Sensor-Guided Pivot Cleaning for Powder-Bed 3D Printed Parts
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Solution Overview
Problem
Existing cleaning devices for three-dimensional objects produced by layer-by-layer application of powdered construction materials are inefficient in removing non-solidified powder, especially from internal structures, and pose health risks due to uncontrolled particle release, which can lead to dust explosions.
Innovation Solution
A cleaning device with a pivoting mechanism controlled by an electronic control device and sensor system that adjusts pivot positions and vibration frequencies to optimize powder removal, ensuring thorough cleaning without manual intervention and minimizing health hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cleaning methods (rotation and vibration) are used, then some powder is removed from the object, but powder remains in internal channels and cavities, resulting in inadequate cleaning
Solution Approach 1:
The cleaning device dynamically adjusts the pivot position of the object during the cleaning process. The pivoting mechanism allows the object to be positioned at different angles relative to the powder flow direction, enabling powder to be dislodged from internal channels and cavities that would be inaccessible at fixed positions. This dynamic repositioning ensures thorough cleaning of complex geometries without requiring multiple cleaning devices.
Solution Approach 2:
The invention introduces a new dimension to the cleaning process by adding pivoting capability around at least one pivot axis. This transforms the cleaning approach from a single-direction powder flow to multi-directional cleaning, where the object can be oriented to expose different surfaces and internal structures to the powder flow, effectively cleaning channels and cavities at various orientations.
2Ease of operation
If manual cleaning methods are used, then cleaning can be performed, but health risks arise from uncontrolled particle release and dust cloud formation
Solution Approach 1:
The cleaning device operates autonomously without requiring manual intervention during the cleaning process. The automated pivoting mechanism and controlled powder flow system perform the cleaning function independently, eliminating the need for operators to be present in the cleaning zone and thereby preventing exposure to released particles and dust clouds.
Solution Approach 2:
The device incorporates a sensor device that detects when powder has been successfully removed from the object. This feedback mechanism allows the control device to monitor the cleaning progress and automatically adjust the pivoting and powder flow parameters, ensuring complete powder removal while maintaining controlled particle containment throughout the process.
3Device complexity
If the object is cleaned in fixed position, then the cleaning process is simple, but cleaning effectiveness is limited and cannot assess cleaning progress
Solution Approach 1:
The sensor device continuously monitors the cleaning process by detecting the presence and quantity of removed powder. This feedback information is provided to the control device, which uses it to assess cleaning progress and determine when the object has been adequately cleaned. The system can automatically adjust pivoting positions and powder flow rates based on real-time cleaning effectiveness data.
Solution Approach 2:
The pivoting mechanism enables dynamic repositioning of the object during cleaning, allowing different surfaces and internal structures to be exposed to the powder flow. This dynamic approach, combined with sensor feedback, enables comprehensive cleaning assessment by monitoring powder removal from various orientations and positions of the object.
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
The device enables efficient and automated cleaning of both external and internal surfaces, reducing health risks and preventing dust explosions by ensuring complete removal of non-solidified powder, thus improving the cleanliness and safety of the process.
Implementation Method 1
a sensor device (19) which detects a cleaning parameter representing a quantity, mass, mass flow rate, volume and/or volumetric flow rate of the powdered build-up material passed through the at least one outlet opening (18)
Data Source
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AI summary
The invention relates to a cleaning device (100) which cleans three-dimensional objects (7, 14) produced by layering and selectively solidifying a powdered build-up material from unsolidified powdered build-up material surrounding the objects (7, 14) and/or remaining in openings or channels of the objects (7, 14), comprising a cleaning chamber (5) in which the cleaning of an object (7, 14) takes place and which has at least one outlet opening (18) for the discharge of the powder cleaned from the object (7, 14) from the cleaning chamber (5), wherein the cleaned powder passes through the outlet opening (18), a pivoting device (16) on which the object (7, 14) can be clamped and by which the object (7, 14) can be pivoted into different pivot positions with respect to at least one pivot axis (11, 12), and an electronic control device (22) which controls the pivoting device controls or regulates,to control or regulate the pivoting positions of the object (7, 14). The invention further provides that it comprises a sensor device (19) which detects a cleaning parameter representing a quantity, mass, mass flow rate, volume, and/or volumetric flow rate of the powdered build-up material passing through the at least one outlet opening and cleaned from or by the object (7, 14), wherein the electronic control device (22) controls or regulates the pivoting device (16) such that the pivoting positions of the object (7, 14) are controlled or regulated depending on the cleaning parameter.