Tilted Optical Tracking for Melt Pool Height Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems lack effective methods to accurately measure the height of a melt pool, which is crucial for controlling the deposition of additional material and ensuring precise part height in manufacturing processes.
Innovation Solution
A tracking optical system with a tilted axis and photodetectors is used to measure the position of the melt pool, employing optical receivers to produce tracking signals based on received radiation, and adjusting the melt pool position using a positioning element responsive to these signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a tracking optical system with tilted axis and photodetectors is used to measure melt pool position, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent tilts the tracking optical axis relative to the processing axis, transforming a one-dimensional height measurement problem into a two-dimensional angular measurement problem. This allows the system to measure melt pool height by detecting angular deviations of reflected radiation, thereby improving measurement precision while using simpler photodetector components.
Solution Approach 2:
The patent introduces an aperture plate as an intermediary element between the focus element and photodetector. This aperture plate creates a reference beam that interferes with the measurement beam, enabling precise height measurement through interference patterns without requiring complex direct measurement optics.
2Manufacturing precision
If optical radiation from melt pool is received and directed to photodetector for position measurement, then manufacturing precision is improved, but loss of energy increases
Solution Approach 1:
The patent extracts only the necessary portion of optical radiation from the melt pool for measurement purposes. By using a tilted optical axis and aperture plate, the system selectively captures and directs specific radiation paths to the photodetector, minimizing energy extraction while obtaining sufficient measurement signal for precise material deposition control.
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
Enables precise measurement and control of the melt pool height, allowing for improved accuracy in material deposition and part fabrication in additive manufacturing processes.
Implementation Method 1
the at least one focus element is situated to receive optical radiation from a melt pool and direct the received optical radiation toward the photodetector
Implementation Method 2
the photodetector includes at least one single pixel photodetector or a linear detector
Data Source
AI summary
Detectors are situated along a tilted optical axis to receive optical radiation from a work surface. Variations in the received optical power are used to estimate a work surface positional along a work surface axis. The received optical power can be emitted from the work surface and an estimated temperature of the work surface used to adjust the received optical power. One or two single element detectors or a linear detector can be used. A position of a focused spot produced from the received optical power at the linear detector can be used to assess work surface axial position.