3D Printer Laser Leveling and Nozzle Fault Detection
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Solution Overview
Problem
Current FDM 3D printers face issues with low assembly accuracy, difficulty in mounting the printing platform, lack of intuitive size feedback during printing, absence of fault detection for nozzle issues, and inefficient leveling methods, which affect the quality and efficiency of the printing process.
Innovation Solution
An online laser leveling detection method is introduced, utilizing a bar-shaped triangular reflecting prism and a photoelectric receiver, along with a laser emitter and plane mirror, to continuously fine-tune the printer head and platform movements for accurate leveling and real-time fault monitoring, ensuring design accuracy and preventing material blockages or breakages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual leveling with a sheet plug is used, then the leveling process can be completed, but the leveling accuracy is low and the process is time-consuming
Solution Approach 1:
The patent replaces the manual mechanical leveling method (using a sheet plug) with an optical detection system. A laser emitter projects a laser beam, and a photoelectric receiver detects the beam's position to automatically determine leveling accuracy, eliminating the need for manual measurement and significantly improving both speed and precision.
Solution Approach 2:
The patent implements a feedback mechanism where the photoelectric receiver continuously monitors the laser beam position and provides real-time feedback on the printing platform's leveling status. This feedback enables automatic adjustment and ensures high leveling accuracy without time-consuming manual interventions.
2Ease of manufacture
If the printer head assembly is simplified for ease of manufacturing, then the device complexity is reduced, but the assembly accuracy and horizontal accuracy deteriorate
Solution Approach 1:
The patent replaces complex mechanical precision mechanisms with an optical detection and feedback system. Instead of relying solely on mechanical assembly precision, the system uses laser emission and photoelectric detection to measure and correct positioning errors, allowing for easier manufacturing while maintaining high accuracy.
3Ease of operation
If the magnetic base sheet mounting process is simplified, then the mounting operation becomes easier, but the positioning accuracy and time efficiency worsen
Solution Approach 1:
The patent replaces manual positioning and measurement operations with an automated optical system. The laser emitter and photoelectric receiver automatically detect the printing platform's position and levelness, eliminating the need for manual measurement tools and ensuring consistent positioning accuracy regardless of mounting simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances the accuracy and efficiency of printer head and platform leveling, enabling quick and precise adjustments, and provides intelligent fault monitoring, improving the overall quality and reliability of the 3D printing process.
Implementation Method 1
fixedly mounting a laser emitter and a plane mirror on the side face of the printer head
Implementation Method 2
the bar-shaped triangular reflecting prism and the bar-shaped photoelectric receiver are arranged as follows: the bar-shaped triangular reflecting prism and the bar-shaped photoelectric receiver are fixedly mounted in a printer shell
Implementation Method 3
the bar-shaped photoelectric receiver is elongated, the length of a photoelectric signal receiving surface of the bar-shaped photoelectric receiver is not less than the length of the bar-shaped triangular reflecting prism
Data Source
AI summary
The present invention provides an online laser leveling detection method of a 3D printer. The method comprises: (1), arranging a bar-shaped triangular reflecting prism and a bar-shaped photoelectric receiver; (2), fixedly mounting a laser emitter and a plane mirror on the side face of a printer head; (3), with the aid of a detection laser beam, fine tuning the mounting azimuths of an X-axis guide rail, a Y-axis guide rail, and the printer head till the motion levelness of the printer head is adjusted to meet requirements of the design accuracy of the printer; (4), with the aid of the detection laser beam, fine tuning the mounting azimuth of a printing platform till the mounting levelness of the printing platform is adjusted to meet the requirements of the design accuracy of the printer; (5), starting the 3D printing program; (6), in the printing process, detecting in real time whether a nozzle of the printer head generates faults including material blockage, shortage, and breakage. The present invention communicates detection signals of a laser detection system with a printer control system and designs the signal processing program to achieve detection of the motion levelness and the mounting levelness as well as monitoring of extrusion faults of the printer head.