3D Shaping Nozzle Flushing Control for Powder Clogging
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Solution Overview
Problem
Existing three-dimensional shaping devices face issues with powder mixing into the nozzle during idle running, leading to liquid ejection failures due to the lack of effective flushing mechanisms, especially when the head is moved over powder layers for extended periods.
Innovation Solution
A three-dimensional shaping device with a control unit that executes a first flushing operation when the distance between the shaping region and the flushing position is less than a threshold value and a second flushing operation with different conditions when the distance is greater than or equal to the threshold value, including higher frequency, voltage, ejection speed, and droplet size of the liquid in the second operation to effectively remove powder from the nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the head is moved on the powder layer for an extended period during idle running, then the coverage area increases, but powder floats up and mixes into the nozzle
Solution Approach 1:
The system performs a flushing operation before the actual shaping operation to prevent powder from mixing into the nozzle during idle running. This preliminary action removes potential contaminants before they can cause ejection failures.
Solution Approach 2:
The control unit determines whether to execute a first or second flushing operation based on the distance between the shaping region and flushing position. This feedback mechanism adjusts the flushing conditions dynamically to match the actual contamination risk.
2Ease of operation
If a flushing operation is performed under the same ejection conditions as shaping, then the control is simplified, but powder mixed into the nozzle cannot be effectively removed
Solution Approach 1:
The system dynamically adjusts the flushing conditions based on the distance between the shaping region and flushing position. When the distance is large (indicating extended idle running), a second flushing operation with different conditions (higher voltage, different waveform) is executed to effectively remove powder.
Solution Approach 2:
The control unit changes the ejection parameters (voltage, waveform frequency, ejection speed) of the flushing operation based on the distance condition. This allows the system to optimize powder removal effectiveness while maintaining manageable control complexity.
3Productivity
If the distance between shaping region and flushing position is large, then more powder can be processed, but powder accumulation in nozzle increases
Solution Approach 1:
The system executes a flushing operation at the flushing position before continuing with the shaping operation. This preliminary cleaning action prevents powder accumulation that would occur during extended idle running across large distances.
Solution Approach 2:
The control unit uses the distance information to determine the appropriate flushing operation type. When the distance exceeds a threshold, a second flushing operation with enhanced parameters is triggered to counteract the increased powder accumulation risk.
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 device effectively prevents powder from accumulating in the nozzle by optimizing flushing conditions based on the distance and idle running time, ensuring reliable liquid ejection and preventing failures.
Implementation Method 1
a head configured to eject a liquid containing a binder from a nozzle to a shaping region of a three-dimensional shaped object on the powder layer; and a control unit configured to control movement of the head with respect to the shaping table and driving of the head by applying a voltage
Data Source
AI summary
A three-dimensional shaping device includes: a shaping table; a layer forming unit configured to form a powder layer on the shaping table; a head configured to eject a liquid containing a binder from a nozzle to a shaping region; and a control unit configured to control movement of the head with respect to the shaping table and driving of the head by applying a voltage. The control unit executes a first flushing operation when a distance between the shaping region and the flushing position is less than a threshold value, and executes a second flushing operation when the distance between the shaping region and the flushing position is equal to or greater than the threshold value.