Welding Bead Shape Control Using Multi-Sensor Trajectory Estimation
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Solution Overview
Problem
In additive manufacturing using a metal material, the management of bead shape and deposit height is challenging due to obstacles around the welding torch, which can lead to measurement failures and decreased reliability of measurement data.
Innovation Solution
A manufacturing method and apparatus that integrate measurement results from multiple instruments with state transitions extracted from a trajectory plan to accurately manage shape indices, update the trajectory plan, and continuously deposit welding beads while maintaining shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measurement instrument is mounted on the welding torch to measure deposit height, then shape management can be performed, but obstacles around the torch cause measurement failures and decrease measurement reliability
Solution Approach 1:
The patent introduces an intermediary system consisting of multiple measurement instruments positioned at different locations around the welding torch. These instruments serve as mediators to capture measurement data from different angles and positions, ensuring that at least one instrument can obtain reliable measurements even when others are blocked by obstacles. The control unit integrates data from multiple instruments to compensate for measurement failures.
Solution Approach 2:
The patent divides the measurement function into multiple independent measurement instruments rather than relying on a single instrument mounted on the torch. Each instrument is positioned at different locations and orientations, creating a segmented measurement system that can independently capture data from different perspectives, thereby maintaining measurement reliability when some instruments are obstructed.
2Reliability
If multiple measurement instruments are used to improve measurement reliability, then measurement coverage increases, but device complexity increases
Solution Approach 1:
The control unit is designed with multi-functionality, serving both as a data integrator for multiple measurement instruments and as a trajectory management system. It universally handles various input data types from different instruments, processes trajectory information, and generates control commands, thereby managing the complexity of the multi-instrument system through a centralized intelligent controller.
Solution Approach 2:
The patent merges the trajectory management function with the measurement data integration function into a unified control system. The control unit simultaneously manages the welding torch trajectory and integrates data from multiple measurement instruments, combining previously separate functions into one system to reduce overall device complexity while maintaining measurement reliability.
3Manufacturing precision
If the trajectory plan is updated based on integrated measurement results, then shape accuracy improves, but processing time increases
Solution Approach 1:
The control unit performs preliminary integration of measurement data from multiple instruments before trajectory updates are required. By continuously maintaining an integrated view of the actual object shape through ongoing data fusion, the system prepares accurate shape information in advance, enabling rapid trajectory adjustments without time-consuming processing when updates are needed.
Solution Approach 2:
The patent implements continuous measurement and continuous data integration rather than periodic batch processing. Multiple measurement instruments continuously capture data, and the control unit continuously integrates this information, maintaining an up-to-date model of the object shape. This continuous action eliminates idle time between measurements and processing, improving both accuracy and efficiency.
Data Source
AI summary
A manufacturing method of an additively manufactured object includes: a process of setting an observation model obtained based on measurement information collected from at least one or more measurement instruments provided in the building device and a state transition model indicating a state transition of a shape index of the additively manufactured object extracted from the trajectory plan; a process of extracting an observation physical quantity of the shape index from the observation model and extracting a state physical quantity of the shape index from the state transition model; a process of obtaining a state transition estimation value of the shape index by integrating the observation physical quantity and the state physical quantity; and a process of updating a formation condition of a welding bead according to the state transition estimation value.