Build height control in directed energy deposition using a model-based feed-forward controller

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

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.

Original languageEnglish (US)
Title of host publicationControl 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
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791851906
DOIs
StatePublished - Jan 1 2018
EventASME 2018 Dynamic Systems and Control Conference, DSCC 2018 - Atlanta, United States
Duration: Sep 30 2018Oct 3 2018

Publication series

NameASME 2018 Dynamic Systems and Control Conference, DSCC 2018
Volume2

Other

OtherASME 2018 Dynamic Systems and Control Conference, DSCC 2018
CountryUnited States
CityAtlanta
Period9/30/1810/3/18

Fingerprint

Controllers
Feedback
Lasers
Time measurement
3D printers
Hatches
Geometry
Feedback control
Repair
Trajectories
Fabrication

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

Cite this

Wang, Q., Li, J., Nassar, A. R., Reutzel, E. W., & Mitchell, W. (2018). Build height control in directed energy deposition using a model-based feed-forward controller. In 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 (ASME 2018 Dynamic Systems and Control Conference, DSCC 2018; Vol. 2). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/DSCC2018-9058
Wang, Qian ; Li, Jianyi ; Nassar, Abdalla Ramadan ; Reutzel, Edward William ; Mitchell, Wesley. / Build height control in directed energy deposition using a model-based feed-forward controller. 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. American Society of Mechanical Engineers (ASME), 2018. (ASME 2018 Dynamic Systems and Control Conference, DSCC 2018).
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abstract = "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.",
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Wang, Q, Li, J, Nassar, AR, Reutzel, EW & Mitchell, W 2018, Build height control in directed energy deposition using a model-based feed-forward controller. in 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. ASME 2018 Dynamic Systems and Control Conference, DSCC 2018, vol. 2, American Society of Mechanical Engineers (ASME), ASME 2018 Dynamic Systems and Control Conference, DSCC 2018, Atlanta, United States, 9/30/18. https://doi.org/10.1115/DSCC2018-9058

Build height control in directed energy deposition using a model-based feed-forward controller. / Wang, Qian; Li, Jianyi; Nassar, Abdalla Ramadan; Reutzel, Edward William; Mitchell, Wesley.

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. American Society of Mechanical Engineers (ASME), 2018. (ASME 2018 Dynamic Systems and Control Conference, DSCC 2018; Vol. 2).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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AU - Li, Jianyi

AU - Nassar, Abdalla Ramadan

AU - Reutzel, Edward William

AU - Mitchell, Wesley

PY - 2018/1/1

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N2 - 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.

AB - 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.

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M3 - Conference contribution

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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. In 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. American Society of Mechanical Engineers (ASME). 2018. (ASME 2018 Dynamic Systems and Control Conference, DSCC 2018). https://doi.org/10.1115/DSCC2018-9058