Optical Fiber Connector Layout for Fast Laser Source Replacement
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Solution Overview
Problem
Additive manufacturing systems face limitations in manufacturing speed and throughput due to the rate of material fusion, which is constrained by laser power levels and the challenges of replacing optical fibers and laser energy sources, particularly when multiple sources are used, leading to reduced reliability and increased system downtime.
Innovation Solution
The system employs a plurality of laser energy sources with an optical fiber connector and alignment fixtures to facilitate easy replacement of optical fibers and laser energy sources without disrupting the manufacturing process, allowing for improved reliability and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser energy sources are used to increase manufacturing speed, then productivity is improved, but device complexity and reliability deteriorate due to the difficulty of replacing optical fibers and laser sources
Solution Approach 1:
The system divides the optical fiber delivery network into modular segments: laser energy sources, optical fiber connectors, and optics assemblies are separated into replaceable units. This allows individual components to be replaced independently without affecting the entire system, reducing the complexity burden of having multiple laser sources.
Solution Approach 2:
The optical fiber connector design creates a universal interface that can accommodate different laser energy sources and optical fiber configurations. The standardized connector type allows any laser source to be paired with any optics assembly through the same connector interface, simplifying the overall system architecture despite multiple components.
2Productivity
If multiple laser energy sources are used to increase manufacturing speed, then productivity is improved, but reliability worsens due to increased failure points and difficulty of maintenance
Solution Approach 1:
The system is designed with pre-prepared replacement laser energy sources and optical fibers that can be quickly swapped in during scheduled maintenance or upon failure detection. Alignment fixtures are pre-positioned to ensure immediate realignment without requiring complex adjustment procedures, maintaining reliability through rapid replacement capability.
Solution Approach 2:
The alignment fixtures are designed to automatically maintain alignment when optical fibers or laser sources are replaced. The self-aligning mechanism reduces the skill level and time required for maintenance, allowing operators to quickly restore system reliability without requiring specialized alignment equipment or procedures.
3Manufacturing precision
If optical fibers are replaced frequently to maintain system performance, then manufacturing precision is improved, but loss of time increases due to replacement operations
Solution Approach 1:
The optical fiber delivery system is segmented into replaceable sections with standardized connectors. When precision degradation is detected, only the affected optical fiber segment needs to be replaced rather than the entire system, minimizing downtime while restoring manufacturing precision.
Solution Approach 2:
The alignment process is replaced by a mechanical alignment fixture system that automatically positions replacement optical fibers and laser sources. This mechanical substitution eliminates time-consuming manual alignment procedures, allowing rapid replacement that preserves manufacturing precision without significant time loss.
4Manufacturing precision
If access to build volume is required for component replacement, then manufacturing precision can be maintained, but productivity decreases due to process disruption
Solution Approach 1:
The optical fiber connectors and alignment fixtures are extracted from the build volume and positioned in externally accessible locations. This allows laser energy sources and optical fibers to be replaced through external access points without requiring entry into the build volume, maintaining manufacturing precision through protected alignment interfaces while avoiding productivity loss from process disruption.
Solution Approach 2:
External access mechanisms and intermediary connection points are introduced between the build volume and the optical fiber replacement system. These intermediaries allow alignment-critical components to be replaced outside the build volume while maintaining the precision alignment relationship, separating the replacement operation from the manufacturing process to avoid throughput disruption.
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 approach enhances manufacturing speed and throughput by enabling rapid component replacement without access to the build volume, maintaining system integrity and reducing downtime.
Implementation Method 1
a first plurality of optical fibers extends between the plurality of laser energy sources and the optical fiber connector... each optical fiber of the first plurality of optical fibers is coupled to a laser energy source of the plurality of laser energy sources
Data Source
AI summary
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.