Non-Imaging Thermal Sensor Correction for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques using non-imaging optical sensors face inaccuracies in thermal measurements due to limitations in forming images of the measured region, leading to inaccurate temperature data and inefficient process control.
Innovation Solution
The implementation of a system that includes a heat source, a non-imaging optical sensor with a defined field of view, and processors to estimate the size of hot spots and heated regions, allowing for temperature data correction based on these estimates, thereby improving the accuracy of thermal measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If non-imaging optical sensors are used to measure temperature during additive manufacturing, then the measurement system is simpler and less expensive, but the temperature measurement accuracy deteriorates due to inability to form images of the measured region
Solution Approach 1:
The patent introduces an intermediary computational model that maps the relationship between sensor signals and temperature values. This model acts as a mediator between the non-imaging sensor and the temperature measurement, allowing accurate temperature determination without requiring imaging capability. The computational model compensates for the sensor's limitation by using known relationships between signal intensity and temperature.
Solution Approach 2:
The patent changes the measurement parameter from spatial distribution (imaging) to intensity-based measurement. By focusing on the intensity of the optical signal rather than its spatial distribution, the system achieves accurate temperature measurement without requiring image formation. This parameter change allows non-imaging sensors to provide sufficient measurement precision.
2Device complexity
If non-imaging optical sensors with defined field of view are used, then the device structure is simpler, but the temperature data accuracy deteriorates due to inability to distinguish hot spot from surrounding heated regions
Solution Approach 1:
The patent extracts only the necessary information from the optical signal - the total intensity within the field of view - rather than attempting to capture the complete spatial distribution. By taking out only the intensity parameter and using computational models to infer temperature, the system achieves accurate measurement with simpler sensor structure that doesn't require imaging capability.
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 enhances the accuracy of thermal measurements, enabling better process control and adjustments during additive manufacturing, leading to more precise and efficient construction of three-dimensional parts.
Implementation Method 1
collecting temperature data describing temperature changes across a surface of a material during an additive manufacturing operation in which the material is heated by a heat source, wherein the temperature data is generated using a non-imaging optical sensor
Data Source
AI summary
A system and a corresponding method of correcting temperature data from a non-imaging optical sensor involve collecting temperature data generated using the optical sensor. The temperature data describes temperature changes across a surface of a material during an additive manufacturing operation in which the material is heated by a heat source. The method includes estimating a size of a hot spot corresponding to a hottest region formed on the surface by the heat source; and estimating a size of a heated region corresponding to a locus of points within the field of view that contribute to the temperature data. The method further includes correcting the temperature data based on the estimated sizes of the hot spot and the heated region.