3D-Printed Building Block With Embedded Position Sensing Pattern
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Solution Overview
Problem
Additive manufacturing in high-quality bearings and actuators is limited by the speed of production and the need for additional encoder discs to measure relative position, which are expensive and add complexity.
Innovation Solution
A system where a building block with a first printed material, embedded or partially embedded in a second material, is used to create a pattern that interacts with a sensor for position information, eliminating the need for additional encoder discs and enhancing accuracy through controlled distribution and high-density magnetic particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used for high-quality bearings or actuators, then design freedom and customization are improved, but production speed remains limited
Solution Approach 1:
The patent combines the structural component (building block) and the measurement component (pattern) into a single integrated element manufactured through additive manufacturing. This merging eliminates the need for separate encoder discs while maintaining design freedom and enabling complex geometries that would be difficult to achieve with traditional manufacturing methods.
Solution Approach 2:
The building block serves multiple functions: it provides the mechanical structure and simultaneously contains the measurement pattern for position sensing. This multi-functionality reduces the number of separate components needed, thereby improving productivity without sacrificing design versatility.
2Measurement precision
If additional encoder discs are used to measure relative position, then measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
The measurement pattern is integrated directly into the building block structure, combining the mechanical component and measurement reference into one element. This eliminates the need for separate encoder discs, reducing device complexity and component count while maintaining position measurement capability.
Solution Approach 2:
The building block itself provides the measurement reference through its embedded pattern, eliminating the need for external measurement components. The structure serves its own measurement needs, reducing overall system complexity.
3Volume of moving object
If pattern is printed on building block surface, then miniaturization and space efficiency are improved, but pattern protection from environmental damage is worsened
Solution Approach 1:
The measurement pattern is nested within the building block structure, with the pattern embedded in cavities or recesses of the building block. This nesting protects the pattern from environmental exposure while maintaining miniaturization and space efficiency.
Solution Approach 2:
The building block structure acts as a protective shell or enclosure for the embedded measurement pattern. This thin-film-like protective layer shields the pattern from environmental damage while allowing the overall miniaturized design to be maintained.
4Stability of the object's composition
If first printed material is embedded in second material, then pattern stability and protection are improved, but manufacturing complexity is worsened
Solution Approach 1:
The patent uses composite materials where the first printed material (containing the measurement pattern) is embedded in the second material (building block structure). This composite approach provides pattern stability and protection while the additive manufacturing process integrates both materials in a single manufacturing step, managing complexity.
Solution Approach 2:
The manufacturing process merges the creation of the building block structure and the embedding of the measurement pattern into a single additive manufacturing operation. This combining of steps stabilizes the pattern during manufacturing rather than requiring separate assembly operations.
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 approach allows for more accurate and robust position measurement with increased design freedom, reduced weight, and protection of the pattern from environmental damage, while minimizing the need for additional components.
Implementation Method 1
the first printed material comprises magnetic particles for cooperating with a magnetic sensor
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~3
AI summary
The invention provides a building block (290, 280) for a mechanical construction. The invention further provides a bearing (200), an actuator system, a gear box, a system and a method of producing the building block. The building block comprises a first printed material (210) printed via an additive manufacturing process on or at least partially embedded in a second material (260). The first printed material is printed in a pattern (212) configured and constructed for cooperating with a sensor (240) for providing, in use, position information of the building block relative to the sensor. The sensor may be a magnetic sensor or an optical sensor. The first printed material may comprise magnetic particles. The method of producing the building block may comprise a step of adding the first printed material to the second material via the additive manufacturing process under the influence of a predefined magnetic field.