Laser Beam Alignment Using Calibration Plate Correction Fields
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Solution Overview
Problem
Current additive manufacturing systems face challenges in accurately calibrating laser beams due to the high cost and difficulty in manufacturing precision calibration plates with flat and parallel surfaces, leading to misalignment issues caused by irregularities in the calibration plates.
Innovation Solution
A method using a coordinate measuring machine to measure the calibration plate's surface at multiple points, generating a correction field, and aligning laser beams within the additive manufacturing system based on this data to compensate for irregularities, allowing for accurate alignment without requiring a completely flat and parallel calibration plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a completely flat and parallel calibration plate is used, then alignment precision is improved, but manufacturing cost increases and ease of manufacture deteriorates
Solution Approach 1:
The patent changes the approach from requiring perfect physical geometry (flat and parallel surfaces) to accepting irregular surfaces and compensating through measurement and computational correction. The CMM measures actual surface deviations, and software algorithms calculate correction factors that adjust laser positioning data, transforming the problem from physical precision to computational compensation.
Solution Approach 2:
The patent replaces the mechanical requirement for perfect flatness and parallelism with a measurement and computation system. Instead of relying on mechanical precision of the calibration plate, the system uses CMM measurement data and software algorithms to determine actual surface geometry and calculate positional corrections, substituting mechanical precision requirements with computational methods.
2Manufacturing precision
If a completely flat and parallel calibration plate is manufactured, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent transforms the requirement from physical geometric parameters (flatness, parallelism) to computational parameters (measurement data, correction factors). By measuring actual surface irregularities with CMM and using software to calculate corrections, the system achieves high alignment precision without requiring expensive precision manufacturing of the calibration plate.
Solution Approach 2:
The patent creates a digital copy or model of the calibration plate's actual surface geometry through CMM measurement. This digital representation is then used to calculate correction factors, allowing the system to compensate for physical irregularities without needing to physically correct or remake the calibration plate, thereby reducing manufacturing costs.
3Device complexity
If traditional calibration methods are used, then alignment process is simplified, but measurement precision deteriorates due to calibration plate irregularities
Solution Approach 1:
The patent performs preliminary measurement of the calibration plate surface using CMM before the actual laser alignment process. This advance measurement captures surface irregularities, allowing the system to pre-calculate correction factors that will be applied during alignment, thereby eliminating the negative impact of irregularities on measurement precision.
Solution Approach 2:
The patent implements a feedback mechanism where CMM measurement data about calibration plate irregularities is fed into the alignment system. This feedback allows the system to automatically adjust laser positioning calculations based on the actual measured surface geometry, compensating for irregularities and maintaining high measurement precision throughout the alignment 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 enables accurate alignment of laser beams, reducing manufacturing costs and improving the precision of components produced by additive manufacturing systems, while accounting for misalignments between the calibration plate and the build plate.
Implementation Method 1
measuring a calibration plate in a coordinate measuring machine to identify irregularities in the calibration plate
Implementation Method 2
writing at least one fiducial mark on the calibration plate with the at least one laser beam
Implementation Method 3
A calibration system then reads the fiducial marks on the calibration plate to determine if the laser beams are aligned with each other and the calibration plate
Data Source
AI summary
A method of aligning at least one laser beam of an additive manufacturing arrangement. The method includes measuring a surface of the calibration plate at a plurality of measurement points using the coordinate measuring machine. The method further includes generating a correction field based on the plurality of measurement points using the coordinate measuring machine. The method further includes writing at least one fiducial mark on the surface of the calibration plate using the at least one laser beam. The method further includes generating calibration data for the surface of the calibration plate using the calibration system. The method also includes aligning the laser beam within the additive manufacturing system based on the calibration data and the correction field using the computing device by comparing a position of the fiducial mark from the calibration data with the correction field to determine a corrected position of the laser beam.