Multi-Scanner Additive Manufacturing Calibration Method
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Solution Overview
Problem
Conventional additive manufacturing with multiple scanners is inefficient due to the need for separate calibration of each scanner, involving multiple steps for installation, trace formation, imaging, and deviation calculation, which limits the ability to correct laser coordinate systems effectively across all scanners.
Innovation Solution
A calibration method and apparatus that simultaneously form and image irradiation traces with different shapes for each scanner on a calibration plate, using an imaging device to specify irradiated positions and generate correction data for each scanner's laser coordinate system, allowing for efficient reduction of mutual errors between scanners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate calibration is performed for each scanner using conventional methods, then each scanner's laser coordinate system can be calibrated individually, but the calibration process becomes time-consuming and inefficient
Solution Approach 1:
The patent combines multiple separate calibration operations into a single integrated calibration process. Multiple scanners simultaneously form irradiation traces on the same calibration plate, and a single imaging operation captures all traces at once. This merging of operations maintains calibration accuracy for each scanner while dramatically reducing the total calibration time required.
Solution Approach 2:
The patent enables continuous calibration by having multiple scanners operate simultaneously rather than sequentially. The imaging device continuously captures irradiation traces from all scanners in one operation, eliminating the idle time between sequential calibrations and maintaining productive use of all calibration resources throughout the process.
2Reliability
If multiple calibration plates are used for each scanner, then each scanner can be calibrated independently, but the process requires multiple installations and replacements of calibration plates
Solution Approach 1:
The patent makes a single calibration plate serve multiple functions by having it simultaneously accommodate irradiation traces from multiple scanners. The calibration plate is designed to receive and maintain relative positions with multiple scanners, allowing one plate to perform the calibration function for all scanners at once, thereby reducing the number of plates needed and simplifying the installation process.
Solution Approach 2:
The patent segments the calibration plate into multiple functional zones, each corresponding to a specific scanner's irradiation pattern. Each scanner creates distinct irradiation traces at predetermined positions on the same plate, allowing independent calibration data to be captured for each scanner while using a unified physical platform.
3Measurement precision
If sequential calibration of multiple scanners is performed, then each scanner's deviation can be measured accurately, but mutual errors between scanners cannot be effectively reduced
Solution Approach 1:
The patent merges the measurement process for multiple scanners into a single simultaneous imaging operation. By capturing irradiation traces from all scanners at the same time on the same calibration plate, the system establishes a common reference frame that enables accurate measurement of each scanner's deviation while also capturing and reducing mutual positioning errors between scanners.
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 reduces mutual errors and calculates deviation amounts quickly, enabling efficient calibration of laser coordinate systems across multiple scanners, thereby improving the accuracy and speed of the additive manufacturing process.
Implementation Method 1
an imaging device that has an imaging sensor and is configured to image the molding region
Implementation Method 2
irradiating the material layer with laser beams respectively scanned by a plurality of scanners to form a solidified layer
Data Source
AI summary
A calibration method of an additive manufacturing apparatus includes an irradiation trace forming step, an imaging step, a specifying step, and a correction step. The irradiation trace forming step scans laser beams with each of a plurality of scanners with respect to a plurality of target positions on a calibration plate installed on a molding region, and forms a plurality of irradiation traces having different shapes for each of the plurality of scanners. The imaging step simultaneously images the plurality of irradiation traces formed with respect to the same target position. The specifying step specifies a plurality of irradiated positions of the laser beam scanned by each of the plurality of scanners. The correction step generates correction data that specifies a deviation amount at any point of a laser coordinate system related to each of the plurality of scanners.