Two-Scale Positioning Mechanism for High-Acceleration Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current direct digital manufacturing machines with larger working volumes operate inefficiently due to the need for stiffer and more massive positioning mechanisms, which increase costs and energy consumption, and struggle with achieving high speeds and accelerations required for efficient operation.

Innovation Solution

A positioning system comprising a smaller scale positioning mechanism and a larger scale positioning mechanism, controlled by a system controller that generates control signals to move the tool from a current position to a commanded position using error and restoring components, allowing for high accelerations and efficient movement within a larger work space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If larger volume direct digital manufacturing machines use stiffer and more massive linkages to achieve high speeds and accelerations, then the working volume and productivity are improved, but the device complexity, cost, and energy consumption increase significantly

Engineering Contradiction:

Improveworking volumeVSAvoidlinkage complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The positioning mechanism is divided into two independent subsystems: a smaller scale positioning mechanism for high-speed, high-acceleration movements within a limited workspace, and a larger scale positioning mechanism for moving the tool across the entire large working volume. This segmentation allows each subsystem to be optimized for its specific function, avoiding the need for a single complex mechanism to handle all requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The smaller scale positioning mechanism acts as an intermediary between the larger scale positioning mechanism and the tool. It receives positioning commands from the controller, coordinates its movements with the larger scale mechanism, and achieves precise high-speed positioning within its workspace, thereby enabling the entire system to achieve both large working volume and high productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If larger volume direct digital manufacturing machines use stiffer and more massive linkages, then the structural strength is improved, but the energy consumption increases

Engineering Contradiction:

Improvelinkage strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the operational parameters of the two positioning mechanisms based on the positioning requirements. The smaller scale mechanism operates at high speeds and accelerations for precise positioning, while the larger scale mechanism moves more slowly across the workspace. This parameter differentiation allows the system to achieve high performance without requiring all components to be over-engineered for maximum strength.

Inventive Principle:

Principle #35Parameter changes

3Power

If larger volume direct digital manufacturing machines use larger motors to move massive linkages, then the power is improved, but the energy consumption increases

Engineering Contradiction:

Improvemotor powerVSAvoidenergy consumption

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The two-scale positioning system provides multi-functionality: the smaller scale mechanism handles high-speed, high-acceleration positioning tasks, while the larger scale mechanism handles gross positioning across the workspace. Together, they enable the system to achieve both large working volume and high productivity without requiring oversized motors that would consume excessive energy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If direct digital manufacturing machines operate at high speeds and accelerations, then the productivity is improved, but the manufacturing precision may deteriorate

Engineering Contradiction:

Improvespeed and accelerationVSAvoidpositioning precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller receives positioning commands and generates control signals that coordinate the movements of both positioning mechanisms. The system uses feedback from the positioning mechanisms to adjust control signals in real-time, ensuring that the tool reaches the desired position with high precision even during high-speed operations. This feedback control compensates for any positioning errors that may occur during rapid movements.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS9278448B2Position control for a positioning system comprising larger scale and smaller scale positioning mechanisms

Publication Date: 2016.03.08 THE BOEING CO

AI summary

A method and apparatus for controlling a positioning mechanism comprising a smaller scale positioning mechanism for moving a tool within a smaller scale work space and a larger scale positioning mechanism for changing a position of the smaller scale work space within the larger scale work space. A commanded position for the tool is received by a processor unit. An error component is determined using a difference between the commanded position and a current position of the tool in the larger scale work space. A restoring component configured to move the tool toward a selected position in the smaller scale work space is determined. Control signals for controlling the smaller scale positioning mechanism and the larger scale positioning mechanism together to move the tool from the current position to the commanded position are generated using the error component and the restoring component.