DED Wire Straightening Rollers for Jam-Free Laser Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current directed energy deposition processes face challenges in wire feeding, particularly with plastic deformation of wire during spooling and maintaining appropriate spool tension, leading to issues like wire jams and misalignment with the laser focal point.
Innovation Solution
An apparatus with adjustable roller bearings and actuators is introduced to straighten and tension the wire, using a combination of motorized rollers, sensors, and a controller to ensure precise alignment and tensioning, and a wear-resistant die to draw down the wire, ensuring minimal plastic deformation and consistent wire feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire is spooled for storage and feeding, then wire can be stored and fed into the DED device, but the wire undergoes plastic deformation and develops bends from spooling
Solution Approach 1:
The wire straightening apparatus performs preliminary straightening action on the wire before it enters the DED printing process. The system includes rollers and guides that pre-condition the wire to eliminate bends and deformations accumulated during spooling, ensuring the wire is properly aligned before feeding into the deposition head
Solution Approach 2:
The patent introduces intermediary components between the spool and the DED head, including straightening rollers, guide rollers, and tensioning mechanisms. These intermediary elements act as mediators to correct wire geometry and maintain proper alignment without requiring changes to the spooling process itself
2Reliability
If spool tension is increased to prevent wire slack, then wire feeding stability improves, but wire jams and misalignment with laser focal point occur
Solution Approach 1:
The system employs dynamic tension control mechanisms that adjust spool tension in real-time based on wire feed conditions. The tensioning system can dynamically respond to variations in wire properties, spool rotation speed, and feed rate requirements, maintaining optimal tension without causing jams or misalignment
Solution Approach 2:
The patent incorporates feedback mechanisms including sensors that monitor wire position, tension, and alignment. This feedback is used to automatically adjust spool tension and guide roller positions, creating a closed-loop control system that prevents wire jams and ensures proper alignment with the laser focal point
3Ease of operation
If manual wire straightening and tension adjustment is used, then wire feeding can be controlled, but the process is time-consuming and inconsistent
Solution Approach 1:
The wire straightening and tension control system is designed to operate automatically without manual intervention. The apparatus self-adjusts roller positions, maintains appropriate tension, and compensates for wire deformations through automated mechanisms, eliminating the need for time-consuming manual straightening while ensuring consistent results
Solution Approach 2:
The patent replaces manual mechanical operations with automated mechanical and electronic systems. Motorized rollers, automated tensioning devices, and electronic control systems substitute for manual wire handling, dramatically increasing straightening speed and consistency while reducing operator involvement
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 enables high-speed, automated wire straightening with minimal plastic deformation, reducing wire jams and inconsistencies in bead deposition, improving the overall efficiency and quality of the directed energy deposition process.
Implementation Method 1
plastically deforming the wire and straightening the wire
Data Source
AI summary
An apparatus for straightening wire in a directed energy deposition additive manufacturing machine. The apparatus includes at least three roller bearings positioned along one side of a longitudinal axis and a first adjustable bearing and a second adjustable bearing positioned along another side of the longitudinal axis. The first adjustable bearing and the second adjustable bearing are connected to a body and are positioned in a staggered alternating pattern with the at least three roller bearings. Further. the first adjustable bearing and the second adjustable bearing are each configured to apply a load to the wire. A directed energy deposition additive manufacturing machine includes the apparatus. A method for straightening a wire including feeding the wire into the apparatus.