Powder Jet Separation Analysis for 3D Metal Flow Homogeneity

The patent replaces the mechanical alignment system (cones) with an optical measurement and control system. A camera captures images of the powder jet, and image processing algorithms analyze the symmetry and distribution of powder particles. This optical system provides precise feedback on powder jet alignment without relying on mechanical cone positioning, thereby resolving the contradiction between ease of mechanical operation and manufacturing precision.

The patent transitions from two-dimensional image capture to three-dimensional powder distribution analysis by using multiple cameras positioned at different angles or by employing stereo vision techniques. The image processing system reconstructs the three-dimensional spatial coordinates of powder particles from multiple two-dimensional images, enabling comprehensive quantification of powder jet distribution in three dimensions while maintaining ease of implementation through conventional imaging equipment.

The patent introduces a controlled lighting environment that minimizes light reflection from powder particles. This may involve using polarized light filters, specific wavelength selection, or creating a dark field illumination setup where only scattered light from powder particles is captured. The image processing system then processes these optimized images to accurately quantify powder distribution without interference from specular reflections, maintaining relatively simple device complexity while significantly improving measurement precision.