Switched Powder Feed Paths for In-Process Flow Calibration
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in accurately calibrating and monitoring powder flow rates, particularly in switching between supply to a head and a reservoir tank, which affects the precision and efficiency of the manufacturing process.
Innovation Solution
The apparatus incorporates a powder feeder connected to both a head and a reservoir tank via flow passages with switching valves and sensors, allowing for the detection and calculation of flow rates using optical sensors, enabling continuous monitoring and calibration without removing the workpiece, and determining abnormalities in the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a weigher is placed below the nozzle for calibration, then the accuracy of the optical sensor can be calibrated, but the workpiece must be removed and the weigher installed, causing production interruption
Solution Approach 1:
The system divides the powder flow measurement function into two separate measurement paths: one for the head (using optical sensor) and one for calibration (using weigher). The flow passage switching valve separates these functions into distinct segments, allowing independent operation of each measurement system without interference.
Solution Approach 2:
The flow passage switching valve acts as an intermediary device that directs powder flow to different destinations based on operational mode. It mediates between the powder feeder and the two different measurement systems (optical sensor path and weigher path), enabling seamless switching without physical reconfiguration.
2Productivity
If the optical sensor is used to detect powder flow rate, then real-time monitoring is achieved, but the calibration accuracy is insufficient without a weigher
Solution Approach 1:
The system performs preliminary calibration using the weigher to establish accurate reference data for the optical sensor. By pre-calibrating the optical sensor against the highly accurate weigher measurements, the system ensures that real-time optical monitoring maintains high precision without requiring the weigher to be present during operation.
Solution Approach 2:
The system uses feedback from both the optical sensor and the weigher to continuously refine and maintain measurement accuracy. The weigher provides periodic calibration feedback to correct any drift in the optical sensor, ensuring long-term measurement precision while maintaining real-time monitoring capabilities.
3Adaptability or versatility
If the flow passage switching valve switches between head and reservoir tank, then powder supply flexibility is improved, but system complexity increases
Solution Approach 1:
The flow passage switching valve is designed as a multi-functional component that not only directs powder flow to different destinations (head or reservoir tank) but also enables calibration operations and provides measurement switching. This universal component consolidates multiple functions into a single device, reducing overall system complexity despite the increased versatility.
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 solution ensures precise control over powder flow rates, allows for continuous operation without stopping production, and facilitates the identification of abnormalities within the system, enhancing the overall efficiency and reliability of the additive manufacturing process.
Implementation Method 1
an optical sensor, a weigher is placed below a nozzle
Data Source
AI summary
An additive manufacturing apparatus includes a powder feeder to feed powder, a head to discharge the powder, a first flow passage connecting the powder feeder and the head, a flow passage switching valve provided disposed in the first flow passage, a reservoir tank configured to receive the powder fed from the powder feeder, a second flow passage connecting the flow passage switching valve to the reservoir tank, a first sensor, and a second sensor. The flow passage switching valve is configured to take a first position and a second position alternatively. The powder feeder is connected to the head via the first flow passage in the first position to supply the powder to the head. The powder feeder is connected to the reservoir tank via the second flow passage in the second position to supply the powder to the reservoir tank.