Weld Bead Measurement Switching for WAAM Shape Control
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Solution Overview
Problem
Existing manufacturing methods for additively-manufactured objects face challenges in accurately controlling weld bead dimensions, particularly when measuring internal structures, as the frame portion often obstructs measurement, leading to increased variation in position information and difficulty in determining the required welding amount.
Innovation Solution
A manufacturing system that includes a torch with a non-contact shape sensor to measure weld bead dimensions, a switching unit to select between representative height and cross-sectional area measurement based on deposition plan information, and a correction unit to adjust deposition conditions, ensuring accurate weld bead formation regardless of the object's shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the frame portion is formed first to create the outer contour, then the structural integrity and shape definition are improved, but the frame portion becomes an obstacle that blocks measurement of internal built portions, increasing variation in position information
Solution Approach 1:
The measurement process is segmented into two distinct phases: first measuring the frame portion to establish outer contour accuracy, then measuring internal built portions after frame formation. This segmentation allows each measurement to be optimized for its specific context without interference from the other.
Solution Approach 2:
The frame portion is formed as a preliminary structure before internal built portions are created. This preliminary action establishes the outer contour and provides a reference framework that guides subsequent internal portion formation and measurement.
2Manufacturing precision
If feedback control is performed using position information from existing weld beads, then the control accuracy of newly formed weld beads is improved, but the variation in position information from obstructed measurements increases, reducing the reliability of feedback data
Solution Approach 1:
The system implements feedback control by measuring the actual position and shape of existing weld beads, comparing them with planned values, and using this information to adjust subsequent weld bead formation parameters. This closed-loop control continuously improves manufacturing accuracy.
Solution Approach 2:
The measurement and feedback process is made dynamic by performing measurements at multiple stages during the additive manufacturing process - after frame formation and during internal portion construction. This allows real-time adjustment of parameters based on actual measured conditions rather than static pre-planned values.
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 the consistent production of additively-manufactured objects with desired shapes and dimensions by accurately adjusting weld bead formation conditions, improving accuracy and reducing variations in internal built portions.
Implementation Method 1
a shape sensor attached to the torch measures, in a non-contact manner, a shape of the weld bead
Data Source
AI summary
A manufacturing system of an additively-manufactured object includes: a torch provided at a robot arm; a measuring unit configured to measure, in a non-contact manner, a shape of a weld bead that is deposited by a shape sensor attached to the torch and output measurement information of at least one of a representative height of the weld bead and a cross-sectional area of the weld bead; a switching unit configured to switch the measurement information output by the measuring unit based on at least one of a shape and position information of a weld bead included in the deposition plan; and a correction unit configured to correct a condition for depositing weld beads based on the measurement information and the deposition plan.