Bearing-Based Leveling Assembly for 3D Printing
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Solution Overview
Problem
Current three-dimensional object printing systems face challenges in accurately leveling surfaces due to rollers with imperfect roundness, leading to costly manufacturing requirements for tight tolerances, which result in inefficient flattening and increased production costs.
Innovation Solution
A leveling assembly for three-dimensional object printers that includes a cylindrical roller with a guide device and actuator to maintain a constant distance between the roller and the conveyor surface, compensating for imperfect roundness and eliminating the ripple effect caused by run-out, thereby allowing for accurate surface flattening without the need for expensive roller manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight roundness tolerances are applied to the roller to eliminate run-out, then surface leveling precision is improved, but manufacturing cost increases significantly
Solution Approach 1:
A guide device is introduced as an intermediary between the roller and the conveyor surface. This guide device maintains a constant distance between the roller and conveyor surface, compensating for the roller's run-out without requiring tight roundness tolerances on the roller itself. The guide device acts as a mediator that transfers the leveling function while isolating the roller from direct contact constraints.
2Adaptability or versatility
If the roller diameter is increased to handle wider parts, then adaptability is improved, but the impact of run-out on surface quality worsens
Solution Approach 1:
The guide device serves as a mediator that decouples the roller's dimensional imperfections from the surface leveling outcome. By maintaining a constant distance between the roller and conveyor surface through the guide device, the system allows use of larger diameter rollers for wider parts while preventing run-out from degrading surface flatness quality.
3Productivity
If the roller is made larger to reduce the number of revolutions needed, then productivity is improved, but the manufacturing cost for tight tolerances increases
Solution Approach 1:
The guide device introduces a mechanical intermediary that allows larger rollers to be used for improved productivity while compensating for their inevitable run-out. The guide device maintains constant spacing, enabling the use of cost-effective, larger diameter rollers without sacrificing surface leveling precision, thus achieving both productivity improvement and cost reduction.
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 solution effectively levels the surface of printed objects without incurring significant manufacturing costs for tight roundness tolerances, ensuring consistent and high-quality part production by maintaining a constant distance between the roller and the conveyor surface, thus overcoming the limitations of imperfect roundness in existing systems.
Implementation Method 1
the bearing is configured to move radially with respect to the longitudinal axis of the roller to compensate for variations in a distance between the outer surface of the roller and the planar surface of the conveyer
Implementation Method 2
the roller being configured to rotate about the longitudinal axis, the roller having an outer surface that moves upon the upper surface of the three-dimensional object to flatten the upper surface of the three-dimensional object
Data Source
AI summary
A three-dimensional object printer comprises a conveyor having a surface configured to convey a three-dimensional object in a first direction; and a leveling assembly configured to level a surface of the three-dimensional object as the conveyer conveys the three-dimensional object in the first direction, the leveling assembly comprising (i) a roller having a cylindrical shape, the roller having an outer surface that moves upon the surface of the three-dimensional object to level the surface of the three-dimensional object; and (ii) a guide device arranged between the roller and the planar surface of the conveyer, the device being configured to mechanically interact with the roller to maintain a constant distance between the outer surface of the roller and the planar surface of the conveyer.