Powder Bed Process Emission Analysis for Online Quality Assessment
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Solution Overview
Problem
Current methods for evaluating the quality of laser-based and powder bed generative manufacturing processes lack suitable analysis methods and algorithms to directly assess component properties from recorded process emissions, relying on simple variance and image comparisons that are not standardized or reliable.
Innovation Solution
A method and device that utilize measurement sensors like photodiodes and high-speed cameras to record process emissions, calculate mean values and standard deviations for volume elements, and use coefficients of variation to evaluate process quality through statistical analysis, including moving averages and distribution checks within specified intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simple output of recorded mean values and variances is used, then the measurement system is simple, but the ability to directly determine process quality and component properties is insufficient
Solution Approach 1:
The patent transforms the evaluation approach by changing from simple statistical parameters (mean, variance) to derived parameters (coefficients of variation, moving averages) that directly correlate with process quality and component properties, enabling meaningful quality assessment without complex additional hardware
Solution Approach 2:
The patent introduces coefficients of variation as an intermediary metric that bridges the gap between raw measured values and process quality assessment, providing a standardized way to evaluate melt pool stability and predict component properties without requiring complex analysis systems
2Reliability
If no standardized analysis method is used, then flexibility in evaluation approaches is maintained, but reliability and consistency of quality assessment deteriorates
Solution Approach 1:
The patent segments the quality assessment into standardized steps: calculating coefficients of variation for individual layers, computing moving averages across multiple layers, and comparing against threshold values. This segmentation creates a reliable, repeatable methodology that can be consistently applied across different production scenarios
Solution Approach 2:
The patent introduces dynamic evaluation through moving averages that adapt to process variations over time, allowing the system to distinguish between normal process fluctuations and actual quality issues, thereby improving reliability without requiring overly complex static thresholds
3Measurement precision
If detailed analysis of multiple influencing factors is performed, then comprehensive quality assessment is achieved, but the complexity of data evaluation and user burden increases
Solution Approach 1:
The patent extracts the essential quality information from complex process data by focusing on key metrics (coefficients of variation of melt pool characteristics) and presenting them in a simplified format with clear threshold comparisons, reducing user burden while maintaining evaluation accuracy
Solution Approach 2:
The patent enables the system to automatically perform the complex analysis work by computing coefficients of variation, moving averages, and threshold comparisons autonomously, providing quality assessment results without requiring users to manually analyze multiple influencing factors, thus improving ease of operation while maintaining comprehensive evaluation
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 provides a standardized and efficient data analysis for assessing process quality, enabling direct conclusions about component properties and immediate error detection, suitable for online monitoring and quality control.
Implementation Method 1
measured values for at least one process emission are recorded... process emissions occur primarily in the form of radiation, particularly electromagnetic wave radiation, and are detected within a specific band
Data Source
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AI summary
The invention relates to a method and a device for analysing an additive manufacturing process, in which method measurement values for at least one process emission are detected during the manufacture of a workpiece, characterised in that standard deviations of the measurement values of predefined volume elements of the workpiece are calculated, and a distribution of the calculated standard deviations of multiple predefined volume elements is analysed as a measure of the process quality.