Optical Fiber Connector Assembly for Self-Aligning Laser Swaps
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Solution Overview
Problem
Additive manufacturing systems face limitations in manufacturing speed and throughput due to the rate of material fusion, which is constrained by the power level of laser energy sources and the challenges of aligning and replacing optical fibers, leading to reduced reliability and increased system downtime.
Innovation Solution
The system incorporates a plurality of laser energy sources with optical fiber connectors that allow for easy replacement and alignment of optical fibers, including stationary and movable fibers, and external positioning of the optical fiber connector to facilitate rapid component exchange without disrupting the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical fibers are aligned and replaced manually in additive manufacturing systems, then manufacturing precision can be maintained, but system downtime increases and productivity decreases
Solution Approach 1:
The patent implements pre-alignment features and positioning mechanisms that are prepared in advance, allowing optical fibers to be quickly connected without time-consuming manual alignment during operation. The connector design includes pre-positioned alignment elements that guide the fiber into correct position automatically.
Solution Approach 2:
The optical fiber connector incorporates self-aligning features such as mechanical guides, keyed positions, and tolerance-compensating designs that enable the fiber to automatically position itself during connection, eliminating the need for manual alignment operations and reducing system downtime.
2Productivity
If the number of laser energy sources is increased to enhance manufacturing speed, then productivity improves, but system complexity and difficulty of maintaining reliability increase
Solution Approach 1:
The patent divides the optical fiber delivery system into modular segments with standardized connectors, allowing each laser energy source to be independently managed and replaced. This segmentation enables parallel maintenance operations and reduces the overall system complexity by creating repeatable, interchangeable units.
Solution Approach 2:
The optical fiber connector design implements universal interfaces and standardized coupling mechanisms that work across all laser energy sources in the system. This universality allows a single connector type to serve multiple functions and positions, simplifying the overall system architecture despite the increased number of laser sources.
3Area of stationary object
If optical fiber connectors are positioned internally within the additive manufacturing system, then space utilization improves, but ease of operation and maintenance accessibility worsen
Solution Approach 1:
The patent employs a nested connector design where the optical fiber coupling mechanism is contained within a compact housing that integrates with the existing system structure. The connector can be accessed through service ports or removable panels, allowing maintenance personnel to reach internal components without disassembling major system parts, thus maintaining small footprint while improving accessibility.
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 enhances manufacturing speed and reliability by enabling quick replacement of failed components, reducing system downtime, and maintaining process continuity, even with a large number of laser energy sources.
Implementation Method 1
a first plurality of optical fibers extending between the plurality of laser energy sources and the optical fiber connector. Each optical fiber of the first plurality of optical fibers is coupled to a laser energy source of the plurality of laser energy sources
Data Source
AI summary
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.