Powder Supply Vessel Weight Tracking in Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing processes, such as L-PBF and DED, face inaccuracies in tracking and managing powder inventory due to uncontrollable variables like waste and trapped powder, leading to inefficiencies and manual labor requirements for data collection and estimation.
Innovation Solution
A system comprising a weight sensor system connected to a supply vessel in an additive manufacturing machine, which automatically tracks powder inventory by measuring weight changes and preventing builds if insufficient powder is available, using flexible connections and load cells for accurate weight measurement and automated tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional manual tracking methods are used to monitor powder inventory, then person hours for data collection and estimation are reduced, but measurement precision and reliability of powder inventory tracking deteriorate due to uncontrollable variables and margin of error
Solution Approach 1:
The patent replaces manual mechanical tracking methods with an automated electronic weighing system. Load cells continuously measure powder weight in the supply vessel, and a controller automatically calculates inventory levels, eliminating the need for manual data collection while providing precise, real-time measurements that resolve the contradiction between time savings and measurement accuracy.
Solution Approach 2:
The system enables self-service automation where the weighing system and controller automatically monitor and track powder inventory without human intervention. The system self-calibrates and continuously updates inventory levels based on weight measurements, resolving the contradiction by providing both time efficiency and high measurement precision through automated self-monitoring.
2Measurement precision
If automated weighing systems are implemented to improve powder inventory tracking accuracy, then measurement precision improves, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The controller serves multiple functions: it receives weight signals from load cells, calculates powder inventory levels, tracks usage throughout the build process, and provides real-time monitoring. This multi-functionality reduces the need for separate dedicated components, thereby improving measurement precision while minimizing the increase in device complexity.
Solution Approach 2:
The patent merges the weighing function (load cells) with the control and monitoring function (controller) into an integrated system. The controller is operatively connected to both the load cells and the display system, combining multiple functions into a single coordinated unit that achieves high measurement precision without proportionally increasing overall system complexity.
3Stability of the object's composition
If the supply vessel is rigidly connected to the additive manufacturing machine for stability, then stability of the object's composition improves, but measurement precision deteriorates due to additional reaction forces interfering with weight measurement
Solution Approach 1:
The patent segments the support functions by using dedicated load cells that exclusively support the supply vessel for measurement purposes, separate from the rigid structural connections of the machine. This segmentation isolates the measurement function from interfering reaction forces, maintaining both vessel stability and measurement precision.
Solution Approach 2:
The load cells act as intermediaries between the supply vessel and the machine structure. They provide a dedicated measurement pathway that transmits only the weight of the powder and vessel, filtering out interfering reaction forces from other machine components while maintaining the necessary structural stability.
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 provides accurate and automated powder inventory tracking, reducing manual errors and ensuring sufficient powder for builds, while minimizing environmental health and safety concerns through real-time usage statistics and improved inventory management.
Implementation Method 1
A weight sensor system 110 can be connected to the supply vessel 108 in any suitable position for measuring a weight of the supply vessel 108
Data Source
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AI summary
A system comprising an additive manufacturing machine (102) configured to fuse stock powder, a supply vessel (108) connected to the additive manufacturing machine (102) for supplying the stock powder to the additive manufacturing machine (102), and a weight sensor system (110) connected to the supply vessel (108). A controller (112) operatively is connected to the weight sensor system (110) configured to receive signals indicative of a weight of the stock powder in the supply vessel (108). The controller (112) is configured to determine weight of the stock powder based on the signals.