3D Shaping Nozzle Flushing Based on Idle Running Time
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Solution Overview
Problem
Three-dimensional shaping devices face issues with powder mixing into nozzles during idle running, leading to liquid ejection failures due to inconsistent flushing operations, especially with varied materials and longer idle times.
Innovation Solution
A control unit adjusts flushing operation conditions based on idle running time, executing flushing at a different position from the shaping region, with varying execution conditions depending on whether the idle time is below or above a threshold, and employing higher frequencies, voltages, and ejection speeds when idle time exceeds the threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flushing operation is performed under the same ejection conditions as shaping, then control is simplified, but powder may mix into the nozzle when idle running time is long
Solution Approach 1:
The patent applies dynamics by making the flushing operation conditions variable rather than fixed. The control unit dynamically adjusts ejection frequency, voltage, and ejection speed based on the measured idle running time. When idle time exceeds a threshold, the system transitions to enhanced flushing conditions with higher frequency and voltage, ensuring reliable powder removal while maintaining simple automated control.
Solution Approach 2:
The patent changes physical parameters of the flushing operation based on idle running time. Specifically, it adjusts ejection frequency, applied voltage, and ejection speed as variable parameters. This allows the system to adapt flushing intensity to actual contamination risk, resolving the contradiction between simplified fixed-control and reliable adaptive control.
2Reliability
If flushing operation is performed frequently, then powder mixing into nozzle is prevented, but liquid waste increases
Solution Approach 1:
The patent uses parameter changes to optimize flushing frequency and intensity based on actual need. By measuring idle running time and comparing it to a threshold, the system adjusts ejection frequency and voltage accordingly. This ensures flushing is performed with appropriate intensity only when necessary, preventing both powder contamination and unnecessary liquid waste.
Solution Approach 2:
The patent implements feedback control by measuring idle running time and using this information to determine flushing operation parameters. The control unit receives feedback about the actual operating conditions and adjusts flushing frequency and intensity accordingly, optimizing the balance between nozzle cleanliness and liquid consumption.
3Productivity
If head moves on powder layer for long idle running time, then more powder floats up and mixes into nozzle, but ejection failure occurs if powder is not removed
Solution Approach 1:
The patent applies preliminary action by performing flushing operations at predetermined intervals based on idle running time thresholds. Before powder contamination can cause ejection failure, the system proactively executes flushing with enhanced frequency and voltage when idle time exceeds the threshold, preventing the problem rather than reacting to it.
Solution Approach 2:
The system uses feedback from idle running time measurement to determine when flushing is needed. This allows the system to maintain high productivity during normal operation while automatically increasing flushing intensity when contamination risk increases, ensuring ejection reliability without unnecessarily reducing productivity.
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
Effectively prevents powder mixing into nozzles, reduces liquid waste, and maintains consistent ejection by optimizing flushing operations based on idle time, ensuring reliable device performance.
Implementation Method 1
a head (3) configured to eject a liquid containing a binder from a nozzle (N) to a shaping region (P1) of a three-dimensional shaped object in the powder layer by applying voltage
Data Source
AI summary
A three-dimensional shaping device includes: a shaping table; a layer forming unit configured to form a powder layer on the shaping table; a head configured to eject a liquid containing a binder from a nozzle to a shaping region; and a control unit configured to control movement of the head with respect to the shaping table and driving of the head by applying a voltage. The control unit changes an execution condition of a flushing operation depending on whether an idle running time during which the head is moved without ejecting the liquid is less than a threshold value or equal to or greater than the threshold value.