Rotary Build Platform Calibration Using Optical Alignment Marks
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Solution Overview
Problem
Rotary additive manufacturing systems face challenges in calibrating the build platform center axis and rotation point, leading to seam and alignment defects, which requires substantial time and affects manufacturing efficiency and component quality.
Innovation Solution
An additive manufacturing system equipped with a controller that uses an optical detector to determine the build platform rotation axis and center point by comparing alignment marks, allowing for precise calibration and control of the consolidation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used to determine build platform rotation axis and center point, then calibration can be performed, but calibration accuracy is poor and setup time is excessive
Solution Approach 1:
The patent replaces traditional mechanical calibration methods with an optical detection system. The optical detector captures images of alignment marks on the build platform, and image processing algorithms automatically determine the rotation axis and center point coordinates, eliminating manual mechanical measurement and significantly improving both accuracy and speed.
Solution Approach 2:
The patent uses alignment marks as optical copies or reference patterns on the build platform. By detecting the positions of these marks through optical imaging and comparing them against expected positions, the system calculates the actual rotation axis and center point, providing a non-contact, high-precision calibration method.
2Reliability
If build platform rotation calibration is not accurately performed, then manufacturing can proceed, but seam and alignment defects occur in components
Solution Approach 1:
The patent implements a feedback mechanism where the optical detector continuously monitors the positions of alignment marks during build platform rotation. The controller compares detected positions with expected positions and adjusts the rotation parameters in real-time, ensuring accurate alignment and preventing seam defects in the manufactured components.
Solution Approach 2:
The patent replaces mechanical alignment methods with optical detection and image processing. The system uses optical images of alignment marks to determine the build platform rotation axis and center point, providing non-contact, high-precision measurement that eliminates mechanical errors and improves component alignment quality.
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 setup time, improves calibration accuracy, enhances component quality, and lowers the cost of manufacturing by streamlining the additive process.
Implementation Method 1
an optical detector to detect locations of at least two alignment marks, the at least two alignment marks on at least one of the build platform and the build layer
Data Source
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AI summary
An additive manufacturing system including a consolidation device, a build platform, an optical detector, and a controller is provided. The consolidation device is configured to form a build layer of a component. The build platform is configured to rotate about a build platform rotation axis extending along a first direction. The optical detector is configured to detect locations of at least two alignment marks. The controller is configured to receive locations of the at least two alignment marks from the optical detector. The controller is also configured to determine the locations of the build platform rotation axis and a build platform rotation center point based on a comparison between the at least two alignment marks, wherein the build platform rotation center point lies along the build platform rotation axis. The controller is further configured to control the consolidation device to consolidate a plurality of particles on the build platform.