FFF Filament Path Length Measuring Device for Feeder Alignment
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Solution Overview
Problem
Existing FFF printing systems face challenges in accurately aligning feeders and prefeeders, leading to potential disturbances in the filament feeding process, and current measuring devices are often error-prone.
Innovation Solution
A filament path length measuring device is introduced, comprising a housing, a slider with a filament channel, and contactless sensors to detect position changes, allowing for accurate measurement of filament path length changes and alignment of feeder and prefeeder actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex measuring devices are used for sensing misalignment between feeder and prefeeder, then alignment capability is improved, but device complexity and error rate increase
Solution Approach 1:
The patent extracts the measurement function from a complex external measuring device and integrates it into the flexible tube itself. The flexible tube acts as both a structural component for guiding the filament and as a measurement element whose deformation directly indicates misalignment, eliminating the need for separate complex sensors and reducing overall device complexity.
Solution Approach 2:
The flexible tube serves multiple functions simultaneously: it guides the filament from the prefeeder to the feeder, provides mechanical flexibility to accommodate movement, and acts as a sensing element that detects misalignment through its deformation. This multi-functionality reduces the need for additional dedicated measurement components.
2Measurement precision
If contactless sensors are used to detect slider position, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces mechanical contact-based position sensing with contactless optical or magnetic sensors. The slider includes a visible element that can be detected by external sensors without physical contact, eliminating wear and friction while maintaining high measurement precision. This substitution reduces mechanical complexity while enabling more accurate measurements.
3Manufacturing precision
If force sensors are used to measure filament feeding force, then control precision is improved, but additional force is applied to filament causing disturbances
Solution Approach 1:
The patent introduces a flexible tube as an intermediary element between the prefeeder and feeder. This tube absorbs and isolates the forces generated during filament feeding, allowing force measurement without directly applying measurement forces to the filament itself. The tube's flexibility acts as a buffer that prevents harmful force transmission to the filament.
Solution Approach 2:
The measurement function is extracted from direct filament interaction and transferred to the flexible tube. By measuring the tube's deformation rather than directly sensing filament tension, the system avoids applying additional forces to the filament that would cause feeding disturbances, while still obtaining accurate control 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
The measuring device provides more accurate measurements with minimal force required, optimizing the control of feeders and prefeeders, and ensuring precise alignment to prevent disturbances in the filament feeding process.
Implementation Method 1
at least one contactless sensor arranged to detect a change of position of the slider relative to the housing to obtain measurement data indicative of a path length change of the filament in the first flexible tube
Data Source
AI summary
The invention relates to an FFF printing system (100), the FFF printing system comprising a print head (105), a feeder (91;126) arranged to feed a filament (4) into the print head (105), and a container (801) for storing the filament on one or more filament spools (88). The system also comprises a prefeeder (81) arranged to feed the filament from the spools to the feeder (91;126), and a first flexible tube (D01;102;121) for guiding the filament (4). A filament path length measuring device (1) is arranged to detect a misalignment between the feeder and the prefeeder. Measurement signals are sent to a processing system to correct any misalignment.