Rotational Additive Manufacturing for Condenser Bushings
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Solution Overview
Problem
Existing manufacturing processes for condenser bushings are inefficient and lack the ability to produce articles with complex geometries and precise control over layer thickness and material properties, particularly in additive manufacturing.
Innovation Solution
A system utilizing a rotational stage, energy source, and controller to apply and cure a liquid formulation in a controlled environment, allowing for the formation of articles with varying layer thickness and geometry, including condenser bushings, through additive manufacturing, using photocurable polymers and conductive materials, with precise control over environmental conditions and energy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used for condenser bushings, then manufacturing time may be reduced, but the ability to produce articles with complex geometries and precise control over layer thickness and material properties is lost
Solution Approach 1:
The condenser bushing is manufactured layer by layer through additive manufacturing, where each layer is formed independently with precise control over thickness and material composition. The liquid formulation is applied in discrete layers that are sequentially cured, enabling complex geometries and varying material properties throughout the structure.
Solution Approach 2:
The invention enables dynamic control of manufacturing parameters including layer thickness, curing energy dosage, and material composition. By adjusting these parameters during the manufacturing process, the system achieves precise control over the final article's geometric and material properties while maintaining manufacturing efficiency.
2Manufacturing precision
If additive manufacturing with rotational stages and energy sources is used, then complex geometries and precise material control are achieved, but device complexity increases
Solution Approach 1:
The rotational stage serves multiple functions: it positions the mandrel for uniform liquid formulation application, enables controlled rotation during curing, and facilitates precise positioning for subsequent layers. The energy source system provides both curing function and acts as a control mechanism for layer formation, reducing the need for separate specialized components.
Solution Approach 2:
The invention replaces complex mechanical layer application systems with a combination of rotational motion and energy-based curing. Instead of using multiple mechanical actuators for precise layer deposition, the system uses centrifugal force from rotation combined with controlled energy application to achieve precise layer formation and material properties.
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
Enables the efficient production of articles with complex geometries and precise control over layer thickness and material properties, improving manufacturing efficiency and enabling the creation of articles suitable for high-voltage electrical systems.
Implementation Method 1
a rotational stage (18) about a horizontal axis of rotation (40), an energy source (20) and a controller (16). The processor (34) executes program instructions (38) to rotate the mandrel (14) and the article (12) being formed about the horizontal axis of rotation (40), to apply liquid formulation (46) to the mandrel (14) and form a layer about the mandrel (14), and to provide a curing energy dose (20) to the liquid formulation (46) to solidify the liquid formulation (46)
Data Source
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AI summary
A method for forming an article of manufacture using additive manufacturing, includes: a processor executing program instructions to: (a) rotate an object continuously about a horizontal axis using a first rotational stage, wherein the object is partially submerged in a bath of energy curable liquid formulation during the rotation; (b) control a rate of rotation of the object to achieve a desired radial thickness of a sub layer of uncured liquid formulation at a desired rotational location on the object; (c) direct an energy source to provide an energy dose onto the object at a desired rotational location, wherein the energy dose is configured to cure and solidify the sub layer; and repeat (a), (b) and (c) until a desired radial thickness of a cured liquid formulation layer is achieved.