Adjustment method, coater, and additive manufacturing device
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- TRUMPF LASER & SYSTEMTECHNIK GMBH
- Filing Date
- 2024-05-22
- Publication Date
- 2026-04-22
AI Technical Summary
Conventional additive manufacturing devices require manual and time-consuming alignment of components, leading to reduced manufacturing speed and automation, and are prone to inaccuracies due to wear and thermal expansion, which negatively impact production quality.
An adjustment method using a coater with a measuring device to automatically align components of the additive manufacturing device by positioning a measuring probe over the process plate and adjusting height until contact is made, allowing for precise alignment independent of operator intervention and enabling automatic production start.
This method enhances production speed and automation while maintaining high accuracy by automatically aligning components, reducing the need for manual adjustments and compensating for inaccuracies caused by wear and thermal expansion.
Smart Images
Figure EP2024064073_19122024_PF_FP_ABST
Abstract
Description
[0001] Adjustment process, coater and additive manufacturing device
[0002] Background of the invention
[0003] The invention relates to an adjustment method for aligning components of an additive manufacturing device. Furthermore, the invention relates to a coating device and an additive manufacturing device.
[0004] Such methods and devices are typically used before the additive manufacturing device is put into operation as well as before the additive manufacturing device produces individual production orders.
[0005] The various components of the additive manufacturing device are coordinated with each other in terms of their coordinate systems and orientations to enable interaction within a predetermined coordinate system of the additive manufacturing device. Inadequate coordination leads to a significant reduction in the manufacturing quality of the additive manufacturing device.
[0006] For example, the alignment of a process chamber or process chamber floor flush with a build plate is crucial for the formation of a layer thickness of the process powder to be solidified. Furthermore, a coater must be positioned in a production plane of the additive manufacturing device to ensure effective introduction of the process powder. Furthermore, with conventional additive manufacturing devices, the substrate plate must be moved to a predetermined production plane, or to a coating and exposure plane, before each production job. This can lead to an offset and / or tilt of the substrate plate relative to the production plane, for example due to wear or thermal expansion of the substrate plate and / or inaccuracies in the height adjustment, which also has a negative impact on production quality.
[0007] Alignment before commissioning of the additive manufacturing device is typically performed by an operator through time-consuming and laborious manual adjustment of the individual components. Proper alignment of the substrate plate is also ensured manually by the operator.
[0008] Although the manufacturing quality of the additive manufacturing device can be maintained at a high level with the known processes, this can only be achieved at a reduced manufacturing speed and a reduced degree of automation of the additive manufacturing speed
[0009] Object of the invention
[0010] The invention is based on the object of specifying a method and a device in which the production speed and the degree of automation can be improved while at the same time maintaining high production accuracy.
[0011] Description of the invention
[0012] This object is achieved according to the invention by an adjustment method according to claim 1. The invention is further achieved by a coater according to claim 9. Furthermore, the invention is achieved by an additive manufacturing device according to claim 16. The subclaims relate to preferred embodiments of the invention. According to the invention, an adjustment method is provided.
[0013] The alignment method is designed for aligning components of an additive manufacturing device. To carry out the method, a coater of the additive manufacturing device, which has a measuring device, is used. In other words, the coater provided in the additive manufacturing device for the production of production orders is used to align the components to one another.
[0014] For this purpose, the coater has a measuring device with at least one measuring probe. The measuring device can be arranged and / or formed on the coater, in particular in a detachable manner.
[0015] The adjustment method is designed to align at least two components of the additive manufacturing device with each other. Preferably, the adjustment method is designed to align several components, in particular all components, of the additive manufacturing device with each other.
[0016] Alignment refers to the prior and subsequent arrangement of the components in a predetermined position, or a predetermined position and orientation, relative to one another. Preferably, the components are aligned relative to one another in a uniform coordinate system of the additive manufacturing device.
[0017] Components of the additive manufacturing device can be understood as including, but not limited to, the coater, the measuring device, a process chamber floor, a process plate and / or a processing unit, in particular a laser processing unit.
[0018] A process plate can be understood, for example, as a build plate for producing a production order of the additive manufacturing device and / or a calibration plate for calibrating the processing unit, in particular the laser processing unit. The calibration plate is typically an optical calibration plate and is designed for placement in a production plane of the additive manufacturing device.
[0019] The adjustment procedure includes at least the following steps:
[0020] A method step d) provides for the positioning of at least one measuring probe of the measuring device, in particular described previously and subsequently, in an alignment position vertically above the process plate of the additive manufacturing device.
[0021] Typically, the measuring device is positioned by moving the coater over the process plate of the additive manufacturing device using a linear guide. Typically, the linear guide is designed to move the coater along or parallel to a second main extension direction of the production plane. In other words, the linear guide is designed to move a working axis of the coater parallel to the second main extension direction.
[0022] The alignment position can be understood as a position perpendicular, preferably vertical, to the production plane in a reference position with predetermined coordinates along a first main extension direction and the second main extension direction of the production plane. The reference position is typically parallel to the production plane.
[0023] The measuring probe has the reference position at a predetermined perpendicular reference distance from the production plane of the additive manufacturing device. In other words, method step d) provides for the use of a measuring probe aligned with the production plane.
[0024] A further method step f) involves aligning the production plane and the process plate with each other by adjusting at least one height adjustment of the additive manufacturing device. The height adjustment is performed until the measuring probe touches the reference position through the process plate.
[0025] The additive manufacturing device typically has multiple height adjustments. A height adjustment can be configured to adjust a vertical position of the process chamber, in particular the process chamber floor, and / or a vertical position of a process plate. For example, the process chamber can have at least one telescopic support leg. Furthermore, for example, a production cylinder of the additive manufacturing device can have a height adjustment in the form of a lifting device for the process plate.
[0026] The height adjustments are preferably motorized. This allows adjustment by the additive manufacturing device.
[0027] According to the invention, the process plate can be moved toward the measuring probe and / or the production plane with the coater equipped with the measuring probe can be moved toward the process plate. The adjustment continues until the process plate is touched by the measuring probe. In other words, contact between the measuring probe and the process plate is detected. Upon contact between the measuring probe and the process plate, the process plate and the production plane are at the alignment point, or the process plate is at a known distance from the production plane.
[0028] Preferably, the manufacturing plane of the additive manufacturing device is configured or aligned horizontally. Further preferably, the process plate is arranged horizontally in the additive manufacturing device. This allows for particularly precise alignment of the manufacturing plane with the process plate.
[0029] In summary, the object underlying the invention is achieved in that the components can be aligned by the additive manufacturing device using a measuring device arranged on the coater of the additive manufacturing device. The measuring device, or the measuring probe, is aligned with a production plane of the additive manufacturing device, so that the process plate can be aligned with the production plane and / or the production plane can be aligned with the process plate in a simple manner by moving the measuring probe over the process plate and adjusting the height until the measuring probe is contacted by the process plate.
[0030] The method according to the invention is thus independent of operator intervention and enables automatic process start of the production order. This can increase the efficiency and automation of the additive manufacturing device.
[0031] Furthermore, the alignment of the components is independent of the setup of the additive manufacturing device, since the components can be adapted to the given position of the additive manufacturing device.
[0032] In a preferred embodiment, the alignment method comprises method step a), which provides for determining a reference section of the additive manufacturing device. In other words, a section of the additive manufacturing device is determined to which the components of the additive manufacturing device are aligned. The reference section is typically formed parallel to the first main extension direction of the manufacturing plane of the additive manufacturing device.
[0033] In this embodiment, the adjustment method additionally includes method step b), which provides for aligning the coater to the reference section of the production plane. Typically, the coater is configured parallel to the first main extension direction, so that aligning the coater to the reference section can be carried out particularly easily.
[0034] Alignment of the coater can be achieved, in particular, by lowering it onto the reference section. In other words, the coater's vertical position is adjusted until tactile contact is established between the coater and the reference section. Alignment can be performed using a lowering device on the coater. By lowering the coater, a particularly quick and easy parallel alignment of the coater to the reference section can be achieved.
[0035] The reference section can be formed in the production plane of the additive manufacturing device. Furthermore, the reference section can be formed at a predetermined distance from the production plane. In other words, the reference section can have a reference section height. This protects the reference section from process-related contamination and thus enables alignment of the coater during operation of the additive manufacturing device.
[0036] If the reference section has a reference section height relative to the production plane, the reference section height is taken into account when aligning the components. For example, the components can be corrected by the reference section height after being contacted by the measuring probe. Furthermore, for example, the measuring probe can protrude beyond the coater by the reference section height. This eliminates the need for a correction by the reference section height.
[0037] The reference section can be formed as a single continuous section or by several subsections. The subsections are preferably identical in their dimensions and configurations, but are spatially spaced apart from one another along or parallel to the first main extension direction.
[0038] The reference section is particularly preferably designed horizontally. This allows the components of the additive manufacturing device to be aligned horizontally in a simple manner. In a preferred development, the adjustment method further comprises method step c), which provides for determining the reference distance of the measuring probe from the production plane by at least once probing the reference section with the measuring probe. In other words, the method step provides for aligning the measuring probe to the production plane. This allows a reference distance of the measuring probe to be set and / or checked. For example, the aligned coater can be moved along the second main extension direction so that the measuring probe is positioned over the reference section. The measuring probe, or a measuring pin of the measuring probe, is deflected by the reference section height in the correctly aligned state.If the deflection of the measuring probe does not correspond to the reference section height, the measuring probe can be adjusted.
[0039] Further preferred is an embodiment in which the adjustment method comprises method step e), wherein a deflection of the measuring pin of the at least one measuring probe takes place in the vertical direction up to the process plate. In other words, the measuring pin is extended in the direction of the process plate until contact is made between the measuring pin and the process plate. The deflection of the measuring pin can be determined as a process plate distance of the process plate from the reference position. Typically, the embodiment comprises, in method step f), an adjustment of the at least one height adjustment by the previously determined process plate distance. In other words, the measuring pin, in the state resting against the process plate, is moved into the alignment position or the reference position of the measuring probe by adjusting the process plate and / or production plate.
[0040] In a preferred embodiment of the adjustment method, method steps d) to f) are performed for at least one further alignment position. The at least one further alignment position is formed vertically above the process plate. The at least one further alignment position is spatially spaced from the at least one alignment position in a plane parallel to the production plane. In other words, the process plate and the production plane are aligned with each other at at least two locations on the process plate. By using more than one alignment position, an inclination between the process plate and the production plane can be determined and corrected.
[0041] A further preferred embodiment of the adjustment method involves alignment at at least one first alignment position and at least one second alignment position. The first alignment position and the second alignment position are arranged parallel to the first main extension direction of the production plane. In other words, the alignment positions are formed perpendicular to a coating device movement. This facilitates alignment of the components around the second main extension direction.
[0042] In a preferred embodiment of the adjustment method, the measuring device has at least two measuring probes. The adjustment of the at least one height adjustment typically occurs until the process plate touches the at least two measuring probes in pairs in the respective reference position. This allows for even faster alignment of the components.
[0043] A further development of the adjustment method is also preferred, in which method steps d) to f) are carried out for at least one further first alignment position and at least one further second alignment position. The at least one further first alignment position and the at least one further second alignment position are arranged at a distance from the at least one first alignment position and the at least one second alignment position along a second main extension direction. Preferably, the further first alignment position and the further second alignment position are offset parallel to the one first alignment position and the one second alignment position in the second main extension direction. In other words, the process plate can be scanned in the second main extension direction in addition to an alignment parallel to the first main extension direction.Preferably, method steps d) to f) are performed for a plurality of pairs of first and second alignment positions along the second main direction of extension. Particularly preferably, the process plate and the production plane are aligned with each other during a continuous movement of the coating device comprising the measuring device along the second main direction of extension. This allows for particularly precise and, at the same time, rapid alignment of the components.
[0044] The alignment method may provide for the aligned process plate to subsequently be used to align further components of the additive manufacturing device. For example, the process plate may be designed as an optical calibration plate, and the laser processing optics may be calibrated using the calibration plate aligned to the production plane.
[0045] The underlying problem is further solved by a coater for an additive manufacturing device.
[0046] The coater is particularly designed to carry out the adjustment procedure described above and below.
[0047] The coater typically has a coating lip. The coating lip is designed to draw off process powder during the production of a production job in the additive manufacturing device. When arranged in the additive manufacturing device, the coating lip is preferably in sliding contact with the production plane or the process chamber floor.
[0048] The coater also has a measuring device with at least one measuring probe. The measuring probe protrudes vertically beyond the coater lip. The measuring probe is designed for tactile probing through the process plate. In a preferred embodiment of the coater, the measuring probe has a probing mechanism and a measuring pin. The measuring pin is typically movable relative to the probing mechanism in order to detect probing through the process plate. Detection by the probing mechanism can occur, for example, by deflecting the measuring pin along a deflection scale. Furthermore, it can be provided that detection of probing is effected by triggering an electronic, mechanical, and / or pneumatic switching process.
[0049] Furthermore, a preferred embodiment of the coating device includes a device for positioning the measuring probe in a reference position by fixing a measuring pin position relative to the contact mechanism. In other words, a non-deflected state of the measuring probe can be determined, from which a deflection of the measuring pin is to be detected. This allows the measuring probe to be adapted to different reference distances.
[0050] A preferred embodiment of the coater is one in which the measuring probe is designed to be extendable in a vertical direction. Preferably, the measuring probe is designed to be extendable incrementally or in steps. This allows the measuring probe to be moved toward a component to be aligned for probing, thereby increasing the coater's flexibility in aligning the components.
[0051] In a preferred embodiment of the coater, the sensing mechanism comprises a pneumatic valve. The measuring pin is preferably designed to switch the pneumatic valve. The deflection of the measuring pin can thereby be detected by means of a pneumatic pressure system present on the coater, thereby keeping the costs for the provision and operation of the coater low. Further preferred is an embodiment of the coater in which the measuring device has at least two measuring probes. The measuring probes are arranged perpendicular to a working axis of the coater. Typically, the working axis of the coater is parallel to the second main extension direction of the production plane.The measuring probes are preferably arranged at a distance from one another in an extension direction of the coater, wherein the extension direction runs parallel to the first main extension direction of the production plane when the coater is arranged in the additive manufacturing device.
[0052] In a preferred embodiment of the coater, the measuring device is detachably mounted on the coater. In other words, the measuring device can be detached from the coater, in particular by the additive manufacturing device. For this purpose, the measuring device preferably has a coater coupling. The detached measuring device can be positioned by the coater in a tool magazine of the additive manufacturing device and removed for aligning the components. This allows the dimensions of the coater to be kept compact and the weight low.
[0053] The underlying task is further solved by an additive manufacturing device.
[0054] The additive manufacturing device is typically designed for additive manufacturing of production jobs in a process chamber. The additive manufacturing device comprises a production cylinder containing the process plate and a coater as described above and below.
[0055] The coater is designed to move the measuring device along the second main extension direction of the production plane of the additive manufacturing device above the process plate. Further features and advantages of the invention emerge from the description, the claims, and the drawings. According to the invention, the features mentioned above and those further explained can each be used individually or in combination in any suitable way. The embodiments shown and described are not to be understood as an exhaustive list, but rather are exemplary in nature for describing the invention.
[0056] Detailed description of the invention and drawing
[0057] Fig. 1 shows a first embodiment of an adjustment method in a schematic representation.
[0058] Fig. 2 shows a second embodiment of the adjustment method in a schematic representation.
[0059] Fig. 3 shows an additive manufacturing device with a coater having a measuring device in a perspective view.
[0060] Fig. 4 shows the additive manufacturing device from Fig. 3 with the coater positioned above a production cylinder in a perspective view.
[0061] Fig. 5 shows a first section of the additive manufacturing device from Fig. 4 in a side view.
[0062] Fig. 6 shows a second section of the additive manufacturing device with the coater positioned over a reference section in a side view.
[0063] Fig. 7 shows a third section of the additive manufacturing device with a measuring probe positioned on the reference section.
[0064] Fig. 8 shows an embodiment of the measuring device with two measuring probes in a sectional side view.
[0065] Fig. 9 shows an open pneumatic valve of a measuring probe of the measuring device from Fig. 8 in a detailed view.
[0066] Fig. 10 shows the measuring device from Fig. 8 with the probes deflected. Fig. 11 shows a closed pneumatic valve of a probe of the measuring device from Fig. 10 in a detailed view.
[0067] Fig. 12 shows an open pneumatic valve of a measuring probe of the measuring device from Fig. 10 in a detailed view.
[0068] Fig. 13 shows a closed pneumatic valve in a schematic representation.
[0069] Fig. 14 shows an open pneumatic valve in a schematic representation.
[0070] Fig. 15 shows a closed pneumatic valve in a schematic representation.
[0071] Fig. 1 shows an adjustment method 10 according to the invention for aligning components of an additive manufacturing device 12.
[0072] Such an additive manufacturing device 12 is schematically illustrated in Fig. 3, for example. The additive manufacturing device 12 typically has a process chamber 14 with a process chamber floor 16. The process chamber floor 16 is typically formed on a side facing the inside of the process chamber 14 as a manufacturing plane 18 of the additive manufacturing device 12. In other words, the process chamber floor 16 forms a plane with respect to which a production order is additively manufactured in the process chamber 14.
[0073] Common additive manufacturing devices 12 for additive manufacturing have a manufacturing cylinder 20 with at least one process plate 22, for example a build plate 24, arranged therein so as to be movable and detachable, for example a build plate 24 for producing a production order. The process plate 22 is typically designed to be movable within the manufacturing cylinder 20 perpendicular to the manufacturing plane 18. During additive manufacturing, the build plate 24 is typically lowered stepwise relative to the manufacturing plane 18, creating a process powder trough (not shown) for receiving process powder (not shown). Typically, the process powder trough thus created is then filled with process powder and partially solidified under the influence of a laser beam. The build plate 24 is then lowered again, and another process powder layer is applied and solidified.The described production steps are repeated until the production order is completed.
[0074] To fill the process powder trough with process powder, the additive manufacturing device 12 has a coater 26. The coater 26 is typically arranged movably in the process chamber 14 by means of a linear guide 28. As shown, the linear guide 28 can have a carriage 30 on which the coater 26 is arranged.
[0075] The carriage 30 extends in a first main extension direction 32 of the production plane 18 from a first guide rail 34 to a second guide rail 36 of the linear guide 28. The guide rails 34, 36 typically extend parallel to one another in a second main extension direction 38 of the production plane 18. The carriage 30 is movably arranged on the guide rails 34, 36 and is thus designed to be movable along the second main extension direction 38 of the production plane 18 together with the coater 26. In other words, the coater 26 can be moved within the process chamber 14 or above the production cylinder 20 and the process plate 22.
[0076] Preferably, the guide rails 34 are configured both parallel to each other and parallel to the production plane 18 or the process chamber floor 16. One method step of the adjustment method 10 may provide for the guide rails 34 to be aligned parallel to each other and parallel to the process chamber floor 16. This can increase the accuracy of the adjustment method 10.
[0077] During the filling of the process powder trough, the coater 26 with a coater tool 39 arranged thereon is moved along the second main extension direction 38 of the production plane 18, wherein process powder (not shown) is dispensed from the coater tool 39 into the process powder trough and is drawn off flush with the production plane 18, for example by means of a coater lip 40 (see Fig. 5) of the coater tool 39.
[0078] The coating tool 39 can be detachably arranged or attached to the coating device 26. Typically, the coating device 26 is designed to accommodate various coating tools 39. The coating tools 39 can be stored, for example, in a tool magazine (not shown) of the additive manufacturing device 12 and removed by the coating device 26, in particular automatically, as needed.
[0079] According to the invention, the adjustment method 10 is carried out using the coater 26 of the additive manufacturing device 12. In other words, existing components can advantageously be used to align the components of the additive manufacturing device 12.
[0080] The coater 26 has a measuring device 42 (see Figs. 3-12). The measuring device 42 can be formed on the coater 26. Preferably, the measuring device 42 is detachably arranged on the coater 26. Particularly preferably, the measuring device 42 can be removed from the tool magazine of the additive manufacturing device 12 by the coater 26, in particular before the start of a production order by the additive manufacturing device 12. The removal of the measuring device 42 can be automated, whereby the degree of automation of the additive manufacturing device 12 can be further increased.
[0081] According to a method step 44 of the adjustment method 10 according to the invention, at least one measuring probe 46 of the measuring device 42 is positioned in an alignment position 48 (see Fig. 5) vertically above the process plate 22 of the additive manufacturing device 12. The measuring probe 46 is located in a reference position 50 with a predetermined vertical reference distance 52 from the production plane 18 of the additive manufacturing device 12. The reference position 50 of the measuring probe 46 can lie in the production plane 18. In other words, the reference distance 52 can have the value zero. The reference distance 52 is typically predetermined, or fixed and / or set to a specific value. The reference distance 52 is taken into account when aligning the components of the additive manufacturing device 12.
[0082] A further method step 54 provides for the alignment of the production plane 18 and the process plate 22 with respect to one another. According to the invention, alignment can be achieved by adjusting at least one height adjustment 56, 58 (see Figs. 4, 5) of the additive manufacturing device 12. The adjustment continues until the measuring probe 46 is contacted by the process plate 22 in the reference position 50.
[0083] The additive manufacturing device 12 typically has a plurality of height adjustments 56, 58. As shown in Fig. 4, the additive manufacturing device 12 can have at least four height adjustments 56 for adjusting a height of the process chamber 14 or the process chamber floor 16. In addition, the additive manufacturing device 12 can have four height adjustments 58 for adjusting a height of the production cylinder 20. The height adjustments 56, 58 can be designed to be bidirectionally adjustable. The height adjustments 56, 58 can be designed to be adjustable individually or together. For reasons of clarity, only one height adjustment 56 and one height adjustment 58 are provided with a reference numeral in Fig. 4.
[0084] Alignment of the production plane 18 and the process plate 22, as shown in Fig. 5, can thus be achieved by lowering the height adjustment 56 of the process chamber floor 16 and / or by raising the height adjustment 58 of the production cylinder 20, together with the process plate 22. Raising the process plate 22 according to Fig. 5 occurs starting from an indeterminate process plate position 60, which has an indeterminate process plate distance 62 from the production plane 18, until the process plate 22 contacts or touches the measuring probe 46. The process plate 22 is then located in the reference position 50 of the measuring probe 46, which is aligned with the coater 26 and the process chamber floor 16.
[0085] In particular, in the case in which a reference position 50 has a reference distance 52 to the production plane 18, a method step of the adjustment method 10 can provide that the process plate 22 is lowered by the reference distance 52 following the method step 54.
[0086] Preferably, the method steps 44, 54 are performed for at least one further alignment position 48, which is arranged in the reference position 50 at a spatial distance from the at least one alignment position 48. This allows an inclined position between the process plate 22 and the production plane 18, or the process chamber floor 16, to be compensated.
[0087] The at least one further alignment position 48 can, for example, be spaced apart from the at least one alignment position 48 along the second main extension direction 38. By probing the process plate 22 at at least two alignment positions 48 along the second main extension direction 38, a rotation of the process plate 22 about the first main extension direction 32 relative to the production plane 18 can be corrected.
[0088] The at least one further alignment position 48 can be further spaced from the at least one alignment position 48, for example, along the first main extension direction 32. By probing the process plate 22 at at least two alignment positions 48 along the first main extension direction 32, a rotation of the process plate 22 about the second main extension direction 38 relative to the production plane 18 can be corrected. A correction can relate both to the alignment of the process chamber 14 or the process chamber floor 16 with respect to the process plate 22 and to an alignment of the process plate 22 with respect to the process chamber floor 16.
[0089] Further preferably, the method steps 44, 54 are carried out for at least one first alignment position 48a (see Fig. 4) and at least one second alignment position 48b (see Fig. 4) by adjusting the at least one height adjustment 56, 58 once. In other words, the components of the additive manufacturing device 12 are aligned at two alignment positions 48, 48a, 48b simultaneously. In this case, the measuring device 42 preferably has at least two measuring probes 46. Typically, the at least one first alignment position 48a and the at least one second alignment position 48b are arranged or formed parallel to the first main extension direction 32 of the manufacturing plane 18.
[0090] Particularly preferably, method steps 44, 54 are performed for additional first alignment positions 48a and additional second alignment positions 48b. For this purpose, the coater 26 can be moved along the second main extension direction 38 above the process plate 22.
[0091] Fig. 2 shows a further embodiment of the adjustment method 10. The embodiment of the adjustment method 10 according to Fig. 2 differs from the embodiment of the adjustment method 10 according to Fig. 1 by upstream method steps, which are explained below with reference to the remaining figures of the drawing.
[0092] A preceding method step 64 provides for the determination of a reference section 66 (see Fig. 3) of the additive manufacturing device 12. The reference section 66 is typically formed parallel to the first main extension direction 32 of the manufacturing plane 18. The reference section 66 can lie in the manufacturing plane 18. Preferably, the reference section 66 has a reference section height 70 perpendicular to the manufacturing plane 18. By raising the reference section 66 relative to the manufacturing plane 18, the reference section 66 can be kept insensitive to process powder located in the process chamber 14. This can improve the robustness of the adjustment method 10.
[0093] A further method step 72 provides for the alignment of the coater 26 with the reference section 66 of the additive manufacturing device 12. In other words, the coater 26 is moved to a known position relative to the production plane 18.
[0094] Alignment of the coater 26 can be achieved, as shown in Fig. 6, by lowering the coater 26 onto the reference section 66.
[0095] The coater 26 can be lowered, for example, by loosening a coater fixation (not shown) on the carriage 30 (see Fig. 3) of the linear guide 28 and displacing the coater 26 in the vertical direction. Preferably, the coater 26 is lowered in the vertical direction until the coater lip 40 contacts or touches the reference section 66. The coater 26 can then be located in a coater position 74 that is offset from the production plane 18 by the reference section height 70.
[0096] Preferably, the measuring probe 46, or a measuring pin 76 of the measuring probe 46, protrudes vertically beyond the coating lip 40. Particularly preferably, the measuring probe 46 protrudes vertically beyond the coating lip 40 by the reference section height 70. This allows the process plate 22 (see Figs. 3-5) to be aligned without subsequent correction. A further method step 78 can provide for determining the reference distance 52 of the measuring probe 46 to the production plane 18 by at least one contact of the reference section 66 with the measuring probe 46. In other words, a reference distance 52 can be checked, corrected, and / or redetermined. The determination of the reference distance 52 is preferably carried out automatically by the additive manufacturing device 12, so that the degree of automation of the additive manufacturing device 12 can be increased and the robustness of the adjustment method 10 can be further enhanced.
[0097] The reference distance 52 can be determined as shown in Fig. 7. As shown, the coater 26 can be moved together with the measuring probe 46 to a position above the reference section 66. By probing the reference section 66, the measuring pin 76 of the measuring probe 46 is deflected in the vertical direction. The deflection can then be determined by a probing mechanism 80, for example a deflection scale, of the measuring probe 46. The measuring probe 46 can then be adjusted relative to the coater 26, if necessary. In other words, a measuring pin position 82 of the measuring pin 76 can be determined relative to the probing mechanism 80.
[0098] Fig. 8 shows an embodiment of a measuring device 42.
[0099] The measuring device 42 has two measuring probes 46. The measuring probes 46 each comprise a measuring pin 76 and a contact mechanism 80. The measuring probes 46 are arranged on a common base body 84 of the measuring device 42.
[0100] The probing mechanisms 80 each have a pneumatic valve 86 and a probe gear 88. The probe gear 88 extends from the respective pneumatic valve 86 of the measuring probe 46 to the measuring pin 76. The pneumatic valves 86 of the measuring probes 46 close off an overpressurized internal volume 90 of the base body 84 from an environment 92 of the measuring device 42. By actuating one of the measuring probes 46, or by deflecting one of the measuring pins 76 in the vertical direction, the deflection movement of the measuring pin 76 is translated via the probe gear 88 to the pneumatic valve 86 of the respective measuring probe 46. This opens the pneumatic valve 86 and causes a pressure drop in the internal volume 90. The pressure drop can be measured by a controller (not shown) of the additive manufacturing device 12 and a touch of the measuring probe 46 can be detected.
[0101] The measuring pins 76 have a different measuring pin deflection 94, 96 relative to the base body 84 or the respective probing mechanism 80. By means of a different measuring pin deflection 94, 96, individual probing of the respective measuring probes 46 against a common internal volume 90 can be achieved, which is explained with reference to the following Figures 9 to 12.
[0102] Fig. 9 shows a detailed view A of the measuring device 42 from Fig. 8.
[0103] If the measuring pin 76 is deflected in the direction of the arrow 98, for example upon contact with the process plate 22 (see Figs. 3-5) or the reference section 66, the measuring pin 76 deflects the pushbutton gear 88 so that a valve head 100 of the pneumatic valve 86 is lifted from a valve seat 102 of the base body 84 and a flow path 104 is released into the environment 92 of the measuring device 42.
[0104] The state of the pneumatic valve 86 is shown schematically in Fig. 14 for clarity.
[0105] The additional measuring probe 46 (see Fig. 8) is not contacted, so that the pneumatic valve 86 of the measuring probe 46 remains closed. The state of the additional measuring probe 46 is shown schematically in Fig. 13 for clarity. Fig. 10 shows the measuring device 42 from Fig. 8 with increasing deflection of the measuring pins 76 in the direction of arrow 98.
[0106] Fig. 11 shows a detailed view B of the measuring device 42 from Fig. 10.
[0107] If the measuring pin 76 is further deflected in the direction of arrow 98, the valve head 100 of the pneumatic valve 86 is increasingly lifted from the valve seat 102 of the base body 84 by the probe gear 88. As shown, a valve stem 106 of the pneumatic valve 86 closes the flow path 104 in this state, so that the overpressure in the internal volume 90 can be restored for a renewed triggering of a measuring probe 46.
[0108] The state of the pneumatic valve 86 is shown schematically in Fig. 15 for clarity.
[0109] Fig. 12 shows a detailed view C of the measuring device 42 from Fig. 10.
[0110] While the pneumatic valve 86 is closed according to Fig. 11, with increasing deflection of the measuring pin 76 in the direction of arrow 98, the pneumatic valve 86 is opened according to Fig. 12 by the probe gear 88 in a manner analogous to Fig. 9. The pressure drop in the internal volume 90 detects contact with the measuring probe 46.
[0111] The state of the pneumatic valve 86 is shown schematically in Fig. 14 for clarity.
[0112] List of reference symbols
[0113] 10 adjustment procedures; 54 process steps;
[0114] 12 additive manufacturing device; 56, 58 height adjustment;
[0115] 14 process chambers; 60 process plate layers;
[0116] 16 process chamber floor; 62 process plate spacing;
[0117] 18 production levels; 64 process steps;
[0118] 20 production cylinders; 66 reference sections;
[0119] 22 Process plate 70 Reference section height;
[0120] 24 building board; 72 process steps;
[0121] 26 coaters; 74 coater layer;
[0122] 28 linear guide; 76 measuring pin;
[0123] 30 slides; 78 process steps;
[0124] 32 first 80 probing mechanism;
[0125] Main direction of extension; 82 measuring pin position;
[0126] 34 first guide rail; 84 base body;
[0127] 36 second guide rail; 86 pneumatic valve;
[0128] 38 second 88 push button gears;
[0129] Main extension direction 90 internal volume;
[0130] 39 Coating tool; 92 Environment;
[0131] 40 Coater lip; 94, 96 Measuring pin deflection;
[0132] 42 measuring device; 98 arrow direction;
[0133] 44 process steps; 100 valve head;
[0134] 46 measuring probe; 102 valve seat;
[0135] 48 alignment position; 104 flow path;
[0136] 48a first alignment position; 106 valve stem;
[0137] 48b second alignment position; A section;
[0138] 50 Reference position; B section;
[0139] 52 Reference distance; C cutout.
Claims
Patent claims 1. Adjustment method (10) for aligning components of an additive manufacturing device (12) using a coater (26) of the additive manufacturing device (12) having a measuring device (42), comprising the method steps: d) positioning (44) of at least one measuring probe (46) of the measuring device (42) in an alignment position (48) vertically above a process plate (22) of the additive manufacturing device (12); wherein the measuring probe (46) has a reference position (50) with a predetermined vertical reference distance (52) to a Manufacturing plane (18) of the additive manufacturing device (12); f) aligning (54) the manufacturing plane (18) and the process plate (22) with respect to one another by adjusting at least one height adjustment (56, 58) of the additive manufacturing device (12); wherein an adjustment is carried out by the process plate (22) until the measuring probe (46) touches the reference position (50).
2. Adjustment method (10) according to claim 1, further comprising the method steps: a) determining (64) a reference section (66) of the additive manufacturing device (12); wherein the reference section (66) is formed parallel to a first main extension direction (68) of the manufacturing plane (18) of the additive manufacturing device (12); b) aligning (72) the coater (26) with the reference section (66), in particular by lowering the coater (26) onto the reference section (66).
3. Adjustment method according to claim 2, further comprising the method step: c) determining (78) the reference distance (52) of the measuring probe (46) to the production plane (18) by at least one probing of the reference section (66) by the measuring probe (46).
4. Adjustment method (10) according to one of the preceding claims, further comprising the method step: e) deflecting a measuring pin (76) of the at least one measuring probe (46) in the vertical direction up to the process plate (22); wherein a process plate distance (62) of the process plate (22) to the production plane (18) is determined; wherein in method step f) an adjustment of the at least one height adjustment (56, 58) by the process plate distance (62) takes place.
5. Adjustment method (10) according to one of the preceding claims, wherein the method steps d) to f) are carried out for at least one further alignment position (48) vertically above the process plate (22), wherein the further alignment position (48) is spatially spaced from the alignment position (48) in the reference position (50).
6. Adjustment method (10) according to claim 5, comprising at least one first alignment position (48a) and at least one second alignment position (48b), wherein the first alignment position (48a) and the second alignment position (48b) are arranged parallel to the first main extension direction (63) of the manufacturing plane (18).
7. Adjustment method (10) according to claim 6, wherein the measuring device (42) has at least two measuring probes (46); wherein an adjustment of the at least one height adjustment (56, 58) until the pairwise contact of the at least two measuring probes (46) in the respective alignment position (48, 48a, 48b) in the reference position (50) is carried out by the process plate (22).
8. Adjustment method (10) according to claim 6 or 7, wherein the method steps d) to f) are carried out for at least one further first alignment position (48a) and at least one further second alignment position (48b), wherein the at least one further first alignment position (48a) and the at least one further second alignment position (48b) are arranged at a distance from the at least one first alignment position (48a) and the at least one second alignment position (48b) along a second main extension direction (38) of the production plane (18).
9. A coater (26) for an additive manufacturing device (12), in particular configured to carry out the adjustment method (10) according to one of the preceding claims, comprising a coater lip (40) and a measuring device (42) with at least one measuring probe (46); wherein the measuring probe (46) protrudes in a vertical direction beyond the coater lip (40); and wherein the measuring probe (46) is configured for tactile probing by a process plate (22).
10. The coater (26) of claim 9, wherein the measuring probe (46) comprises a probing mechanism (80) and a measuring pin (76); wherein the measuring pin (76) is displaceable relative to the probing mechanism (80) to detect probing by the process plate (22).
11. Coater (26) according to claim 10, wherein the measuring probe (46) is designed to be arranged in a reference position (50) by fixing a measuring pin position (82) of the measuring pin (76) relative to the probing mechanism (80).
12. Coater (26) according to one of claims 9 to 11, wherein the measuring probe (46) is designed to be extendable in a vertical direction, in particular incrementally.
13. Coater (26) according to claim 9 or 12, wherein the probing mechanism (80) comprises a pneumatic valve, wherein the measuring pin (76) is designed to switch the pneumatic valve (86).
14. Coater (26) according to one of claims 9 to 13, wherein the measuring device (42) has at least two measuring probes (46), wherein the at least two measuring probes (46) are arranged perpendicular to a working axis of the coater (26).
15. Coater (26) according to one of claims 9 to 14, wherein the measuring device (42) is detachably arranged on the coater (26).
16. Additive manufacturing device (12) for the additive manufacturing of production orders in a process chamber (14) of the additive manufacturing device (12); comprising a production cylinder (20) having a process plate (22) and a coater (26) according to one of claims 9 to 15; wherein the coater (26) is designed to move the measuring device (42) along a second main extension direction (38) of a production plane (18) of the additive manufacturing device (12) above the process plate (22).