Pneumatic Powder Recycling System for Metal Additive Manufacturing
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Solution Overview
Problem
Current metal additive manufacturing processes face inefficiencies and waste due to manual recycling of metal powder, which can lead to powder deformation, oxidation, and safety hazards, particularly in large-scale systems where manual operation is inadequate.
Innovation Solution
A closed pneumatic powder recycling system comprising a supply tank, continuous loss in weight module, pneumatic module, transfer channel, recycle module, and refilling tank, which uses a rotary output pipe, pneumatic conveying, and ultrasonic vibration sieving to maintain powder quality and reduce manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual operation is used to collect and transfer metal powder, then the system complexity is reduced, but powder attrition increases and quality deteriorates
Solution Approach 1:
The patent replaces manual mechanical operations with an automated pneumatic conveying system. The powder is transferred through a closed pneumatic pipeline using air flow, eliminating the need for manual handling and mechanical conveyors that cause powder attrition and quality deterioration.
Solution Approach 2:
The patent employs pneumatic conveying technology to transport metal powder through a closed pipeline system. The powder is suspended and conveyed by pressurized air, preventing mechanical contact and deformation, thus maintaining powder quality while enabling automated operation.
2Productivity
If mechanical apparatus such as screw conveyor is used to transfer metal powder, then the transfer efficiency is improved, but powder deformation and attrition occur
Solution Approach 1:
The patent uses pneumatic conveying to transfer powder through a closed pipeline system. The powder is suspended in an air stream and conveyed without mechanical contact, eliminating the deformation and attrition caused by screw conveyors while maintaining high transfer efficiency.
Solution Approach 2:
The patent replaces mechanical conveying systems like screw conveyors with a pneumatic conveying system. This substitution eliminates mechanical contact that causes powder deformation, preserving powder roundness while achieving efficient automated transfer.
3Device complexity
If manual operation is used for powder recycling, then the equipment cost is reduced, but safety hazards increase due to dust explosion risk
Solution Approach 1:
The patent employs a closed pneumatic conveying system that encapsulates the powder transfer process. This closed system prevents powder dust from escaping into the environment, eliminating the dust explosion hazard associated with manual operations while maintaining cost-effectiveness.
Solution Approach 2:
The pneumatic conveying system creates a closed environment that isolates the metal powder from the surrounding atmosphere. This prevents the formation of explosive dust clouds in the workspace, addressing the safety hazard while avoiding the need for expensive manual handling procedures.
4Device complexity
If manual operation is used to remove powder from working platform, then the equipment complexity is reduced, but working efficiency decreases
Solution Approach 1:
The patent uses pneumatic conveying to automatically remove powder from the working platform through a closed pipeline system. This automated process significantly improves working efficiency compared to manual removal, while the relatively simple pneumatic system keeps equipment complexity manageable.
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 system significantly reduces powder attrition, improves recycling efficiency, prevents oxidation, and enhances safety by automating the recycling process, maintaining powder quality and reducing waste, making it suitable for large-scale additive manufacturing.
Implementation Method 1
The pneumatic module enables the recycling powder to float and move in the transfer channel
Implementation Method 2
a vibration module, configured to vibrate the mesh of the sieve
Data Source
AI summary
A powder recycling system includes a supply tank, a continuous loss-in-weight module, a pneumatic module, a transfer channel, a recycle module, and a refilling tank. The supply tank accommodates recycling powder. The continuous loss-in-weight module includes a storage tank receiving the recycling powder from the supply tank and a rotary output pipe connected to the storage tank to output the recycling powder. The continuous loss-in-weight module controls the mass flow rate of the output of the recycling powder according to the weight change of the storage tank. The pneumatic module enables the recycling powder to float and move in the transfer channel. The recycle module is connected to the transfer channel to receive the recycling powder, sieves the recycling powder, provides virgin powder, and mixes the virgin powder with the recycling powder. The refilling tank is connected to the recycle module to receive the recycling powder and the virgin powder.