3D Powder Feed Control Using Imaging-Based Distance Feedback
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Solution Overview
Problem
Three-dimensional additive manufacturing devices face challenges in achieving manufacturing accuracy due to unevenness in powder supply, such as varying powder supply amounts and convergence diameters, which are not adequately addressed by existing feedback control methods that adjust laser output.
Innovation Solution
A three-dimensional additive manufacturing device that includes a powder supply unit, a light irradiation unit, an imaging unit, and a feedback controller to adjust the moving speed of the powder supply unit based on distance detection from the manufacturing site, ensuring precise powder deposition and improved manufacturing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser output is feedback-controlled based on molten pool area, then manufacturing accuracy is improved, but powder supply unevenness (supply amount and convergence diameter) cannot be adequately addressed
Solution Approach 1:
The patent implements feedback control by detecting the distance between the powder supply unit and the manufacturing site using an imaging unit, and adjusting the moving speed of the powder supply unit based on this detection result. This closed-loop feedback mechanism dynamically compensates for powder supply unevenness, ensuring stable powder deposition despite variations in supply conditions.
Solution Approach 2:
The system uses the imaging unit to automatically detect and measure the distance parameter, eliminating the need for external measurement devices. The detected distance information is directly fed into the control system, which autonomously adjusts the powder supply speed without human intervention, enabling the system to self-regulate and maintain manufacturing accuracy.
2Manufacturing precision
If the moving speed of the powder supply unit is adjusted based on distance detection, then powder deposition accuracy is improved, but system complexity increases due to additional imaging and control components
Solution Approach 1:
The imaging unit serves multiple functions: it captures images of the manufacturing site for distance detection, monitors the molten pool area for laser control, and provides visual feedback for process optimization. By making the imaging unit multi-functional, the patent reduces the need for separate measurement devices, thereby limiting the increase in system complexity while achieving improved powder deposition accuracy.
Solution Approach 2:
The patent combines the imaging, measurement, and control functions into an integrated system. The imaging unit is merged with the distance detection and speed control mechanisms, creating a unified control architecture that manages both laser parameters and powder supply parameters through a single coordinated system, thus avoiding the complexity of entirely separate control loops.
3Productivity
If real-time imaging and distance detection are implemented, then dynamic speed adjustment is achieved, but measurement and detection difficulty increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical imaging-based distance detection. Instead of using physical probes or mechanical gauges to measure the distance between the powder supply unit and the manufacturing site, the system uses an imaging unit to capture visual information and calculate distance through image processing, thereby simplifying the detection mechanism and enabling real-time measurements.
Solution Approach 2:
The imaging unit creates a visual copy (image) of the manufacturing site and the powder supply unit, which is then processed to extract distance information. This optical copy allows the system to measure distances without physical contact, enabling real-time detection while avoiding the complexity of direct mechanical measurement in the harsh manufacturing environment.
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
The device effectively maintains the height of the deposited beads and enhances manufacturing accuracy by dynamically adjusting the feed speed and light beam output based on real-time imaging data, overcoming the limitations of traditional control methods.
Implementation Method 1
an imaging unit that captures an image of a manufacturing site where the layered structure is being manufactured
Implementation Method 2
a light irradiation unit that irradiates the powder with a light beam to melt and harden the powder
Implementation Method 3
irradiates the powder with a light beam to melt and harden the powder
Data Source
AI summary
A three-dimensional additive manufacturing device manufactures a layered structure by supplying powder for manufacturing the layered structure while changing the positional relationship between a discharge port from which the powder is discharged and the layered structure. The three-dimensional additive manufacturing device includes: a powder supply unit that supplies powder from the discharge port toward the layered structure; a light irradiation unit that irradiates the powder with a light beam to melt and harden the powder to thereby manufacture the layered structure; an imaging unit that captures an image of the manufacturing site where the layered structure is being manufactured; a distance detector that detects a distance from the manufacturing site to the powder supply unit on the basis of the image; and a feedback controller that adjusts a moving speed of the powder supply unit relative to the layered structure on the basis of a detection result of the distance.