Perpendicular Motion Additive Manufacturing Machine
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Solution Overview
Problem
Existing additive manufacturing machines for creating three-dimensional models from powder material in the foundry industry face inefficiencies due to long work cycles, mutual waiting times, and technical complexities, such as synchronized motion requirements and potential material accumulation issues, leading to decreased productivity and accuracy.
Innovation Solution
The design of an additive manufacturing machine featuring systems for powder and fusing substance application that move in perpendicular planes, utilizing rolls with grooves, longitudinally vibrating parts, and scissor-type lifting systems, allowing for simultaneous operation without redundant motions and enabling the creation of complex molds with integrated cores without technical layout constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the powder adding system and fusing substance system move in the same direction sequentially, then the machine structure is simple, but mutual waiting times occur and productivity decreases
Solution Approach 1:
The patent applies dimensional change by transitioning from sequential one-dimensional motion to simultaneous two-dimensional motion. The powder adding system moves along the X-axis while the fusing substance system moves along the Y-axis, allowing both systems to operate independently and simultaneously without mutual interference, thereby eliminating waiting times and improving productivity
2Device complexity
If an auger is used for adding powder material, then material distribution is simplified, but material accumulation occurs and system weight increases
Solution Approach 1:
The patent extracts and removes the auger component from the material distribution system. Instead of using an auger, the system employs a shaking table with vibration mechanisms to distribute powder material, thereby eliminating material accumulation issues and reducing system weight while maintaining reliable material distribution
Solution Approach 2:
The patent replaces the mechanical auger system with a vibration-based shaking table system. The vibration mechanism uses oscillatory motion to distribute powder material uniformly, substituting the rotary mechanical action of the auger with vibrational forces, thereby preventing material accumulation and reducing overall system weight
3Manufacturing precision
If a ball screw lifting system is used, then precise vertical positioning is achieved, but synchronized motion requirements increase complexity and maintenance needs
Solution Approach 1:
The patent extracts and removes the ball screw mechanism from the lifting system. Instead of using ball screws for vertical positioning, the system employs a shaking table with vibration-based lifting mechanisms, thereby eliminating the complex synchronized motion control requirements and frequent maintenance needs while maintaining precise positioning capabilities
Solution Approach 2:
The patent replaces the ball screw mechanical system with a vibration-based lifting system. The shaking table uses controlled vibrations to achieve vertical positioning and material layering, substituting the threaded mechanical action of ball screws with oscillatory vibrational forces, thereby reducing mechanical complexity and maintenance requirements
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 configuration significantly reduces production time, increases accuracy, and enhances productivity by eliminating redundant motions and material accumulation issues, making the process more efficient and cost-effective for creating complex molds and cores.
Implementation Method 1
The rolls have grooves for dosing the necessary material and one of the rolls works in one direction and the other in the opposite direction
Implementation Method 2
The system for applying powder material includes a longitudinally vibrating part, which has a special coating
Implementation Method 3
a lifting system for lifting the movable bottom of the container
Data Source
Figure 1
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Figure 3
AI summary
Additive manufacturing machine for creating a three-dimensional model from powder material, that consists of chassis (1), in which are located one below the other a loading system (4), system for applying powder material (2), system for applying fusing substance (3), container (5) with a removable bottom, fixating system (6) for the container (5), lifting system (7) for lifting and lowering the removable bottom of the container (5) and a control unit (9), which is located at the top end of the chassis (1). The system for applying powder material (2) and the system for applying fusing substance (3) are mounted on the chassis (1) in such a way as to be able to move on planes that are perpendicular to each other.