Acoustic Sensor Array for Additive Manufacturing Malfunction Detection
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Solution Overview
Problem
In additive manufacturing systems, undetected binding or backlash during the movement of the build platform can lead to defects in the fabricated parts and equipment damage due to the variability introduced in the build process, which existing monitoring technologies often fail to detect effectively.
Innovation Solution
A method and system utilizing a sensor array, including acoustic sensors, to detect undesirable events by monitoring sound levels and identifying sonic pulse signals outside a defined threshold range, which indicate malfunctions such as binding or backlash, allowing for real-time logging and adjustment of the build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing monitoring technologies are used to monitor build platform movement, then the system can log positioning feedback, but undetected binding or backlash events occur causing part defects and equipment damage
Solution Approach 1:
The patent replaces mechanical monitoring systems with acoustic sensing technology. Acoustic sensors detect sonic pulse signals generated by binding or backlash events in the actuating mechanism, converting mechanical phenomena into detectable acoustic signals for real-time malfunction detection
Solution Approach 2:
The patent introduces acoustic sensors as an intermediary detection mechanism between the actuating mechanism and the control system. These sensors capture sonic pulse signals that serve as intermediaries to indicate binding or backlash events, enabling indirect but effective monitoring of mechanical issues
2Measurement precision
If acoustic sensors are used to detect sonic pulse signals, then real-time detection of binding or backlash events is achieved, but the system complexity increases
Solution Approach 1:
The acoustic sensor array serves multiple functions: detecting binding events, detecting backlash events, and providing real-time alerts for both types of malfunctions. This multi-functionality justifies the added complexity by consolidating multiple detection capabilities into a single sensor system
Solution Approach 2:
The system implements real-time feedback through acoustic sensors that continuously monitor for sonic pulse signals and immediately alert operators to binding or backlash events, enabling prompt corrective action and preventing defect accumulation
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
This solution ensures improved part quality by detecting and addressing malfunctions, reducing equipment damage, and maintaining consistent material properties by providing real-time feedback on the additive manufacturing process.
Implementation Method 1
A sensor array, including acoustic sensors, to detect undesirable events by monitoring sound levels and identifying sonic pulse signals
Data Source
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AI summary
A method of detecting a malfunction event in an additive manufacturing system includes building a workpiece with the additive manufacturing system. The additive manufacturing system includes a housing (12), a build chamber (14) disposed within the housing, a recoater (18) disposed within the build chamber, a build platform (20) configured to receive the workpiece, a shaft (22) mounted to the build platform, a sensor (28) in operable communication with the additive manufacturing system, and an actuating mechanism (24) engaged with the shaft such that the actuating mechanism is configured to move the shaft relative to the actuating mechanism. The undesirable event is sensed with the sensor.