of a background x-ray intensity. The method further comprises forming an x-ray signal time series using subsequent intensity modulated x-ray signals, each resulting from scanning the energy beam along the energy beam target in one of a plurality of directions at one of a plurality of speeds, and determining the position of the energy beam based upon a received x-ray signal strength based on the x-ray signal time series and the model of the background x-ray intensity.