Systems and methods for controlling additive manufacturing
A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to cause the additive manufacturing machine to discharge a path of composite material, including a continuous fiber and a matrix at least partially coating the continuous fiber. The processor may also be configured to execute the computer-executable instructions to monitor an energy level within the continuous fiber during discharging, to make a determination that the continuous fiber has lost continuity based on a reduction in the energy level, and to selectively interrupt the discharging based on the determination.
1. A system for additively manufacturing a structure, comprising:
an additive manufacturing machine;
an energy monitoring peripheral device
a memory having computer-executable instructions stored thereon; and
a processor configured to execute the computer-executable instructions to:
cause the additive manufacturing machine to discharge a path of composite material, including a continuous fiber and a matrix at least partially coating the continuous fiber;
monitor an energy level within the continuous fiber during discharging with the energy monitoring peripheral device;
make a determination that the continuous fiber has lost continuity based on a reduction in the energy level; and
selectively interrupt the discharging based on the determination.
2. The system of claim 1 , wherein the energy level is electrical current passing through the continuous fiber.
3. The system of claim 1 , wherein the energy level is light passing through the continuous fiber.
4. The system of claim 1 , further including an output device located in at least one of an anchor of the path of composite material and a supply of the continuous fiber, wherein:
the energy monitoring peripheral device is located in another of the at least one of the anchor and the supply of the continuous fiber; and
the processor is further configured to execute the computer-executable instructions to:
cause the output device to generate the energy level; and
cause the energy monitoring peripheral device to measure the energy level.
5. The system of claim 1 , wherein the energy level is associated with a level of tension in the continuous fiber.
6. The system of claim 5 , wherein:
the additive manufacturing machine includes a nozzle configured to move in multiple dimensions during discharge of the path of composite material;
the system further includes:
a first input device configured to track a distance moved by the nozzle; and
a second input device configured to track a length of continuous fiber supplied to the nozzle; and
the processor is further configured to execute the computer-executable instructions to determine the reduction in energy level based on a difference between the distance moved by the nozzle and the length of continuous fiber supplied to the nozzle.
7. The system of claim 6 , wherein the processor is further configured to execute the computer-executable instructions to determine that the continuous fiber has broken when the distance moved by the nozzle is greater than the length of continuous fiber supplied to the nozzle by at least a threshold amount.
8. The system of claim 7 , wherein the processor is further configured to execute the computer-executable instructions to determine that the continuous fiber has bunched up inside the nozzle when the distance moved by the nozzle is less than the length of continuous fiber supplied to the nozzle by at least a threshold amount.
9. The system of claim 5 , wherein, when the processor determines that a reduction of tension within the continuous fiber has occurred that is less than a threshold amount associated with breakage of the continuous fiber, the processor is further configured to execute the computer-executable instructions to cause the additive manufacturing machine to increase tension in the continuous fiber.
10. The system of claim 9 , wherein, when the processor is further configured to execute the computer-executable instructions to cause the additive manufacturing machine to increase tension in the continuous fiber by increasing a nozzle travel speed.
11. The system of claim 1 , wherein the processor is further configured to execute the computer-executable instructions to cause the additive manufacturing machine to implement a repair of the continuous fiber when the processor determines that a loss of continuity in the continuous fiber has occurred.
12. A system for additively manufacturing a structure, comprising:
an additive manufacturing machine;
a peripheral device configured to monitor a signal;
a memory having computer-executable instructions stored thereon; and
a processor configured to execute the computer-executable instructions to:
cause the additive manufacturing machine to discharge a path of composite material, including a continuous fiber and a matrix at least partially coating the continuous fiber;
monitor the signal at the continuous fiber with the peripheral device, the signal corresponding to a continuity of the continuous fiber during discharging; and
selectively interrupt the discharging based on a reduction in the continuity.
13. The system of claim 12 , wherein the continuity includes a level of energy passing through the continuous fiber during discharging.
14. The system of claim 13 , wherein the energy is electrical current.
15. The system of claim 13 , wherein the energy is light.
16. The system of claim 13 , wherein the energy is tension.
17. The system of claim 12 , further including an output device located in at least one of an anchor of the path of composite material and a supply of the continuous fiber, wherein
the peripheral device is located in another of the at least one of the anchor and the supply of the continuous fiber; and
the processor is further configured to execute the computer-executable instructions to:
cause the output device to generate the signal; and
cause the peripheral device to measure a level of energy of the signal.
18. The system of claim 16 , wherein the supply is a spool mounted to the additive manufacturing machine.
19. The system of claim 12 , wherein:
the additive manufacturing machine includes a nozzle configured to move during discharge of the path of composite material;
the system further includes:
an input device configured to track a length of continuous fiber supplied to the nozzle; and
the processor is further configured to execute the computer-executable instructions to determine the continuity of the continuous fiber based on a difference between a distance moved by the nozzle and the length of continuous fiber supplied to the nozzle.
20. The system of claim 19 , wherein the processor is further configured to execute the computer-executable instructions to:
determine that the continuous fiber has broken when the distance moved by the nozzle is greater than the length of continuous fiber supplied to the nozzle by at least a threshold amount; and
determine that the continuous fiber has bunched up inside the nozzle when the distance moved by the nozzle is less than the length of continuous fiber supplied to the nozzle by at least a threshold amount.