Forming Control via Interval Width in Directed Energy Deposition-Arc Process

A novel controller, employing a variable-structure single-neuron adaptive PSD (proportional integral derivative) approach, was proposed for regulating the deposition width variation in the Directed Energy Deposition-Arc (DED-Arc) layer. During experimental trials, the deposition speed was chosen as the manipulated variable, while the width of the deposition layer served as the measured parameter. To facilitate controller design, a vision sensor was custom-designed to accurately detect the width of the deposition layer. The captured image of the deposition layer's dimensions enabled the precise determination of the deposited thickness, forming the basis for subsequent controller development. In performance assessments, deliberate interference was intentionally introduced into the deposition current, deposition layer height, and the targeted deposition layer width. The assessment involved the controlled deposition of ten-layer components, focusing on width regulation for each deposition layer. The results demonstrate that the proposed controller significantly enhances the deposition process stability, particularly within a range of desired deposition widths from 7.5 mm to 8.3 mm.