3D Printer Table Self-Levelling With Optical Angle Detection
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Solution Overview
Problem
Existing 3D printer table levelling systems are prone to inaccuracies due to reliance on single gravity sensors, manual adjustments, or designs that are not gravity-independent, leading to poor print quality and inability to function in non-horizontal or weightless conditions.
Innovation Solution
A system with a Z-axis movable table and a detection mechanism using spherical nuts and linear bearings, combined with mirrors and a camera, ensures precise levelling by adjusting stepper motors to maintain the table's horizontal position regardless of gravitational orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single gravity sensor is used to level the table, then the levelling process is simple and automated, but the print quality deteriorates when the printer is placed on an inclined surface
Solution Approach 1:
The patent divides the levelling system into two independent parts: (1) a gravity sensor system that levels the table to be perpendicular to gravity, and (2) an optical sensor system that measures the angle between the table and the substrate. This segmentation allows each system to perform its specific function without interfering with the other, resolving the contradiction between simple automation and print quality.
Solution Approach 2:
The patent introduces an intermediary optical sensor system that acts as a mediator between the gravity-levelled table and the substrate. This intermediary measures the relative angle and provides correction data, allowing the system to maintain print quality even when the table is levelled based on gravity alone.
2Device complexity
If the table is levelled perpendicular to gravity using a single sensor, then the levelling algorithm is simple, but the nozzle-to-table distance becomes non-constant on inclined surfaces
Solution Approach 1:
The patent separates the levelling function (perpendicular to gravity) from the print plane alignment function (parallel to substrate). The gravity sensor handles the first function with a simple algorithm, while the optical sensor handles the second function with additional measurements, ensuring distance consistency without complicating the basic levelling algorithm.
Solution Approach 2:
The patent implements a feedback loop where the optical sensor continuously measures the angle between the table and substrate, and this information is fed back to adjust the table position or nozzle position to maintain constant nozzle-to-table distance during printing.
3Manufacturing precision
If manual height adjustment of heads is used, then nozzle height equality can be achieved, but the system remains sensitive to mechanical position changes
Solution Approach 1:
The patent implements automatic levelling systems (gravity sensors and/or optical sensors) that perform the height adjustment function automatically, eliminating the need for manual intervention. The system self-corrects any height discrepancies and maintains stability through continuous monitoring and adjustment, removing the sensitivity to mechanical position changes associated with manual adjustment.
4Adaptability or versatility
If gravity-dependent levelling systems are used, then levelling can be achieved on Earth, but the system cannot function in weightless or low-gravity conditions
Solution Approach 1:
The patent employs optical sensors that measure angles and positions based on light reflection and geometry rather than gravitational force. This universal measurement method works equally well in high-gravity, low-gravity, and weightless conditions, making the levelling system adaptable to various gravitational environments while maintaining reliable function.
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
Ensures accurate table levelling resistant to shocks and vibrations, maintaining print quality across varying gravitational conditions, including weightlessness.
Implementation Method 1
It is based on mirrors and a laser beam that goes from the laser source to the detector after being reflected several times.
Implementation Method 2
The control algorithm positions the table so that the acceleration sensor shows zero acceleration in the X and Y axes and maximum acceleration in the Z axis - that is, that the gravity vector is perpendicular to the table surface.
Data Source
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AI summary
The subject of the present invention is a system for self-levelling a table in 3D printers, which comprises a system for moving the table in the Z-axis and a system for detecting the level of the table, characterised in that the system for moving the table in the Z-axis comprises three platforms attached to the table and mounted on three drive screws, each of which is driven by an individual motor, each platform comprising a first element and a second element, a drive screw nut is mounted on the first element, said nut being spherical in shape and seated in a spherical pan, a rod is stalked from the first platform element, moving in a linear bearing embedded in the second platform element so that the second element can rotate and move, said second platform element being fixed to the 3D printer table, preferably from below; and the table level detection system comprises two mirrors, a left mirror and a right mirror embedded in two adjacent corners of the table from below, a laser and a camera d for detecting the unevenness of the table with respect to the machine base.