3D Printing Calibration Tool for Tank and Robotic Arm Alignment
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Solution Overview
Problem
Inaccuracies and misalignments in the position and orientation of the robotic arm in 3D printing systems lead to misalignment between the robotic arm and the resin tank, resulting in printed objects that differ from the CAD model and have defects.
Innovation Solution
A calibration tool is integrated into the 3D printing system, comprising a tank, an arm, a rigid base, and a light source, with a calibration tool connected to the tank to align the tank and/or the arm, using an alignment actuator and calibration plate to adjust the position and orientation, and a camera to detect and correct misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robotic arm is used to move the rigid base for repeating the printing process, then productivity is improved, but manufacturing precision deteriorates due to position and orientation inaccuracies
Solution Approach 1:
The calibration tool performs preliminary calibration of the robotic arm's position and orientation before the actual printing process. By pre-adjusting the arm's coordinates and alignment relative to the resin tank using the calibration plate and alignment actuators, the system ensures accurate printing positions without requiring continuous manual adjustment during production, thus maintaining both productivity and precision
Solution Approach 2:
The calibration plate with known geometric features provides feedback reference points that allow the system to detect and correct robotic arm positioning errors. The alignment actuators use this feedback to automatically adjust the resin tank or arm position, creating a closed-loop control system that maintains manufacturing precision while enabling automated high-speed printing
2Ease of operation
If the robotic arm position and orientation are inaccurate, then ease of operation is improved, but manufacturing precision deteriorates due to misalignment between the robotic arm and resin tank
Solution Approach 1:
The calibration tool acts as an intermediary between the robotic arm and the resin tank. It provides a common reference frame (the calibration plate with known geometry) that mediates the alignment process, allowing the system to compensate for robotic arm inaccuracies without complicating the operation. The alignment actuators serve as intermediaries that automatically adjust positioning based on calibration data
Solution Approach 2:
The system replaces manual mechanical alignment procedures with automated optical/electronic calibration. Instead of physically adjusting the robotic arm through trial and error, the system uses camera-based detection of calibration plate features to computationally determine and correct positioning errors, substituting mechanical adjustment with automated measurement and calculation
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 calibration tool enhances the accuracy of the printing process by precisely aligning the tank and arm, reducing misalignment and improving the fidelity of printed objects to the CAD model.
Implementation Method 1
curing portions of a light curable photopolymer resin layer by layer, one layer at a time, within a printing area of a tank filled with the photopolymer resin. A curing device, such as an ultraviolet light source, is projected through a transparent substrate or bottom wall of the tank curing each layer of the object
Data Source
AI summary
A three-dimensional printing system includes a tank, an arm, a rigid base, a light source, and a calibration tool. The tank contains a liquid photopolymer resin. The arm is configured to be movable relative to the tank. The rigid base is connected to the arm. The light source is configured to emit light to the tank to form an object on the rigid base. The calibration tool is connected to the tank. The calibration tool is configured to calibrate at least one of the tank and the arm.