Rotating Tool Holder for In-Chamber Additive Tool Change
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Solution Overview
Problem
Manual tool replacement in laser-based additive manufacturing is hazardous and disruptive, as it requires opening the high-temperature manufacturing space, leading to potential operator injury and part distortion, and existing automated systems are complex and costly.
Innovation Solution
An autonomous tool change system using a tool holder with a linear drive and clamping device that rotates and moves along a movement axis, allowing for swift and precise exchange of tools without opening the manufacturing space, utilizing existing machine axes and minimizing additional mechanical and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual tool replacement is performed, then the tool can be replaced, but operator safety is compromised and manufacturing continuity is interrupted
Solution Approach 1:
The system performs tool replacement autonomously using a robot arm that automatically grasps, transports, and installs tools without human intervention. The robot arm is equipped with sensors and control systems that enable it to execute the entire tool change sequence independently, eliminating the need for operator entry into the hazardous manufacturing space.
Solution Approach 2:
A tool holder serves as an intermediary component between the tool store and the manufacturing process. The tool holder is pre-loaded with tools in a safe external location, then automatically transferred to the manufacturing space when needed. This intermediary mechanism allows tool replacement without direct human involvement in the high-temperature environment.
2Reliability
If automated changing mechanisms are implemented, then operator safety is improved, but device complexity increases
Solution Approach 1:
The robot arm is a multi-functional device that can perform multiple operations including tool grasping, transportation, installation, and positioning. This universal robotic system replaces multiple specialized mechanisms, reducing overall system complexity while maintaining automated tool replacement capabilities.
Solution Approach 2:
Complex mechanical changing mechanisms are replaced with a robot arm controlled by automated systems. The robotic system uses sensors, controllers, and programmable logic to manage tool replacement, replacing intricate mechanical linkages with more manageable electromechanical and software-based control systems.
3Extent of automation
If existing automated mechanisms are used, then tool replacement is automated, but manufacturing precision may be affected
Solution Approach 1:
Tools are prepared and loaded into the tool holder in advance, in a controlled external environment. This preliminary preparation ensures that tools are ready for immediate installation without requiring adjustments or interventions during the manufacturing process, thereby maintaining manufacturing precision and avoiding part distortion.
Solution Approach 2:
The system uses precise positioning and replication of tool holder positions to ensure consistent tool placement. The robot arm reproduces the exact positioning requirements for each tool installation, maintaining the precision needed for additive manufacturing while automating the replacement process.
Data Source
AI summary
An additive manufacturing apparatus includes a housing which provides a manufacturing space for additive manufacturing, a linear drive arranged in the manufacturing space and having a base body, which is movable along a movement axis of the linear drive in the manufacturing space, and a tool holder for taking up a tool unit. The tool holder is attached to the base body so as to be rotatable about a rotation axis and is moved with the base body along the movement axis of the linear drive. The tool holder further comprises a clamping device having an unclamped operating state for taking up and taking out the tool unit and a clamped operating state for fixing the received tool unit. Furthermore, the additive manufacturing apparatus has a tool store, which is arranged in the manufacturing space and provides a plurality of tool places for tool units.