Mobile 3D Production Unit With Fine Positioning for Large Workpieces
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Solution Overview
Problem
Existing additive layer construction methods for producing large three-dimensional workpieces face inefficiencies and quality issues, particularly in maintaining short production cycles and achieving desired geometries.
Innovation Solution
An apparatus comprising a carrier and a mobile production unit with a solidification device, material supply, gas supply system, and sensing units to ensure precise positioning and controlled atmosphere for additive layer construction, allowing for efficient production of large workpieces using selective laser melting or material jetting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stationary production apparatus is used for additive layer construction, then manufacturing precision can be maintained, but productivity decreases when producing large workpieces
Solution Approach 1:
The patent applies the dynamics principle by transforming the production apparatus from a stationary configuration to a mobile one. The solidification device is mounted on a mobile platform that can move across the carrier, enabling the system to dynamically access different areas of large workpieces. This mobile configuration allows the production apparatus to maintain manufacturing precision while significantly improving productivity for large workpiece production, as the device can efficiently cover extensive areas without requiring a massively scaled stationary structure.
2Productivity
If the carrier area is increased to produce larger workpieces, then productivity improves, but manufacturing precision becomes harder to maintain
Solution Approach 1:
The patent applies the local quality principle by concentrating the solidification capability in a localized mobile unit that maintains consistent processing conditions regardless of the overall workpiece size. The mobile production unit delivers controlled solidification at each local position on the carrier, ensuring uniform manufacturing precision across the entire large workpiece area. This approach allows the system to produce large workpieces with high precision by maintaining optimal local processing conditions at each position rather than requiring the entire system to be scaled proportionally.
3Productivity
If a mobile production unit is introduced to improve productivity, then production efficiency increases, but positioning precision becomes more challenging
Solution Approach 1:
The patent applies the feedback principle by implementing sensing units that continuously monitor the position and operational parameters of the mobile production unit. These sensors provide real-time feedback to the control system, enabling dynamic adjustment and compensation for positioning deviations. The feedback mechanism ensures that the mobile unit maintains the required positioning precision and solidification parameters throughout its movement across the carrier, thereby preserving manufacturing quality while achieving improved productivity through mobile operation.
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 apparatus enhances production efficiency and quality by enabling accurate and controlled layer deposition across large areas, maintaining a controlled atmosphere, and ensuring precise positioning, thus overcoming the limitations of existing methods in producing complex shapes and large workpieces.
Implementation Method 1
a raw material powder layer is applied onto a carrier and subjected to laser radiation in a site selective manner... The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 2
Said process chamber may be sealable against the ambient atmosphere, i.e. against the environment surrounding the process chamber, in order to be able to maintain a controlled atmosphere, in particular an inert atmosphere within the process chamber
Data Source
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AI summary
The invention relates to an apparatus (10) for producing a three-dimensional workpiece, comprising: a carrier (12) adapted to receive material (14) for producing the workpiece; at least one mobile production unit (24), a moving unit (18) that is adapted to move the mobile production unit (24) relative to the carrier (12) so as to position the mobile production unit (24) oppositely to different sections of the carrier (12); a sensing unit that is adapted to generate sensor signals relating to a relative arrangement of the mobile production unit (24) and the carrier (12); and a control unit that is configured to, in addition to the positioning of the mobile production unit (24) via the moving unit (18), provide at least one fine positioning function to compensate for an offset from a desired relative arrangement of the mobile production unit (24) and the carrier (18) based on the sensor signals generated by the sensing unit. The invention further relates to a method for producing a three-dimensional workpiece.