In-Place Workpiece Interface Detection for Extension Segment Printing
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Solution Overview
Problem
Current methods for additively printing extension segments on workpieces, such as turbine blades, face challenges in accurately determining the workpiece interface within the additive manufacturing machine, leading to potential misalignment and extensive rework or scrapping due to the need for separate measurement systems and subsequent repositioning.
Innovation Solution
The method involves using an additive manufacturing machine with a print head that scans the workpiece interface with an electromagnetic radiation beam, receiving reflection data to determine the interface location, and controlling the print head to additively print extension segments directly on the workpiece interface, ensuring precise alignment without the need for external measurement systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If separate measurement systems are used to determine workpiece interface location, then measurement capability is provided, but alignment precision deteriorates due to repositioning requirements
Solution Approach 1:
The patent combines the measurement function and additive manufacturing function into a single integrated system. The build plate serves dual purposes: as a support structure for the workpiece and as a measurement reference surface. The electromagnetic radiation beam system is used both to scan/detect the workpiece interface location and to additively manufacture the extension segment, eliminating the need for separate measurement systems and repositioning operations.
Solution Approach 2:
The build plate is designed with multi-functionality, serving as both a mechanical support structure and a measurement reference surface. The electromagnetic radiation beam system performs multiple functions: scanning the build plate to locate the workpiece interface, detecting interface characteristics, and subsequently adding material to manufacture the extension segment. This universal system eliminates the need for separate measurement and manufacturing equipment.
2Difficulty of detecting and measuring
If workpiece repositioning is performed after measurement, then measurement is completed, but time consumption increases and alignment precision deteriorates
Solution Approach 1:
The system performs preliminary scanning and measurement of the workpiece interface location using the electromagnetic radiation beam before the additive manufacturing process begins. The build plate is scanned to detect the interface characteristics and determine the precise location where the extension segment should be deposited. This preliminary action is performed while the workpiece remains in its original position on the build plate, eliminating the need for subsequent repositioning.
3Difficulty of detecting and measuring
If workpiece repositioning is performed after measurement, then measurement is completed, but manufacturing precision deteriorates due to position changes
Solution Approach 1:
The measurement and manufacturing operations are merged into a single coordinated process. The electromagnetic radiation beam system continuously tracks the workpiece interface location on the build plate, and the additive manufacturing system uses this same reference frame to deposit material with high precision. Since the workpiece never leaves the build plate, the reference frame remains constant, ensuring high alignment precision.
4Difficulty of detecting and measuring
If external measurement systems are used, then interface location can be detected, but system complexity increases
Solution Approach 1:
The build plate and electromagnetic radiation beam system are designed to perform multiple functions. The build plate serves as both a mechanical support and a measurement reference surface with encoded positional information. The electromagnetic radiation beam system functions as both a detection device for scanning the build plate and locating the workpiece interface, and as a manufacturing tool for adding material. This multi-functionality eliminates the need for separate external measurement systems, reducing overall system complexity.
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 approach ensures accurate and precise alignment of extension segments, reducing rework and scrap rates by maintaining the workpiece's original position relative to the machine during printing, thereby improving the efficiency and reliability of the additive manufacturing process.
Implementation Method 1
receiving data associated with reflections of the electromagnetic radiation beam off of the build plate
Implementation Method 2
an extension segment is additively printed on the determined workpiece interface
Data Source
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AI summary
A method for additively printing extension segments on workpieces using an additive manufacturing machine includes controlling, with a computing system, an operation of a print head of the machine such that a region of interest of a build plate of the machine is scanned with an electromagnetic radiation beam. Additionally, the method includes receiving, with the computing system, data associated with reflections of the beam off of the build plate as the region interest is scanned. Furthermore, the method includes receiving, with the computing system, data associated with a location of the beam relative to the build plate. Moreover, the method includes determining, with the computing system, a location of a workpiece interface based on the received data. In addition, the method includes controlling, with the computing system, the operation of the print head such that an extension segment is additively printed on the determined workpiece interface.