Melt Pool Sensor Calibration Using Reference Radiation Correction
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Solution Overview
Problem
Existing calibration methods for melt pool monitoring sensors in additive manufacturing machines require precise positioning of a calibrated light source, which limits calibration to identical machines and often involves complex adjustments that may be difficult or impossible to execute, especially if the monitoring system is not designed for such adjustments.
Innovation Solution
A method that involves measuring and recording sensor signals with and without reference radiation, calculating a correction coefficient, and recording it in a correction table, allowing for calibration without precise mechanical assembly or complex adjustments, using a calibrated light source positioned independently within the machine using a laser aiming beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a calibrated light source is positioned precisely on a calibration platform with positioning means, then measurement precision is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The patent extracts the calibration function from a complex mechanical positioning system and implements it through a simplified method using existing machine positioning capabilities. The calibration light source is positioned using the machine's own positioning system rather than requiring an external calibration platform with specialized positioning means, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent makes the calibration process universal by using the additive manufacturing machine's existing positioning system for both production operations and calibration operations. This eliminates the need for machine-specific calibration platforms and positioning means, allowing the same calibration method to be applied across different machine types without requiring specialized equipment.
2Measurement precision
If precise positioning of the calibrated light source is required, then measurement precision is improved, but adaptability deteriorates
Solution Approach 1:
The patent achieves universality by utilizing the additive manufacturing machine's own positioning system, which is already present in all such machines, to position the calibration light source. This approach allows the calibration method to be adapted to any additive manufacturing machine without requiring machine-specific calibration equipment, thereby maintaining both measurement precision and adaptability across different machine types.
3Measurement precision
If complex adjustments are made to the monitoring system, then measurement precision is improved, but ease of operation and reliability deteriorate
Solution Approach 1:
The patent replaces complex mechanical and electronic adjustment operations with a computational approach. Instead of physically adjusting optical components, filters, or sensor gains, the method calculates correction coefficients based on measurements taken during calibration and applies these coefficients computationally to correct sensor readings, thereby improving ease of operation while maintaining measurement precision.
Solution Approach 2:
The patent changes the approach from physically adjusting system parameters (optical focus, filter position, electronic gain) to computationally adjusting measurement parameters through correction coefficients. This parameter transformation simplifies the calibration procedure while achieving the same measurement precision improvement.
4Measurement precision
If physical adjustments are made to the monitoring system, then measurement precision is improved, but reliability deteriorates
Solution Approach 1:
The patent replaces physical mechanical adjustments with computational corrections, eliminating the reliability issues associated with mechanical wear, misalignment, and component failure. The correction coefficients are calculated based on measurements and applied through software, which is more reliable and consistent than manual physical adjustments.
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 calibration of melt pool monitoring sensors in any type of additive manufacturing machine, regardless of machine design, by providing a correction table for signal correction, improving measurement accuracy and ease of implementation.
Implementation Method 1
a sensor for measuring the thermal emission level of this melt pool
Implementation Method 2
exposing the monitoring sensor to the reference radiation
Data Source
AI summary
A method for calibrating a sensor for monitoring a melt pool belonging to a system for monitoring a melt pool of an additive manufacturing machine comprises at least the following steps: measuring and recording the value of the signal transmitted by the monitoring sensor when it is not exposed to a reference radiation, exposing the monitoring sensor to the reference radiation, measuring and recording the value of the signal transmitted by this monitoring sensor when it is exposed to a reference radiation, calculating a correction coefficient for this monitoring sensor from a reference value associated with the reference radiation and the values of the signals, and recording in a correction table the correction coefficient for this monitoring sensor and the value of the signal transmitted by the monitoring sensor when it is not exposed to a reference radiation.