Arc-Welded Metal 3D Printing With Melt Bead Height Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In metal 3D printing, errors in estimating the height and shape of molten metal layers lead to inaccuracies and potential interference between the molten bead and the laminating device, affecting the quality of the shaped object.
Innovation Solution
A system and method that uses a welding robot, cutting robot, height measuring device, and control device to accurately control the height of each molten metal layer by measuring and adjusting the height of the melt beads, ensuring they align with planned positions and preventing collisions, thereby maintaining the integrity of the shielding gas and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If melt beads are laminated by arc welding using an automatic machine, then productivity is improved, but manufacturing precision deteriorates due to height deviation and interference
Solution Approach 1:
The patent implements a feedback mechanism where the actual height of each melt bead is measured and used to adjust the lamination position of subsequent beads. The control device calculates the height deviation from the planned height and determines the actual lamination position based on this measured height, creating a closed-loop control system that maintains precision despite automation
Solution Approach 2:
The patent performs preliminary measurement of each melt bead's height before the next bead is laminated. By measuring the actual height h_now of the previously formed bead and calculating the required lamination position in advance, the system prevents position deviations and interference before they occur
2Ease of manufacture
If the actual height of melt bead deviates from planned height, then ease of manufacture is improved by simple lamination process, but reliability deteriorates due to shielding gas instability and potential damage
Solution Approach 1:
The control device continuously monitors the actual height of each melt bead and uses this feedback to adjust the lamination parameters. When height deviation is detected, the system automatically modifies the torch position and lamination depth to maintain reliable shielding gas coverage and prevent device interference
Solution Approach 2:
The patent prepares compensation strategies in advance by calculating the relationship between bead height and lamination position. The control device has pre-programmed adjustment rules that activate when height deviations are detected, cushioning against potential shielding gas instability or device interference before they occur
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 ensures accurate layering, maintains shielding gas stability, and prevents device collisions, resulting in improved quality and accuracy of the shaped object by maintaining the planned molten metal lamination position and distance.
Implementation Method 1
laminates melt beads by arc welding
Implementation Method 2
the shielding properties of shield gas SG may become unstable
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A welding robot (20) forms a laminate-molded object (11) by forming and laminating a melt bead (61) of each layer (L1 to Lk) so that a height (hnow) of the melt bead (61) of each layer (L1 to Lk) is within a range of a tolerance (ε) with respect to a planned height (hk). When the height (hnow) of the melt bead (61) is lower than a value obtained by subtracting the tolerance (ε) from the planned height (hk), the welding robot (20) forms another melt bead (61a) over the melt bead (61). When the height (hnow) of the melt bead (61) is higher than a value obtained by adding the tolerance (ε) to the planned height (hk), the melt bead (61) is removed by a cutting robot (30).