Irradiation Control Data for Multi-Laser Build Time Balancing
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Solution Overview
Problem
In additive manufacturing processes with multiple irradiation resources, existing systems face inefficiencies due to fixed assignments of resources to specific areas, leading to uneven utilization and conflicts between speed and component quality, which can delay manufacturing and negatively impact quality characteristics.
Innovation Solution
A method for generating an irradiation control data set that dynamically allocates work packages to irradiation resources based on execution time and evaluation rules, optimizing the distribution of layer segments and irradiation patterns to improve resource utilization and component quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple irradiation resources are used in parallel to increase process speed, then productivity is improved, but uneven utilization of irradiation resources occurs due to fixed area assignments
Solution Approach 1:
The patent implements dynamic work package assignment where irradiation resources are not permanently assigned to fixed areas but are dynamically allocated based on current layer requirements. The control device calculates execution times and assigns work packages flexibly, allowing resources to move between areas as needed, thus achieving balanced utilization while maintaining high productivity
Solution Approach 2:
The system changes the parameter of resource assignment from static (fixed area assignment) to dynamic (execution time-based assignment). By calculating and comparing execution times of different irradiation resources for various work packages, the system optimizes resource allocation to eliminate uneven utilization while preserving the parallel processing speed advantage
2Device complexity
If irradiation resources are permanently assigned to specific areas, then device complexity is reduced, but manufacturing precision suffers due to uneven resource utilization
Solution Approach 1:
The control device performs preliminary calculations of execution times for all irradiation resources before actual manufacturing. By pre-determining the optimal assignment based on calculated parameters, the system ensures high manufacturing precision without requiring complex real-time decision-making during the manufacturing process itself
Solution Approach 2:
The patent introduces an intermediary control device that acts as a mediator between the simple fixed-assignment hardware and the complex requirement for optimized resource utilization. This control device handles the complexity of dynamic assignment calculations, allowing the irradiation resources themselves to remain relatively simple while achieving high manufacturing precision through intelligent control
3Ease of operation
If a fixed irradiation strategy is determined before production, then ease of operation is improved, but loss of time occurs due to uneven resource utilization
Solution Approach 1:
The system performs preliminary determination of the irradiation strategy including execution time calculations for all resources before production starts. This pre-calculation approach maintains ease of operation by establishing a clear plan in advance while minimizing build time through optimized resource allocation that prevents idle time and uneven utilization during the actual manufacturing process
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 enhances the productivity of additive manufacturing by optimizing the utilization of irradiation resources, reducing build time, and improving component quality by ensuring the most suitable resource is used for each task, while maintaining adherence to specified irradiation sequences and quality standards.
Implementation Method 1
the build material is selectively solidified by spatially limited irradiation of the locations which, after manufacture, are to form part of the manufactured product to be produced, in that the powder grains of the build material are partially or completely melted with the aid of the energy introduced locally at this location by the radiation
Data Source
AI summary
Disclosed is a method for generating an irradiation control data set for creating control data for a device for additive manufacturing of a number of components in a manufacturing process in which at least one layer of a build material is introduced into a process space and the build material of the layer is selectively solidified to form at least one component layer by irradiating at least one section of the layer using a plurality of irradiation resources, wherein layer data are divided into a plurality of work packages, these work packages are put in an order and an irradiation resource is selected taking into account an execution time determined for the irradiation resource to which one of the work packages is assigned taking into account a specified set of evaluation rules, and this is repeated until to a predetermined termination criterion is reached.