Cavity Filling Material Removal Using Gravity and Geometry Data
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Solution Overview
Problem
Existing additive manufacturing methods, such as powder-bed and liquid-based processes, face challenges in efficiently and quickly removing filling materials from cavities within components, particularly in complex geometries, leading to time-consuming processes and incomplete removal.
Innovation Solution
A method involving a computer program that processes geometry data to calculate optimal positioning and movement sequences for a component, considering gravitational forces and flow properties of the filling material, aided by robotic movements and optional ultrasonic vibrations, to ensure complete and rapid removal through connection openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the component is moved, turned or pivoted to transport filling material to the connection opening, then the filling material can be removed from the cavity, but the process becomes time-consuming and may not remove powder completely
Solution Approach 1:
The system pre-calculates the optimal movement sequence and component positioning before the actual removal process begins. The computer program processes geometry data of the cavity and connection opening to determine the precise sequence of movements that will efficiently transport filling material to the opening, eliminating trial-and-error adjustments and reducing overall process time
Solution Approach 2:
The system dynamically adjusts the component's position and orientation during the removal process. Based on real-time feedback and pre-calculated trajectories, the component is moved through optimized sequences of positions that maximize the flow of filling material toward the connection opening, adapting to the specific geometry of each cavity
2Manufacturing precision
If manual methods are used to remove filling material from complex cavity geometries, then complete removal can be achieved, but the process is extremely time-consuming
Solution Approach 1:
The system replaces manual mechanical operations with an automated computer-controlled system. The computer program calculates optimal movement sequences and controls the positioning system to automatically transport filling material through the connection opening, eliminating manual labor while maintaining complete removal effectiveness even from complex cavity geometries
Solution Approach 2:
The system enables the component to essentially empty itself by utilizing gravity and optimized positioning. The computer-calculated movement sequences create conditions where filling material naturally flows out through the connection opening without requiring external intervention, significantly reducing manual effort and increasing productivity
3Manufacturing precision
If the component geometry is complicated or cavity is large, then filling material removal becomes incomplete with traditional methods, but automated systems increase process complexity
Solution Approach 1:
The system creates a digital copy or model of the component's geometry and cavity structure. The computer program processes this digital representation to calculate optimal movement sequences, allowing the system to adapt to any cavity geometry without requiring physical prototypes or manual programming for each case, thereby managing complexity through virtual modeling
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 enables the efficient and complete removal of filling materials from cavities in the shortest time, reducing manual effort and minimizing residual material, even in complex geometries, while allowing for feedback of recovered materials into the manufacturing process.
Implementation Method 1
a processor (P) processes the geometry data of the component (13), a computer program that runs on the processor (P) taking into account the geometry of the cavity and of the connection opening (24) in the component (13), while taking gravitational force into account
Implementation Method 2
aided by robotic movements and optional ultrasonic vibrations
Data Source
AI summary
Various embodiments may include a method for removing filling material from a cavity in a manufactured component with a connection from the cavity opening to surroundings of the component, the method comprising: holding the component in a movable mounting; moving the component and at the same time removing the filling material through the connection opening; and executing a computer program with a processor, wherein the computer program instructs the processor to: analyze geometry data of the component including the connection opening; and calculate a necessary positioning of the component, based on the geometry data and gravitational force; and direct the movable mounting through a sequence of movements for moving the component in space to spill the filling material from the cavity through the connection opening out of the component.