Additive Processing Imaging for Melt Pool and Solidified Part Observation
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Solution Overview
Problem
Existing processing systems face challenges in properly observing both the workpiece and the melt pool during additive processing, as the high intensity of the melt pool light often overwhelms the workpiece light, making it difficult to generate an image that accurately represents both components.
Innovation Solution
The system employs an illumination apparatus that emits light in a wavelength range different from the melt pool light, allowing for the separation and distinct observation of the workpiece and melt pool, with a filter member that adjusts transmittance to balance the intensity difference, enabling proper imaging and control of the processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the imaging apparatus optically receives light from the melt pool, then the melt pool can be observed, but the workpiece cannot be properly observed due to overwhelming intensity of the melt pool light
Solution Approach 1:
The imaging apparatus is divided into multiple imaging units, each equipped with wavelength-selective filters. One imaging unit captures light in a first wavelength range to observe the melt pool, while another imaging unit captures light in a second wavelength range to observe the workpiece. This segmentation allows simultaneous observation of both the melt pool and workpiece without the melt pool light overwhelming the workpiece image.
2Device complexity
If a single imaging apparatus is used to capture both melt pool and workpiece, then device complexity is reduced, but image quality deteriorates due to intensity imbalance
Solution Approach 1:
The system dynamically switches between different imaging modes based on processing requirements. The imaging apparatus can selectively activate different imaging units and wavelength ranges depending on whether the priority is melt pool observation or workpiece observation, providing adaptive imaging capability that maintains image quality while managing device complexity.
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 allows for effective observation and control of both the workpiece and melt pool, enabling precise formation of three-dimensional structural objects by extracting relevant images for processing conditions, thereby improving the accuracy and quality of additive processing.
Implementation Method 1
an illumination apparatus that is configured to illuminate a part of a solidified part where the melt pool is solidified at least with a second light having a wavelength range that is different from a wavelength range of a first light emitted from the melt pool
Implementation Method 2
with a filter member that adjusts transmittance to balance the intensity difference
Implementation Method 3
an imaging apparatus that is configured to optically receive at least a part of the first light and at least a part of a third light from a part of the solidified part that is illuminated with the second light
Data Source
AI summary
A processing system includes: an irradiation part for irradiating an object with an energy beam; a powder supply part for supplying powder to a melt pool formed by an irradiation of the energy beam; an illumination apparatus for illuminating a position of a solidified part where the melt pool is solidified with a second light having a wavelength different from a wavelength of a first light emitted from the melt pool; an imaging apparatus for optically receive at least a part of the first light and at least a part of a third light from a part of the solidified part that is illuminated with the second light; and a display apparatus for displaying, based on an output of the imaging apparatus, an image related to the melt pool and the solidified part.