Re-coater Blade Alignment Using Optical Measurement
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Solution Overview
Problem
Conventional methods for aligning re-coater blades in rapid prototyping and manufacturing machines are prone to inaccuracies due to reliance on tactile skills and shims, leading to defective components and increased machine downtime, with significant variations in gauge repeatability and reproducibility between machines.
Innovation Solution
An optical measurement apparatus is used to align the re-coater blade in parallel with a reference plane defined by the material surface, employing energy devices to measure radial distances and calibrate the alignment, eliminating the need for shims and reducing operator skill dependence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional shim-based alignment method is used, then alignment can be performed with simple equipment, but alignment precision deteriorates due to reliance on tactile skills and manual measurement
Solution Approach 1:
The patent replaces the mechanical shim-based measurement system with an optical measurement system. The optical measurement apparatus uses light-based measurement to determine the position and orientation of the re-coater blade, eliminating the need for manual tactile measurement and shim insertion. This substitution dramatically improves alignment precision while the modular design of the optical system keeps equipment complexity manageable.
Solution Approach 2:
The patent introduces alignment targets as intermediary elements that facilitate the optical measurement process. These targets are positioned on the re-coater blade and support platform, serving as reference points for the optical measurement apparatus to accurately determine spatial relationships without direct contact between the measurement device and the components being aligned.
2Productivity
If manual alignment process is used, then equipment structure remains simple, but machine downtime increases due to repeated measurements and adjustments
Solution Approach 1:
The optical measurement apparatus enables continuous measurement and real-time feedback during the alignment process. Multiple measurements can be taken rapidly without stopping the alignment procedure, allowing for immediate detection and correction of misalignments. This continuous measurement capability significantly reduces the total time required for alignment compared to the sequential nature of manual shim-based methods.
Solution Approach 2:
The system incorporates feedback mechanisms where the optical measurement apparatus continuously monitors the alignment status and provides information for adjustment. This feedback loop allows operators to make precise adjustments based on quantitative data rather than trial-and-error, reducing the number of iterative adjustments needed and thereby reducing machine downtime.
3Reliability
If shim-based measurement method is used, then measurement process is simple, but gauge repeatability and reproducibility deteriorate due to operator skill variations
Solution Approach 1:
The optical measurement system is designed to be self-calibrating and self-measuring, reducing dependence on operator skill. The system automatically performs measurements and calculations, with the alignment targets providing inherent reference standards. This self-service capability ensures that measurements are consistent regardless of which operator performs the alignment, dramatically improving gauge repeatability and reproducibility across different operators and machines.
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 method ensures precise and consistent alignment of the re-coater blade, decreasing machine downtime and improving gauge repeatability and reproducibility by using optical measurements to align the re-coater blade with the material surface, allowing for efficient and accurate component production across machines.
Implementation Method 1
receiving a plurality of reflected first energy from the surface of the material
Implementation Method 2
measuring a plurality of first radial distances between the surface of the material and the optical measurement apparatus based on the plurality of reflected first energy
Data Source
AI summary
A method and an optical measurement apparatus for a re-coater blade alignment are disclosed. The method includes adjusting an optical measurement apparatus over a surface of a material to align the optical measurement apparatus with a reference plane of the material. Further, the method includes positioning a re-coater assembly, the optical measurement apparatus, and the material such that the re-coater assembly is between the optical measurement apparatus and the material, and so a re-coater blade of the re-coater assembly is positioned proximate to the material. The method further includes adjusting the re-coater assembly via a plurality of second aligning elements to align the re-coater blade in parallel with the optical measurement apparatus.