Rotating Laser Beam Control for Precise Powder Bed Fusion
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Solution Overview
Problem
Manufacturing tolerances and adjustment errors in beam-generating and beam-rotating devices lead to undesirable faltering of non-rotationally symmetrical energy beams, causing defects such as rough surfaces and dimensional deviations in additive manufacturing of components.
Innovation Solution
A manufacturing device with a beam-generating device, beam-rotating device, scanner device, and control device that corrects the scanner device's control based on the current angle of rotation to align the beam profile accurately, using a correction function to compensate for wobbling movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manufacturing tolerances and adjustment errors are reduced to prevent beam profile faltering, then manufacturing precision is improved, but device complexity and cost increase excessively
Solution Approach 1:
The control device receives feedback about the current angle of rotation from the beam-rotating device and dynamically adjusts the scanner device control parameters accordingly. This closed-loop feedback mechanism compensates for beam profile faltering caused by manufacturing tolerances and adjustment errors, maintaining precise alignment without requiring excessively complex manufacturing tolerances or adjustment procedures.
Solution Approach 2:
The control device changes operational parameters (scanner control parameters) based on the angle of rotation to compensate for beam profile deviations. By dynamically adjusting parameters rather than relying on fixed precision manufacturing, the system achieves consistent beam alignment while reducing device complexity and manufacturing cost.
2Manufacturing precision
If the beam profile is rotated to align with the irradiation vector, then manufacturing precision is improved, but beam profile stability deteriorates due to wobbling movements
Solution Approach 1:
The control device applies preliminary corrective actions to the scanner control parameters before the beam rotation causes significant misalignment. By anticipating and compensating for the wobbling movements through angle-dependent correction, the system maintains beam profile stability throughout the rotation process while achieving proper alignment with the irradiation vector.
Solution Approach 2:
The system continuously monitors the angle of rotation and dynamically adjusts scanner parameters in real-time to counteract wobbling movements. This feedback mechanism ensures that the beam profile remains stable and properly aligned during rotation, preventing defects while maintaining manufacturing precision.
3Manufacturing precision
If extreme precision adjustment is applied to the energy beam, then manufacturing precision is improved, but ease of operation deteriorates due to frequent readjustment requirements
Solution Approach 1:
The control device automatically adjusts beam alignment based on angle of rotation feedback, eliminating the need for manual readjustment operations. This automated feedback system maintains extreme precision throughout the manufacturing process without requiring operator intervention, thereby preserving ease of operation while achieving high manufacturing precision.
Solution Approach 2:
The system performs self-adjustment of beam alignment through automated control based on rotation angle. The manufacturing device adjusts its own parameters without external intervention, maintaining precision automatically throughout operation and eliminating the operational burden of frequent manual readjustments.
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 solution effectively prevents defects in manufactured components by ensuring precise alignment of the beam profile, reducing rough surfaces and dimensional deviations while being cost-effective and easy to implement.
Implementation Method 1
a beam-generating device (5) configured to generate an energy beam (7) having a beam profile (8) that is not rotationally symmetrical about a beam axis (A) of the energy beam (7)
Implementation Method 2
a beam-rotating device (15) configured to rotate the beam profile (8) of the energy beam (7) about the beam axis (A)
Implementation Method 3
a scanner device (9) configured to move the energy beam (7) in a working region (11) and to locally selectively irradiate the working region (11) with the energy beam (7) in order to produce, by the energy beam (7), a component (3) from the powder material located in the working region (11)
Data Source
AI summary
A manufacturing device for additive manufacturing of components from a powder material includes a beam-generating device configured to generate an energy beam having a beam profile that is not rotationally symmetrical about a beam axis of the energy beam, a beam-rotating device configured to rotate the beam profile of the energy beam about the beam axis, a scanner device configured to move the energy beam in a working region and to locally selectively irradiate the working region with the energy beam in order to produce, by the energy beam, a component from the powder material located in the working region, and a control device operatively connected to the beam-rotating device and to the scanner device, and configured to control the beam-rotating device and the scanner device. The control device is configured to correct a control of the scanner device according to a current angle of rotation of the beam-rotating device.