3D Laser Melting Monitoring With Optical Focus Tracking
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Solution Overview
Problem
Existing laser sintering and melting devices face challenges in optimizing process monitoring, particularly when the laser focus and spot size vary, leading to incomplete detection of the melting spot and inaccurate data collection, especially in edge regions.
Innovation Solution
Incorporating an optical focus tracking device between the scanner and sensor system, actuated by electronic machine data, which automatically adjusts the field of view and focus to ensure accurate monitoring of the melting spot, regardless of changes in laser spot size, using 3D scanning optics and motor-adjustable focusing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the laser spot size is varied by focus adjustment, then the melting depth and process flexibility are improved, but the detection accuracy of the melting spot by the sensor device deteriorates due to incomplete coverage of the melting spot
Solution Approach 1:
The patent implements dynamic adaptation of the sensor system's field of view to match the dynamically changing laser spot size. The sensor device adjusts its detection area in real-time according to the current focus setting, ensuring that the entire melting spot remains within the detection range regardless of spot size variations. This dynamic coordination resolves the contradiction between process flexibility and measurement precision.
Solution Approach 2:
The system changes the field of view parameter of the sensor device based on the laser spot size. When the laser focus is adjusted to create different spot sizes, the sensor device相应ly adjusts its field of view to ensure complete coverage of the melting spot, maintaining detection accuracy across all process conditions.
2Measurement precision
If manual adjustment of the sensor system is used to track focus changes, then the detection accuracy can be maintained, but the operation complexity and time consumption increase
Solution Approach 1:
The patent implements an automated feedback mechanism where the sensor system automatically receives focus position information and adjusts its field of view accordingly. This eliminates the need for manual intervention while maintaining detection accuracy, as the system self-regulates based on real-time process parameters.
Solution Approach 2:
The sensor device performs self-adjustment of its field of view based on the laser focus position. The system automatically tracks and adapts to focus changes without requiring manual operation, thereby maintaining measurement precision while simplifying the operating procedure.
3Reliability
If the field of view of the sensor device is enlarged to cover larger melting spots, then the complete detection of the melting spot is ensured, but the resolution and detail detection capability of the sensor device decreases
Solution Approach 1:
The sensor device dynamically adjusts its field of view size to match the actual melting spot size. When the laser creates a small melting spot, the sensor uses a smaller field of view to maintain high resolution. When the melting spot enlarges, the field of view automatically expands to ensure complete coverage. This dynamic adaptation resolves the contradiction between complete detection and resolution.
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 solution enables comprehensive and accurate process monitoring by ensuring the melting spot is fully detected, providing improved data for quality evaluation, even as the spot size changes, thereby enhancing the overall monitoring performance and eliminating the need for manual adjustments.
Implementation Method 1
an optical focus tracking device 20 is arranged between the scanner 10 and the sensor device 8 of the process monitoring system, which can be actuated by electronic machine data 21, 22 to track focus
Implementation Method 2
a component is produced by successive solidification of individual layers of construction material, especially powder material, as the result of the impact of a radiation 4 by melting on the construction material 5
Implementation Method 3
impact of a radiation by melting on the construction material
Implementation Method 4
The melting section 6 created by a point-type or linear energy input is detected using a sensor device 8 of a process monitoring system regarding its dimension shape and/or regarding its temperature
Data Source
AI summary
Device for production of three-dimensional components, namely a laser melting device or laser sintering device, in which a component is produced by successive solidifying of individual layers made from solidifiable construction material, by radiation, through melting of the construction material, wherein the dimensions and/or temperature of the melt area generated by a point-shaped or line-shaped energy input can be captured by a sensor device of a process monitoring system, and sensor values for evaluation of a component quality can by deduced therefrom, wherein the radiation created by the melt area and used for the generation of the sensor values passes through the scanner used for the melt energy input, and guided to the sensor device of the process monitoring system, wherein an optical focus tracking device is arranged in the radiation path used for generation of the sensor values between the scanner and the sensor device.