Servo Progressive Cavity Pump for Viscous Material Dispensing
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Solution Overview
Problem
Current direct digital manufacturing techniques lack precision and control, especially when working with viscous materials, and are unable to effectively handle fine lines or large area printing with the required accuracy and flow rate control.
Innovation Solution
A direct write print head system combining a servo valve with a servo progressive cavity pump, utilizing a servo motor-controlled valve and actuator for precise control of material flow, and integrating sensors for real-time feedback and control, allowing for fine control of segment beginnings, endings, and flow rates during printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional direct digital manufacturing system is used, then it can process materials, but it lacks precision and control especially with viscous materials
Solution Approach 1:
The system incorporates sensors that provide real-time feedback on material flow, pressure, and position. This feedback loop enables closed-loop control of the progressive cavity pump and valve actuator, allowing the system to automatically adjust and maintain precise flow rates and positioning accuracy despite variations in viscous material properties
Solution Approach 2:
The patent replaces conventional mechanical positioning and flow control systems with a servo-driven progressive cavity pump and electronically controlled valve actuator. This substitution of mechanical systems with servo-controlled mechanisms enables precise digital control of material flow rates and head positioning, significantly improving manufacturing precision and reliability
2Productivity
If material flow is increased for large area printing, then productivity improves, but control over segment beginnings and endings deteriorates
Solution Approach 1:
The system dynamically adjusts the valve actuator position and pump flow rate in real-time based on the printing requirements. The servo-controlled valve can rapidly open and close to precisely control segment beginnings and endings, while the progressive cavity pump simultaneously adjusts flow rate to match the increased productivity demands of large area printing
Solution Approach 2:
Real-time feedback from position sensors and flow sensors enables the control system to monitor and adjust material deposition during printing. This allows the system to maintain precise segment control even at high printing speeds by automatically compensating for variations in flow rate and positioning
3Manufacturing precision
If a servo valve with servo progressive cavity pump is used, then flow rate control improves, but device complexity increases
Solution Approach 1:
The patent merges the servo valve and progressive cavity pump into an integrated material delivery system. The servo valve is positioned directly at the pump outlet, and both components are controlled by a unified control system that coordinates valve timing with pump cycles. This merging reduces the number of separate components and simplifies the overall system architecture while maintaining precise flow rate control
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 precise and accurate direct write printing of viscous materials with fine feature control, ensuring neither excessive nor insufficient material deposition, and allowing for compatibility with both fine lines and large area printing on various substrates.
Implementation Method 1
a progressive cavity pump configured to meter and force material from the material source onward through the apparatus
Implementation Method 2
a servo motor controlled valve opens and closes to control at what locations in the pattern material is dispensed
Implementation Method 3
A syringe of material which is pressurized with air to transport material
Data Source
AI summary
An apparatus may include a pressurized source of viscous material for dispensing onto a substrate. The apparatus may include a progressive cavity pump configured to meter and force material from the material source onward through the apparatus. The apparatus may include a valve operatively connected to the progressive cavity pump and configured to turn on and off flow of material from the progressive cavity pump. Moreover, the device may include an output nozzle for directing the viscous material to the substrate when the valve is in an open position.