Solid-State Additive Process Control for Continuous Filler Feeding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity of solid-state additive manufacturing processes requires a sophisticated process control system to manage various materials, substrates, and operations, necessitating precise control of multiple variables such as down force, torque, temperature, and filler flow rate, while also accommodating different tool geometries and auxiliary operations.
Innovation Solution
A process control system with multiple operationally-synchronized open and closed control loops, utilizing sensors and detectors to monitor and adjust process variables, allowing for automatic or manual intervention to ensure accurate control of the solid-state additive manufacturing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sophisticated process control system with multiple synchronized control loops is implemented to precisely control multiple variables (down force, torque, temperature, filler flow rate), then manufacturing precision and reliability are improved, but device complexity increases
Solution Approach 1:
The control system is segmented into multiple independent control loops, each responsible for a specific process variable (down force control loop, torque control loop, temperature control loop, filler flow rate control loop). This segmentation allows precise control of each variable while maintaining modularity, reducing the complexity of managing all variables simultaneously as a single monolithic system.
Solution Approach 2:
The control system employs dynamic adjustment capabilities where control parameters can be modified in real-time based on process conditions. The synchronized control loops can adapt their setpoints and control gains dynamically, enabling the system to maintain precision across varying operating conditions without requiring an overly complex fixed-configuration system.
2Productivity
If continuous feeding systems are used to supply filler material (rod, wire, granules, powder) to the solid-state additive manufacturing system, then productivity is improved, but device complexity and difficulty of detecting and measuring increase
Solution Approach 1:
The continuous feeding system incorporates feedback mechanisms with sensors and detectors that monitor filler material flow rate, material build-up conditions, and deposition parameters. This feedback enables real-time detection and measurement of process variables, allowing the control system to adjust feeding rates and prevent issues like material jamming or inconsistent deposition, thereby maintaining high productivity with reliable measurement capability.
3Use of energy by moving object
If solid-state additive manufacturing processes are used to deposit filler material with frictional heating and mechanical stirring, then energy efficiency is improved, but manufacturing precision and control difficulty increase due to the complexity of managing thermally-sensitive materials
Solution Approach 1:
The system employs parameter change strategies where process variables (temperature, pressure, rotational speed, feed rate) are dynamically adjusted based on material properties and desired outcomes. For thermally-sensitive materials, the control system modifies parameters to maintain temperatures below degradation thresholds while still achieving adequate plastic deformation and bonding, thus maintaining precision without sacrificing energy efficiency.
Solution Approach 2:
The solid-state additive manufacturing process maintains continuous useful action through uninterrupted frictional heating and mechanical stirring during filler material deposition. This continuity ensures consistent material softening and mixing, improving energy efficiency by avoiding intermittent heating cycles. The synchronized control loops maintain continuous monitoring and adjustment, ensuring precision is preserved throughout the continuous process.
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 system enables high-quality adhesion, efficient energy use, and reproducibility in manufacturing, particularly for thermally-sensitive materials, with improved automation and reduced mechanical challenges, such as minimizing downtime due to consumable material build-up.
Implementation Method 1
heat is generated by the friction between the rotating tool and the workpiece surface
Implementation Method 2
the generated heat enables significant amount of plastic deformation in the vicinity of the rotating tool
Data Source
AI summary
A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.