Powder container for additive manufacturing processes

Abstract

A powder container for handling powder in an additive manufacturing process comprising a powder container 100 having a powder inlet at the top of the powder container and a powder outlet at the bottom of the container, a set N of n sensors for determining a set of n observable quantities, and a first actuator 428, 438, 488, 498, 858 for driving a first mechanical function of the powder container 1 provides additional safety and versatility if it further comprises a second actuator 428, 438, 488, 498, 858 for driving a second mechanical function of the powder container 1 and / or a multi-port connector 500 configured to be connected with a corresponding connector of a powder handling station in the additive manufacturing process.

Description

Technical Field

[0001] The present invention relates to additive manufacturing related to a powder bed fusion process. More particularly, the present invention relates to a powder storage device, a so-called "powder container", for use in a powder bed process. The powder container comprises at least one powder container (simply "container") mounted on a support frame.

Background Art

[0002] What is generally referred to as the powder bed fusion bonding process is an additive manufacturing process. In this process, powder layers are applied one on top of the previous layer to form a powder bed on a support plate. Before applying a new powder layer, a portion of the already applied layer is exposed to radiation that causes some of the powder particles in the layer to adhere to each other and to the already applied layer by melting, sintering, fusion bonding, and / or welding or any similar process. The powder bed fusion bonding process can be thought of as fusing a series of cross-sections of a workpiece to be manufactured on a corresponding series of powder layers, thereby forming the workpiece. This fusion bonding is obtained by scanning the cross-section with a radiation beam. In this specification, the term powder bed fusion bonding process is used to refer to any other process that enables selective adhesion of a portion of a powder bed by applying radiation to the portion of the powder bed to be adhered, regardless of whether the adhesion is obtained by fusion bonding, melting, welding, sintering, etc. The powder bed fusion bonding process, unlike most other additive manufacturing processes, enables the production of metal workpieces by selectively fusing metal powder particles. Numerous reviews have been published on different aspects and variations of the powder bed fusion bonding process. An overview of at least some of them is provided by Yi Zhang, Yeon-Gil Jung and Jing Zhang in Multiscale Modeling of Additively Manufactured Metals: Application to Laser Powder Bed Fusion Process (Additive Manufacturing Materials and Technologies) (Elsevier, Amsterdam, 2020, ISBN 978-0128196007).

[0003] Powder oxidation results in lower workpiece quality, so powder particles typically have a diameter on the order of sub-microns and must be stored under well-defined conditions, typically in an inert gas or vacuum atmosphere.

[0004] International Publication No. WO 2021 / 123782 relates to a coupling system for an additive manufacturing process. The coupling system comprises a conduit for transferring material between a powder container and a further component of the additive manufacturing process. The conduit comprises a first and a second part connected via an extendable intermediate part. An actuator is operable to act on at least a part of the conduit so as to extend or contract the intermediate part to control the length of the conduit. This enables the coupling system to be coupled and decoupled to the powder discharge opening of the powder container. The coupling system comprises a mechanical support with four tapered pins configured to extend upwardly and be received by fitting into through holes in a support structure of the powder container.

[0005] The authors of International Publication No. WO 2016 / 046539 propose a powder container for transporting metal powder from a manufacturing site to an additive manufacturing (AM) machine. The container has a pressure vessel for containing the powder and a protective framework for physical protection of the pressure vessel, and is mounted on an industry-standard pallet system to enable the use of a fork-lift truck. The pressure vessel consists of an upper part, a lower part, and a removable lid. The upper part is a hollow cylinder and the lower part is a hollow frustum of a cone. At the lower end of the frustum of the cone there is an outlet pipe having an outlet control valve. The outlet pipe has a flange for connecting the outlet pipe to the AM machine. At the upper end of the hollow cylinder there is a removable lid enabling the pressure vessel to be filled when the lid is removed. The lid is then bolted in a sealed state to the upper outer periphery of the hollow circular cylinder. The atmosphere inside the pressure vessel is monitored by data logging means connected to a communication module with a GSM transceiver. A remote monitoring station polls the communication module, thereby triggering the transmission of sensor readings by the communication module. These sensor readings are provided by a pressure sensor, an oxygen sensor, a humidity sensor, a strain gauge, an accelerometer, a temperature sensor, and a GPS position sensor. SUMMARY OF THE INVENTION PROBLEM TO BE SOLVED BY THE INVENTION

[0006] The problem to be solved by the present invention is to provide an improved powder container for storing and transporting powders used in a powder bed fusion process.

Means for Solving the Problem

[0007] The solution to the problem is set forth in the independent claims. The dependent claims relate to further improvements of the present invention.

[0008] The present invention is based on several observations. First, it should be noted that several different powder containers are used in an additive manufacturing plant for handling powders at different manufacturing stages, and only one of the manufacturing stages is the fusion process. For example, when the fusion is complete, the workpiece must be separated from the powder bed in which it is embedded, and such obtained powder is preferably prepared for reuse in a powder bed fusion process. Further, a station (recycling station) for preparing for reuse necessarily has at least three powder containers, a supply source container, a recycled powder container, and a waste container. Similarly, an AM machine has, in addition to a powder supply source container, a powder overflow container, and often a waste container and a buffer container. The present invention makes it possible to use a single type of container instead of all these different containers.

[0009] More specifically, a powder container for handling powders in an additive manufacturing process (the “AM process”) may herein simply be provided with a powder container as well as a container. The container may essentially be an outer shell structure (a set of container walls) surrounding a container volume for storing powders (i.e., the volume of the container). As usual, the container has a lower end, at least one side wall, and an upper end.

[0010] The container preferably has a powder inlet and / or a powder outlet. The powder inlet is preferably an opening in the container configured to receive powder from a powder source, for example via a powder supply line, i.e., in the outer shell structure. The powder inlet is preferably in the upper part of the container, for example in the upper half of the container, preferably in the upper one-third, one-fourth, one-fifth and / or one-tenth of the container. In a preferred example, the powder inlet is at the upper end of the container. Correspondingly, the powder outlet may be installed below the powder inlet, i.e., in the lower part of the container, for example in the lower half of the container, preferably in the lower one-third, one-fourth, one-fifth and / or one-tenth of the container. In a preferred example, the powder outlet is at the lower end of the container. As usual, the terms "upper side" and "lower side" herein refer to the normal orientation of the container such that it can be expected to be oriented during normal use, which is also referred to as the "first orientation" in this specification. As will be described in more detail below, the container may be rotatably supported, for example, in a second orientation, which may be, for example, a so-called "upside-down" orientation that is reversed with respect to the first orientation. Such a reverse orientation may be obtained by rotating the container, for example, by 180°±α h which may be obtained by rotating the container, for example, by 180°±α h ", where "±α h " indicates that the interval [180° - |α h |; 180° + |α h |] is acceptable, and α h ∈ {30°, 20°, 15°, 10°, 5°, 2.5°, 1°, 0}, and a smaller absolute value of α h is preferred. The axis of rotation is preferably at least approximately horizontal, i.e., approximately perpendicular to the vertical line. As used herein, at least approximately horizontal means [-α h , α hIt means that the deviation from the horizontal within the interval is acceptable. At least a part of the lower end is preferably a cone or a frustum of a cone. The opening angles β of the cone or the frustum of the cone are preferably 48° - 62° (β ∈ [48°, 62°]), more preferably 50° - 60° (β ∈ [50°, 60°]), and even more preferably 51° - 58° (β ∈ [51°, 58°]), respectively. A particularly preferred opening angle is β = 54° ± 1° (β ∈ [53°, 55°]). These opening angles are preferred because they do not require mechanically driven powder conveying means or fluidizing means such as vibrators and powder scrapers to completely remove the powder from the container while maximizing the volume of the container.

[0011] The normal "up" and "down" are directions defined with reference to the direction of gravity (down is parallel to the direction of gravity, and up is in the opposite direction, i.e., anti - parallel). References to the "upper end" or "lower end" assume the orientation of the corresponding parts observed during normal operation. During normal operation, the powder inlet is typically above the center of the container (mainly at the upper end of the container), and the powder outlet is typically below the center of the container (mainly at the lower end). The lower end of the container is the part of the container that delimits the container volume below. The upper end of the container is the part of the container that delimits the container volume above. The side wall connects the lower end and the upper end of the container.

[0012] Preferably, the powder container is equipped with a set N of n sensors for determining a set of n observable quantities, where n is an integer greater than or equal to 2, i.e., n ∈ {2, 3, 4,..., n max}. There is no theoretical limit regarding n max , but in practice, it can be assumed that n max is a small two - digit number (e.g., 20). As already shown, larger numbers for n max , such as 100, 1000, or 10,000, or more, are possible, but currently, such a large number of sensors are not expected without giving excessive redundancy to at least the sensor equipment.

[0013] A set N of n sensors may comprise at least one, preferably two or more sensors from the following list of sensors: a vessel pressure sensor for measuring the pressure within the vessel volume, a force sensor (e.g., a strain gauge) for measuring the force exerted by the vessel on the frame, a powder level sensor, a pressure sensor for measuring the pressure upstream of the powder inlet valve, a pressure sensor for measuring the pressure downstream of the powder outlet valve, a differential pressure sensor for measuring the pressure difference between the vessel volume and the space upstream of the powder inlet valve, a differential pressure sensor for measuring the pressure difference between the vessel volume and the space downstream of the powder outlet valve, and a gas concentration sensor for at least determining the partial pressure and / or concentration of the gas components of the gas within the vessel volume and / or within the space upstream of the powder inlet valve and / or within the space downstream of the powder outlet valve. Each of these sensors provides information that enables monitoring of the conditions under which the powder within the vessel is stored and / or transported, either within the vessel or outside the vessel. The force sensor can be used to determine the amount of powder within the vessel and, by analyzing the force as a function of time and / or by determining the center of mass of the vessel and the powder therein, to determine a measure of the compaction of the powder due to the vibration of the vessel. If the set N includes a powder level sensor, the set N preferably includes at least one upper powder level sensor and / or at least one lower powder level sensor. The upper powder level sensor is preferably installed at the upper part of the powder container, e.g., at the upper one-third, one-fourth, one-fifth, one-sixth, one-seventh, one-eighth, one-ninth, one-tenth, or one-twentieth, and is configured to determine whether the powder level within the powder container is above (including being at the position of the upper powder level sensor) or below the position of the upper powder level sensor. Similarly, the lower powder level sensor is preferably installed at the lower part of the powder container, e.g., at the lower one-third, one-fourth, one-fifth, one-sixth, one-seventh, one-eighth, one-ninth, one-tenth, or one-twentieth, and is configured to determine whether the powder level within the powder container is above (including being at the position of the lower powder level sensor) or below the position of the lower powder level sensor.

[0014] When the upper powder level sensor and the lower powder level sensor provide a sensor signal indicating a powder level equal to or higher than an upper threshold value, which may be, for example, the upper powder level sensor position, it is possible to efficiently prevent powder overflow by blocking the powder flow into the powder container.

[0015] The lower powder level sensor can be arranged so as not to impede the flow of powder through the powder outlet at the lower end of the powder container. For example, when the lower powder sensor provides a sensor signal indicating a powder level below a given lower threshold value, the manufacturing process of drawing powder from the powder container can be decelerated or completely interrupted. The lower threshold value may be the lower powder level sensor position.

[0016] The sensor signal of the powder level sensor may be used as a cross-check, for example, to verify the signal provided by a force sensor.

[0017] To avoid ambiguity, generally, there are multiple types of powder level sensors. For example, a distance measurement device may determine the gap between the distance measurement device and the uppermost layer of powder in the container. An increase in distance reflects a decrease in powder level. In one example, the distance can be measured, for example, by an optical distance measurement device and / or an acoustic distance measurement device (including ultrasonic waves). In yet another example, the powder level sensor only determines whether the powder level is below, above (including being at) a predetermined level. Such a powder level sensor may include a light barrier, a capacitance sensor, etc. Needless to say, all of these different types of powder level sensors can be combined to obtain accurate, reliable, and / or redundant measurement values.

[0018] The powder container may further comprise a multi-port connector configured to be connected to a corresponding mating connector of the powder handling device in an AM process. The optional multi-port connector may be a plug or socket connector having a number of ports. At least one of the ports may comprise an electrical contact of the multi-port connector. Further, the multi-port connector may comprise fluid ports such as, for example, a pressurized gas port and / or a vacuum port. The multi-port connector may also comprise a waveguide port for connecting a waveguide such as, for example, an optical fiber waveguide. As usual, the multi-port connector should be understood as a plug connector or socket connector of a plug-socket connection having at least two, preferably more ports. Each port is configured to effect or contribute to fluid, data, and / or energy exchange with a corresponding mating port of a corresponding mating connector of the powder handling device in an AM process. The fluid ports may include gas ports such as a pressurized air port, a vacuum port, an inert gas supply port, etc. Energy exchange can be obtained by power line terminals (electrical ports), but also by coils for inductive coupling (inductive ports) or by rotary coupling. Pressurized gas may be used as an energy source (pressurized fluid port). Data exchange can be obtained by electromagnetic signals (including optical signals) transmissible via electrical cables and / or waveguides. The corresponding electrical cable may have terminals configured as electrical ports of the multi-port connector, and the waveguide may have a waveguide port.

[0019] In a preferred example, the first sensor of the set N of sensors is preferably connected to the first port of the multi-port connector via the first measurement line. As usual, the ports of the connector are terminals or the like that enable the transmission of electricity (e.g., voltage signals), fluids, or electromagnetic waves (e.g., light) to the corresponding ports of the mating connector. In the case of a purely electrical connector, each port is represented by a contact of the connector. The term "port" is used as a generalization of "contact" to also include fluid connections or waveguide connections.

[0020] More specifically, the first end of the first measurement line may be connected to the first sensor, and the second end of the first measurement line may be connected to the first port of the multi-port connector. Thus, when the multi-port connector is connected to its counterpart, herein referred to as the "mating connector", of an AM machine or any other powder handling machine (collectively herein referred to as the "powder handling station"), the corresponding powder handling station may read the sensor signal (the first sensor signal) of the first sensor.

[0021] Similarly, the second sensor of the set N of sensors may be connected to the second port of the multi-port connector via the second measurement line. More specifically, the first end of the second measurement line may be connected to the second sensor, and the second end of the second measurement line may be connected to the second port of the multi-port connector.

[0022] For the sole purpose of avoiding ambiguity, a pressure sensor for measuring the pressure within a volume (also called a space) defined by a container or conduit has at least one fluid opening in fluid communication with the volume and / or is at least partially installed within the volume. In this sense, the pressure sensor may be configured to measure the pressure within the volume. Thus, for example, a container pressure sensor for measuring the pressure within a container volume is preferably configured to measure the pressure within the volume of the container. In another example, assuming that a powder inlet valve should be closed and any valve has a valve member that can move between an open position and a closed position to open and close the valve, a pressure sensor for measuring the pressure upstream of the powder inlet valve is preferably a pressure sensor configured to measure the pressure within a volume delimited in the downstream direction by the powder inlet valve member. Also, a pressure sensor for measuring the pressure downstream of a powder outlet valve is preferably configured to measure the pressure within a volume delimited in the upstream direction by the valve member of the powder outlet valve (when the powder outlet valve is closed). A differential pressure sensor is preferably configured to measure the pressure difference between two volumes. For example, a differential pressure sensor for measuring the pressure difference between the volume of a container and the space downstream of a powder outlet valve may be in fluid communication with the container volume, and the volume of the space is delimited in the upstream direction by the valve member of the powder outlet valve assuming the powder outlet valve is closed.

[0023] In summary, the powder container may comprise a set N of n sensors. At least one subset M of m sensors of the set N of n sensors, preferably each sensor of the set N of n sensors, may be connected to a separate contact of a multiport connector via a separate measurement line. This improves the operational safety of the powder container.

[0024] For the sole purpose of avoiding ambiguity, the port numbering does not necessarily follow any convention or standard of port numbering of a multi-port connector. The port numbering in this specification is merely a linguistic measure for distinguishing different ports. When an electrical line is connected, it means, as usual, that an electrical contact is established between the corresponding contacts. Similarly, if a fluid flow or a powder flow can be established through the connection respectively, a fluid line or a powder line is connected. For example, the "signal output" contact of a sensor may be electrically connected (electrically contacted) to the first end of the corresponding measurement line. The second end of the measurement line may be electrically connected to the terminal of the corresponding port. Therefore, the measurement line may be a conductive cable.

[0025] In a preferred example, the powder container may further comprise a first actuator for driving the first mechanical function of the powder container. For example, the first actuator may drive a valve member, a mixer, etc. Examples of these actuators are further provided below.

[0026] In a particularly preferred example, the powder container may further comprise a second actuator for driving the second mechanical function of the powder container. In one example, the second actuator may drive another valve member, another mixer, etc. In other words, by controlling the first and / or second actuators, it becomes possible to operate the mechanical devices of the powder container, such as the powder inlet and / or outlet valves. For the sake of simplicity of language, it is assumed that a single actuator drives a single mechanical device. However, this is intended to include the case where a single actuator drives a plurality of mechanical devices, as well as the case where a plurality of actuators drive a single mechanical device together, or the case where a plurality of actuators drive any number of mechanical devices.

[0027] For example, the powder container may comprise at least one powder inlet valve having a powder inlet valve inlet and a powder inlet valve outlet, the powder inlet valve outlet being connected to the powder inlet of the container. As already explained, an actuator may be provided to move the valve member of the powder inlet valve from the open position to the closed position and / or from the closed position to the open position. In many cases, such a valve actuator is a solenoid drive, but the present invention is not limited thereto. Another example is a pneumatic actuator.

[0028] In addition to or instead of this, the powder container may further comprise a powder outlet valve having a powder outlet valve inlet and a powder outlet valve outlet. The powder outlet valve inlet is preferably connected to the powder outlet of the container. By connected is meant in the context of powder transfer as would be normally understood by a person skilled in the relevant art, i.e., the powder flows through the powder outlet of the container to the powder outlet valve inlet when the valve is open with respect to the powder outlet valve outlet. When the valve is closed, naturally, the powder flow is interrupted.

[0029] Generally speaking, the powder container may comprise a first actuator control line having a first end and a second end, the first actuator being connected to the first end of the first actuator control line. A second actuator control line having a first end and a second end may be connected to the second actuator. More generally, the powder container may comprise a set L of l actuators each configured to drive a mechanical function. Preferably, each actuator of the set L of l actuators is connected to the first end of a corresponding control line. Thus, there may be a set C of l control lines each connecting a different actuator. In other words, the i-th actuator may be connected to the first end of the i-th control line (∀ i ≦ l).

[0030] The powder container may comprise a set L of l actuators for driving the mechanical devices of the powder container, where l ∈ N\{0,1}, and each actuator of at least one subset K of k actuators out of the set L of l actuators (i.e., k ≤ l, k ∈ {1,2,3,4,...,n max ) is connected to a separate contact of the multiport connector via a separate actuator control line.

[0031] For example, a powder inlet valve having a powder inlet flow path with a powder inlet valve inlet and a powder inlet valve outlet may be attached to the powder inlet of the container. Also, the inlet valve member of the powder inlet valve may be movably supported with respect to the valve seat of the powder inlet valve and may be configured to be movable between a closed position and an open position. The powder inlet valve is closed by the inlet valve member when the inlet valve member is in its closed position, and the powder inlet valve is opened when the inlet valve member is in its open position. The inlet valve member may be coupled to at least one actuator of the set L of l actuators, preferably to a subset K of k actuators. In other words, at least one actuator of the set L of l actuators may be configured to move the inlet valve member of the powder inlet valve between a closed position and an open position.

[0032] For example, a powder outlet valve having a powder outlet flow path with a powder outlet valve inlet and a powder outlet valve outlet may be attached to the powder outlet of the container. The outlet valve member of the powder outlet valve may be movably supported with respect to the valve seat of the powder outlet valve and may be configured to be movable between a closed position and an open position. The powder outlet valve is closed by the outlet valve member when the outlet valve member is in its closed position, and the powder outlet valve is opened when the outlet valve member is in its open position. The outlet valve member may be coupled to at least one actuator of the set L of l actuators, preferably to a subset K of k actuators. In other words, at least one actuator of the set L of l actuators may be configured to move the outlet valve member of the powder outlet valve between a closed position and an open position.

[0033] In one example, the funnel may be connected to the powder inlet and / or the powder outlet of the container. In one example, the funnel may be connected to the powder inlet of the container, and an optional powder inlet valve may be installed between the funnel and the container volume. Similarly, the funnel may be connected to the powder outlet of the container, and a powder outlet valve may be installed between the funnel and the container volume. Thus, when the corresponding valve is open, fluid communication between the container volume and the funnel is established, and when the corresponding valve is closed, the fluid communication is interrupted. However, although the corresponding connection is generally considered to provide fluid communication herein, the fluid communication can be interrupted when the corresponding valve is in the closed state.

[0034] Each of the optional funnels enables facilitating the refilling of the container through the corresponding opening. In a preferred example, the funnel is removably connected to the powder inlet and / or the powder outlet of the container. For the sole purpose of avoiding misunderstanding, the funnel is understood to generally be a conduit having an inlet end and an outlet end, and the cross-sectional area of the inlet end is significantly larger than that of the cross-sectional outlet end. Significantly larger means that the free diameter of the inlet opening increases by more than twice the wall thickness of the conduit. In a preferred example, the cross-sectional area A i of the inlet opening is x times larger than the cross-sectional area A o of the outlet opening, i.e., A i ≧x·A o where x ∈ {1.1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 10}.

[0035] Preferably, the powder container comprises a container support structure. The container support structure may be, for example, a frame that supports and preferably protects the powder container. For example, conveying means such as rollers or wheels may be attached to the container support structure.

[0036] In a preferred example, the container support structure comprises a rotary bearing for rotatably supporting the container. Such rotation enables the container to be in a so-called "upside-down" orientation that converts the powder inlet to the powder outlet (and / or vice versa), and further enables the decomposition of clusters of adhered powder within the container. Thus, the rotary bearing enables the powder inlet to be used as the powder outlet and vice versa. That is, a single powder opening suffices, thereby reducing potential leaks and the number of expensive valves. For the sake of linguistic consistency, such a bidirectionally usable powder opening of the container and the "powder inlet" are referred to.

[0037] In the first "normal" orientation, powder can be poured into the container volume (e.g., via an optional funnel) using the powder inlet. In the inverted "upside-down" orientation, the same powder inlet may be used as the powder outlet. Thus, a single powder inlet may suffice. The rotary bearing may preferably have a rotation axis that is at least essentially horizontally oriented. Here, "substantially horizontal" indicates that while horizontal is preferred, any deviation can be accepted as long as the rotation enables the powder within the container to be discharged through the powder inlet when the container is rotated in the reverse direction. "Normally 'horizontally oriented'" means that when the container support structure is oriented as intended during normal operation, the rotation axis is at least essentially vertical. Being at least essentially vertical means that orthogonality is preferred, but deviations within an angle ±α h are to be accepted. Examples of values of ±α h are 30°, 20°, 10°, 5°, 2.5°, 1°, that is, α h ∈{30°, 20°, 10°, 5°, 2.5°, 1°, 0°}. The acceptable deviation α h actually depends on the shape of the container. As long as at least substantially all of the powder flows out of the powder inlet, when the container is in its second orientation, the corresponding deviation α h is acceptable even if it is greater than one of the values in the above examples.

[0038] In a preferred example, the funnel is supported by a container support structure and is provided with a coupling. The coupling connects the lower opening of the funnel to the powder inlet when the container is in its first orientation (the so-called "vertical" orientation), and does not connect the lower opening of the funnel to the powder inlet when the container is rotated from the first orientation.

[0039] In a preferred example, the container support structure may include a locking mechanism configured to releasably prevent rotation of the container relative to the container support structure. Thus, the locking mechanism can, for example, prevent unintentional rotation of the container in the first ("normal") orientation and / or the second ("inverted" or "upside-down") orientation. The locking mechanism can prevent rotation by a releasable positive lock between the container and the container support structure and by a releasable clamping mechanism. In addition or alternatively, the powder container may include an actuator for rotating the container relative to the container support structure. The actuator may preferably include an automatic locking transmission, which may also be referred to as a self-locking transmission. An example of such a transmission is an automatic locking worm gear (see Introduction to Worm Gearing, James K. Simonelli; Gear Technology, 1993 Vol. 2, pages 34 to 40).

[0040] In a preferred example, the container has a grid or at least grid bars extending within the container volume. Such a grid or grid bars contribute to breaking up potential powder aggregates within the container while rotating the container. This enhances continuous and complete powder removal from the container.

[0041] In another example, the powder container may comprise a container support structure that is rotatably supported. For example, the support frame can rotatably support the container support structure. The container support structure may have at least a lower end, preferably at least one side support, such as side walls and / or at least one post attached to the lower end of the support structure. The powder container may be removably disposed at the lower end of the container support structure. In other words, the lower end of the container support structure may be configured to receive the lower end of the powder container and thus preferably to support the powder container, such as a powder barrel. Such a powder container may be subject to standardization, i.e., the powder barrel may be a barrel according to some industry standards. The side support may be configured to support the container, for example, during rotation of the container support structure, for example, to prevent the container from tilting with respect to the lower end of the support structure. Thus, within the disclosure of the present application, there is a powder container in which the powder container is not installed or removed. Such a powder container may be considered a precursor of the powder container.

[0042] In a preferred example, the container support structure may further include a powder removal funnel. For example, the powder removal funnel (abbreviated as the removal funnel in this specification) may be movably attached to another part of the rotatable container support structure, such as a side support of the rotatable container support structure. The inlet end of the powder removal funnel preferably faces towards the lower end of the support structure. An example in the movable attachment is a hinge that enables the powder removal funnel to rotate relative to the side support. Another example is a linear bearing that enables the translation of the powder removal funnel relative to the side support. Two examples for movably supporting the powder removal funnel can also be combined in the same way. In any case, the powder removal funnel may have at least a first position and / or a first orientation directly above the lower end of the support structure when the lower end of the support structure is in its lowest position, and preferably a second position and / or a second orientation where the powder outlet funnel is not directly above the lower end of the support structure (assuming the lower end is still in its lowest position), thus freeing up a path for moving the powder container onto the lower end of the support structure. The movable attachment enables the powder outlet funnel to be moved between at least the first position and / or the first orientation and the second position and / or the second orientation. Just to avoid ambiguity, "directly above" in this context does not refer to the distance between the powder removal funnel and the lower end of the support structure, but rather, it should be noted that the projection of the powder removal funnel in a direction perpendicular to the surface provided by the lower end of the support structure configured to receive the powder container indicates that the powder removal funnel provides an image of the lower end of the support structure. To provide a clear example, it can be assumed that the lower end of the support structure is horizontally oriented and in its lowest position, in which case, "directly above" means that a protrusion vertically downward causes the removal funnel to protrude towards the lower end of the support structure (assuming no other surface exists between the removal funnel and the lower end of the support structure).

[0043] During operation, the support structure may first be oriented such that the lower end of the support structure, i.e., the lower end of the support structure, is in its lowest position. The powder removal funnel is preferably moved to a position where the path of the powder container to the lower end of the support structure is released, i.e., not blocked by the powder removal funnel. For example, the powder removal funnel may be in its second position and / or second orientation. Next, the powder container, e.g., a standardized powder barrel, may be moved to the lower end of the support structure. The upper end cap of the container may be removed either before or after moving the container at the lower end of the container support structure, thereby opening the upper end opening of the container. Thus, the upper end opening of the container is preferably open and preferably directed upward (when the lower end of the support structure is still in its lowest position).

[0044] Subsequently, the powder removal funnel may attach its inlet end to the upper end opening of the container by moving the container to its first position and / or orientation. Preferably, the powder removal funnel has a gasket on its inlet side that provides at least a powder-tight seal with the container. Thus, the powder removal funnel and the container volume are in fluid communication via the container opening, but when the powder removal funnel is in its first position and / or first orientation, powder is not inadvertently released through the gap between the powder removal funnel and the powder container.

[0045] In a preferred example, the movable attachment of the powder removal funnel may be blocked at least in the first position and / or orientation, whereby the powder container is fixed in its position and orientation relative to the rotatably supported support structure. In other words, the powder removal funnel can clamp the container against the lower end of the support structure when the container is in its first position and / or orientation.

[0046] Thus, by rotating the support structure, the powder container held in a predetermined position relative to the support structure can be inverted. Here, the upper end opening of the powder container faces downward, and the powder can flow down to the inlet opening of the powder removal funnel. Thus, such powder may be drawn out through the outlet of the powder removal funnel or may be supplied to the powder drain through an optional powder conduit.

[0047] Thus, if not yet connected, the outlet end of the powder outlet funnel is preferably connected to a powder removal conduit for conveying the powder to the powder drain. Examples of the powder drain may be an additive manufacturing machine and / or a powder recycling device and / or a powder filling station, etc.

[0048] Preferably, the funnel outlet valve may be installed at the powder outlet end of the powder outlet funnel. Thereby, the powder drain can be connected after rotating the support structure. When the powder outlet valve is open, the powder may flow out from the powder outlet end and flow into, for example, an optional powder removal conduit. When the powder outlet valve is closed, there is no fluid communication between the removal funnel and the environment even if the removal conduit is not connected. Thus, the support structure may be rotated as needed without having a restraint powder removal conduit attached thereto.

[0049] When removing the powder container from the powder container, the support structure may be rotated again, for example, until the lower end returns to its lowest position again. The powder removal funnel may be moved to its second position and / or second orientation, thereby releasing the powder container and freeing up a path for removing the powder container from the support structure. Once removed, another (or the same) powder container may be repositioned at the lower end of the support structure.

[0050] It should be noted that in the above, the lower end of the support structure must be in its lowest position in order to insert or remove the powder container, and it was assumed that in this lowest position, the lower end is oriented at least essentially horizontally and parallel. However, none of these features are required. It can also be advantageous if the lower end is not horizontally parallel and / or the lower end is not in its lowest position during the insertion or removal of the powder container. In this case, the powder container can slide on the side supports of the support structure when entering and exiting the support structure. This may also be required, for example, if the ceiling of the room is too low to vertically lift the powder container into and / or out of the container support structure. In the above, the term "lowest position" was used only to make the description clearer and it can always be replaced by the "powder container removal position", where the lower end of the support structure is preferably below the powder removal funnel, and in the inverted position, the outlet end of the powder removal funnel is preferably below the lower end of the support structure. However, it should be noted that the lowest position of the lower end of the support structure is a preferred example of the powder container removal position.

[0051] Furthermore, the inventors assumed that in the second position and / or orientation, the powder removal funnel does not directly cover the lower end of the support structure. This is also not necessary. All that is required is that when moving the powder removal funnel from its first position and / or location to its second position and / or location, a path for the insertion and / or removal of the powder container is cleared.

[0052] Preferably, the powder container may have an inert gas intake port. The powder container may further have a pressure reducing valve having a high pressure inlet and a low pressure outlet, and the container may be provided with an inert gas inlet opening. The inert gas intake port is preferably in fluid communication with the high pressure inlet of the pressure reducing valve, and the low pressure outlet of the pressure reducing valve is preferably in fluid communication with the inert gas opening. Thereby, the pressure supplied to the container via the inert gas intake connector (inert gas intake port) is reduced to a predetermined pressure in the vicinity of the container. The length of the line from the pressure reducing valve to the inert gas opening of the container can be made much shorter and thus can have a much smaller diameter. This helps to reduce costs. Further, the pressure supplied to the container of a given powder container does not change. Essentially, i.e., by the design of the powder container, the container is excluded from being exposed to a pressure higher than specified, which can lead to explosion of the container and / or release of the powder, which is important since the submicron powder used in the AM machine can enter the human lungs.

[0053] Preferably, the inert gas control valve may be disposed in a gas line providing fluid communication between the inert gas port and the inert gas inlet of the container. For example, the high pressure input of the pressure reducing valve may be connected to the outlet of the inert gas control valve, and the inlet of the inert gas control valve may be in fluid communication with the inert gas inlet port (by a corresponding conduit). Alternatively, the inert gas inlet port may be connected to the inlet of the pressure reducing valve and the outlet of the pressure reducing valve may be connected to the inlet of the inert gas control valve. The outlet of the inert gas control valve is in fluid communication with the inert gas inlet of the container. Both alternatives further enhance the safety of operation.

[0054] When the inert gas control valve has an inert gas control valve actuator, it is particularly preferred that the inert gas control valve actuator is a member of a subset K of k actuators out of a set L of l actuators. Thereby, when the corresponding port of the fitting connector of the powder container handling station (i.e., the inert gas valve actuator control port) is simply omitted or not connected to the controller of the container handling station, an unintended pressure increase or pressure drop in the container by the powder container handling station can be avoided.

[0055] Preferably, the powder container is provided with a gas removal port. The gas removal port is preferably in fluid communication with the container volume via a gas removal control valve. More precisely, the container may be provided with a gas removal outlet, and the gas removal outlet may be connected to the inlet opening of the gas removal control valve via a first portion of the gas removal line. The outlet of the gas removal control valve may be connected to the gas removal port by a second portion of the gas removal line. In other words, the gas removal port may be configured to draw gas from the container and can be opened and closed by opening the gas removal control valve. The gas removal control valve may have a gas removal control valve member coupled to an actuator of a subset K of k actuators of a set L of l actuators. This also makes it possible to prevent an unintended operation of the gas removal control valve in the powder container handling station if the corresponding port of the mating connector of the powder container handling station is not simply connected to the corresponding controller or is completely omitted. The gas removal port can be used, for example, to reduce the gas pressure in the container by coupling a vacuum pump or any other low-pressure source to the gas removal port and to open the gas removal control valve. Gases harmful to the powder and / or the AM process, such as water vapor (moisture) and / or oxygen, can be removed from the container via the gas removal port. The gas removal control valve can also be opened when flooding the container with an inert gas via an inert gas inlet, allowing the gas to be pushed out (or sucked) from the container via the gas removal port.

[0056] In a preferred example, the powder container is provided with a pressure sensor configured to determine the gas pressure upstream and / or downstream of the gas removal control valve. In addition to or instead of this, the powder container may be provided with a differential pressure sensor configured to measure the pressure difference between the first and second portions of the gas removal line. The pressure sensor and / or the differential pressure sensor is preferably a member of a subset M of a set N of n sensors.

[0057] Preferably, the gas removal port connection sensor is connected to the first end of the gas removal port connection sensor line. The second end of the gas removal port connection sensor line may be connected to a port of the multi-port connector. In other words, the gas removal port connection sensor is preferably also a member of a subset M of a set N of n sensors.

[0058] In a preferred example, the powder container may comprise a support frame understood as a preferred example of a container support structure. The container support structure may have a mount for attachment to a crane and / or receptacle to receive the forks (protrusions or teeth) of a forklift. Preferably, the container is inside the container support structure and is thus at least somewhat protected from mechanical damage, for example due to collisions, by the frame structure. The multi-port connector may be attached to the container support structure and / or the container and preferably does not extend across the contour of the container support structure. Thereby, the connector is also protected by the container support structure. The ports of the multi-port connector are preferably outward-facing, thereby facilitating connection of the multi-port connector to the mating connector of the powder handling station.

[0059] The powder container may preferably comprise at least one locking shaft. The locking shaft may be rotatably supported with respect to the container. This does not necessarily mean that the corresponding bearing is directly mounted on the container, although it may be so, but rather that the rotation of the locking shaft is with respect to the coordinate system of the container. In a preferred example, the bearing supporting the locking shaft is mounted on an (optional) container support structure, for example on the lower end section of the container support structure. The locking shaft has a proximal end and a distal end. Here, the proximal end is closer to the container than the distal end. In a preferred example, the distal end faces at least essentially in the same direction (within a range of angles ±α, α ∈ {30°, 20°, 10°, 5°, 2.5°, 1°, 0°}) as the lower end of the container and / or the side wall of the container. The locking member may be torque-transmittably coupled to the distal end of the locking shaft. Also, the coupling member is preferably coupled to the locking shaft to transmit axial force. Preferably, the locking shaft is driven by a locking shaft actuator. The locking shaft enables the powder container to be connected to the powder handling station. This enhances the safety of the operation of the powder container as it can simply prevent the powder container from falling from the powder container support in the case of an earthquake and / or an impact, for example by a forklift. In a preferred example, the locking member has a broken rotational symmetry with respect to the axis of rotation of the locking shaft. This broken symmetry allows the locking member to be inserted into the locking member opening while positioning the powder container on and / or within the powder container support, and the locking member can be securely locked by a structure defining the locking member opening by rotating the locking shaft. In another example, the locking member may be a thread that can engage with a mating thread on the opposite side of the powder container support by rotating the locking shaft. In both examples, the axial movement of the locking shaft, and thus the axial movement of the powder container away from the powder container support, is prevented by a secure lock. The locking shaft actuator is preferably a member of a subset K of a set L of l sensors.

[0060] The features described above contribute together to an improvement in the operational safety of the powder container. For example, in a powder handling station, an unintended powder release due to an incorrect interpretation of sensor readings resulting in an incorrect opening of a valve can be avoided because only the sensors that are intended to be read by the corresponding powder handling station can be read by the corresponding handling station. Similarly, the actuator control ports of the mating multi-port connectors that are not required at a particular powder handling station can be omitted or left unconnected. For example, in a gas pressure regulation station and / or a gas mixing regulation station, there is no need to open or close a powder inlet valve or a powder outlet valve. In this station, the mating ports that come into contact with the ports of the actuator that drives the corresponding valve member (via the corresponding lines) are simply not connected to the controller of the powder handling station. Thus, an unintended powder release due to, for example, a software bug is essentially avoided. Similarly, in other powder handling stations, the mating ports of the multi-port connectors that are connected to sensors and / or actuators that are not required to perform the operations of the respective powder handling stations are preferably omitted and / or not connected to the controller of the respective powder handling stations.

[0061] As already apparent, the control lines are preferably conductive cables, but are not limited thereto. For example, when the actuator is hydraulically controlled / operated (i.e., by a pressurized fluid), the control line may be a hydraulic line or a pneumatic line depending on the fluid. The purpose of the control line is to connect the corresponding actuator, preferably via the ports of a multi-port connector, to the controller of an AM-powder handling station, which is synonymous with a device for handling powder supplied to, or supplied from, or stored in a powder container and / or a powder container service station.

[0062] The powder handling station may be the powder for AM, i.e., any machine configured to use the AM apparatus itself, but may also be a powder bed and / or a powder recycling station and / or a powder container filling station and / or a work piece removal station for removing the work piece from a station for adjusting the gas composition and / or pressure within the container. In short, any device useful for providing, preparing, or collecting powder in an AM manufacturing environment is a powder handling station, also referred to as a powder handling machine or a powder handling device.

[0063] The terms "connected" or "connection" are used above to denote that two parts are joined to each other to provide an implicit function to the parts. For example, when two conduits are connected, the corresponding connection results in fluid communication, i.e., a flow of fluid or powder from the first of the two conduits to the other conduit (as long as the flow is not blocked by a closed valve). Similarly, the connection of two electrical contacts allows the flow of electric current between the two contacts. A waveguide connection provides the ability for an electromagnetic wave to propagate from a first waveguide to another waveguide connected thereto, etc. A transmission gear may, for example, connect an input shaft and an output shaft. The term "line" as used above is used as an umbrella covering the terms electric cable, conduit, and waveguide, and can be replaced with "electric cable and / or conduit and / or waveguide". All three examples all allow the transmission of power and / or information from the first end of the line to the other end of the line.

[0064] The term "port" is used herein as an umbrella term for the electrical terminals of a connector, fluid terminals (fluid ports), and / or waveguide ports. A port may be incorporated into the corresponding connector, but it is not necessary to be incorporated. A multi-port connector has at least two ports, which may be of different types. However, the at least two ports are not necessarily of different types. A multi-port connector may have a first number of electrical terminals (electrical ports), a second number of fluid ports, and a third number of waveguide ports, but not all of these ports need to be connected to the corresponding lines.

[0065] Hereinafter, examples of embodiments will be described by way of example of the present invention without limiting the general inventive concept, with reference to the drawings.

Brief Description of the Drawings

[0066]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Modes for Carrying Out the Invention

[0067] Figure 1 shows a first embodiment of a powder container 1 for handling powder in the context of an AM process (powder bed process). The powder container comprises a container 100. The container 100 may comprise an upper end 110 and a frustoconical lower end 120 that essentially form a funnel. In the illustrated example, the opening angle β of the frustoconical lower end 120 is 54°, but other values of the opening angle β are possible. The preferred interval for the opening angle β is [48°; 62°], i.e., β ∈ [48°; 62°]. The side wall 130 connects the upper end 110 and the lower end 120 of the container.

[0068] As shown in the figure, the powder container 1 may further comprise a frame 200, which is an example of a container support structure 200. In this example, the frame has four vertical posts 230, but other numbers of posts are possible. The posts are each connected to their adjacent ones by cross beams 235. The lower part of the posts may be attached to an optional lower end section 800, which will be described in more detail with reference to FIG. 7.

[0069] The powder container 1 may have several interfaces for interacting with a powder handling station in an AM process. Some of these optional features are a pressure compensation port 420 and a gas removal port 430. The powder container may further comprise a multi-port connector 500. The multi-port connector 500 may be mounted inside the frame 200, i.e., as shown in the figure, it does not extend across the frame 200 but faces outwards with its connection ports so as to be connected by the mating connectors of the powder handling station.

[0070] Figure 2 shows the details of the powder container 1. As can be seen from the figure, the container 100 may preferably be characterized by an inert gas inlet 410 at the upper end 110 of the container 100. The container 100 may further be characterized by a pressure sensor 440 and / or a safety valve 450 and / or a spare socket 460 for measuring the pressure inside the container 100.

[0071] The powder container 1 may further include a powder inlet port 480. The powder inlet port 480 may be in fluid communication with the inlet of the powder inlet valve 485. The outlet of the powder inlet valve is in fluid communication with the powder inlet 180 of the container 100, and thus the volume is surrounded by the container 100. Correspondingly, by controlling the powder inlet valve actuator 488, the powder inlet valve 485 can be opened and closed.

[0072] As can be seen from FIGS. 3 and 4, a grid 489 is provided on the upstream side of the powder inlet valve 485 to prevent a person operating the powder container from being injured by the movement of the valve member 486 of the powder inlet valve.

[0073] FIG. 5 is a detailed view of the lower part of the powder container. For example, some parts such as an optional frame 200 are omitted to simplify the figure. Shown is a part of the container 100, namely, the frustum-shaped lower end 120. At the lower end of the frustum-shaped lower end 120, there is a powder outlet 190. An inlet of a powder outlet valve 495 may be attached to the powder outlet 190 of the container, and the powder outlet 190 of the container can also be considered as the powder inlet of the powder outlet valve 495. Note that the outlet of the powder outlet valve 495 may be provided by a powder outlet port 490 or attached to the powder outlet port 490. The powder outlet valve 495 may include a valve member driven by a powder outlet valve actuator 498.

[0074] As can also be seen in FIG. 5, the side of the inert gas inlet port facing the container may be connected to the first end of the pressure compensation valve 425. The other end of the pressure compensation valve 425 may be connected to a pressure compensation conduit 421 that is in fluid communication with the pressure compensation opening 141 (see FIG. 2) of the container 100 as shown.

[0075] The gas removal opening 142 (see FIG. 2) at the upper end 110 of the container 100 may be connected to the inlet side of the gas removal valve 435 via a gas removal conduit. The outlet side of the gas removal valve 435 may be in fluid communication with the gas removal port 430 (see FIG. 5). The valve member of the gas removal valve 435 may be driven by a gas removal valve actuator 438 (FIG. 5).

[0076] As can be seen in FIG. 5, the container support mount 105 may be attached to the container 100. At least one of the container support mounts 105 is preferably attached to the container support structure 200 (see FIG. 1) via a strain gauge 106. The strain gauge can be replaced by any other load or force sensor 106 that enables determination of the gravity of the container supported by the container support structure 200. In this sense, the term strain gauge should be regarded as a pars-pro-toto for any force measurement sensor. The force measurement sensor 106 enables determination of the amount of powder in the container (since the empty mass of the container 100 is known or at least can be determined), as well as measurement of the acceleration of the container 100 that can result in compaction of the powder within the container 100.

[0077] A first portion of the inert gas conduit 412 may connect the inert gas inlet 410 to the outlet of the inert gas inlet valve 418. In the illustrated example, the inert gas inlet valve 418 is a bistable solenoid valve (i.e., the valve actuator is a solenoid drive), but other valves can be used as well. The inlet of the inert gas inlet valve 418 may be connected to the outlet of any pressure reducing valve 419 by another portion of the inert gas conduit 412. The inlet of the pressure reducing valve 419 is preferably connected to the inert gas inlet 410 of the powder container 1.

[0078] The tenth lowest part of the conical lower end 120 (more generally i thThe second lowest, where i ≧ 5, for example, i = 10, 12, 15, 20, 25, ···; although there is no theoretical maximum value for i, generally, it can be assumed that i should not be greater than 100), preferably, the i of the conical lower end 120 th There is a powder sensor 620 configured to determine whether the second lowest part of the conical lower end 120 is filled with powder. This sensor can be a light barrier sensor, a capacitance sensor, an ultrasonic sensor, etc. When this powder sensor 620 indicates that there is no powder remaining at the height of the powder sensor, the amount of powder remaining in the container can be accurately estimated, and appropriate measures (for example, stopping the AM process, starting container swapping and / or replenishment,...) can be taken.

[0079] Figure 5 also shows the connector 500. The connector 500 has a number of ports. Some of these ports are electrical ports, that is, electrical contacts that are electrically contacted by corresponding ones of the mating connectors. Other ports may also be fluid ports, such as the inert gas inlet port 410 for example. Other fluid ports may also be connectors to actuators that are operated based on fluid pressure.

[0080] An exemplary connection scheme of the powder container 1 is shown in FIG. 6. As can be seen from the figure, all the actuators 418, 428, 438, 488, 498 are directly connected to the corresponding ports of the connector 500 by separate actuator control lines. It is not necessary for all the actuators 418, 428, 438, 488, 498 to be directly connected, but it is preferred. It is sufficient if a subset of the actuators 418, 428, 438, 488, 498 is directly connected to the corresponding ports of the connector. This can avoid malfunction of the actuators in a powder handling station where it is not necessary to operate the corresponding actuators simply by not connecting (which is equivalent to simply omitting) the corresponding ports of the mating connector. Of course, the actuators can share a common ground port or can be powered at the supply port, but each actuator of the subset can be controlled by supplying signals to separate ports or a plurality of separate ports of the connector. The powder container 1 may include a container controller 107 connected to the data link port of the connector by some data link, but the container controller 107 is preferably not configured to control the operation of the subset of actuators by omitting the control line connection between the container controller 107 and the corresponding actuators. In this case, the container controller 107 is connected to the force sensor 106 and provides a signal representing the mass of the container to the port of the connector 500. This signal can be transmitted via a data link or, as in this example, an analog signal (i.e., a voltage representing the mass).

[0081] FIG. 7 shows a perspective bottom view of an exemplary lower section 800, i.e., the lower end side is shown upward. The exemplary lower section 800 may have a lower section support structure 820 with a forklift receptacle. Preferably, there is a powder outlet port protector 825 between the forklift receptacles. The powder outlet port protector 825 is a structural element that blocks the path from the side of the container support structure 200 to the powder outlet port. Thus, if the forklift is improperly positioned relative to the powder container 1, the powder outlet port cannot be torn and will otherwise be damaged by the forks.

[0082] Furthermore, the powder container 1 may comprise one or more locking shafts 850. The locking shaft 850 may be rotatably supported by a support structure of the container support structure 820, as shown, for example, by the support structure 200 of the lower end section 800. In this example, two locking shafts 850 are shown, although any other number may be appropriate (e.g., 1, 3, 4, 5, ...). The locking shaft 850 has a proximal end and a distal end 852. As can be seen from the figure, the distal end 852 may face downward and may be torque-coupled to the locking member 853 in a transmissible manner. The coupling may also be an elastic coupling. A locking shaft actuator 858 may be coupled to rotate the locking shaft (850) from the open position to the closed position and from the closed position to the open position (the coupling may be an elastic coupling). In this example, the change in position is strictly only a change in orientation, but not only the superposition of translation and rotation, but also translation can serve the same purpose. In this example, the locking member 853 is provided by a bar forming two pins extending radially across the contour of the locking shaft 850. Thus, in the open position, the locking member 853 may be inserted through an elongated slot of the powder container support of the powder handling station, and then the lock actuator may be controlled to move the locking shaft 850, and thus the locking member 853, to a closed position engaging the material forming the slot. The locking shaft actuator 858 may be connected, preferably directly, to a separate port of the connector 500 by a lock actuator control line.

[0083] To facilitate proper positioning of the powder container 200 on the powder container support of the powder handling station, the container support structure 200 preferably includes a guide plate 890, for example, at its lower end section 800 attached to the lower end section support structure 820. This guide plate 8'90 can interact with complementary guide means of the powder container support of the powder handling station to move the powder container to a predetermined position and orientation when the powder container 1 is lowered onto the powder container support.

[0084] The powder container of FIG. 9 has a rotatable container support structure 200 and a frame 300 with the container support structure, briefly described herein. Thus, the support structure 200 is attached to the frame 300 via a rotary bearing 250. The rotation axis of the rotary bearing 250 is preferably at least essentially horizontal when the rollers of the frame 300 are on a horizontal ground. A rotary drive 255 with a crank handle 260 enables the container support structure 200 to be easily rotated around the rotation axis of the rotary bearing. Of course, the manual rotary drive 255 can be replaced by an electrically or hydraulically powered drive (or a drive powered by any other energy source). The drive may be omitted. In this case, the rotation can be performed manually, that is, without a drive support.

[0085] The rotatable support structure may include a lower end 220 and side supports 225. An optional powder removal funnel 150 of the support structure is movably attached to the side structure 225 and / or the lower end 220 of the support structure. Thus, any powder removal funnel 150 can rotate with other parts of the rotatable support structure while being movable between a first position and / or a first orientation and a second position and / or a second orientation, as is apparent from FIGS. 9.1 to 9.4. Thus, the change in the position and / or orientation of the referenced powder removal funnel 150 is the position and / or orientation relative to the other support structure lower end 220 (which is itself rotatably supported relative to the frame 300).

[0086] In FIG. 8, the optional powder removal funnel 150 is shown in its first position and first orientation. As can be seen in FIG. 9.1, when the powder removal funnel is moved to its second position and / or orientation, the powder container 100 can be removed from the support structure 200. The movable attachment 125 of the powder removal funnel 150 to the support structure 200 is hidden in FIG. 8 but is schematically shown in FIGS. 9.1 to 9.4. Implicitly, the powder removal funnel 150 has a powder inlet end with a powder inlet opening and a powder outlet end with a powder outlet opening 190. As shown in FIG. 8, an optional powder outlet valve 495 may be attached to the powder outlet opening 190. The optional powder outlet valve 495 may have a powder outlet valve actuator 498. Other details of FIG. 8 have already been described with reference to other figures and the same reference numbers are used as needed.

[0087] Inserting a new powder container 100 into the powder container as shown in FIG. 8 is schematically shown in FIGS. 9.1 to 9.4 and starts from the situation shown in FIG. 9.1.

[0088] The powder container 100 may be installed outside the powder container, the support structure may be rotated such that the lower end 220 of the support structure is below the powder removal funnel 150, and the powder removal funnel 150 may be in a second position and / or orientation providing a path for the powder container 100 from the outside to the lower end 220 of the support structure (see FIG. 9.1). Next, as shown in FIG. 9.2, the powder container 100 may be moved onto the lower end 220 of the support structure, for example, by a lifter or a crane. Thus, the lower end 120 of the container is present on and supported by the lower end 220 of the rotatable support structure 200. Further, the upper cap 115 of the powder container 100 can be removed if still present. Subsequently, the powder removal funnel 150 can be moved to its first position and / or first orientation. In this position and / or first orientation, the wider inlet end of the powder removal funnel is sealingly attached to the powder container, thereby providing fluid communication between the powder container volume and the powder removal funnel. Further, the powder container is preferably fixed relative to the lower end of the support structure. This can be achieved, for example, by locking the powder removal funnel in its first position and / or first orientation relative to the lower end of the support structure. In addition or alternatively, other fixing means may be used as well. Examples are clamp jaws, suction cups, etc.

[0089] As seen in FIG. 9.4, the powder support structure may be rotated in the reverse direction here, i.e., the powder removal funnel may be here below the lower end of the container and / or at the lower end of the support structure. Thus, any optional powder in the powder container can flow into the powder removal funnel and can be drawn out through the powder outlet of the powder removal funnel 150. The outlet 190 of the powder removal funnel 150 and the optional powder outlet valve 495 are shown in FIG. 8 and are omitted in FIGS. 9.1 to 9.4 for simplicity only.

Explanation of Reference Numerals

[0090] 1 Powder tank 100 Powder container / Container 105 Container support mount 106 Force sensor, e.g., strain gauge 107 Container controller / Controller 110 Upper end of powder container / Upper end of container 115 Cap 120 Lower end of container 125 Attachment of powder removal funnel 150 to support structure 200 130 Side wall of powder container 142 Pressure compensation opening 144 Gas removal opening 180 Powder inlet of container 190 Powder outlet of container 200 Container support structure, e.g., support frame 220 Lower end of support structure / Lower end of support structure 230 Vertical post 235 Cross beam 240 Rotary bearing 250 Rotary drive 300 Support frame 410 Inert gas inlet port 411 Inert gas conduit 418 Inert gas inlet valve 419 Pressure reducing valve 420 Pressure compensation port 421 Pressure compensation conduit 425 Pressure compensation valve 428 Pressure compensation valve actuator 430 Gas removal port 431 Gas removal conduit 435 Gas removal valve 438 Gas removal valve actuator 440 Container pressure sensor 450 Safety valve 480 Powder inlet port 482 Grid 485 Powder inlet valve 486 Powder inlet valve member 488 Powder inlet valve actuator 489 Grid 490 Powder outlet port 495 Powder outlet valve 498 Powder outlet valve actuator 500 Connector 620 Powder sensor 800 Lower section 820 Lower section support structure 825 Powder outlet port protector 850 Lock shaft 852 Distal end 853 Lock member 858 Lock shaft actuator 890 Guide plate

Claims

1. A powder container (1) for handling powder in an additive manufacturing process, comprising: An optional powder container (100) surrounding a container volume for storing the powder; A set N of n sensors for determining a set of n observables, where n is an integer greater than or equal to 2, i.e., n ∈ {2, 3, 4,..., n max}, the set N of n sensors, and A first actuator (428, 438, 488, 498, 858) for driving a first mechanical function of the powder container (1); In a powder container (1) comprising at least: (i) A second actuator (428, 438, 488, 498, 858) for driving a second mechanical function of the powder container (1), and / or (ii) A multi-port connector (500) configured to be connected to a corresponding connector of a powder handling station in an additive manufacturing process. A powder container (1), characterized in that it further comprises at least the above.

2. A powder inlet valve (485) with a powder inlet valve inlet and a powder inlet valve outlet, wherein the powder inlet valve outlet is connected to a powder inlet (180) of the powder container (100), and the powder inlet valve inlet is connected to a powder inlet port (480) of the powder container (1), and / or, A powder outlet valve (495) with a powder outlet valve inlet and a powder outlet valve outlet, wherein the powder outlet valve inlet is connected to a powder outlet (190) of the powder container (100), and the powder outlet valve outlet is connected to a powder outlet port (480) of the powder container (1). The powder container (1) according to claim 1, further characterized in that it further comprises at least the above.

3. At least one funnel is in fluid communication with a powder inlet and / or a powder outlet of the container, and / or when dependent on claim 2, the at least one funnel is in fluid communication with the container volume via the powder inlet valve and / or the powder outlet valve when the respective valves are in an open state. The powder container (1) according to claim 1 or 2, characterized in that it has the above features.

4. The powder container (100) is supported by a container support structure (200), and a support frame (300) rotatably supports the container support structure (200) by at least one rotary bearing having a rotation axis. The powder container (1) according to any one of claims 1 to 3, characterized in that it has the above features.

5. The container support structure (200) comprises a powder removal funnel (150). The powder removal funnel is movably attached to the container support structure (200), wherein the movable attachment of the powder removal funnel (150) enables the powder removal funnel (150) to be moved from at least a first position and / or a first orientation to a second position and / or a second orientation, and rearward, with respect to the container support structure (200). The powder container according to claim 4, characterized in that.

6. The powder container (100) has a lower end of the powder container (120), and the lower end of the powder container is supported by a lower end of the support structure (220) of the rotatable support structure (200), the powder container according to claim 4 or 5.

7. The powder removal funnel (150) has a powder inlet of the powder removal funnel, and the powder inlet of the powder removal funnel is in fluid communication with the container volume through an opening of the powder container, the powder container according to claim 5 or 6.

8. The powder container according to claim 7, characterized in that the powder removal funnel (150) covers the opening of the powder container.

9. Comprising a locking mechanism, the locking mechanism being configured to releasably prevent rotation of the container support structure (200) with respect to the support frame (300), the powder container according to any one of claims 4 to 8.

10. The set N of n sensors,[[]]END]] a container pressure sensor (440) for measuring the pressure within the volume of the container (100), a force sensor (106) for measuring the force exerted by the powder container (100) on the frame (200), a pressure sensor for measuring the pressure upstream of the powder inlet valve (485), a pressure sensor for measuring the pressure downstream of the powder outlet valve (495), a differential pressure sensor for measuring the pressure difference between the volume of the container (100) and the space upstream of the powder inlet valve (485), a differential pressure sensor for measuring the pressure difference between the volume of the container (100) and the space downstream of the powder outlet valve (495), a gas concentration sensor for determining at least the partial pressure and / or concentration of the gas component of the gas within the volume of the container (100) and / or within the space upstream of the powder inlet valve (485) and / or within the space downstream of the powder outlet valve (495), An upper powder level sensor installed in the upper one-third of the powder container (100), for determining whether the powder level in the powder container (100) is above or below the position of the upper powder level sensor. A lower powder level sensor installed in the lower one-third of the container, for determining whether the powder level in the powder container (100) is above or below the position of the lower powder level sensor. The powder container (1) according to any one of claims 1 to 9, characterized by comprising at least one of the above.

11. The powder container (1) according to any one of claims 1 to 10, characterized in that each sensor of a subset M of m sensors of a set N of n sensors (m ≤ n; m, n are integers) is connected to a separate port of the multiport connector (500) via a separate measurement line.

12. The powder container (1) according to any one of claims 1 to 11, further comprising a set of l actuators (428, 438, 488, 498, 858) for driving at least one mechanical device of the powder container (1), where l is an integer, and each actuator of at least one subset K of k actuators of the set L of l actuators (i.e., k ≤ l; k, l are integers) (428, 438, 488, 498, 858) is connected to a separate contact and / or port of the multiport connector (500) via a separate actuator control line.

13. The powder container (1) has an inert gas intake connector. The powder container (1) has a pressure reducing valve (419) with a high-pressure inlet and a low-pressure outlet. The powder container (100) has an inert gas inlet opening. The powder container (1) according to any one of claims 1 to 12, characterized in that the inert gas intake connector is in fluid communication with the high-pressure inlet of the pressure reducing valve (419), and the low-pressure outlet of the pressure reducing valve is in fluid communication with the inert gas opening (410).

14. An inert gas inlet valve (818) and / or a pressure reducing valve (819) is installed in an inert gas line that provides fluid communication between the inert gas port (410) of the powder container (1) and the inert gas inlet (410) of the container (100), characterized in that the powder container (1) according to any one of claims 1 to 13.

15. A control valve with a control valve actuator (428, 438, 488, 498) is provided, and the control valve actuator (428, 438, 488, 498, 858) is a member of a subset K of k actuators of a set L of l actuators, characterized in that the powder container (1) according to any one of claims 5 to 7.

16. The powder container (1) is provided with a gas removal port (430) that is in fluid communication with the container volume via at least one gas removal control valve (435), (i) the gas removal control valve (435) has a gas removal control valve actuator (438), and the gas removal control valve actuator (438) is a member of a subset K of k actuators of a set L of l actuators, and / or (ii) the powder container (1) is provided with at least a pressure sensor configured to determine the gas pressure upstream or downstream of the gas removal control valve, and the pressure sensor configured to determine the gas pressure upstream or downstream of the gas removal control valve is a member of a subset M of a set N of n sensors characterized in that the powder container (1) according to any one of claims 8 to 11.

17. The gas removal port connection sensor is connected to the first end of the gas removal port connection sensor line, and the second end of the gas removal port connection sensor line is connected to the port of the multi-port connector (500), characterized in that the powder container (1) according to claim 16.

18. The powder container (100) is installed inside a support frame (200), the multi-port connector (500) is attached to the frame (200), and the port of the multi-port connector (500) faces outward, characterized in that the powder container (1) according to at least one of claims 1 to 17.

19. The powder container (1) has a lock shaft (850) that is rotatably supported with respect to the powder container (100). The lock shaft (850) has a proximal end portion (851) and a distal end portion (852). A lock member (853) is torque-transmittably coupled to the distal end portion (852) of the lock shaft (850). The powder container (1) according to at least one of claims 1 to 18, characterized in that the lock shaft (850) is driven by a lock shaft actuator (858).

20. The powder container (1) according to claim 19, which incorporates claim 8, characterized in that the lock shaft actuator (858) is a member of a subset K of the set L of sensors.

21. The powder container (1) according to any one of claims 1 to 20, characterized in that the powder container is not provided, and / or the powder container is outside the container support structure according to claim 4.

22. A powder handling station for powder supplied to, or supplied from, or stored in the powder container (1) according to any one of claims 1 to 21, characterized in that it has a mating multi-port connector for connection to the multi-port connector of the powder container (1).

23. The powder handling station according to claim 17, characterized in that the plurality of mating port connectors have ports to the left of the plurality of port connectors (500) of the powder container (1), and / or not all ports of the plurality of mating port connectors are connected to corresponding connection lines of the device.

24. An additive manufacturing device comprising the powder container according to any one of claims 1 to 21, and / or the powder handling station according to claim 22 or 23, wherein a controller of the additive manufacturing device is connected to the at least one sensor of the set N of the first actuator(s) (428, 438, 488, 498, 858) and / or the second actuator(s) (428, 438, 488, 498, 858) and / or sensors via the multi-port connector (500).

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