Control of deposition geometry is critical for repair and fabrication of complex components through directed energy deposition (DED). However, current limited sensing technology is often one of the bottlenecks that make it difficult to implement a real-time, measurement-feedback control of build geometry. Hence, this paper proposes to implement the control trajectories from a model-based, simulated-output feedback controller (where the controller uses simulated rather than measured outputs for feedback) as a feed-forward controller in a real DED process. We illustrate the effectiveness of such feed-forward implementation of a model-based, simulated-output feedback controller in the height control of a L-shaped structure via varying laser power in a DED process. Experimental validation shows that by applying the proposed feed-forward controller for laser power, the resulting build has (30%–50%) increased accuracy in achieving the target build height than applying laser with constant power or experience-based, hatch-dependent laser power. Results in this paper indicate that applying a simulated-output feedback controller could be a practical alternative for the control of DED (or other additive manufacturing processes) before the sensing technologies are matured enough to support real-time, measurement-feedback controller.
- Dynamic Systems and Control Division
Build Height Control in Directed Energy Deposition Using a Model-Based Feed-Forward Controller
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Wang, Q, Li, J, Nassar, AR, Reutzel, EW, & Mitchell, W. "Build Height Control in Directed Energy Deposition Using a Model-Based Feed-Forward Controller." Proceedings of the ASME 2018 Dynamic Systems and Control Conference. Volume 2: Control and Optimization of Connected and Automated Ground Vehicles; Dynamic Systems and Control Education; Dynamics and Control of Renewable Energy Systems; Energy Harvesting; Energy Systems; Estimation and Identification; Intelligent Transportation and Vehicles; Manufacturing; Mechatronics; Modeling and Control of IC Engines and Aftertreatment Systems; Modeling and Control of IC Engines and Powertrain Systems; Modeling and Management of Power Systems. Atlanta, Georgia, USA. September 30–October 3, 2018. V002T23A003. ASME. https://doi.org/10.1115/DSCC2018-9058
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