Resin Support Drive Control for Tension and Feed Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems face challenges in accurately advancing the resin support a predefined distance while maintaining the target tension range during the tape casting process, which affects the precision and reliability of the manufacturing process.
Innovation Solution
A drive system with first and second control devices is implemented to control the translation distance and tension of the resin support, utilizing a computing system for real-time control through feedforward and feedback algorithms, enhancing the accuracy and reliability of the resin support advancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a drive system advances the resin support a predefined distance, then the translation distance is controlled, but the tension may deviate from the target range
Solution Approach 1:
The drive system incorporates feedback control mechanisms that continuously monitor the tension of the resin support during advancement. Sensors detect tension deviations from the target range and automatically adjust drive parameters to maintain tension within specified limits while achieving the predefined translation distance, thereby resolving the contradiction between distance precision and tension reliability.
Solution Approach 2:
The system dynamically adjusts drive parameters such as speed and torque during the resin support advancement process. By making real-time modifications to operational parameters based on monitored conditions, the system maintains both accurate translation distance and proper tension control, overcoming the static control limitations that cause the contradiction.
2Reliability
If the drive system maintains tension within target range, then reliability is improved, but translation distance accuracy may be compromised
Solution Approach 1:
Bidirectional feedback loops simultaneously monitor both tension levels and position/translation distance. The control system processes both feedback signals and makes coordinated adjustments to drive parameters, ensuring that both tension reliability and translation distance accuracy are maintained together rather than traded off against each other.
Solution Approach 2:
The system employs multiple controllable parameters including drive speed, acceleration, and torque that can be independently adjusted. By changing these parameters in coordinated fashion based on real-time conditions, the system achieves both proper tension maintenance and accurate translation distance control, resolving the contradiction between these two requirements.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An additive manufacturing apparatus (10) includes a stage (20) configured to hold a component (12). A radiant energy device (22) is operable to generate and project radiant energy toward the stage (20). An actuator is configured to change a relative position of the stage (20) relative to the radiant energy device (22). A feed module (24) is configured to support a feed roll (74) of a resin support (28) upstream of the stage (20) about a feed mandrel (24A). A first control device (32) is operably coupled with the feed mandrel (24A). A take-up module (26) is configured to support a take-up roll (106) of the resin support (28) downstream of the stage (20) about a take-up mandrel (26A). A second control device (34) is operably coupled with the take-up mandrel (26A). A computing system (66) is operably coupled with one or more sensors. The computing system (66) is configured to provide commands to at least one of the first control device (32) or the second control device (34) to respectively rotate the first control device (32) or the second control device (34) to obtain a target tension on the resin support (28).