Multi-Nozzle Extruder Roll Alignment via Cross-Process Swath Measurements
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Solution Overview
Problem
Multi-nozzle extruders in three-dimensional object printers face challenges with nozzle misalignment due to undesirable rotation or 'roll' during operation, leading to overlapping or gaps in extruded material patterns, which affects the quality and precision of printed objects.
Innovation Solution
A method and system that utilize a first actuator to move a multi-nozzle extruder in different process directions within a print zone, combined with an optical sensor to generate scanned image data of swaths, and a controller to identify the measured two-dimensional location of nozzles and calculate the angle of roll, allowing for precise alignment and correction of the extruder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multi-nozzle extruders are used to improve manufacturing speed and high-resolution structure formation, then productivity and manufacturing precision are improved, but nozzle alignment stability deteriorates due to roll during operation
Solution Approach 1:
The system performs preliminary alignment measurement by printing test patterns before actual manufacturing. The controller measures the actual positions of multiple nozzles using vision systems and calculates roll angles in advance, then pre-compensates the nozzle arrangement data to prevent alignment issues during high-speed manufacturing.
Solution Approach 2:
The system implements closed-loop feedback by continuously monitoring nozzle positions through vision systems during operation. The controller compares actual nozzle positions with target positions, detects roll deviations, and dynamically adjusts the nozzle arrangement data to maintain precise alignment throughout the manufacturing process.
2Productivity
If multi-nozzle extruders operate at high speed, then productivity is improved, but measurement precision of nozzle positions deteriorates due to motion blur and vibration
Solution Approach 1:
The vision system captures images of printed test patterns at controlled, lower speeds during the alignment measurement phase before high-speed manufacturing begins. This preliminary measurement at stable conditions ensures high precision nozzle position detection without motion blur, establishing accurate baseline data for subsequent fast manufacturing.
Solution Approach 2:
The system uses optical copying through vision systems to create digital representations of physical nozzle positions by imaging printed test patterns. This non-contact optical copying method enables precise position measurement without physical interference, and the digital copies can be analyzed offline to determine accurate nozzle arrangement data.
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 accurate detection and correction of extruder roll, ensuring proper alignment of nozzles and preventing overlapping or gaps in extruded material patterns, thereby improving the quality and precision of three-dimensional printed objects.
Implementation Method 1
generating, with an optical sensor, scanned image data of the first swath, the second swath, the third swath, and the fourth swath
Data Source
AI summary
A method for identifying an angle of roll for a multi-nozzle extruder includes moving the extruder in a first process direction to form a first set of swaths of extrusion material using two nozzles in the extruder and moving the extruder in a second process direction to form a second set of swaths of extrusion material. The method further includes identifying a location of one nozzle relative to the other nozzle in two dimensions based on cross-process direction distances between the first and second sets of swaths and identifying the angle of extruder roll for the extruder based on the location of the one nozzle and a predetermined geometry of the extruder.