3D Metal Lamination Control for Deposition Position Accuracy
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Solution Overview
Problem
Existing methods for laminating molten metals in 3D printing face errors between the planned and actual deposition positions, necessitating significant corrections.
Innovation Solution
A lamination control device and method that adjusts the deposition direction of molten metals based on the actual laminated state, using a track determination device to minimize errors by setting the torch angle and deposition position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the deposition position of molten metal is set in advance according to the laminated state, then the lamination process can proceed systematically, but errors occur between the planned deposition position and the actual deposition position
Solution Approach 1:
The patent implements a feedback mechanism where the actual deposition position is detected during the lamination process, and this detected position is used to correct the planned deposition position for subsequent layers. The control device adjusts the torch movement based on the detected deviation, creating a closed-loop control system that continuously refines the deposition accuracy.
Solution Approach 2:
The patent performs preliminary detection of the actual deposition position before finalizing the deposition plan for the next layer. By detecting the actual position early in the process and using it to correct the planned position beforehand, the system proactively prevents error accumulation rather than reacting to errors after they occur.
2Manufacturing precision
If the deposition position is corrected to match the actual laminated state, then the accuracy of subsequent layers improves, but additional control operations and time are required
Solution Approach 1:
The patent integrates the detection and correction operations into the continuous lamination process without interrupting the workflow. The control device performs detection and correction operations in conjunction with the normal deposition operations, ensuring that the useful action of building the laminated structure continues without停顿, thereby minimizing time loss while maintaining high precision.
3Manufacturing precision
If the torch angle and deposition direction are adjusted to minimize errors, then the alignment between planned and actual deposition positions improves, but the complexity of the control system increases
Solution Approach 1:
The patent adjusts the torch angle and deposition direction parameters dynamically based on the detected actual deposition position. By changing these physical parameters of the deposition process, the system achieves better alignment between planned and actual positions. The control device calculates the optimal parameters and applies them automatically, managing the complexity through algorithmic control rather than mechanical 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
Reduces the need for correction by aligning the planned deposition position with the actual laminated state, thereby minimizing errors and improving the accuracy of the lamination process.
Implementation Method 1
a metal powder or a metal wire is melted using a heat source, such as a laser or an arc
Implementation Method 2
a weld torch that feeds droplets of a metal wire melted by arc discharge
Implementation Method 3
molten metals are laminated to form a formed object
Data Source
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AI summary
In a track determination device, a CAD data acquisition unit acquires shape data that represents a shape of a three-dimensional formed object. A deposition direction setting unit generates control information for controlling a lamination device that laminates the molten metal in order to form a formed object, based on the shape data acquired by the CAD data acquisition unit. The control information is information indicating at least a specific deposition direction of the molten metal such that an error between a first deposition position set in advance and a second deposition position in accordance with an actual laminated state is reduced. A control program output unit outputs the control information generated by the deposition direction setting unit.