Laser Beam Focus Calibration Using Frequency Scan Analysis
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Solution Overview
Problem
Current methods for determining irradiation parameters in additive manufacturing are cumbersome and time-consuming, requiring complex optical systems and multiple measurement positions to calibrate energy beams effectively.
Innovation Solution
A method involving generating an energy beam and guiding it across a structured test surface to detect emitted radiation, with parameters determined through Fourier transformation of the signal, allowing for efficient calibration of irradiation devices without the need for extensive optical setups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex optical systems and multiple measurement positions are used to determine irradiation parameters, then measurement precision is improved, but device complexity and time consumption increase
Solution Approach 1:
The patent extracts the essential measurement information by analyzing only the frequency spectrum of the signal at a single measurement position. Instead of using complex optical systems at multiple positions, the invention extracts the beam caustic parameters from the spectral content of the signal obtained at one location, thereby simplifying the measurement setup while maintaining determination accuracy
Solution Approach 2:
The patent applies partial action by determining irradiation parameters through frequency analysis of a signal obtained at a single measurement position rather than performing complete spatial mapping. The Fourier transformation of the signal provides sufficient information to characterize the beam caustic without requiring exhaustive measurements across multiple positions, thus reducing device complexity and measurement time
2Measurement precision
If complex optical systems are used to calibrate energy beams, then measurement precision is improved, but the time required for calibration increases
Solution Approach 1:
The patent replaces mechanical measurement approaches (physical displacement to multiple positions, complex optical alignment) with signal processing methods. By using Fourier transformation to extract beam caustic parameters from the frequency spectrum of a signal obtained during normal operation, the invention eliminates time-consuming mechanical calibration procedures while maintaining measurement precision
Solution Approach 2:
The measurement system utilizes the signal already generated during energy beam operation on the workpiece. Instead of requiring separate calibration procedures with additional equipment, the system self-calibrates by analyzing the frequency characteristics of the signal produced during normal manufacturing operations, thereby eliminating dedicated calibration time
3Measurement precision
If multiple measurement positions are used to determine irradiation parameters, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The patent extracts all necessary beam characterization information from the frequency spectrum of a signal obtained at a single measurement position. The Fourier transformation reveals beam caustic parameters embedded in the spectral content, eliminating the need for time-consuming measurements at multiple positions and thereby improving calibration efficiency without sacrificing accuracy
Solution Approach 2:
The patent performs preliminary frequency analysis on the signal during normal operation to pre-determine beam caustic parameters. This preliminary characterization of the energy beam allows for rapid identification of irradiation parameters without requiring subsequent time-consuming measurements, thus improving overall productivity
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 simplifies the determination of irradiation parameters, enabling faster and more efficient calibration of energy beams for additive manufacturing processes, reducing the complexity and time required for beam calibration across the build plane.
Implementation Method 1
generating a signal by detecting radiation that is emitted, in particular reflected, from the test surface
Implementation Method 2
generating a signal by detecting radiation that is emitted, in particular reflected, from the test surface
Data Source
AI summary
Methods of determining at least one parameter of an irradiation device of an apparatus for additively manufacturing three-dimensional objects may include generating an energy beam and guiding the energy beam across a structured test surface, generating a signal by detecting radiation that is emitted from the test surface, and determining the at least one parameter based on a frequency spectrum of the signal.