Build Material Supply Unit Distance Sensor
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Solution Overview
Problem
Additive manufacturing systems face challenges in accurately determining the amount of build material within the supply unit, which can lead to inefficient production and potential depletion during the printing process.
Innovation Solution
The use of an electromagnetic distance sensor to emit and receive signals along a beam pathway, determining a length parameter that calculates the amount of build material based on the distance and geometry of the supply volume, allowing for precise measurement and monitoring of the material's volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If no distance sensor is used to monitor build material, then the system is simpler, but the build material may deplete during printing causing production inefficiency
Solution Approach 1:
The patent replaces manual monitoring and estimation of build material levels with an automated electromagnetic distance sensor system. The sensor emits electromagnetic signals and measures the reflected signal duration to calculate distance to the material surface, eliminating the need for physical measurement tools or manual inspection while providing continuous automated monitoring of material levels.
Solution Approach 2:
The system implements feedback by continuously measuring the distance to the build material surface using the electromagnetic sensor and comparing it against predetermined thresholds. When the material level drops below the threshold, the system generates alerts or notifications to prompt replenishment, ensuring material is added before depletion occurs and maintaining continuous production capability.
2Measurement precision
If manual monitoring of build material is used, then the device is simpler, but measurement precision is insufficient leading to material depletion
Solution Approach 1:
The patent replaces imprecise manual monitoring methods with an electromagnetic distance sensor that provides automated, continuous, and precise measurement of the build material surface level. The sensor uses electromagnetic signal reflection and time-of-flight calculation to determine distance with high accuracy, eliminating human error and providing reliable data for timely material replenishment decisions.
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
This method enables accurate determination of the build material's volume, ensuring sufficient supply during printing and preventing depletion, thus enhancing the efficiency and reliability of the additive manufacturing process.
Implementation Method 1
The sensor includes an integral emitter and receiver. The electromagnetic distance sensor is caused to emit an electromagnetic signal along a beam pathway. A length parameter corresponding to a length of the beam pathway is determined by the electromagnetic distance sensor.
Implementation Method 2
A reflector is provided to reflect the beam pathway, received from the electromagnetic distance sensor, towards a surface level of the build material. The beam pathway is reflected back to the sensor to enable distance measurement.
Data Source
AI summary
There is disclosed a build material supply unit, comprising: a supply chamber body enclosing a supply volume to contain a build material for additive manufacture; an electromagnetic distance sensor to determine a length parameter relating to a length of a beam pathway extending from an emitter of the sensor to a surface level of build material in the supply volume; and a reflector to reflect the beam pathway between the emitter and the surface level of build material; wherein the reflector is spaced apart from the emitter.