Wire-Fed Additive Manufacturing Control for Bead Height Uniformity
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Solution Overview
Problem
Additive manufacturing apparatuses face challenges in achieving high machining accuracy due to irregularities in the deposition of beads, which result from heat accumulation and other factors, leading to uneven height differences and difficulties in stabilizing the contact state between the wire and the workpiece.
Innovation Solution
A numerical control device that includes an error detecting unit to monitor height irregularities and an adjustment unit to adjust the material supply based on detected errors, ensuring stable machining conditions and uniform bead deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If material is supplied at a constant rate to maintain stable machining conditions, then the contact state between wire and workpiece is stabilized, but height irregularities and uneven bead deposition occur due to heat accumulation
Solution Approach 1:
The system implements feedback control by detecting height irregularities of the workpiece and using this information to adjust the material supply rate. The error detecting unit measures the actual height deviations, and this feedback is fed to the control unit which modifies the supply rate accordingly, creating a closed-loop control system that resolves the contradiction between stable contact and height uniformity
Solution Approach 2:
The material supply rate is changed from a constant static value to a dynamic variable that adjusts in real-time based on detected height irregularities. The supply rate becomes adaptive, increasing or decreasing according to the actual machining conditions and workpiece geometry, allowing the system to maintain both contact stability and height uniformity through continuous adjustment
2Manufacturing precision
If material supply rate is increased to compensate for height irregularities, then machining accuracy improves, but contact state stability deteriorates
Solution Approach 1:
The control unit continuously monitors height irregularities through the error detecting unit and uses this feedback to make precise, incremental adjustments to the material supply rate. This feedback mechanism ensures that supply rate changes are proportional to the actual deviations needed, preventing excessive adjustments that would destabilize the wire-workpiece contact while still achieving the required machining accuracy
Solution Approach 2:
The system dynamically changes the material supply rate parameter based on detected height errors. By adjusting this critical parameter in real-time according to actual machining conditions, the system achieves high machining accuracy without compromising contact stability, as the parameter changes are precisely controlled and adapted to the specific situation
3Reliability
If material supply rate is decreased to maintain contact stability, then contact state is stabilized, but height irregularities increase
Solution Approach 1:
When height irregularities are detected, the feedback control system responds by adjusting the material supply rate upward to compensate for the deficiencies caused by reduced supply. This feedback loop ensures that any reduction in supply rate is counterbalanced by subsequent corrective increases, maintaining both contact stability during the reduction and height uniformity through the corrective feedback action
Solution Approach 2:
The system applies preliminary anti-action by detecting height irregularities before they propagate further and adjusting the material supply rate preemptively to counteract the adverse effects of reduced supply. This anticipatory adjustment prevents the worsening of height irregularities while maintaining contact stability, as the correction is applied before the problem fully develops
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
The solution enables the additive manufacturing apparatus to perform machining with high accuracy by stabilizing the contact state and uniformizing the height of the workpiece, thereby improving the overall machining precision.
Implementation Method 1
irradiating a material fed by a driving force of a driving unit with a beam and applying the molten material to a workpiece
Data Source
AI summary
A numerical control device controls an additive manufacturing apparatus that manufactures a modeled object by irradiating a wire, which is a material fed by a driving force of a rotary motor, which is a driving unit, with a beam, and applying the molten material to a workpiece. The numerical control device includes an error detecting unit that detects an error in the height of the workpiece in the height direction in which the material is deposited. The numerical control device includes a condition adjusting unit, which is an adjustment unit that adjusts the supply amount of the material on the basis of the error.