Docking Arrangement for Additive Manufacturing Processes

Abstract

The present invention relates to an operating handle for controlling an operational state of a valve arrangement associated with a container to control the distribution of material from the container to a component in an additive manufacturing process, the operating handle comprising a rotatable shaft coupled to the valve arrangement, the shaft rotatable between a plurality of angular positions corresponding to one or more operational states of the valve arrangement, a lever operably coupled to the shaft, the lever configured to rotate the shaft between the plurality of angular positions in response to rotation of the lever, a rotational retention mechanism configured to retain the lever in one of the plurality of rotational positions, and an actuator engagement member extending axially outward from the handle, wherein an actuator provided as part of a docking arrangement associated with the component is operable to operate the actuator engagement member to engage and disengage the rotational retention mechanism.

Description

[Technical field]

[0001] The present invention relates to a docking arrangement, in particular for use in additive manufacturing processes for supplying material, such as powder, held in a container (e.g. a hopper) to additive manufacturing machines. [Background technology]

[0002] Additive manufacturing generally refers to the process of producing 3D objects by building up one or more layers of material. Traditionally, material is fed to the additive manufacturing machine in the form of powder (e.g. metal powder). For small-scale manufacturing processes, the powder is fed in containers (e.g. plastic jars). For large-scale manufacturing processes, hoppers are designed to transport and deliver the powder in bulk to the additive manufacturing machine. Such hoppers have been improved to ensure that the environmental conditions (atmosphere, moisture, etc.) in the hopper are controlled. For example, some powders may oxidize in air and need to be stored under a controlled atmosphere. Furthermore, in most cases it is desirable to prevent the powder from getting wet, which may cause problems when feeding the powder to the additive manufacturing machine, i.e. the powder may not flow out of the hopper. However, to date no complete solution has been provided. Summary of the Invention [Problem to be solved by the invention]

[0003] For example, there is a demand for a docking arrangement where a hopper containing material (e.g., powder) for a manufacturing process may be docked and coupled to a component of an additive manufacturing process (e.g., an additive manufacturing machine) to deliver the powder from the hopper to the component.

[0004] In some situations, there is a demand for providing an arrangement whereby the dispensing of material from a hopper can be controlled (e.g., automatically and / or manually). For example, the feeding of material from a hopper is typically by gravity, and in large scale processes manual control may be inappropriate (e.g., out of reach). It would therefore be advantageous to provide an arrangement whereby the dispensing of material from a hopper can be controlled without the need for an operator to physically contact the hopper (e.g., by opening the hopper outlet).

[0005] There is a need to provide an arrangement that can adequately secure the hopper to the component, to ensure that the hopper-component coupling is stable and / or that the necessary environmental control is maintained (e.g., air / water tight seals provided at the hopper-component coupling), and to ensure that the coupling between the hopper and the component remains fixed in place during the dispensing of material.

[0006] It is therefore an object of one or more embodiments of the present invention to overcome or at least partially alleviate one or more problems associated with the prior art. [Means for solving the problem]

[0007] According to a first aspect of the present invention there is provided an operating handle for controlling an operational state of a valve arrangement associated with a container to control distribution of material from the container to a component in an additive manufacturing process, the operating handle comprising a rotatable shaft coupled to the valve arrangement, the shaft rotatable between a plurality of angular positions corresponding to one or more operational states of the valve arrangement, a lever operably coupled to the shaft, the lever configured to rotate the shaft between the plurality of angular positions in response to rotation of the lever, a rotational retention mechanism configured to retain the lever in one of the plurality of rotational positions, and an actuator engagement member extending axially outwardly from the handle, wherein an actuator provided as part of a docking arrangement associated with the component is operable to operate the actuator engagement member to engage and disengage the rotational retention mechanism.

[0008] Advantageously, the operating handle has been found to overcome tolerance issues associated with the docking position of the hopper in the docking arrangement. In particular, the provision of an actuator engagement member extending axially outwardly from the handle means that the rotary retention mechanism can be reliably engaged and disengaged in a simple manner regardless of the docking position of the hopper in the docking arrangement.

[0009] The operating handle may be manually operated or automatically operated via an actuator, and the lever may be rotatable under the action of the actuator.

[0010] The lever is operably coupled to the rotatable shaft via a coupling portion located approximately midway along the length of the lever to define first and second lever arms on either side of the coupling portion.

[0011] The actuator engagement member may extend outwardly from a central region of the operating handle. Suitably, the actuator engagement member may extend from or proximate to the coupling portion.

[0012] The actuator engagement member may have a conical shape. Suitably, the actuator engagement member is frusto-conical in shape. A free end of the frusto-conical engagement member may be open to define a female portion adapted to receive a corresponding male portion provided by the actuator.

[0013] In some embodiments, the actuator engagement member may be wedge-shaped.

[0014] The actuator engagement member may be removably attachable to the coupling portion, for example by screwing or magnetic attachment, however, in some embodiments the actuator engagement member may be integrally formed with the coupling portion or part of the operating handle near the coupling portion.

[0015] The actuator engagement member may be in the form of a cap.

[0016] In some embodiments, the rotational retention mechanism may be configured to retain the lever and rotatable shaft in a predetermined rotational position when the rotatable shaft (or a component of the rotatable shaft) is in a first axial position. Similarly, the rotational retention mechanism may be configured to allow the lever and rotatable shaft to rotate between a plurality of rotational positions when the rotatable shaft (or a component of the rotatable shaft) is in a second axial position. In use, linear movement of the actuator engagement member moves the rotatable shaft (or a component thereof) from the rotatable shaft first axial position to the rotatable shaft second axial position and disengages the rotational retention mechanism. Similarly, movement of the rotatable shaft (or a component thereof) from the rotatable shaft second axial position to the rotatable shaft first axial position (e.g., under operation of a biasing member) may engage the rotational retention mechanism. In this manner, the operating handle may be configured such that the rotational retention mechanism is engaged unless the actuator engagement mechanism is linearly moved (e.g., manually or via an actuator) to cause axial movement of the rotatable shaft.

[0017] In some embodiments, the rotational retention mechanism may comprise a slot in an outer sheath disposed about the rotatable shaft, the slot configured to receive a protrusion associated with the rotatable shaft, and the operating handle may be configured such that upon rotation of the rotatable shaft, for example by rotation of a lever, the protrusion moves along the slot in the outer sheath.

[0018] In an embodiment, a slot provided in the outer sheath includes a plurality of notches for receiving the protruding portion. The plurality of notches may be configured to function to prevent rotation of the shaft by retaining the protruding portion in the plurality of notches. In practice, the plurality of notches may define a plurality of angular positions in which the rotatable shaft, i.e. the lever, can be retained. The plurality of notches may consist of three notches corresponding to a first, intermediate, and second rotational position of the lever. Thus, the plurality of notches may correspond to three operating states of the valve arrangement, e.g., a fully closed state, an intermediate / partially open state, and a fully open state, for controlling the flow of manufacturing material from the container.

[0019] The operating handle may be configured such that the actuator engagement member, the first lever arm and the second lever arm may be directly actuated by one or more components of an associated actuator.

[0020] The lever may be fixed to the rotatable shaft or may be integrally formed with the rotatable shaft. In embodiments, the lever may be operably coupled to the rotatable shaft via a coupling portion. The coupling portion may be located approximately midway along the length of the lever. Thus, in such embodiments, the location of the coupling portion may define first and second lever arms of the lever located on either side of the coupling portion. In other embodiments, the lever is operably coupled to the rotatable shaft at or proximal to an end of the lever.

[0021] In some embodiments, the lever (and thus the rotatable shaft) may be rotatable between a first rotational position and a second rotational position. The first and second rotational positions may correspond to fully closed and fully open configurations of an associated valve arrangement. The lever may be rotatable between the first and second rotational positions via an intermediate position provided between the first and second rotational positions. The intermediate position may correspond to a partially open configuration of the valve arrangement. The intermediate positions of the lever may thus allow the flow of material from the container to be controlled.

[0022] The rotatable shaft may be coupled to the valve arrangement via coupling means, which may be provided at an end of the rotatable shaft. In some embodiments, the coupling means comprises a female coupler, e.g. a bore in the end of the shaft configured to receive a corresponding operating shaft of the valve arrangement. Means for fixing the operating handle to the valve arrangement during use and further fixing means for fixing may be provided.

[0023] In some embodiments, the rotatable shaft includes first and second shaft portions. The first shaft portion may be coupled to the lever, thereby providing an operable coupling between the lever and the rotatable shaft. The second shaft portion may be coupled, in use, to the valve arrangement.

[0024] The first and second shaft portions may be operably coupled. In some embodiments, the first and second shaft portions may be coupled via one or more rods. The one or more rods may be disposed in corresponding slots in the first and second shafts. In use, the rods may provide an interface between the first and second shaft portions and ensure that the second shaft portion rotates upon rotation of the first shaft portion, e.g., upon rotation of a lever under manual manipulation by an actuator or a user.

[0025] The rotatable shaft (or at least a component of the rotatable shaft) may be axially movable. In an embodiment, the rotatable shaft (or a component of the rotatable shaft) may be axially movable under operation of an actuator acting on an actuator engagement member.

[0026] In some embodiments, the first and / or second shaft portion may be axially movable. In currently preferred embodiments, the first shaft portion is axially movable between a first axial position and a second axial position under operation of an actuator acting on the actuator engagement member. In particular, the first shaft portion may be axially movable upon linear movement of the actuator engagement member. In such embodiments, the position of the second shaft portion may be axially fixed. This may be necessary to ensure that the rotatable shaft remains securely coupled to the valve arrangement, for example via coupling means provided on or by the second shaft portion, regardless of the axial position of the rotatable shaft, in particular the axial position of the first shaft portion of the rotatable shaft.

[0027] In some embodiments, the operating handle comprises a biasing member. The biasing member may include a spring. The biasing member may be configured to provide a biasing force acting in one or more directions with or against the movement of one or more components of the operating handle, such as, for example, a rotatable shaft or a lever. In some embodiments, the biasing member may be configured to provide a biasing force acting with or against the axial movement of a rotatable shaft.

[0028] In some embodiments, the first and second shaft portions may be operably coupled via a biasing member. Thus, in such embodiments, the biasing member may be configured to provide a biasing force that acts with or against movement of the first shaft portion relative to the second shaft portion.

[0029] In some embodiments, the biasing force provided by the biasing member acts against movement of the first shaft portion from the first axial position to the second axial position and acts with movement of the first shaft portion from the second axial position to the first axial position. In this manner, the biasing force may otherwise act to bias / retain the first shaft portion in the first axial position.

[0030] In some embodiments, the operating handle may be configured such that the lever is directly acted upon by one or more components of an associated actuator, for example in embodiments in which the lever comprises first and second lever arms, each lever arm may be configured to be acted upon by a respective component of the actuator to rotate the lever in use.

[0031] In some embodiments, the operating handle may comprise coupling means for coupling the operating handle to the actuator in use. The coupling means may comprise a female coupler, e.g. a bore provided by a component of the operating handle to receive a corresponding male coupler provided by the actuator. The coupling means may be provided on or by the lever. In some embodiments, the coupling means is provided on or by a coupling portion of the lever.

[0032] In embodiments, the operating handle may comprise a right-angle drive type arrangement. In such embodiments, the operating handle may be configured to be coupled to and acted upon by an actuator having an operating axis oriented in a different direction (e.g., vertical) than the operating handle. For example, in some embodiments, the operating handle may comprise a right-angle drive type arrangement configured to receive a vertically oriented actuator (e.g., a vertical actuator drive shaft). The operating handle may comprise a gear arrangement, which in embodiments includes a pair of bevel gears, to effect, under operating rotation of the actuator, a corresponding rotation of a differently oriented (e.g., horizontally oriented) drive shaft of the valve arrangement (via a rotatable shaft of the operating handle).

[0033] In embodiments, the operating handle may be specific to the type of material held within the container. For example, in some embodiments, the operating handle may include a coupling means in the form of a bore, or the bore or female portion may include a configuration specific to the type of material held within the container, such that the actuator engagement member includes a female portion. Thus, in such embodiments, the operating handle must be acted upon using a specially configured actuator to open or close the associated valve arrangement. In this manner, the operating handle may be configured to prevent the wrong type of material from being deposited in the wrong location or on the wrong component of an additive manufacturing process.

[0034] According to a second aspect of the present invention there is provided an actuator for controlling an operational state of a valve arrangement associated with a container to control the distribution of material from the container to a component of an additive manufacturing process, the actuator being provided as part of a docking arrangement associated with the component, the actuator comprising at least one movable component configured to engage with an operating handle of the present invention, and the at least one movable component being operable, in use, to act on an actuator engagement member to cause engagement and disengagement of a rotational holding mechanism.

[0035] In an embodiment, the at least one moveable component comprises a linear actuator, which may include a piston, which may be movable between a plurality of positions for engaging and disengaging with an actuator engagement member.

[0036] In use, the actuator may be configured to move linearly between a first position and a second position, where movement of the actuator between the first position and the second position causes linear movement of the actuator engagement member (and thus the rotatable shaft) thereby disengaging the rotation retention mechanism and allowing rotation of the lever.

[0037] In embodiments, the actuator may be configured to move between a retracted position and a first position and may be configured such that, in use, the actuator contacts at least a portion of the actuator engagement member when moving from the retracted position to the first position.

[0038] In some embodiments, the actuator comprises an end portion that forms a contact surface for contacting the actuator engagement member to induce linear motion, for example, the actuator may comprise a spring plunger, such as a ball spring plunger, a roller, or a gear.

[0039] In some embodiments, the actuator may comprise a second movable component and a third movable component configured to operate the operating handle. The second and third movable components may be located on either side of a movable component that operates the actuator engagement member. In particular, the second and third movable components may be arranged and configured to operate respective lever arms of a lever to rotate the lever. Each of the second and third movable components may comprise a linear actuator.

[0040] The end of each of the second and third actuators may have a contact surface at the end released from contact with the lever when the actuator moves from the first position to the second position (and corresponding rotation of the lever). In some embodiments, the contact surface at the end of the actuator may be angled relative to the lever. For example, when the actuator is in the actuator first position and the lever is in the lever first rotational position, the contact surface at the end of the lever may be disposed perpendicular to the longitudinal axis of the lever. Additionally, when the actuator is in the actuator second position and the lever is in the lever second rotational position, the contact surface may be disposed parallel to the longitudinal axis of the lever.

[0041] In some embodiments, at least one movable component of the actuator includes a drive shaft. The drive shaft may be rotatable. The drive shaft may be configured as a male coupling part that is received in a corresponding female coupling provided by the operating handle, or vice versa. For example, the drive shaft may be configured to be received in a component of the operating handle, e.g., a lever or actuator engagement member, or in a female coupling in the form of a bore provided by a component of the operating handle. The drive shaft may be axially movable to cause linear movement of the actuator engagement member (and thus the rotatable shaft) as required, e.g., for engagement and disengagement of a rotation retention mechanism.

[0042] In some embodiments, the operation of the actuator may be controllable via a control system, for example, in embodiments, a control system may be provided for controlling the movement of at least one moveable component of the actuator.

[0043] The control system may be configured to take into account an operational state of one or more components of an associated docking arrangement when controlling movement of the (or each) movable component. For example, in some embodiments, the control system may be configured to take into account an operational state of a locking mechanism associated with the container when controlling movement of the at least one movable component. The control system may be configured to require the locking mechanism to be in a locked state prior to moving the at least one movable component to actuate dispensing of material from the container.

[0044] According to a third aspect of the present invention there is provided a docking arrangement for an additive manufacturing process comprising an operating handle according to the first aspect of the present invention and an actuator according to the second aspect of the present invention. The docking arrangement according to the third aspect of the present invention may therefore optionally include any or all of the features described in relation to the first and second aspects of the present invention.

[0045] According to a fourth aspect of the present invention there is provided a method for controlling the operational state of a valve arrangement associated with a container to control the distribution of material from a container to a component of an additive manufacturing process using a docking arrangement according to the third aspect of the present invention, comprising rotating a lever under operation of the actuator to couple an outlet of the container with an inlet of a dock associated with the component of the additive manufacturing process and to disengage from the rotary holding mechanism under control of an actuator which, in use, operates an actuator engagement member and opens the valve arrangement for distribution of material from the container to the component. [Brief description of the drawings]

[0046] In order that the invention may be more clearly understood, one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] A perspective view of the docking arrangement. [Diagram 2] FIG. 2 is a perspective view of the docking arrangement of FIG. [Diagram 3] FIG. 3 is an enlarged view of area A in FIG. [Figure 4] FIG. 4 is a side cross-sectional view of the docking arrangement shown in FIGS. [Diagram 5] FIG. 5 is an enlarged view of section B of FIG. [Figure 6] FIG. 2 is a side view of one embodiment of an operating handle. [Figure 7A] FIG. 7 is a side view of one state of the operating handle shown in FIG. 6. [Figure 7B] 7 is a side view of the operating handle shown in FIG. 6 in another state. [Figure 8] FIG. 13 is a perspective view of another embodiment of the operating handle. [Figure 9] 9 is a perspective view of another embodiment of the operating handle shown in FIG. 8. FIG. [Figure 10A] 10 is a cross-sectional view of the operating handle of FIGS. 8 and 9 in a certain state. FIG. [Figure 10B] FIG. 10B is an enlarged view of region C in FIG. 10A. [Figure 11A] 10 is a cross-sectional view of the operating handle of FIGS. 8 and 9 in another state. FIG. [Figure 11B] FIG. 11B is an enlarged view of region D in FIG. 11A. [Figure 12] FIG. 13 is a perspective view of one embodiment of a locking mechanism. [Figure 13] FIG. 13 is a perspective view of components of the locking mechanism of FIG. [Figure 14A] 14 is a cross-sectional view of the locking mechanism of FIGS. 12 and 13 in one state. FIG. [Figure 14B] FIG. 14B is an enlarged view of region E in FIG. 14A. [Figure 15A] FIG. 14B is a view corresponding to FIG. 14A, but with the locking mechanism in another state. [Figure 15B] FIG. 15B is an enlarged view of region F in FIG. 15A. [Figure 16] FIG. 13 is a perspective view of a further embodiment of a locking mechanism. [Figure 17] FIG. 17 is a cross-sectional view of the locking mechanism of FIG. 16. [Figure 18A] 1 is a flow chart illustrating a control strategy for operating the docking arrangement described herein. [Figure 18B] FIG. 18B is a flow chart illustrating a continuation of the control strategy of FIG. 18A. [Figure 19] FIG. 19 is a side cross-sectional view illustrating further features of the docking arrangement shown in FIGS. 1 to 18; and [Figure 20] FIG. 13 is a further cross-sectional side view of the docking arrangement. [Figure 21] FIG. 13 is a perspective view of an alternative docking arrangement with an alternative operating handle. [Figure 22A] 22 is a side view and an enlarged side view of the operating handle shown in FIG. 21. [Figure 22B] 11 is an enlarged side view showing the operating handle in another state. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] The invention relates to a docking arrangement 10 for a manufacturing process, such as an additive manufacturing process.

[0048] 1 and 2, a docking arrangement 10 includes a dock 11 to which a container in the form of a hopper 12 may be coupled. These figures show the hopper 12 undocked from and docked to the dock 11, respectively. In use, the dock 11 may correspond to a machine in an additive manufacturing process, and the hopper 12 contains powder (such as metal powder) to be fed to the machine.

[0049] The hopper 12 includes a stand 22 and a number of support arms 24 for supporting the container 14 of the hopper 12 on the stand 22. In the embodiment shown, three support arms 24 are provided. The container 14 may contain powder for an additive manufacturing process. The container includes an upper cylindrical portion above a frusto-conical portion that leads to an outlet.

[0050] The hopper 12 includes an outlet 16 that is coupled and secured to an inlet 18 on the dock 11. The coupling between the outlet 16 and the inlet 18 of the hopper 12 includes a locking mechanism 100. The locking mechanism 100 provides a means for locking and securing the outlet 16 and the inlet 18 to allow material from the container 14 of the hopper 12 to be fed through the dock 11 to further components of the manufacturing process. In the embodiment shown, the inlet 18 is provided with a conduit 20 for feeding material from the hopper 12 to further components of the manufacturing process.

[0051] The stand 22 of the hopper 12 includes a plurality of openings 21 in the base of the stand for receiving a corresponding plurality of protruding members 23 on the dock 11. As shown, the plurality of protruding members 23 protrude upwardly from the surface 13 of the dock 11. Each protruding member 23 can function to further secure the hopper 12 to the dock 11 during use.

[0052] The hopper 12 is provided with a valve arrangement 26 for controlling the flow of material from the container 14 of the hopper 12. In a presently preferred embodiment, the valve arrangement includes an outlet valve in the form of a butterfly valve, although it will be understood that the invention is not limited in this sense and the valve arrangement 26 may comprise any suitable valve type. In the illustrated embodiment, the outlet valve is controlled via an operating handle 50. As described herein, the operating handle 50 is used to open and close the outlet valve of the valve arrangement 26 through rotation of an operating lever 52. This may be done in an embodiment via an actuator 40 operably coupled to the operating handle 50. In the illustrated embodiment, the actuator 40 forms part of the dock 11, and upon docking of the hopper 12 on the dock, the operating handle 50 and the actuator 40 are positioned relative to one another for subsequent actuation of the operating handle 50.

[0053] The hopper 12 is further provided with a gas inlet 32. In use, the gas inlet 32 ​​can be used to control the pressure level within the container 14 of the hopper 12, as will be explained with reference to Figures 19 and 20. It may be desirable to increase the pressure within the hopper 12 to aid the flow of material from the outlet 16.

[0054] As described herein, the docking arrangement 10 includes a dock 11 corresponding to (or forming part of) a machine of an additive manufacturing process (e.g., an additive manufacturing machine or a sieve) and a hopper 12 for containing powder to be fed to that machine. However, it may be desirable, for example, to replenish the material therein, and in some cases, powder / material is fed to the hopper 12. The hopper 12 is therefore provided with an openable hatch 30 on its top surface that provides access to the interior of the container 14 of the hopper 12. In some cases, material from another hopper may be deposited in the hopper 12. For example, a docking arrangement 10 may be used in which the inlet 18 (and optionally the conduit 20) serves as the inlet to the hopper 12, and in which separate hoppers are docked on the dock 11. This may be useful in embodiments in which material in two different hoppers is interconnected. In an embodiment, material from one hopper or additive manufacturing machine may pass through a sieve before being deposited in the hopper 12. In such case the docking arrangement 10 is adapted to receive the sieve.

[0055] 3-7B show one embodiment of the operating handle 50 and how the actuator 40 is used to actuate the operating handle 50 to open and close the outlet valve of the valve arrangement 26.

[0056] The operating handle 50 includes a lever 52 that can be rotated between a plurality of rotational positions, and a rotatable shaft 56 connected to the lever 52. As described herein, rotation of the lever 52 in turn causes a corresponding rotation of the shaft 56, which in turn acts on an outlet valve (not shown) to control the flow of material out of the hopper 12.

[0057] The lever 52 is coupled (e.g. suitably fixed or integrally formed) to a rotatable shaft 56 of the operating handle 50 via a coupling portion 64, approximately halfway along its length, such that the lever 52 is pivoted about a lever centre which defines first and second lever arms 53a, 53b on either side of the coupling member 64. In use, the lever 52 (and thus the rotatable shaft 56) is rotatable between two rotational positions which correspond to fully closed and fully open configurations of the associated valve arrangement 26.

[0058] In this embodiment, the actuator 40 takes the form of a dual piston arrangement including a first piston 42 and a second piston 45. The first and second pistons 42, 45 are movable between a plurality of positions to effect rotation of the lever 52. As shown and described herein, the first piston 42 is configured to act on the first lever arm 53a and the second piston 45 is configured to act on the second lever arm 53b to rotate the lever arms 53a, 53b as required.

[0059] The first piston 42 includes a pair of piston arms 41a, 41b and an upper support member 43 to which the piston arms 41a, 41b are coupled. A first roller 49a is attached to the support member 43 and is arranged to interact, in use, with a first lever arm 53a of the lever 52. The piston arms 41a, 41b are configured to move in and out of the first piston chamber 47, for example via a hydraulic or pneumatic arrangement that introduces or removes fluid into the first piston chamber 47. Alternatively, the actuator 40 may comprise an electric actuator, such as a solenoid or motor, configured to move the arms 41a, 41b. On moving in and out of the first piston chamber 47, the piston arms 41a, 41b cause corresponding movement of the support member 43 and thus of the rollers 49a, which through interaction with the first lever arm 53a, cause movement (linear and / or rotational) of the lever 52.

[0060] Similarly, the second piston 45 includes a second pair of piston arms 44a, 44b and an upper support member 46 to which the piston arms 44a, 44b are coupled. A second roller 49b is attached to the support member 46 and is arranged to interact, in use, with a second lever arm 53b of the lever 52. The piston arms 44a, 44b are configured to move in and out of the second piston chamber 48, for example, via a hydraulic or pneumatic arrangement, in use, to introduce or remove fluid into the second piston chamber 48. Alternatively, as discussed above, the actuator 40 may include an electric actuator. In moving in and out of the second piston chamber 48, the piston arms 44a, 44b cause corresponding movement of the support member 46 and thus of the roller 49b, which through interaction with the second lever arm 53b, causes movement (linear and / or rotational) of the lever 52.

[0061] The pistons 42, 45 are configured to move linearly between a retracted position and first and second positions, and when moving from the retracted position to the first position, depending on the rotational position of the lever 52, the pistons 42, 45 may come into contact with their respective lever arms 53a, 53b.

[0062] Specifically, with the lever 52 in the lever 52 first rotational position, moving the first piston 42 from the first piston 42 retracted position to the first piston 42 first position causes the first roller 49a to contact the first lever arm 53a. As described herein, contacting the first roller 49a with the first lever arm 53a may cause linear movement of the first lever arm 53a. Thereafter, moving the first piston 42 from the first piston 42 first position to the first piston 42 second position acts on the first lever arm 53a to rotate the lever 52 from the lever 52 first rotational position to the lever 52 second rotational position. As described herein, this may act to open the valve arrangement 26.

[0063] Similarly, when the lever 52 is in the lever 52 second rotational position, moving the second piston 45 from the second piston 45 retracted position to the second piston 45 first position causes the second roller 49b to contact the second lever arm 53b. As described herein, moving the second piston 45 from the second piston 45 first position to the second piston 45 second position may then act on the second lever arm 53b to rotate the lever 52 from the lever 52 second rotational position to the lever 52 first rotational position. This may act to close the valve arrangement 26.

[0064] The first and second rollers 49a, 49b are configured to linearly move the lever 52 from a first linear position to a second linear position when the first and / or second rollers 49a, 49b contact the respective lever arms 53a, 53b, i.e., when the respective pistons 42, 45 move from the retracted position to the first position. This linear movement of the lever 52 is necessary to release a rotation retention mechanism that prevents rotation of the lever 52. As shown in FIG. 6 (and described in more detail below with reference to FIGS. 8-11B), the operating handle 50 includes an outer sheath 54 that houses a rotatable shaft 56 therein. The sheath 54 includes a slot 60 configured to receive a protruding portion 58 associated with the shaft 56. The slot 60 includes a series of notches 62a, 62b, 62c that define a rotational position of the lever 52, and thus the shaft 56 of the operating handle 50. The protruding portion 58 is configured to move along a slot 60 in the outer sheath 54 upon rotation of the lever 52 and corresponding rotation of the shaft 56. When the lever 52 is in its first linear position, the protruding portion 58 may be received in one of the notches 62a, 62b, 62c to prevent rotation of the shaft 56 under operation of the lever 52. Thus, moving the lever 52 to its second linear position (e.g., by contacting the rollers 49a or 49b with the respective lever arms 53a, 53b of the lever 52) is necessary to move the protruding portion 58 out of contact with one of the notches 62a, 62b, 62c, thereby allowing rotation of the shaft 56 under operation of the lever 52.

[0065] The roller 49a and lever 52 are configured such that when the first piston 42 moves from the first position of the first piston 42 to the second position of the first piston 42, i.e., rotating the lever 52 from the first rotational position of the lever 52 to the second rotational position of the lever 52, the first lever arm 53a moves out of contact with the roller 49a. This allows the lever 52 to move linearly from the second linear position of the lever 52 to the first linear position of the lever 52 (e.g., under the action of a biasing member, see below) and re-engage the rotational retention mechanism to prevent further rotation of the lever 52. In this way, the lever 52 may be retained in the second rotational position of the lever 52 following actuation by the first piston 42. Specifically, this is achieved by angling the roller 49a with respect to the lever 52 such that with the first piston 42 in the first position and the lever in the first rotational position, the roller 49a is disposed perpendicular to the longitudinal axis of the first lever arm 53a. When the lever 52 moves to the second rotational position of the lever 52 at an angle of 90°, the first piston 42 moves to the second position of the first piston 42 and the roller 49a moves to a position disposed parallel to the longitudinal axis of the first lever arm 53a, thereby removing the lever arm 53a from contact with the roller 49a.

[0066] The roller 49b is similarly configured. Specifically, the roller 49b is configured to move such that the second lever arm 53b is removed from contact with the roller 49b when the second piston 45 moves from the first position of the second piston 45 to the second position of the second piston 45, i.e., rotates the lever 52 from the second rotational position of the lever 52 to the first rotational position of the lever 52. This allows the lever 52 to move linearly from the second linear position of the lever 52 to the first linear position of the lever 52 (e.g., under the action of a biasing member, see below) and re-engage the rotational retention mechanism to prevent further rotation of the lever 52. In this way, the lever 52 may be retained in the first rotational position of the lever 52 following actuation by the second piston 45. Specifically, this is accomplished by angling the roller 49b with respect to the lever 52 such that with the second piston 45 in a first position and the lever 52 in a second rotational position, the roller 49b is disposed perpendicular to the longitudinal axis of the second lever arm 53b. When the lever 52 moves to the first rotational position of the lever 52 at an angle of 90°, the second piston 45 moves to the second position of the second piston 45 and the roller 49b moves to a position disposed parallel to the longitudinal axis of the second lever arm 53b. This removes the lever arm 53b from contact with the roller 49b.

[0067] 8 to 11B show modified examples of the operating handle 50 shown in the above-mentioned figures. Unless otherwise specified below, the operating handle 50 shown in Fig. 8 to 11B is substantially the same in configuration as the operating handle 50 shown in the above-mentioned figures. Therefore, unless otherwise specified, the following description will provide a more detailed description of the configuration of the operating handle 50 already shown and described.

[0068] As described herein, the operating handle 50 is configured, in use, to control operation of an outlet valve (not shown) of the valve arrangement 26 for controlling the flow of manufacturing material out of the outlet 16 of the hopper 12. The operating handle 50 includes a lever 52, a rotatable shaft 56 including first and second shaft portions 56a, 56b, and an outer sheath 54 in which the rotatable shaft 56 is disposed. The first shaft portion 56a is connected to the lever 52 such that rotation of the lever 52 causes a corresponding rotation of the shaft 56 which acts on the outlet valve (not shown) to control the flow of material from the hopper 12. In the illustrated arrangement, the end of the shaft 56 is provided with a bore 80 which functions as a female coupling for interacting with a corresponding male coupling on the valve arrangement 26. When coupled, rotation of the shaft 56 acts to effectively cause a corresponding rotation in the rotation of the male coupling of the valve arrangement 26 to open and close the outlet valve.

[0069] The lever 52 includes a coupling portion 64 which is coupled to (e.g., integrally formed with or suitably connected to) the first shaft portion 56a via the coupling portion 64. It will be appreciated that the coupling portion 64 may itself be integrally formed with or suitably connected to the remainder of the lever 52.

[0070] At the end of the outer sheath 54, specifically the opposite end of the sheath 54 relative to the lever 52, the sheath 54 comprises a connection point 70 for connecting and fixing the operating handle 50 to the valve arrangement 26 on the hopper 12 of the docking arrangement 10. Furthermore, this end of the sheath 54 is provided with openings 74a, 74b for receiving screws 72 for fixing the second shaft portion 56b in a suitable position within the sheath 54. The openings may be provided with a threaded surface for interacting with the screws 72. Corresponding (threaded) openings 76a, 76b are provided at the end of the second shaft portion 56b.

[0071] The first and second shaft portions 56a, 56b are operably coupled via a number of rods 66 configured to sit within corresponding slots 67a, 67b in the first and second shaft portions 56a, 56b. The number of rods 66 provide an interface between the first and second shaft portions 56a, 56b and ensure that the second shaft portion 56b rotates with the first shaft portion 56a upon rotation of the lever 52 (e.g., through operation of an actuator).

[0072] The length of the slots 67a, 67b is sufficient to allow the corresponding rod 66 to move within the slots 67a, 67b such that, for example, the first shaft portion 56a can move axially relative to the second shaft portion 56b between first and second axial positions along an axis that is substantially central along the length of the shaft 56. In use, the first shaft portion 56a moves between the first and second axial positions in response to linear movement of the lever 52, which can be moved manually or under operation of an actuator (e.g., actuator 40) as described herein.

[0073] Similarly, the length of the slots 67a, 67b is small enough such that with the first shaft portion 56a in either the first axial position or the second axial position, at least a portion of the corresponding rod 66 is received within the opposing slot 67a, 67b, respectively, so that the first and second shaft portions 56a, 56b remain operably coupled at all times, thereby ensuring that the first and second shaft portions 56a, 56b cannot rotate independently.

[0074] In a first axial position of the first shaft portion 56a, the first shaft portion 56a is separated from the second shaft portion 56b by a gap 78 between the first shaft portion 56a and the second shaft portion 56b (see FIGS. 10A and 10B). In a second axial position of the first shaft portion 56a, the first shaft portion 56a is disposed proximal to the second shaft portion 56b, substantially eliminating the gap 78 between the first shaft portion 56a and the second shaft portion 56b (see FIGS. 11A and 11B).

[0075] The first and second shaft portions 56a, 56b are further operably coupled via a biasing member in the form of a spring 68 located at either end of the bores 69a, 69b of the first and second shaft portions 56a, 56b, respectively. The spring 68 is configured to provide a biasing force acting with or against movement of the first shaft portion 56a between the first and second axial positions. In the illustrated embodiment, the biasing force provided by the spring 68 acts against movement of the first shaft portion 56a from the first axial position of the first shaft portion 56a to the second axial position of the first shaft portion 56a. Similarly, the biasing force provided by the spring 69 acts with movement of the first shaft portion 56b from the second axial position of the first shaft portion 56b to the first axial position of the first shaft portion 56b. In this manner, the biasing force acts to bias / retain the first shaft portion 56a in the first axial position of the first shaft portion 56a unless acting, for example, through interaction of a user or actuator with the lever 52 or other component of the operating handle 50.

[0076] Configuring the shaft 56 in this manner ensures that both the first and second shaft portions 56a, 56b rotate together, but allows the second shaft portion 56b to remain substantially axially stationary, for example to an outlet valve (not shown), so as to remain operably coupled to the outlet valve at all times, and allows the first shaft portion 56a to move axially relative to the second shaft portion 56b as required, for example to engage / disengage a rotational retention feature as described thus far.

[0077] As briefly described above, the operating handle 50 optionally includes a rotational retention mechanism for retaining the lever 52, i.e., the shaft 56, in one of a number of rotational positions. Specifically, the outer sheath 54 includes a slot 60 configured to receive a protruding portion 58 associated with the first shaft portion 56a. The protruding portion 58 is configured to move along the slot 60 in the outer sheath 54 upon rotation of the lever 52 and corresponding rotation of the shaft 56. In the illustrated embodiment, the protruding portion 58 takes the form of a dowel suitably positioned and secured within an opening in the first shaft portion 56a, protruding from an outer surface of the first shaft portion 56a.

[0078] The slot 60 includes a number of notches 62a, 62b, 62c for receiving the protruding portion 58. The notches 62a, 62b, 62c function to prevent the shaft 56 from rotating by retaining the protruding portion 58. In effect, the notches 62a, 62b, 62c define three angular positions in which the shaft 56 and the lever 52 can be retained. The notches 62a correspond to a first rotational position of the lever 52, the notches 62c correspond to a second rotational position of the lever 52, while the notches 52b correspond to an intermediate rotational position between the first and second rotational positions of the lever 52. The notches 62a, 62b, 62c thus correspond to three operating states of an outlet valve (not shown), such as a fully closed state, an intermediate state and a fully open state, for example to control the flow of manufacturing materials.

[0079] The first shaft portion 56a, and thus the entire shaft 56, can rotate when the first shaft portion 56a is in the second axial position of the first shaft portion. Similarly, the first shaft portion, and thus the shaft 56, cannot rotate when the first shaft portion 56b is in the first axial position of the first shaft portion 56 as a result of contact between the protruding portion 58 and one of the notches 62a, 62b, 62c in the slot 60. By providing the spring 68, the contact between one of the notches 62a, 62b, 62c is maintained to prevent rotation of the shaft 56 unless the handle 50 is operated (by the user or by the actuator). It is ensured that the first shaft portion 56a is held in its first axial position and is held together with the protruding portion 58 in the first axial position of the first shaft portion. In order to rotate the shaft 56, i.e., to open or close the associated outlet valve, the first shaft portion 56a must be moved against the biasing force provided by the spring 68. It must be moved (e.g., by linear movement of the lever 52) to a second axial position of the first shaft portion 56a, thereby disengaging the protruding portion 58 from the notches 62a, 62b, 62c. This then allows the protruding portion 58 to move along the slot 60, i.e., as the shaft 56 rotates. After the shaft 56 has been rotated to a desired angular position of the shaft 56 (corresponding to the associated operational state of the outlet valve), any external force acting on the first shaft portion 56a, such as a force exerted by a user on the lever 52 or via an actuator, may be released and the spring 68 acts to urge the first shaft portion 56a back to the first axial position of the first shaft portion with the protruding portion 58 and the shaft 56 retained engaged with the notches 62a, 62b, 62c in the corresponding slots 60 and the rotated position of the lever 52.

[0080] In the variant shown in Figures 8 to 11B, the lever 52 does not pivot about the operating handle 50 at its center, as in the case of the operating handle 50 shown in the figures described so far, but at the end of the operating handle. The configuration of the actuator 40 may therefore be inappropriate for use in this variant. Thus, in the variant shown in Figures 8 to 11B, the coupling portion 64 of the lever 52 includes a bore 65 that serves as a female coupling configured to receive a corresponding male coupling of an associated actuator (not shown). When coupled via the male / female coupling, the actuator may be configured to cause linear movement and / or rotation of the shaft 56, i.e. without the user manually manipulating the lever 52. In this way, this arrangement provides an operating handle that, depending on the circumstances, can be controlled manually or automatically without manual input. However, in this variant, after positioning the hopper 12 in the dock 11, the actuator may need to be individually aligned and connected to the bore 65. However, similar to the embodiment shown in Figures 1 to 7B, it may be desirable to align the actuator with the operating handle when the hopper is docked.

[0081] In a further variation (not shown), the operating handle may be provided with a right-angle drive type arrangement whereby a vertically oriented actuator (e.g., a vertical actuator drive shaft) may be received within a correspondingly oriented coupling on the operating handle upon docking of the hopper 12. In such an arrangement, the operating handle may include a gear arrangement that may include a pair of bevel gears that effect corresponding rotation of a horizontally oriented drive shaft of the valve arrangement 26 under operation / rotation of the actuator.

[0082] In some embodiments, the operating handle 50 may be of a type specific to the material contained in the hopper 12. For example, in the variation shown in FIGS. 8-11B, the bore 65 may include a configuration specific to the type of material contained in the hopper 12. Thus, a specially configured actuator must be used to act on the operating handle 50 to open or close the associated outlet valve. The actuator may be associated with a particular component of the manufacturing process. In this manner, the configuration of the operating handle 50 may be such that the handle 50 can only be used for a particular component (and material to be added from the hopper 50) in the manufacturing process. Thus, the operating handle 50 may be configured to prevent the wrong type of material from being added to the wrong location or to the wrong component.

[0083] 21, 22A and 22B show further modified versions of the docking handle 50 and docking arrangement 10 shown in the previously described figures. Except as expressly specified below, the docking arrangement 10 and operating handle 50 shown in Figs. 21 to 22B are substantially identical in configuration to the docking arrangement and operating handle 50 shown in the previously described figures. Therefore, unless otherwise specified, the following description will provide a more detailed description of the configuration of the docking arrangement and operating handle 50 shown and described in the previously described figures.

[0084] As described herein, the operating handle 50 is configured to, in use, control operation of an outlet valve (not shown) of the valve arrangement 26 for controlling the flow of manufacturing material out of the outlet 16 of the hopper 12. The operating handle 50 includes a lever 52, a rotatable shaft 56 including first and second shaft portions 56a, 56b, and an outer sheath 54 in which the rotatable shaft 56 is disposed. The first shaft portion 56a is connected to the lever 52 via a coupling portion 64 such that rotation of the lever 52 causes a corresponding rotation of the shaft 56 which in turn acts on the outlet valve (not shown) to control the flow of material out of the hopper 12.

[0085] In the illustrated arrangement, the coupling portion 64 is provided with an outwardly extending actuator engaging member 80. The actuator engaging member 80 is frusto-conical in shape and has an opening at a free end thereof defining a female portion 81 adapted to receive a corresponding male portion 82 of the actuator. The actuator engaging member 80 may be integrally formed with the coupling portion or may be removably attachable, for example by threaded or magnetic connection means. For example, the actuator engaging member 80 may be in the form of a cap.

[0086] As best shown in Figure 21, the actuator 40 takes the form of a triple piston arrangement including a first piston 42, a second piston 45 and a third piston 90. The first and second pistons 42, 45 are movable between a plurality of positions to effect rotation of the lever 52 when a rotation retention mechanism is released. As shown and described herein, the first piston 42 is configured to act on the first lever arm 53a and the second piston 45 is configured to act on the second lever arm 53b to rotate said lever arms 53a, 53b as required.

[0087] As best shown in Figures 22A and 22B, the third piston 90 comprises piston arms 91a, 91b configured to couple and engage the male actuator part 82 with the female part 81 of the actuator engagement member 80. This configuration is achieved by movement of the piston arms 91a, 91b between a first vertical position and a second vertical position. An L-shaped housing 83 is provided on a support member 84 to which the piston arms 91a, 91b are connected. The male part 82 is partially contained within a vertical cross section of the L-shaped housing 83. In this embodiment, the male part 82 is a ball spring plunger, the ball 85 of said plunger protruding from the vertical surface of the L-shaped housing 83 facing the operating handle 50. When the male part 82 is coupled to the female part 81 of the actuator engagement member 80, linear movement of the first shaft portion 56a is produced. Specifically, the first shaft portion 56a moves from a first axial position of the first shaft portion where the protruding portion 58 maintains contact with one of the notches 62a, 62b, 62c to a second axial position of the first shaft portion where the protruding portion 58 is disengaged from said one of the notches 62a, 62b, 62c. In this configuration, the protruding portion 58 can be moved along the slot 60 by rotation of the shaft 56 until a desired angular position is achieved (corresponding to an operational state associated with the outlet valve). Moving the third piston 90 from the third piston 90 second vertical position (where the male actuator portion 82 is mated and engaged with the female portion 81 of the actuator engagement member) to the third piston 90 second vertical position releases the male portion 82 from contact with the female portion 81. This in turn causes the spring 68 to urge the first shaft portion 56a back to its first axial position, and the protruding portion 58 re-engages with the corresponding notches 62a, 62b, 62c in the slot 60 to retain the rotational position of the lever and shaft 56.

[0088] The illustrated embodiment of the operating handle 50 shown in Figures 21-22B overcomes the tolerance problems associated with the position of the hopper 12 after it has been docked with the docking arrangement 10, allowing the operating handle to be operated in a more reliable and simplified manner, such as that associated with the arrangement shown in Figures 3-7, which relies on rollers 49a, 49b to impart linear motion to the respective lever arms 53a, 53b to disengage the rotary holding mechanism. Advantageously, the illustrated embodiment eliminates the need for the first and second pistons 42, 45 to include rollers 49a, 49b for engaging and disengaging the rotary holding mechanism.

[0089] 12 to 15B show an embodiment of a locking mechanism 100 according to the present invention. The locking mechanism 100 is configured to couple and secure the outlet 16 of the hopper 12 to an inlet 18 of a further component of an additive manufacturing process, such as an additive manufacturing machine. In particular, the locking arrangement 100 is provided with the inlet 18 and is positioned such that it can act on an outer surface of the outlet 16 when the outlet 16 is received within an open top end of the inlet 18.

[0090] The locking mechanism 100 includes a pair of opposing locking members in the form of rollers 102a, 102b that are movable in a direction perpendicular to the axis of rotation of the rollers 102a, 102b. In the orientation shown in the figure, this includes horizontal movement. The movement of the rollers 102a, 102b is controlled via respective linear actuators in the form of pistons 104a, 104b. The rollers 102a, 102b are attached to respective pistons 104a, 104b via respective clevis-type fasteners 106a, 106b that allow rotational movement of the rollers 102a, 102b about their respective axes of rotation. This mounting arrangement is shown in FIG. 13. Alternatively, the rollers may include an outer collar that is rotatably attached to the remainder of the roller, for example via a needle roller bearing.

[0091] In use, the pistons 104a, 104b are configured to control movement of the respective rollers 102a, 102b between a first longitudinal position (shown in FIGS. 14A and 14B) and a second longitudinal position (shown in FIGS. 15A and 15B). In the illustrated embodiment, the first longitudinal position of the rollers 102a, 102b corresponds to an “unlocked” state of the locking mechanism 100, and the second longitudinal position corresponds to a “locked” state of the locking mechanism 100.

[0092] In an alternative embodiment, the roller is attached to an actuator other than a piston and cylinder arrangement, which may be an electrical actuator such as a solenoid.

[0093] The outlet 16 of the hopper 12 is provided with a groove 112 around the outer surface of the outlet 16, here depicted by opposing groove sections 112a, 112b. The groove sections 112a, 112b correspond to the rollers 102a, 102b, respectively. The groove 112 may be provided around the entire circumference of the outlet 16. In such an embodiment, the hopper 12 may be secured within the docking arrangement 10 without the need to position the hopper 12 so that the groove 112 is precisely aligned with the respective rollers 102a, 102b.

[0094] In use, the groove sections 112a, 112b are configured to receive at least a portion of the respective rollers 102a, 102b to secure the outlet 16 of the hopper 12 to the inlet 18. Specifically, the process of coupling and securing the outlet 16 and the inlet 18 begins with the rollers 102a, 102b in a first longitudinal position. When the rollers 102a, 102b are in the first longitudinal position, the outlet 16 of the hopper 12 can be positioned proximal to, and preferably in contact with, the inlet 18. In the illustrated embodiment, the outlet 16 is positioned within a recess 107 in the open end of the inlet 18, as shown in Figures 14A and 14B. Once the outlet 16 is in this position, the rollers 102a, 102b move to a second longitudinal position (as shown in Figures 15A and 15B) under the operation of the respective pistons 104a, 104b. When in the second longitudinal position, the rollers 102a, 102b are at least partially received in the groove 112, specifically corresponding groove sections 112a, 112b in the outer wall of the outlet 16, preventing the outlet 16 from being pulled out of the recess 107 in the inlet 18. In this manner, the locking mechanism 100 is used to couple and secure the outlet 16 to the inlet 18.

[0095] The pistons 104a, 104b are pneumatically controlled through the introduction and / or removal of gas into the respective piston chambers 108a, 108b. Gas is supplied to and / or removed from the piston chambers 108a, 108b via respective supply tubes 110a, 110b. As will be appreciated, introduction of gas into the piston chambers 108a, 108b causes the pistons to move inward (in the configuration shown) and thus the rollers 102a, 102b to move to the second longitudinal position. Removal of gas from within the piston chambers 108a, 108b causes the pistons to move outward (in the configuration shown) and the rollers 102a, 102b to move to the first longitudinal position.

[0096] The locking and unlocking of the locking mechanism 100 is preferably controlled centrally via a control system (not shown). The centralized control system may also take into account other operational states of the components of the docking arrangement 10 when controlling the operation of the locking mechanism 100. For example, the centralized control system may require that the outlet valve of the valve arrangement 26 be in a closed state before allowing / controlling the unlocking of the locking mechanism 100. Similarly, the centralized control system may be configured to prevent the outlet valve of the valve arrangement 26 from opening unless the locking mechanism 100 is locked with the outlet 16 and inlet 18 coupled and fixed in position.

[0097] An alternative locking mechanism 100' is shown in FIGS.

[0098] The locking mechanism 100' includes a pair of locking members in the form of cams 102a', 102b' rotatably mounted on respective primary pivot points 109a', 109b'. In use, rotation of the cams 102a', 102b' about their respective primary pivot points 109a', 109b' moves the cams 102a', 102b' into and out of the inlet 18 to engage and disengage the outlet 16 of the hopper 12 between locked and unlocked positions in a similar manner to the rollers 102a, 102b previously shown in the figures.

[0099] The cams 102a', 102b' are further rotatably mounted to the ends of respective linear actuators in the form of pistons 104a', 104b' via second pivot points 107a', 107b'. In use, the movement of the cams 102a', 102b' is controlled via the pistons 104a', 104b' as described herein. In particular, the pistons 104a', 104b' are configured to control the movement of the respective cams 102a', 102b' between a first rotational position corresponding to an "unlocked" state of the locking mechanism 100' and a second rotational position corresponding to a "locked" state of the locking mechanism 100'. In the unlocked state, the cams 102a', 102b' are positioned substantially out of the interior of the inlet 18 (as shown in FIG. 17). In the locked position, the cams 102a', 102b' project inwardly into the inlet 18 and engage the outer surface (eg, groove 112) of the corresponding outlet 16 of the hopper 12, as described above.

[0100] As can be appreciated, the pistons 104a', 104b' are pneumatically controlled through the introduction and / or removal of gas into the respective piston chambers 108a', 108b'. Gas is supplied to and / or removed from the piston chambers 108a', 108b' via respective supply conduits 110a', 110b'.

[0101] Introduction of gas into the piston chambers 108a', 108b' causes the pistons to move upward (in the configuration shown), thus rotating the cams 102a', 102b' about their respective primary pivot points 109a', 109b' from a first rotational position to a second rotational position. Conversely, removal of gas from within the piston chambers 108a', 108b' causes the pistons 108a', 108b' to move downward (in the configuration shown), thus rotating the cams 102a', 102b' about their respective primary pivot points 109a', 109b' in the opposite direction, from the second rotational position to the first rotational position.

[0102] In the illustrated embodiment, the cams 102a', 102b' are "over-centre" cams. Rotation of the cams 102a', 102b' about their respective primary pivot points 109a', 109b' beyond the horizontal, i.e. beyond the position where the primary pivot points 109a', 109b' are horizontally aligned with the secondary pivot points 107a', 107b', effectively locks the cams 102a', 102b' in their respective second rotational positions in place unless acted upon otherwise by the respective pistons 104a', 104b'. In particular, such an arrangement prevents internal forces / pressures on the cams 102a', 102b' that would unintentionally "unlock" the locking mechanism 100', for example, by the outlet 16 of the hopper 12 in use.

[0103] As with locking mechanism 100, the locking and unlocking of locking mechanism 100' is preferably controlled centrally via a control system (not shown), which may also take into account other operational states of the components of the docking arrangement 10 when controlling the operation of locking mechanism 100'.

[0104] An exemplary control strategy 200 of the integrated control system is illustrated in the flow chart of Figures 18A and 18B, which include representative diagrams showing the operational states of the locking mechanism 100 and operating handle 50 / actuator 40 arrangement at each step of the control strategy 200, where applicable.

[0105] FIG. 18A shows an initial stage of a control strategy 200 which involves securing the hopper 12 on the dock 11 and subsequently opening the valve arrangement 26 to allow the material in the hopper 12 to be deposited on an associated further component of the manufacturing process.

[0106] Specifically, at 202, the locking mechanism 100 is provided in an open state, i.e., the rollers 102a, 102b are held in their respective first longitudinal positions, allowing the outlet 16 of the hopper 12 to be positioned relative to the inlet 18 of the dock 11, as described herein. In this step, the first and second pistons 42, 45 of the actuator 40 are held in a retracted position with the rollers 49a, 49b not in contact with the respective lever arms 53a, 53b. The lever 52 is provided in a first rotational position, as shown, which corresponds to a closed configuration of the associated valve arrangement 26.

[0107] At 204, a check is performed to verify that the outlet 16 of the hopper 12 is located within the entrance 18 of the dock 11. If not, the locking mechanism 100 remains in the open position.

[0108] Once the outlet 16 of the hopper 12 is in position within the inlet 18, the locking mechanism 100 may be closed in step 206. As described herein, closing the locking mechanism 100 includes powering the pistons 104a, 104b to move the respective rollers 102a, 102b to a second longitudinal position, specifically into contact with the respective groove sections 112a, 112b in the outer surface of the outlet 16. During this step, the first and second pistons 42, 45 are held in their respective retracted positions.

[0109] In steps 208 and 210, a pressure check is performed to ensure that a sealed connection is made between the outlet 16 and the inlet 18. If a sealed connection is not made, the process returns to step 202 where the locking mechanism 100 is opened to repeat the locking process of steps 202-206.

[0110] Once a sealed connection is confirmed, power is applied to move pistons 42, 45 to their respective first positions in step 212. Specifically, roller 49a associated with piston 42 contacts first lever arm 53a of lever 52, thereby depressing lever 52 out of engagement with the rotational retention mechanism.

[0111] If the actuator includes a third piston 90, power is applied to the third piston 90 in step 212 before power is applied to the pistons 42, 45, thereby disengaging the rotational retention mechanism before bringing the roller 49a into contact with the lever arm 53a.

[0112] In step 214, the piston 42 is powered to its second position, which rotates the lever 52, and thus the shaft 56 of the operating handle 50, through an angle of 90° to a second rotational position of the shaft 56 as shown. The second rotational position of the lever 52 corresponds to an open state of the valve arrangement 26, thereby allowing material to exit the hopper 12 through the outlet 16 and enter further components of the manufacturing process via the inlet 18.

[0113] Once the desired amount of material has been removed from the hopper 12, the reverse process is carried out to close the valve arrangement 26 and unlock the locking mechanism 100, thereby allowing the hopper 12 to be removed from the dock 11. This is shown in Figure 18B.

[0114] In step 216, the second piston 45 is powered to move to its second position, and the roller 49b acts on the second lever arm 53b of the lever 52, thereby rotating the lever 52 through an angle of 90° back to its first rotational position, thereby closing the valve arrangement 26 to prevent more material from exiting the hopper 12.

[0115] In step 218, both the first and second pistons 42, 45 are returned to their retracted positions, thereby releasing the rollers 49a, 49b from contact with the respective lever arms 53a, 53b, such that the lever 52 is free to move under the biasing force provided by the spring 68 and engages the rotational retention mechanism to secure the lever 52 in its first rotational position (with the valve arrangement 26 closed).

[0116] In embodiments in which a third piston 90 is present, the third piston 90 is moved to the retracted position after, or simultaneously with, the first and second pistons 42, 45 such that the male portion 82 is out of contact with the female portion 81 of the actuator engagement member 80 and the rotational retention mechanism can be re-engaged such that the lever 52 is held in the desired position.

[0117] In step 220, a check is performed to ensure that the valve arrangement 26 is closed. If it is not closed, the process returns to step 216 and steps 216 and 218 are repeated to close the valve arrangement 26.

[0118] Once it is determined that the valve arrangement 26 is closed, the process proceeds to step 222 where the locking mechanism 100 is opened. Specifically, power is provided to move the pistons 104a, 104b to move the respective rollers 102a, 102b to a first longitudinal position, specifically out of contact with the respective groove sections 112a, 112b in the outer surface of the outlet 16. This releases the hopper 12 from the dock 11 so that the hopper 12 can be removed.

[0119] 19 and 20 show further features of the docking arrangement 10. In particular, these figures show the operation for the use of gas inlet 32. As shown in the figures, a gas supply unit 34 is coupled to the gas inlet 32 ​​and connected via a gas supply line 33 to a gas source 35 associated with the dock 11. To effect this coupling, supply tubes 36a, 36b of the supply line are coupled via couplers 38a, 38b to respective couplers 37a, 37b of the dock 11.

[0120] The gas provided by the gas source may include air in some cases, but may also include a specific type of gas depending on the requirements of the material contained within hopper 12. As described herein, some materials may oxidize in air and therefore must be stored under a controlled atmosphere. Thus, gas source 35 may include an inert gas (e.g., argon, nitrogen, etc.) that can adequately inhibit oxidation or other degradation of the material within hopper 12.

[0121] In a further use case, the gas source 35 provides a source of gas to the hopper 12 to control the pressure level within the hopper 12 to aid in the flow of material from the outlet 16 of the hopper 12. The hopper 12 may additionally include a gas outlet (not shown) to act as a bleed valve, for example, to ensure that the pressure level within the container 14 is maintained at a desired level, or below a maximum allowable pressure level. This allows gas to be vented from the hopper 12 and the gas source 35 may be used to purge the gas contained within the hopper 12 and replace it with gas from the gas source 35.

[0122] Gas supply unit 34 may include one or more pressure sensors for monitoring the pressure in hopper 12 and control the supply of gas to hopper 12 based on the monitored pressure levels. Operation of gas supply unit 34 may be controlled by a control system (not shown).

[0123] In further embodiments, the gas source 35 may be coupled to a gas inlet (not shown) at the interface between the outlet 16 of the hopper 12 and the inlet 18 of the dock 11. In such embodiments, the gas source 35 may be used to purge the interface between the hopper 12 and a component of the manufacturing process to prevent degradation of the material as it is transported to the component.

[0124] One or more embodiments have been described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims

1. an operating handle for controlling an operational state of a valve arrangement associated with the container for controlling the dispensing of material from the container to a component of an additive manufacturing process, a rotatable shaft coupled to the valve arrangement, the shaft being rotatable between a plurality of angular positions corresponding to one or more operational states of the valve arrangement; a lever operably coupled to the shaft, the lever configured to rotate the shaft between the plurality of angular positions in response to rotation of the lever; a rotational retention mechanism configured to retain the lever in one of a plurality of rotational positions; and An operating handle comprising an actuator engagement member extending axially outward from the handle, the actuator being operable by an actuator provided as part of a docking arrangement associated with the component to operate the actuator engagement member to engage and disengage the rotational retention mechanism.

2. 2. The operating handle of claim 1, wherein the lever is operably coupled to the rotatable shaft via a coupling portion located approximately midway along the length of the lever to define first and second lever arms of the lever located on either side of the coupling portion.

3. The operating handle of claim 1 , wherein the actuator engagement member extends outwardly from a central region of the operating handle.

4. The operating handle of claim 2 , wherein the actuator engagement member extends outwardly from or near the coupling portion.

5. 2. The operating handle of claim 1, wherein the actuator engagement member is frusto-conical in shape.

6. 6. An operating handle as claimed in claim 5, wherein a free end of said frusto-conical actuator engaging member is open to define a female portion adapted to receive a corresponding male portion provided by said actuator.

7. 2. The operating handle of claim 1, wherein said actuator engagement member is wedge-shaped.

8. 3. The operating handle according to claim 2, wherein the actuator engaging member is removably mountable to the coupling portion.

9. The operating handle of claim 8 , wherein the actuator engagement member is in the form of a cap.

10. The rotation holding mechanism includes: configured to hold the lever and rotatable shaft in a predetermined rotational position when the first shaft portion is in a first axial position; and 2. The operating handle of claim 1, wherein the lever and rotatable shaft are configured to be rotatable between a plurality of rotational positions when the first shaft portion is in the second axial position.

11. 11. The operating handle of claim 10, further comprising a slot disposed within an outer sheath disposed around the rotatable shaft, the slot configured to receive a protrusion associated with the rotatable shaft.

12. 12. The operating handle of claim 11, wherein the slot in the outer sheath includes a plurality of notches for receiving the protruding portion, the plurality of notches configured to function to prevent rotation of the shaft by retaining the protruding portion within the plurality of notches.

13. The operating handle of claim 2 , wherein the actuator engagement member, the first lever arm and the second lever arm are configured to be directly actuated by one or more components of an associated actuator.

14. an actuator for controlling an operational state of a valve arrangement associated with the container to control a distribution of material from the container to a component of an additive manufacturing process, the actuator is provided as part of a docking arrangement associated with the component; The actuator comprises at least one movable component configured to engage an operating handle according to claim 1 ; and An actuator, the at least one moveable component being operable, in use, to act on the actuator engagement member to cause engagement and disengagement of the rotational retention feature.

15. The actuator of claim 14 , wherein the at least one moveable component is linearly moveable.

16. The actuator of claim 14 , wherein the actuator is a linear actuator.

17. The actuator of claim 14 comprising a second movable component and a third movable component arranged to move the operating handle.

18. The actuator of claim 17 , wherein the second and third moveable components are operable to rotate the lever to control the operational state of the valve arrangement.

19. The actuator of claim 14 , wherein the at least one moveable component acting on the actuator engagement member comprises a ball spring plunger.

20. The actuator of claim 14 , wherein the at least one moveable component for operating the actuator engagement member comprises a wheel or gear.

21. A docking arrangement for an additive manufacturing process, comprising an operating handle according to claim 1 and an actuator according to claim 14.

22. 22. A method for controlling an operational state of a valve arrangement associated with a container in order to control the distribution of material from said container to a component of an additive manufacturing process using a docking arrangement according to claim 21, comprising: coupling an outlet of the container to an inlet of a dock associated with the component of the additive manufacturing process; disengaging the rotational retention mechanism under the action of an actuator acting on the actuator engagement member during use; Rotating the lever under action of the actuator to open the valve arrangement for dispensing material from the container to the component.

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