Irradiation System Calibration Using Digital Pattern Comparison
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Solution Overview
Problem
Current calibration methods for irradiation systems in three-dimensional work piece production are inaccurate and unreliable, relying on burn-off foils and additional caustic measurements, which are costly and time-consuming, and prone to errors.
Innovation Solution
A device and method that use a control unit and sensor arrangement to irradiate a calibration pattern onto an irradiation plane, generating a digital image of the actual pattern for comparison with a reference, allowing precise calibration of the irradiation system without burn-off foils and additional measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If burn-off foils and additional caustic measurements are used for calibration, then measurement capability is provided, but measurement precision and reliability remain insufficient
Solution Approach 1:
The patent uses a digital reference image (a copy of the ideal irradiation pattern) to compare against the actual burn-off pattern. This digital copying approach replaces physical measurement standards and enables precise, repeatable calibration without relying on fragile physical foils or complex caustic measurements.
Solution Approach 2:
The patent replaces the mechanical/physical calibration methods (burn-off foils, caustic measurements) with an optical-digital system. The radiation beam itself is used to create the measurement pattern, and digital image processing replaces physical measurement instruments, thereby eliminating the limitations of traditional mechanical calibration approaches.
2Measurement precision
If burn-off foils and additional caustic measurements are used for calibration, then calibration capability is provided, but calibration time increases
Solution Approach 1:
The patent merges the calibration function with the normal irradiation process. The same radiation beam used for production is used to create the calibration pattern on the burn-off foil, and the same sensor system used for monitoring is used for calibration measurement. This eliminates the need for separate calibration procedures and reduces calibration time.
Solution Approach 2:
By using digital image copying and processing, the patent eliminates time-consuming manual measurement and analysis steps. The digital reference image allows for rapid automated comparison and calibration determination, significantly reducing the time required for calibration while maintaining high precision.
3Measurement precision
If burn-off foils and additional caustic measurements are used for calibration, then calibration process is provided, but costs increase
Solution Approach 1:
The patent uses digital copies (reference images) instead of expensive physical calibration standards. The digital reference image can be stored and reused indefinitely without degradation, eliminating the need to repeatedly purchase or replace physical calibration artifacts while maintaining measurement precision.
Solution Approach 2:
The patent uses a disposable burn-off foil that is inexpensive compared to traditional calibration standards. The foil is consumed during calibration but replaced at low cost, while the expensive calibration knowledge is captured in the reusable digital reference image, inverting the traditional cost 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
This approach enables accurate and reliable calibration of the irradiation system, eliminating the need for burn-off foils and caustic measurements, reducing costs and time, while ensuring high precision and reliability in focusing and compensating for beam distortions.
Implementation Method 1
The irradiation system comprises a radiation source, in particular a laser source
Implementation Method 2
A sensor arrangement is provided which, for calibrating the irradiation system, is arranged in the irradiation plane and which outputs signals in response to being irradiated with the radiation beam
Data Source
AI summary
A device (48) for calibrating an irradiation system (18) of an apparatus (10) for producing a three-dimensional work piece comprises a control unit (50) adapted to control the irradiation system (18) so as to irradiate a radiation beam (22; 22a, 22b) onto an irradiation plane (52) according to a calibration pattern. The device (48) further comprises a sensor arrangement (56) adapted to be arranged in the irradiation plane (52) and to output signals to the control unit (50) in response to being irradiated with the radiation beam (22; 22a, 22b) according to the calibration pattern. The control unit (50) further is adapted to generate a digital image of an actual irradiation pattern produced by the radiation beans (22; 22a, 22b) incident on the sensor arrangement (56) based on the signals output by the sensor arrangement (56), to compare the digital image of the actual irradiation pattern with a digital image of a reference pattern so as to determine a deviation between the actual irradiation pattern and the reference pattern, and to calibrate the irradiation system (18) based on the determined deviation between the actual irradiation pattern and the reference pattern.