Robot-Arm 3D Printing With Nozzle Position Correction
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Solution Overview
Problem
Current 3D printing systems with Cartesian manipulators are limited in size, unable to print objects larger than 50 cm in each dimension, as they have a restricted operational range and limited degrees of freedom, making it difficult to produce larger three-dimensional objects.
Innovation Solution
A printing system utilizing an industrial robot with multiple degrees of freedom, equipped with a control unit and a printing unit featuring a print nozzle, which anticipatorily determines and adjusts its position to ensure accurate application of print material along a predetermined path, allowing for the printing of larger objects by suppressing material application if deviations exceed a certain limit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a Cartesian manipulator is used for 3D printing, then the system can print objects with high precision, but the size of printable objects is limited to approximately 50 cm in each dimension
Solution Approach 1:
The patent applies an industrial robot system that can perform multiple functions including positioning, printing, and quality control. The robot arm with multiple degrees of freedom serves as both the positioning mechanism and the printing mechanism, replacing the dedicated Cartesian manipulator with a more versatile robotic system that handles both small and large scale objects.
Solution Approach 2:
The patent introduces dynamic position correction by continuously monitoring the actual position of the print nozzle and comparing it with the target position. The system dynamically adjusts the printing process by suppressing material application when position deviations exceed a threshold, enabling accurate printing on large-scale objects that would otherwise be beyond the static capabilities of traditional manipulators.
2Volume of moving object
If an industrial robot with multiple degrees of freedom is used, then the operational range is extended to print larger objects, but position accuracy may deviate from the predetermined path
Solution Approach 1:
The patent implements a feedback mechanism where the actual position of the print nozzle is continuously determined and compared with the target position from the robot program. This feedback loop enables real-time detection of position deviations and triggers corrective actions by suppressing material application when deviations exceed acceptable limits, thus maintaining printing accuracy despite the robot's extended operational range.
Solution Approach 2:
The patent performs anticipatory determination of the print nozzle's actual position before material application occurs. By predicting and checking the position in advance, the system prevents inaccurate material deposition, ensuring that printing accuracy is maintained even when operating beyond the precise controlled range of traditional manipulators.
3Volume of moving object
If the print nozzle position deviates from the predetermined path, then larger objects can be accommodated, but the quality of printed objects deteriorates due to inaccurate material placement
Solution Approach 1:
The system continuously monitors the actual position of the print nozzle and compares it with the target position. When a deviation exceeding a predetermined limit is detected, the system provides feedback to suppress material application, thereby preventing quality deterioration while still allowing the robot to operate over extended ranges for larger objects.
Solution Approach 2:
The patent applies preliminary anti-action by suppressing material application in advance when position deviations are anticipated to exceed acceptable limits. This preventive measure ensures that inaccurate material placement does not occur, maintaining printed object quality even when operating with the flexibility needed for large-scale printing.
Data Source
AI summary
A printing system for three-dimensional objects has a control unit for storing and executing a robot program and an industrial robot which is controlled by the control unit and which has an arm with several members, wherein the tip of the arm is movable along a predetermined movement path according to path data of the robot program. A printing unit is mounted on the tip of the robot arm and is controlled by the control unit, which has at least one print nozzle for applying pointwise a respective portion of a print material at respective coordinates according to object data of the robot program.