Device and system for 3D printing a product

Abstract

Proposed are a device for controlling a product 3D printing process and a system for 3D printing a product using said device, both the device and the system comprising (i) a telemetry controller containing a microcontroller for processing data about the working parameters of an extruder and about the working parameters of a filament feed system, and further containing another microcontroller for processing data about the parameters of a product 3D printing process, and (ii) a processor module for controlling at least one of the actuating devices of the extruder by issuing control commands to a control board of the extruder on the basis of the results obtained by said microcontrollers.

Description

[0001] DEVICE AND SYSTEM FOR 3D PRINTING OF PRODUCTS

[0002] AREA OF TECHNOLOGY

[0003] The present invention relates to the field of 3D printing of products using an extruder, in particular to a device for controlling the process

[0004] 3D printing of a product and to a system for 3D printing of a product with such a device.

[0005] LEVEL OF TECHNOLOGY

[0006] It should be noted that additive manufacturing or 3D printing

[0007] 3D printing (3D printing) is a method for producing three-dimensional objects of virtually any geometric shape by depositing successive layers of material. Specifically, to form a three-dimensional object on a substrate, a thermoplastic material (filament) is extruded in successive layers through the nozzle of a 3D printer.

[0008] A heater, installed in close proximity to the nozzle, heats the thermoplastic material (filament) to melting point, followed by extrusion of the molten mass. The extruder itself is driven by stepper motors or servomotors, which ensure three-dimensional positioning of the print head. The extruder's movement is controlled by the extruder's control board.

[0009] Currently, various controllers are known for monitoring the extrusion parameters of a 3D printer, the use of which allows for extending the service life of the functional components of a 3D printer, preventing breakdowns of the functional components of a 3D printer, and reducing the risk of emergency situations associated with violations of industrial safety during the operation and maintenance of a 3D printer.

[0010] In particular, the prior art discloses a 3D printer control system disclosed in Chinese Patent No. 105224265 (hereinafter CN 105224265), issued under Chinese application No. 201510616166, published on January 6, 2016. The control system of the 3D printer disclosed in CN 105224265 comprises an MCU microcontroller for controlling the printing device and interacting with an external device, wherein the MCU microcontroller is connected to a USB interface circuit, an SD card interface circuit, an X-axis position sensor, a Y-axis position sensor and a Z-axis position sensor, a rotation angle sensor, a heating table temperature sensor, nozzle temperature sensors, an X-axis drive, a Y-axis drive, a Z-axis drive, extruder drives, fans, a heating table heater, nozzle heaters and an OLED screen, and the USB interface circuit is connected to a UART0 data transmission interface circuit and the MCU microcontroller via an ATMEGA16U2 chip to form a UART interface.

[0011] One of the drawbacks of the 3D printer control system disclosed in CN 105224265 is that the entire computational load is placed on the MCU, which may cause it to fail prematurely due to overheating due to the increased computational load.

[0012] Therefore, the primary technical problem solved by the present invention is to create a device for controlling the 3D printing process and a system for 3D printing that at least partially eliminates the aforementioned drawback of increased failure. An additional technical problem solved by the present invention is to expand the arsenal of tools for 3D printing.

[0013] DISCLOSURE OF THE ESSENCE OF THE INVENTION

[0014] The objective of the present invention is to create a device for controlling the process of 3D printing of a product and a system for 3D printing of a product, each solving at least the above-mentioned main technical problem.

[0015] Another objective of the present invention is to create an alternative device for controlling the process of 3D printing of a product in relation to a device known in the art for controlling the process of 3D printing of a product, as well as to create an alternative system for 3D printing of a product in relation to a system known in the art for 3D printing of a product.

[0016] Each of the stated tasks is solved in the first aspect of the present invention due to the fact that the proposed device for controlling the process of 3D printing of an article contains: (i) a telemetry controller on a system board, containing two microcontrollers, one of which is configured to establish communication with the control board of the extruder for processing data on the operating parameters of the extruder and communication with the control board of the filament supply system for processing data on the operating parameters of the filament supply system, wherein the other microcontroller of said microcontrollers is configured to establish communication with sensors for monitoring the process of 3D printing of an article for processing data on the parameters of the process of 3D printing of an article;and (ii) a processor module on the board specified by the system for controlling the process of 3D printing of the product, connected with the ability to exchange data with the said microcontrollers and configured to control at least one of the actuators of the extruder by issuing control commands to the control board of the extruder depending on the said results of the operation of the microcontrollers.

[0017] In addition, each of the stated problems is solved in the second aspect of the present invention due to the fact that the proposed system for 3D printing of an article comprises (i) a film pulling motor for automatically updating the build platform for 3D printing of the article; (ii) an extruder with a control board operatively connected to the extruder motor and the extruder heater; (iii) a filament supply system with a control board;(iv) a telemetry controller on a system board comprising (a) a microcontroller configured to communicate with an extruder control board for processing data on the operating parameters of the extruder and to communicate with a filament feed system control board for processing data on the operating parameters of the filament feed system, and (b) another microcontroller configured to communicate with sensors for monitoring the 3D printing process of the product for processing data on the operating parameters of the 3D printing process of the product, and (y) a processor module on said system board for controlling the 3D printing process of the product, connected with the ability to exchange data with said microcontrollers and configured to control the extruder motor and / or the extruder heater by issuing control commands to the extruder control board depending on said operating results of the microcontrollers.

[0018] The device for controlling the 3D printing process and the 3D printing system each provide the primary technical result of increased performance. This increased performance is achieved by distributing the computational load between two microcontrollers, which are part of the telemetry controller and are used to process different data streams, and a processor module that generates control commands based on the results of both microcontrollers and sends these generated control commands to at least one of the extruder actuators (specifically, the extruder motor and / or the extruder heater).

[0019] In addition, the device for controlling the process of 3D printing of a product according to the first aspect of the present invention provides an additional technical result consisting in increasing the discreteness of control of the process of 3D printing of a product or providing the ability to control the process of 3D printing of a product in real time, in particular by minimizing the likelihood of overloads and overheating of computing components during the implementation of computing operations.

[0020] Furthermore, the 3D printing system according to the second aspect of the present invention provides an additional technical result, namely, increased discreteness of the 3D printing process, which in turn minimizes the downtime of the actuators. Specifically, the increased discreteness of the 3D printing process in the 3D printing system according to the second aspect of the present invention is achieved by minimizing the likelihood of overloads and overheating of the computing components during computational operations. This is due to the distribution of the computing load between two microcontrollers included in the telemetry controller and used to process different data streams, and the processor module.

[0021] In addition, the device for controlling the process of 3D printing of an article according to the first aspect of the present invention and the system for 3D printing of an article according to the second aspect of the present invention each provide an additional technical result consisting in increasing their service life or their operating life, in particular by minimizing the likelihood of overloads and overheating of the computing components during the implementation of computing operations, which is due to the distribution of the computing load between two microcontrollers included in the telemetry controller and used to process different data streams, and the processor module.

[0022] In addition, the device for controlling the process of 3D printing of an article according to the first aspect of the present invention and the system for 3D printing of an article according to the second aspect of the present invention provide another additional technical result, which consists in increasing the safety of their operation or maintenance, in particular due to the distribution of the computing load between two microcontrollers included in the telemetry controller and used to process different data streams, and the processor module, which reduces the likelihood of their overheating due to excessive computing load.

[0023] In addition, the device for controlling the process of 3D printing of an article according to the first aspect of the present invention and the system for 3D printing of an article according to the second aspect of the present invention provide another additional technical result, which consists in increasing the accuracy of control of the parameters of the process of 3D printing of an article.

[0024] The above technical advantages of the claimed group of inventions are not limiting. Additional advantages of the claimed group of inventions and individual inventions within this group, including specific embodiments thereof, will be apparent to those skilled in the art from the detailed description of the present invention below and the accompanying drawings, which explain the essence of the present invention. In particular, depending on the specific embodiment of the present invention, it can accelerate the process of 3D printing of a product, simplify the process of 3D printing of a product, improve the technical characteristics or parameters of a printed product, increase the reliability of computing components, etc.

[0025] BRIEF DESCRIPTION OF DRAWINGS

[0026] The accompanying drawings, which are provided to provide a better understanding of the essence of the present invention, form a part of this document and are included herein to illustrate the embodiments and aspects of the present invention described below. The accompanying drawings, in combination with the description below, serve to explain the essence of the present invention, wherein in the drawings: Fig. 1 shows a diagram of a control device for a 3D printer; Fig. 2 shows a diagram of a telemetry controller.

[0027] IMPLEMENTATION OF THE INVENTION

[0028] Some examples of possible embodiments of the present invention are described below, but it should not be considered that the description below defines or limits the scope of the present invention.

[0029] The serial 3D printing control system includes a processor module mounted on the system board, printer control modules including microcontrollers, motor drivers, and other peripherals, a telemetry controller, a power supply system containing removable unified power modules, an adapter board for connecting to actuators (motors, heaters, temperature sensors), and a CAN interface converter for diagnostics, collecting system operation data, and communicating with individual equipment components. The processor module is connected to the control module via a USB port.

[0030] The control modules are connected to the system board via an edge SO-DIMM connector and contain analog inputs for connecting temperature sensors, outputs for controlling the actuators of the actuator block (stepper motors, discrete inputs for connecting limit switches, buttons, etc., discrete outputs for controlling heaters, fans, etc.), a USB connector for connecting to the processor module, system lines for remote rebooting and firmware.

[0031] The CAN interface converter provides diagnostics, collects information about the extruder's operation, and is connected to the extruder board, which includes a stepper motor driver, inputs for temperature sensors, inputs for limit switches, outputs for controlling fans and an extruder heater, and an accelerometer.

[0032] The use of CAN interface provides high throughput and interference resistance and ensures system performance.

[0033] The telemetry controller is implemented in the 200-contact SO-DIMM form factor and is built on the basis of two microcontrollers 1, 2 type RP2040.

[0034] The 3D printer telemetry controller, connected to the system board via SO-DIMM slot 3 and equipped with a power supply system 4, is designed to receive, process, record, and transmit measurement (telemetry) data. Data from the actuator unit's sensors is collected to monitor objects and processes occurring during 3D printing.

[0035] The telemetry controller is designed to process data coming from: • sensors for monitoring production parameters of the 3D printing process: temperature sensors (table temperature sensor; chamber air heater temperature sensor; extruder temperature sensor), limit switches of the extreme points of the 3D printer (maximum table position limit switch sensors; minimum table position limit switch; axis limit switches; extruder change mechanism limit switches; door limit switches; cell opening limit switch; electronics compartment door opening limit switch), switch-on sensors (fans, heaters); and

[0036] • sensors for monitoring the operating parameters of the equipment (temperature sensors for the axle motor, temperature sensor for the film feed motor for 3D printing of the product, temperature sensors for the door motor; temperature sensors for the control module, voltage sensor (signals critically low voltage on the line), emergency power off sensor, backup power supply activation sensor.

[0037] Microcontroller 1 is responsible for operating CAN interface converter 5 in the system to ensure communication with the print head and the filament feed system control board. To display the operation of microcontroller 1, device 10 is equipped with status LED driver 6.

[0038] Microcontroller 2 is equipped with analog multiplexers and 1 2 With port expanders including 1 2With isolator 7, expander 8 analog inputs, expander 9 discrete inputs. Microcontroller 2 is responsible for collecting information about the temperatures of the printing system components and the normal operation of the power outputs. Thanks to analog multiplexers and 1 2 With expanders, the solution is scalable and allows for the processing of incoming data from all nodes of the printing complex at a sufficient processing speed: up to 32 discrete signals and up to 24 analog signals.

[0039] Both microcontrollers 1 and 2 communicate with the head unit via a USB interface. In the event of a failure, a remote reboot is possible. If a software update is required, remote firmware update mode can be accessed without direct access to the board. A power control output allows for standard control of heaters, fans, etc.

[0040] During testing and programming, the board is powered via the USB Type-C port. Power is also supplied via the motherboard connector, which is part of the serial 3D printing control system.

[0041] The controller board design allows for quick replacement in the event of failure, reducing downtime. The telemetry controller, based on two microcontrollers, enables monitoring of all filament feed and 3D printing process parameters, minimizing the number of maintenance personnel, increasing the speed of response to emergency situations, thereby reducing the risk of downtime and improving the quality of manufactured products.

[0042] The use of two microcontrollers in device 10 ensures its speed and organization of access to shared resources.

[0043] Device 10 operates as follows:

[0044] The software that controls the printing process runs on the processor module and controls the control modules via the USB module, and the extruder board and telemetry module via the CAN interface converter (4).

[0045] Microcontroller 2 of the telemetry module collects data from sensors monitoring production and operational parameters of the 3D printing process, including table temperature sensors, chamber air heater temperature sensors, axis motor temperature sensors, film feed motor temperature sensor for 3D printing of a product, door motor temperature sensors, control module temperature sensors, voltage sensor of the limit switches of the 3D printer extreme points (maximum table position limit switch, minimum table position limit switch; axis limit switches, door limit switches, electronics compartment door opening limit switch), fan and heater activation sensors, emergency power shutdown sensors, backup power supply activation sensor.

[0046] Microcontroller 1 provides data collection from the extruder actuators, including limit switches for the extruder changeover mechanisms and limit switches for cell extraction.

[0047] Control of actuators (motors, heaters, fans) is carried out through control modules.

[0048] The scope of the present invention is limited only by the appended claims.

Claims

CLAUSES OF THE INVENTION 1. A device for controlling the 3D printing process of a product, comprising: a telemetry controller on a system board, containing two microcontrollers, one of which is configured to establish communication with the extruder control board for processing data on the operating parameters of the extruder and communication with the filament feed system control board for processing data on the operating parameters of the filament feed system, wherein the other microcontroller of said microcontrollers is configured to establish communication with sensors for monitoring the 3D printing process of the product for processing data on the parameters of the 3D printing process of the product, and a processor module on said system board for controlling the 3D printing process of the product,connected with the possibility of exchanging data with the said microcontrollers and configured to control at least one of the actuators of the extruder by issuing control commands to the control board of the extruder depending on the said results of the operation of the microcontrollers.

2. A system for 3D printing of a product, comprising: a film feed motor for automatically updating the build platform for 3D printing of a product, an extruder with a control board operatively connected to the extruder motor and an extruder heater, a filament feed system with a control board, A telemetry controller on a system board, comprising a microcontroller configured to establish communication with an extruder control board for processing data on the operating parameters of the extruder and a communication with a filament feed system control board for processing data on the operating parameters of the filament feed system, and another microcontroller configured to establish communication with sensors for monitoring the 3D printing process of the product for processing data on the parameters of the 3D printing process of the product, and a processor module on said system board for controlling the 3D printing process of the product, connected with the ability to exchange data with said microcontrollers and configured to control the extruder motor and / or the extruder heater by issuing control commands to the extruder control board depending on said operating results of the microcontrollers.

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