Sensor Data Allocation to Scan Vectors in Powder Bed 3D Printing
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Solution Overview
Problem
Current methods for analyzing sensor data in additive manufacturing processes, such as selective laser melting, fail to effectively allocate individual data points to specific scanning vectors, leading to lost information and the inability to monitor and adjust irradiation parameters in real-time during the layering process.
Innovation Solution
A device and method that associate sensor data with scanning vectors based on predefined similarity criteria, allowing for the comparison of data values to determine quality measures and adjust process parameters in real-time, enabling online monitoring and adjustment of the irradiation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If sensor data is analyzed as a time series without allocation to scanning vectors, then the analysis process is simple, but valuable information is lost and quality monitoring is impossible
Solution Approach 1:
The patent segments the continuous sensor data time series into discrete data sets, each corresponding to a specific scanning vector. This segmentation allows allocation of sensor measurements to individual scan paths, enabling detailed quality analysis without overwhelming complexity. The control unit divides the build area into multiple scanning vectors and assigns sensor data accordingly.
Solution Approach 2:
The patent performs preliminary allocation of sensor data to scanning vectors before quality analysis. The control unit pre-establishes the relationship between sensor measurements and scanning vectors based on process data, so that when quality monitoring is needed, the data is already organized and ready for comparison and evaluation.
2Reliability
If the entire layer irradiation is completed before data evaluation, then the complete process data is available, but online monitoring and real-time adjustment are impossible
Solution Approach 1:
The patent implements feedback by continuously monitoring sensor data during the irradiation process and comparing it against reference values. The control unit receives sensor data in real-time, performs quality analysis, and can trigger alerts or adjustments while the layer is still being processed, enabling online monitoring rather than post-processing evaluation.
Solution Approach 2:
The system performs preliminary quality assessment during the irradiation process itself. By allocating sensor data to scanning vectors as they are processed and comparing them against reference values immediately, the system can identify quality issues early in the layer processing rather than waiting for complete layer evaluation.
3Measurement precision
If individual scanning vectors are compared to reference values, then quality measurement is precise, but the system requires extensive reference data and complex comparisons
Solution Approach 1:
The patent segments the comparison process by grouping scanning vectors into categories (e.g., by orientation, position, or process parameters). Instead of comparing every scanning vector against all reference values, the system creates specific reference value sets for each group, reducing computational complexity while maintaining precise quality measurement for each segment.
Solution Approach 2:
The patent applies local quality assessment by creating reference values specific to different regions and orientations of the build area. Each scanning vector is compared against reference values appropriate to its local characteristics (e.g., contour vectors vs. hatch vectors, different build orientations), enabling precise quality measurement tailored to local conditions rather than using a single global reference.
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 enables the identification of unusual data values and quality changes in the work piece, allowing for immediate adjustments to process parameters, thereby improving the quality and consistency of the three-dimensional work piece production.
Implementation Method 1
the pyrometer receives thermal radiation emitted from the melt pool and is configured to measure at least one intensity value of the thermal radiation
Implementation Method 2
The radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 3
heating and consequently melting or sintering of the raw material powder particles
Implementation Method 4
heating and consequently melting or sintering of the raw material powder particles
Data Source
AI summary
A device is provided, for analyzing sensor data of a sensor arranged in an apparatus for producing a three-dimensional work piece via irradiation of layers of raw material with an energy beam. Further, a corresponding method and a corresponding computer program product are provided.