Scanner Optical System for Additive Manufacturing Base Element Measurement
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Solution Overview
Problem
Existing methods for measuring base elements in additive manufacturing are inflexible, require significant installation space, and provide limited information, making it difficult to accurately align and correct for tilting and deformation during the manufacturing process.
Innovation Solution
A method using a scanner optical system to deflect a laser beam and generate differently directed laser beams for measuring the base element, allowing for flexible measurement patterns without structural changes, with a camera positioned laterally to capture images for position and orientation data, enabling precise correction of the base element before manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If three laser diodes are used to measure the base element, then measurement capability is provided, but installation space requirement increases and device complexity increases
Solution Approach 1:
The patent combines multiple measurement functions into a single camera system. Instead of using three separate laser diodes with individual detection paths, the invention uses one camera to capture images of laser lines projected by a scanner optical system, integrating measurement capabilities that would otherwise require multiple separate components.
Solution Approach 2:
The camera system serves multiple measurement purposes simultaneously. The same camera and optical system are used to capture both the position and orientation of the base element, as well as to monitor the laser line patterns for alignment correction, providing universal measurement functionality that reduces the need for multiple specialized devices.
2Measurement precision
If three laser diodes are used to measure the base element, then measurement capability is provided, but the alignment procedure becomes complex and inflexible
Solution Approach 1:
The measurement system is made dynamic and adaptable through software control. The scanner optical system can be programmed to project laser lines at various positions and angles, and the camera captures images that are processed by evaluation software to determine base element alignment. This dynamic, software-driven approach replaces complex mechanical alignment procedures with flexible computational methods.
Solution Approach 2:
The invention replaces mechanical alignment procedures with optical and computational methods. Instead of physically adjusting and measuring with multiple laser diodes, the system uses a scanner optical system to project laser lines and a camera with evaluation software to automatically determine alignment parameters, substituting mechanical complexity with optical simplicity and computational power.
3Loss of information
If laser diodes are used to measure base element tilt, then tilt information is obtained, but the information available is limited
Solution Approach 1:
The system transitions from limited one-dimensional laser diode measurements to comprehensive two-dimensional camera imaging. The camera captures the entire laser line pattern across the base element surface, providing information about position, orientation, and tilt in multiple dimensions simultaneously, rather than limited measurements from individual laser diodes.
Solution Approach 2:
The camera creates a visual copy or image of the laser line pattern as it appears on the base element surface. This optical copy contains rich information about the base element's alignment, position, and orientation that can be analyzed through image processing, providing more complete measurement information than direct laser diode detection alone.
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 allows for accurate and flexible measurement of base elements with high resolution, reducing the need for extensive installation space and enabling real-time correction of tilting and deformation, improving manufacturing accuracy and efficiency.
Implementation Method 1
a measurement pattern is produced from laser light that illuminates at least part of the base element... by deflecting a laser beam of a measuring laser by a scanner optical system
Implementation Method 2
sites of incidence of the laser light are monitored, e.g., observed, and evaluated with a camera
Data Source
AI summary
The disclosure provides methods and systems for measuring a base element of a construction cylinder arrangement in machines for the additive manufacture of 3D objects using a high-energy beam, wherein a measurement pattern is produced from laser light that illuminates the base element, and sites of incidence of the laser light are monitored and evaluated with a camera to produce measuring data about the base element, e.g., position information, orientation information, and/or information about the shape of the surface of the base element. The measurement patterns are produced by deflecting measuring laser beams by an optical scanner system towards the base element, and the camera is arranged laterally offset from the deflected laser beams. The new methods and systems enable measuring base elements in a simple and flexible manner, and require only a small amount of space in the processing chamber.