Laser Focusing Telescope for Multi-Tow Additive Manufacturing
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Solution Overview
Problem
Conventional Additive Manufacturing Machines (AMMs) require multiple end effectors for different tow sizes, leading to increased costs, storage, and maintenance, as well as longer application times.
Innovation Solution
The implementation of a telescope box system in AMMs, which includes a support structure, optical lenses, and mechanical attachment structures, allows for the adjustment of laser beam size to match different tow widths, eliminating the need for multiple end effectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple end effectors are used for different tow sizes, then the laser heating can be precisely controlled for each tow size, but the equipment cost, storage requirements, and operational time increase significantly
Solution Approach 1:
A single end effector is designed to handle multiple tow sizes by incorporating an interchangeable lens system. The lens holder can be quickly swapped between different lens configurations, allowing the same end effector to accommodate various tow widths (e.g., 6mm, 12mm, 24mm) while maintaining precise laser heating control for each size.
Solution Approach 2:
The optical parameters of the end effector are made changeable through interchangeable lenses. By replacing lenses with different focal lengths or optical properties, the laser beam characteristics are adjusted to match different tow sizes, enabling precise heating control without requiring multiple dedicated end effectors for each tow size.
2Manufacturing precision
If multiple end effectors are used for different tow sizes, then the laser heating can be precisely controlled for each tow size, but the time to apply multiple tow sizes on a workpiece increases
Solution Approach 1:
The end effector transitions from a static, single-configuration design to a dynamic, multi-configuration system. The interchangeable lens mechanism allows rapid reconfiguration between different tow sizes during operation, enabling the system to adapt to different production requirements without replacing entire end effectors, thus reducing changeover time and improving productivity.
Solution Approach 2:
Multiple lens configurations are pre-prepared and can be quickly swapped into the lens holder position. This preliminary preparation of interchangeable components allows for rapid changeover between different tow sizes, minimizing the time lost during transitions and maintaining high productivity while preserving manufacturing precision.
3Manufacturing precision
If multiple end effectors are used for different tow sizes, then the laser heating can be precisely controlled for each tow size, but the cost and maintenance requirements increase
Solution Approach 1:
Instead of manufacturing and maintaining multiple dedicated end effectors for different tow sizes, a single universal end effector is created with interchangeable lens capabilities. This reduces the total number of units that need to be manufactured, stored, and maintained, significantly lowering equipment costs while preserving the ability to precisely control laser heating for various tow sizes through lens selection.
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 solution reduces the cost and time associated with operating AMMs by allowing for efficient switching between different tow sizes using a single end effector, thereby minimizing equipment requirements and operational complexity.
Implementation Method 1
The one or more optical lenses are arranged to achieve a predetermined projected size of a received laser beam to correspond with a selected tow size
Implementation Method 2
The laser source is configured to supply heat, via a laser beam, to at least the first tow as it is applied to the workpiece
Data Source
AI summary
A laser focusing telescope includes one or more lenses arranged to focus a laser beam to a size corresponding with a selected tow width. An additive manufacturing machine selects an appropriate laser focusing telescope from a plurality of laser focusing telescopes each having an arrangement of one or more lenses that corresponds to a respective different tow width.