Powder Delivery Valve Control for Stable Additive Deposition
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Solution Overview
Problem
Conventional powder delivery systems in additive manufacturing are slow to adjust to changes in powder demand, leading to inconsistencies in deposition and slowing down the manufacturing process due to their reliance on open-loop control.
Innovation Solution
A powder delivery system with a powder control valve that separates the input fluid flow into output and return flows, allowing for quick adjustments to meet changing powder demands by routing excess powder back for reuse, and using carrier gas makeup to maintain constant nozzle velocity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional powder delivery systems use open-loop control to provide constant powder flow rate, then the system structure is simple, but the system is slow to adjust to changes in powder demand and introduces inconsistencies in deposition
Solution Approach 1:
The patent implements a feedback control system where a flow sensor measures the actual powder-carrying gas flow rate and feeds this information back to a controller. The controller adjusts the powder delivery based on this feedback, ensuring consistent powder delivery even when disturbances occur. This resolves the contradiction by providing reliable, consistent powder delivery through feedback control while managing system complexity through efficient sensor and controller integration.
2Manufacturing precision
If conventional powder delivery systems use feedback control to adjust powder delivery rate, then the consistency of deposition improves, but the system response is slow and manufacturing process speed decreases
Solution Approach 1:
The patent uses a fast-acting diverter valve that can quickly redirect the powder-carrying gas flow in response to controller signals. This preliminary action capability allows the system to make rapid adjustments to powder delivery rates, maintaining manufacturing precision while improving response speed and overall productivity. The valve's fast response characteristic is key to resolving the contradiction between precision and productivity.
3Adaptability or versatility
If the velocity of relative movement between deposition head and substrate changes, then the deposition process adapts to different manufacturing requirements, but inconsistencies in deposition track morphology occur with conventional systems
Solution Approach 1:
The feedback control system continuously monitors powder delivery and adjusts it based on actual flow conditions, enabling the system to maintain consistent deposition track morphology even when velocity changes occur. The flow sensor and controller work together to compensate for velocity variations, ensuring manufacturing precision is maintained across different operating conditions and improving adaptability.
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
Enables rapid and consistent powder delivery, reducing inconsistencies and improving the efficiency of the additive manufacturing process by ensuring a stable powder flow even during changes in deposition parameters.
Implementation Method 1
The carrier gas source generates an input fluid flow of carrier gas through the input section and the powder feeder introduces powder into the input fluid flow so that powder particles are entrained in and carried by the input fluid flow
Data Source
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AI summary
A powder delivery system for use in an additive manufacturing device includes a powder control valve configured to selectively divert at least a portion of an input fluid flow to a return line while a remainder of the input flow is delivered to a delivery nozzle. In some embodiments, the powder delivery valve may be modulated to alter the percentage of input flow diverted to the return line. Alternatively, the powder delivery valve may be either fully open or closed. In each embodiment, the powder delivery valve permits rapid changes in the amount of powder delivered to the nozzle.