3D Printer Nozzle Distance Measurement via Segmented Detection
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Solution Overview
Problem
Existing three-dimensional modeling devices face accuracy issues due to the need for replacing or recalibrating detection units when the modeling unit is changed, and reliance on pre-stored distances can result in inaccuracies affecting the positioning of the stage relative to the nozzle.
Innovation Solution
A three-dimensional modeling device with a measuring unit that measures distances to both a reference surface and the nozzle's distal end surface, allowing the control unit to calculate the actual distance between these surfaces for precise positioning, independent of unit replacements, and includes a heating unit for improved material adhesion and object strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a second detection unit supported in a unified manner with the modeling unit is used, then the available modeling distance can be detected, but the detection unit needs to be replaced when the modeling unit is replaced
Solution Approach 1:
The patent divides the distance measurement function into two independent parts: a first detection unit that moves with the modeling unit to detect the nozzle-to-detection-unit distance, and a second detection unit that remains stationary on the stage to detect the stage-to-detection-unit distance. This segmentation allows the modeling unit to be replaced without replacing the second detection unit, as each unit performs a specific measurement function independently.
Solution Approach 2:
The patent introduces a reference unit as an intermediary element with a reference surface that serves as a fixed reference point on the stage. The second detection unit measures its distance to this reference surface rather than directly to the modeling unit. This intermediary approach allows the measurement system to remain stable and independent of the modeling unit's position or replacement status.
2Productivity
If pre-stored distance or corrected distance is used, then the available modeling distance can be acquired, but the actual distance may differ from the stored value affecting positioning accuracy
Solution Approach 1:
The patent implements a feedback mechanism where the second detection unit continuously measures the actual distance between itself and the reference surface, and this measured value is fed back to the control unit. The control unit then calculates the actual nozzle-to-stage distance by combining the first detection unit's measurement with the feedback from the second detection unit, ensuring the positioning accuracy reflects the true physical distance rather than relying on pre-stored or corrected values.
Solution Approach 2:
The patent replaces the mechanical approach of physically measuring and storing distance values with an electronic sensing system. The second detection unit uses optical or electrical sensing (such as laser distance measurement or capacitive sensing) to continuously monitor and report the distance to the reference surface, eliminating the need for mechanical measurement and manual storage of distance values.
3Device complexity
If the measuring unit is integrated with the modeling unit, then the distance can be measured, but recalibration is needed when the modeling unit is replaced
Solution Approach 1:
The patent segments the measurement system into two independent detection units with different functional assignments. The first detection unit integrated with the modeling unit measures only the nozzle-to-detection-unit distance, while the second detection unit on the stage measures the stage-to-detection-unit distance. This segmentation means that when the modeling unit is replaced, only the first detection unit needs to be replaced, and no recalibration of the second detection unit is required, significantly reducing the time loss associated with unit replacement.
Data Source
AI summary
A three-dimensional modeling device includes a modeling unit having a nozzle configured to eject a modeling material, a stage, a movement mechanism unit for changing a relative position between the nozzle and the stage, a measuring unit, a reference unit having a reference surface arranged at a position that corresponds to a deposition surface of the stage in an intersecting direction and where the reference surface can face the measuring unit, the reference unit being separate from the nozzle, and a control unit controlling the modeling unit and the movement mechanism unit. The control unit controls the measuring unit to measure a first distance between the measuring unit and the reference surface and a second distance between the measuring unit and the distal end surface, and decides a distance between a distal end surface of the nozzle and the deposition surface, based on the first and second distances.