Lamination Molding Spatter Image Analysis for Real-Time State Estimation

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Solution Overview

Problem

Existing lamination molding technologies face challenges in monitoring and correcting the molding state of solidified layers in real-time, leading to potential quality deterioration due to changes in laser irradiation states and other factors.

Innovation Solution

A system comprising an image acquisition unit and an analysis unit that acquires and analyzes image data of spatters generated around molten pools during lamination molding to estimate parameters representing the molding state, allowing for real-time monitoring and correction of apparatus settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If individual measurement devices are installed for each parameter to be monitored, then measurement capability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvemolding state monitoring capabilityVSAvoidmeasurement device configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple measurement functions into a single imaging device. The imaging device captures images that contain information about multiple parameters simultaneously (molten pool temperature, spatter characteristics, keyhole state), eliminating the need for separate measurement devices for each parameter.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The imaging device is designed to perform multiple measurement functions universally. By analyzing different features within the captured images (spatter particle distribution, molten pool geometry, keyhole characteristics), a single device can monitor various molding state parameters that would traditionally require dedicated sensors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If real-time measurement of molding parameters is implemented, then quality control is improved, but measurement accuracy deteriorates due to process interruptions

Engineering Contradiction:

Improvereal-time monitoring capabilityVSAvoidmolding state accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The imaging measurement system operates continuously during the laser irradiation process without requiring interruptions. The imaging device captures images in real-time as the laser processes the material, maintaining continuous monitoring of the molding state throughout the entire manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If comprehensive monitoring of molding parameters is performed, then molding state control is improved, but loss of time increases due to measurement interruptions

Engineering Contradiction:

Improvemolding state controlVSAvoidprocess interruption time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system maintains continuous imaging and measurement throughout the lamination molding process. The imaging device operates without interruption during laser irradiation, material layer formation, and solidification phases, ensuring comprehensive monitoring without halting the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

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

Enables real-time estimation of previously difficult-to-monitor parameters, reducing the need for individual measurement devices and minimizing interruptions in the lamination molding process, thereby improving the quality and efficiency of the manufacturing process.

Implementation Method 1

the material layer is sintered or melted to form a solidified layer by irradiating a predetermined position of the material layer with a laser beam using a laser beam irradiation device

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

the image acquisition unit is configured to acquire image data of a spatter generated around a molten pool formed by irradiation with the laser beam

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS12280427B2Lamination molding apparatus, molding state estimation system, molding state estimation method, molding state estimation program, and learning method of learning model for molding state estimation

Publication Date: 2025.04.22 SODICK CO LTD

AI summary

The present invention provides a system capable of estimating a molding state in a manufacturing process of the lamination molded object. According to the present invention, provided is a system for estimating a molding state in a manufacturing process of the lamination molded object including an image acquisition unit and an analysis unit. The lamination molded object is manufactured by repeating a material layer forming step of forming a material layer by supplying material powder onto a molding region and a solidified layer forming step of forming a solidified layer by irradiating the material layer with a laser beam. The image acquisition unit is configured to acquire image data of a spatter generated around a molten pool formed by irradiation with the laser beam. The analysis unit is configured to analyze the image data to estimate a parameter representing the molding state.