Additive Manufacturing Component Emptying via Sensor-Triggered Poses
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Solution Overview
Problem
The existing methods for removing excess material from additively manufactured components, such as those produced by the powder bed method, are time-consuming, especially when dealing with components having complex geometries, as they often rely on manual or machine-based shaking or rotation.
Innovation Solution
A method and assembly that utilize spatially resolved structural data to simulate and optimize the emptying process of additively manufactured components, involving sensor detection of material movement, trigger signals for positional changes, and mechanical vibrations to efficiently separate excess material by moving the component into advantageous poses based on simulated data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or machine-based rotating or shaking methods are used to remove excess material, then the component can be emptied of excess material, but the process becomes very time-consuming especially for complex geometries
Solution Approach 1:
The system performs a simulation of the emptying process before actual emptying to determine the optimal sequence of emptying poses. This preliminary computational action identifies the most efficient path for material removal, avoiding trial-and-error approaches and significantly reducing the actual emptying time required.
Solution Approach 2:
The system dynamically adjusts the emptying process by using sensors to detect material movement in real-time and automatically transitioning between different emptying poses based on detected conditions. This dynamic adaptation allows the system to respond to actual material behavior rather than following a fixed predetermined sequence.
2Loss of time
If a simulated emptying process is used to determine emptying poses, then the emptying duration is reduced, but the system complexity increases due to simulation and sensor integration
Solution Approach 1:
The system creates a virtual copy or simulation model of the component's cavity and excess material distribution. This digital twin allows for computational analysis and optimization of the emptying process without requiring complex physical experimentation, reducing the need for multiple physical prototypes or trial runs.
Solution Approach 2:
The system implements a feedback loop where sensors continuously monitor material movement during emptying and provide real-time information to the control system. This feedback enables automatic adjustment of the emptying sequence and poses, simplifying the control logic compared to pre-programming all possible scenarios while maintaining high efficiency.
3Productivity
If the component is moved into multiple emptying poses based on simulation, then material removal efficiency is improved, but the handling time and mechanical operations increase
Solution Approach 1:
The emptying process is divided into discrete poses or positions, each optimized for removing material from specific regions of the component. This segmentation allows the system to focus on removing material from accessible regions first, then progressively address harder-to-reach areas, improving overall efficiency without requiring excessive repositioning.
Solution Approach 2:
The system maintains continuous material removal action by seamlessly transitioning between different emptying poses as material is removed. The simulation optimizes the sequence to ensure that each pose change immediately contributes to further material removal, minimizing idle time and maintaining continuous productive action throughout the emptying process.
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 approach significantly reduces the emptying duration by prioritizing trigger signals over simulated processes and using mechanical vibrations to effectively shake out excess material, even from complex geometries.
Implementation Method 1
a material movement is detected by one or more sensors
Implementation Method 2
mechanical vibrations to effectively shake out excess material
Implementation Method 3
a pouring direction, in which this path length shortens, can then be ascertained and assigned to the respective spatial region
Data Source
AI summary
In order to separate excess material from an additively manufactured component, spatially resolved structural data on the component are received. On the basis of the structural data, a process for emptying material from the component is simulated, wherein a sequence of emptying poses of the component is determined. For an associated emptying pose: the component is moved into the associated emptying pose in accordance with the simulated emptying process, movement of material is detected by sensors, as a result of a detection of a decrease in the movement of material, a trigger signal is generated, and a movement of the component into a subsequent emptying pose is initiated by the trigger signal, the trigger signal being considered higher priority than the simulated emptying process.