Mobile Production Unit Positioning for Large 3D 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 and method featuring a movable carrier with a mobile production unit, including a solidification device, material supply, gas supply system, and sensing unit, which allows for precise positioning and controlled atmosphere processing to improve production efficiency and quality of large workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stationary production system is used for additive layer construction, then manufacturing precision can be maintained, but productivity decreases when producing large workpieces
Solution Approach 1:
The production unit is transformed from a stationary system to a mobile system that can move along the carrier. The mobile production unit includes a solidification device mounted on a movable platform, allowing it to dynamically reposition across different sections of the carrier to process large workpieces efficiently while maintaining precision through active positioning control.
Solution Approach 2:
The production system is divided into a mobile production unit that can be independently moved and positioned. This segmentation allows the solidification device to service different areas of the carrier sequentially, improving productivity for large workpieces without requiring a completely stationary complex system covering the entire area.
2Adaptability or versatility
If the carrier area is increased to accommodate large workpieces, then adaptability improves, but manufacturing precision deteriorates
Solution Approach 1:
The mobile production unit incorporates dynamic positioning control that actively maintains precise positioning relative to the carrier regardless of the carrier's size. The system can adapt to different carrier dimensions while maintaining manufacturing precision through real-time position adjustment and control.
Solution Approach 2:
A sensing unit detects the relative arrangement between the mobile production unit and the carrier, providing feedback to a control unit. This feedback mechanism enables the system to compensate for positioning deviations and maintain manufacturing precision even when processing large workpieces on extended carrier areas.
3Productivity
If production speed is increased to improve productivity, then manufacturing time decreases, but manufacturing precision deteriorates
Solution Approach 1:
The mobile production unit combines high-speed movement capability with dynamic positioning control. The system can move quickly between different sections of the carrier while maintaining precise positioning during the solidification process, thereby achieving both high productivity and manufacturing precision through coordinated motion control.
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 the efficiency and quality of additive layer production for large workpieces by enabling accurate positioning and controlled processing, ensuring consistent layer formation and maintaining a controlled atmosphere, thereby overcoming previous inefficiencies.
Implementation Method 1
a sensing unit (46) that is adapted to generate sensor signals relating to a relative arrangement of the mobile production unit (24) and the carrier (12)
Implementation Method 2
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 3
Selective laser melting or laser sintering can be used in particular for the production of prototypes, tools, replacement parts or medical prostheses
Data Source
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); anda 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.