Automated Interlayer Wall Height Compensation for Wire Based Directed Energy Deposition Additive Manufacturing.

Part quality monitoring and control in wire-based directed energy deposition additive manufacturing (w-DEDAM) processes has been garnering continuous interest from both the academic and industrial sectors. However, maintaining a consistent layer height and ensuring that the wall height aligns closely with the design, as depicted in computer-aided design (CAD) models, pose significant challenges. These challenges arise due to the uncertainties associated with the manufacturing process and the working environment, particularly with extended processing times. To achieve these goals in an industrial scenario, the deposition geometry must be measured with precision and efficiency throughout the part-building process. Moreover, it is essential to comprehend the changes in the interlayer deposition height based on various process parameters. This paper first examines the behaviour of interlayer deposition height when process parameters change within different wall regions, with a particular focus on the transition areas. In addition, this paper explores the potential of geometry monitoring information in implementing interlayer wall height compensation during w-DEDAM part-building. The in-process layer height was monitored using a coherent range-resolved interferometry (RRI) sensor, and the accuracy and efficiency of this measurement were carefully studied. Leveraging this information and understanding of deposition geometry, the control points of the process parameters were identified. Subsequently, appropriate and varied process parameters were applied to each wall region to gradually compensate for wall height. The wall height discrepancies were generally compensated for in two to three layers.

Framework for Bidirectional Knowledge-Based Maintenance of Wind Turbines.

Artificial intelligence (AI) techniques, such as machine learning (ML), are being developed and applied for the monitoring, tracking, and fault diagnosis of wind turbines. Current prediction systems are largely limited by their inherent disadvantages for wind turbines. For example, frequency or vibration analysis simulations at a part scale require a great deal of computational power and take considerable time, an aspect that can be essential and expensive in the case of a breakdown, especially if it is offshore. An integrated digital framework for wind turbine maintenance is proposed in this study. With this framework, predictions can be made both forward and backward, breaking down barriers between process variables and key attributes. Prediction accuracy in both directions is enhanced by process knowledge. An analysis of the complicated relationships between process parameters and process attributes is demonstrated in a case study based on a wind turbine prototype. Due to the harsh environments in which wind turbines operate, the proposed method should be very useful for supervising and diagnosing faults.

Artificial Intelligence and 3D Scanning Laser Combination for Supervision and Fault Diagnostics.

In this work, we combine some of the most relevant artificial intelligence (AI) techniques with a range-resolved interferometry (RRI) instrument applied to the maintenance of a wind turbine. This method of automatic and autonomous learning can identify, monitor, and detect the electrical and mechanical components of wind turbines to predict, detect, and anticipate their degeneration. A scanner laser is used to detect vibrations in two different failure states. Following each working cycle, RRI in-process measurements agree with in-process hand measurements of on-machine micrometers, as well as laser scanning in-process measurements. As a result, the proposed method should be very useful for supervising and diagnosing wind turbine faults in harsh environments. In addition, it will be able to perform in-process measurements at low costs.

Vibration Analysis for Fault Detection of Wind Turbines by Combining Machine-Learning Techniques and 3D Scanning Laser.

With this research, we apply range-resolved interferometry (RRI) to the maintenance of wind turbines using some of the most relevant machine-learning (ML) techniques. The degeneration of electrical and mechanical components of wind turbines can be predicted, detected, and anticipated using this method of automatic and autonomous learning. The vibrations in two different failure states are detected with the help of a scanner laser. In-process measurements taken by RRI agree with manual measurements, laser scanning measurements, and in-process hand measurements made following each working cycle. Consequently, the proposed method will be very useful for monitoring and diagnosing faults in wind turbines. The system will also be able to perform low-cost in-process measurements.