3D Printer Filament Feed Control for Buildup and Jamming
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Solution Overview
Problem
Additive manufacturing systems for fused deposition modelling face issues such as inefficient filament feeding, jamming, and filament engagement with system parts, particularly in large prints or when using elastic filament, due to filament buildup between extruder and auxiliary motors.
Innovation Solution
Incorporating a filament accumulation sensing arrangement to detect filament buildup between motors, with a system controlling arrangement that adjusts motor speeds (increasing extruder speed and/or decreasing auxiliary speed) to prevent filament accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an auxiliary motor is added to translate filament in series with the extruder motor, then the system can handle larger prints and elastic filament, but filament accumulation occurs between the motors causing jamming and inefficient feeding
Solution Approach 1:
The patent implements a feedback control system where a sensor detects filament accumulation between the extruder motor and auxiliary motor, and the controlling arrangement dynamically adjusts the speed of one or both motors in response to the detected accumulation, preventing jamming and ensuring reliable filament feeding throughout the printing process
Solution Approach 2:
The patent makes the motor speeds dynamic by allowing the controlling arrangement to vary the rotation speeds of the extruder motor and/or auxiliary motor based on real-time filament accumulation detection, transitioning from fixed synchronized speeds to adaptive variable speeds that respond to actual filament flow conditions
2Ease of operation
If the extruder motor and auxiliary motor operate at synchronized speeds, then the filament feeding is simple to control, but filament builds up between the motors during long prints
Solution Approach 1:
The patent replaces simple synchronized speed control with a feedback-controlled system where the sensor monitors filament accumulation and the controlling arrangement adjusts motor speeds accordingly, maintaining feeding consistency throughout long prints while preserving ease of operation through automated control
3Productivity
If filament accumulates between the extruder motor and auxiliary motor, then the system continues operating, but the risk of jamming and filament engaging with system parts increases
Solution Approach 1:
The patent applies preliminary anti-action by detecting filament accumulation early through the sensor and adjusting motor speeds before the accumulation causes jamming or filament engagement with system parts, preventing harmful effects before they occur while maintaining continuous operation
Solution Approach 2:
The feedback control system continuously monitors filament accumulation and dynamically adjusts motor operation to prevent jamming and harmful filament engagement, ensuring continuous productive operation without increasing risk to the system
Data Source
Figure 1~2
Figure 3a~4
Figure 5~6
AI summary
The invention relates to an additive manufacturing system comprising: a printhead (2); an extruder motor (3); an auxiliary motor (4); and a system controlling arrangement (8). The additive manufacturing system further comprises: a filament accumulation sensing arrangement (9) configured to detect accumulation of the filament (6) along a feeding path between the auxiliary motor and the extruder motor. The system controlling arrangement is configured to: operate the additive manufacturing system in a first operational state in which the extruder motor is controlled at an initial extruder motor speed and the auxiliary motor is controlled at an initial auxiliary motor speed; detect the accumulation of the filament via an accumulation signal from the sensing arrangement; and switch from the first operational state to a second operational state in which: the extruder motor is controlled at an increased extruder motor speed; and/or the auxiliary motor is controlled at a decreased auxiliary motor speed.