Additive Manufacturing Plant with Digital Component Storage
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Solution Overview
Problem
Existing manufacturing plants face downtime and operational challenges due to component failures, requiring extensive component warehouses and time-consuming data acquisition for replacement parts, which can be cumbersome and inefficient.
Innovation Solution
Integration of a determination unit to generate and store component data for additively manufacturing spare parts using an additive manufacturing apparatus, allowing for on-demand production of replacement components based on determined geometrical, chemical, and physical parameters, reducing the need for physical component storage and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a component warehouse is maintained to store replacement components, then the plant can quickly replace failed components, but the plant requires extensive storage space and capital investment
Solution Approach 1:
The patent creates digital copies (3D scan data, CAD models) of replacement components and stores them in a database rather than maintaining physical copies in a warehouse. When a component fails, the digital model is used to rapidly manufacture a replacement via additive manufacturing, eliminating the need for extensive physical storage space while maintaining quick replacement capability
Solution Approach 2:
The patent changes the state of component storage from physical to digital by converting physical components into 3D scan data and CAD models. This parameter change allows the system to store component information in a compact digital format, dramatically reducing the storage space required while enabling on-demand physical reproduction through additive manufacturing
2Reliability
If component data is acquired through traditional methods when needed, then the plant can replace failed components, but the process is time-consuming and delays production
Solution Approach 1:
The patent performs preliminary actions by creating and storing digital component data (3D scans, CAD models) in advance before components actually fail. The system proactively digitizes components and maintains them in a database, so when a component fails, the replacement can be manufactured immediately from pre-existing digital data without time-consuming data acquisition
Solution Approach 2:
The patent replaces traditional mechanical data acquisition methods (manual measurements, physical inspection) with optical scanning and automated 3D modeling systems. This substitution dramatically accelerates the data acquisition process, enabling rapid capture of component geometry and immediate preparation of manufacturing files for additive manufacturing
3Ease of manufacture
If traditional manufacturing methods are used for replacement components, then components can be produced, but the process is slow and increases plant downtime
Solution Approach 1:
The patent changes the manufacturing process from traditional subtractive or formative methods to additive manufacturing. This parameter change enables rapid production of complex geometries directly from digital models, dramatically increasing component production speed while maintaining manufacturing capability for various materials and designs
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
Enables rapid and efficient replacement of malfunctioning components, reducing plant downtime and eliminating the need for extensive component storage, by using additive manufacturing to produce exact replicas of failed parts with precise features.
Implementation Method 1
additively manufacturing of three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source
Implementation Method 2
selective laser sintering apparatus, a selective laser melting apparatus or a selective electron beam melting apparatus
Implementation Method 3
a determination unit that is adapted to determine component data relating to at least one component of the plant
Data Source
Figure 1
Figure 2
AI summary
Plant (1), comprising at least one apparatus (2) for additively manufacturing of three-dimensional objects (3) by means of successive layerwise selective irradiation and consolidation of layers of a build material (4) which can be consolidated by means of an energy source (5), wherein the plant (1) comprises at least one operable component (7, 12 - 14), wherein a determination unit (9) is provided that is adapted to determine component data relating to at least one component (7, 12 - 14) of the plant (1), wherein a data storage (10) is provided for storing the component data, wherein the at least one apparatus (2) is adapted to manufacture the at least one component (7, 12 - 14) based on the component data.