Powder Hopper Docking Lock for Sealed Additive Manufacturing Transfer
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Solution Overview
Problem
Existing docking arrangements for additive manufacturing processes lack a reliable and controlled mechanism for securing and dispensing powders from hoppers to additive manufacturing machines, leading to issues with powder flow and environmental control.
Innovation Solution
A locking mechanism comprising movable locking members, such as rollers or cams, actuated by pneumatically or electrically controlled actuators, which securely couple the outlet of a container to the inlet of an additive manufacturing component, enabling controlled dispensing of powders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional locking mechanisms (e.g., cam-type) are used to couple the hopper outlet to the machine inlet, then the coupling can be achieved, but the locking mechanism may be obstructed by powders leading to malfunction
Solution Approach 1:
The locking mechanism is divided into separate functional components: locking members that engage with the hopper outlet, actuators that drive the locking members, and sealing members that maintain environmental control. This segmentation allows each component to be optimized independently and reduces the risk of total system failure due to powder obstruction in any single component.
Solution Approach 2:
The patent replaces conventional cam-type mechanical locking mechanisms with an actuator-driven system that uses controlled movement of locking members. This substitution reduces susceptibility to powder obstruction by eliminating complex cam surfaces that can become blocked, using instead a more straightforward actuation system with locking members that can be cleanly engaged and disengaged.
2Ease of operation
If manual control is used for dispensing powder from the hopper, then the operator can control the dispensing process, but the operator is out of reach and manual control is unsuitable for large scale processes
Solution Approach 1:
The system incorporates automated dispensing control where the additive manufacturing machine itself controls the powder dispensing from the hopper through integrated actuators and control systems. This self-service capability eliminates the need for manual intervention while maintaining precise control over the dispensing process, thereby improving productivity without sacrificing operational control.
Solution Approach 2:
The patent introduces an intermediary control system that acts as a bridge between the operator and the powder dispensing mechanism. This intermediary system includes sensors, actuators, and control logic that automatically manage the dispensing process based on machine requirements, allowing the operator to control the process remotely without being physically out of reach of the hopper.
3Reliability
If the hopper is securely coupled to the component, then environmental control (air/water tight seal) is maintained, but the coupling must remain secured during powder dispensing which creates design constraints
Solution Approach 1:
The patent merges multiple functions into the coupling mechanism: locking members that secure the hopper to the machine inlet, sealing members that maintain environmental control, and actuators that enable controlled engagement and disengagement. This integration reduces overall system complexity by combining what would otherwise be separate systems into a unified coupling assembly that achieves both secure attachment and environmental sealing simultaneously.
Solution Approach 2:
The coupling mechanism is designed with multi-functionality, where the same assembly performs both mechanical securing and environmental sealing functions. The locking members and sealing members work together in a single integrated unit that can be engaged and disengaged through actuator control, providing universal functionality for both attachment and environmental protection without requiring separate mechanisms.
Data Source
AI summary
A locking mechanism (100) for coupling an outlet (16) of a container (12) to an inlet (18) for a component of an additive manufacturing process. The locking mechanism (100) includes one or more locking members (102a, 102b) which are moveable, in use, between at least a first position and a second position. One or more actuators (104a, 104b) are provided and are configured, in use, to control movement of the one or more locking members (102a, 102b) between the first and second positions. The one or more locking members (102a, 102b) are configured to engage an exterior surface of the outlet (16) of the container (12) when in the second position so as to couple the outlet (16) to the inlet (18) for the component of the additive manufacturing process.