Telescopic Fiber Tow Feed Path for Synchronized 3D Deposition
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Solution Overview
Problem
The existing methods for manufacturing fiber-reinforced plastics face challenges in matching the supply rate of fiber filaments with the deposition rate, leading to inefficiencies in the additive manufacturing process.
Innovation Solution
A filament feeding device with a telescopic tubular assembly, position sensor, and controller is used to measure and adjust the translation speed of the filament, ensuring synchronization with the deposition rate, and includes a heater to adjust radiation based on position measurements for optimal filament delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filament is supplied at a fixed speed, then the supply process is simple, but the supply rate cannot match the variable deposition rate
Solution Approach 1:
The patent implements dynamic speed adjustment of the filament supply system based on real-time position feedback. The first tube can telescopically extend and retract, and the filament feed rate is continuously adjusted according to the deposition head position and speed, transforming a static supply system into a dynamic one that adapts to varying deposition requirements
Solution Approach 2:
The patent employs feedback control mechanisms where position sensors monitor the deposition head location and the filament supply speed is adjusted accordingly. The system uses the position information to calculate required filament feed rates and implements closed-loop control to maintain synchronization between supply and deposition rates
2Speed
If the filament is supplied faster, then the deposition speed increases, but friction and twisting issues worsen
Solution Approach 1:
The patent changes physical parameters of the filament path including tube diameter, surface roughness, and lubrication characteristics to reduce friction. The system adjusts filament supply parameters such as acceleration rates, tension forces, and bending radii to minimize twisting while maintaining high deposition speeds
Solution Approach 2:
The patent introduces intermediary elements such as guide tubes, rollers, and lubrication layers between the filament and surrounding components. These intermediaries reduce direct friction and prevent twisting by providing smooth, controlled contact surfaces that guide the filament through the deposition path
3Adaptability or versatility
If a rigid filament path is used, then the structure is stable, but the filament cannot adapt to position changes
Solution Approach 1:
The patent divides the filament path into multiple segmented sections with different degrees of flexibility. Some sections use rigid tubes for stability while others use flexible or telescopic segments for adaptability. This segmentation allows the system to maintain structural integrity while accommodating position changes during deposition
Solution Approach 2:
The patent employs nested telescopic tube structures where one tube can extend within another. This nested configuration provides a stable overall structure while allowing inner tubes to extend or retract for position adaptation, enabling the filament path to maintain stability while accommodating dynamic position changes
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 solution ensures a consistent and efficient supply of filaments, reducing friction and twisting issues, and improving the overall additive manufacturing process by matching the supply rate with the deposition rate, enhancing the quality and reliability of fiber-reinforced plastics production.
Implementation Method 1
the position sensor comprises an optical sensor
Implementation Method 2
a heater to adjust radiation based on position measurements
Data Source
AI summary
One example provides a filament feeding device and a method for guiding a filament into an additive manufacturing apparatus, the filament feeding device comprising: a filament travel path; a filament buffer comprising a telescopic tubular assembly comprising a filament entrance at a first end of the tubular assembly and a filament exit at a second end of the tubular assembly, the tubular assembly comprising: a first tube having a first tube longitudinal centerline; and a second tube comprising a portion into which a portion of the first tube is telescopically inserted; and a position sensor; a controller connected to the position sensor; and a computer-readable non-volatile storage device, wherein the position sensor is configured for measuring a position of the first tube with respect to a reference point.