Vibration Exciter for 3D Printed Object Cleaning
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Solution Overview
Problem
Existing methods for separating unsolidified building material from objects created through layer-by-layer application and selective solidification often cause damage to the object and environmental pollution, due to excessive vibrations and noise during the cleaning process.
Innovation Solution
A method involving a test phase to determine optimal vibration frequencies and amplitudes that avoid excessive vibration amplitudes and accelerations, using a vibration exciter controlled by an electronic controller, and a cleaning phase where the object is excited with frequencies and amplitudes that do not exceed predetermined limits to minimize damage and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the object is excited with high vibration amplitude to separate unsolidified build material, then the separation effectiveness is improved, but the object may be damaged and excessive noise is generated
Solution Approach 1:
The patent applies parameter changes by systematically varying excitation frequency and amplitude during a test phase to identify optimal vibration parameters that achieve effective separation while staying below damage thresholds. The electronic controller adjusts these parameters dynamically based on detected vibration amplitudes and accelerations, allowing the system to operate at high effectiveness levels without causing harm to the object.
Solution Approach 2:
The patent implements feedback control by continuously monitoring vibration amplitudes and accelerations during the cleaning phase and using this information to adjust the excitation parameters in real-time. The electronic controller receives feedback from sensors, compares the measured values against predetermined limits, and modifies the vibration excitation accordingly to maintain effective separation while preventing object damage and excessive noise.
2Productivity
If external vibrations are applied to detach powder from the object, then the cleaning effectiveness is improved, but the object may experience excessive vibration amplitudes causing damage
Solution Approach 1:
The patent applies preliminary action by conducting a test phase before the actual cleaning phase to determine the optimal excitation parameters. During the test phase, the system identifies the frequency and amplitude ranges that achieve effective powder detachment without causing excessive vibrations. These predetermined safe parameters are then used during the cleaning phase to ensure both effectiveness and object integrity are maintained.
Solution Approach 2:
The patent implements dynamics by using an electronically controlled vibration exciter that can dynamically adjust excitation frequency and amplitude based on real-time feedback. This dynamic control allows the system to adapt to different object characteristics and cleaning stages, maintaining optimal cleaning effectiveness while preventing excessive vibrations that could compromise object integrity.
3Speed
If the excitation frequency and amplitude are increased to improve separation, then the separation speed is improved, but excessive acceleration and vibration amplitudes are generated
Solution Approach 1:
The patent applies parameter changes by systematically optimizing excitation frequency and amplitude to achieve the highest possible separation speed while remaining below predetermined limits for acceleration and vibration amplitude. The electronic controller adjusts these parameters to operate at the optimal point on the separation performance curve without exceeding safe thresholds.
Solution Approach 2:
The patent implements feedback control by continuously monitoring acceleration and vibration amplitude during the cleaning phase and adjusting excitation parameters in real-time. The system uses sensor feedback to ensure that separation speed is maximized without generating excessive acceleration or vibration that could harm the object, thereby maintaining both high performance and safety.
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
Effectively separates unsolidified building material from objects while preventing damage and excessive noise, ensuring a cleaner and safer process.
Implementation Method 1
exciting the object to vibrations by means of an electronically controlled vibration exciter with an excitation frequency fe and/or with an excitation amplitude Ae
Implementation Method 2
the remaining unconsolidated material can be fluidized, allowing it to flow away from the object more easily
Data Source
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AI summary
A method for separating unsolidified build material remaining from at least one real object (3) created by layer-by-layer application and selective solidification of the build material within the framework of an additive manufacturing process, wherein the method comprises a step (500) of exciting the real object (3) to vibrations by means of a vibration exciter (11, 12) controlled by an electronic control (16) with an excitation frequency (fe) and/or with an excitation amplitude (Ae) in order to separate unsolidified build material remaining from the real object (3) within the framework of a cleaning phase.In a test phase, the object and/or a computer-generated model of the object is excited with a bandwidth (fe1; fe2) of excitation frequencies fe and/or with a bandwidth (Ae1; Ae2) of excitation amplitudes (Ae). The test then examines for which excitation frequency(ies) (fe) and/or excitation amplitude(s) (Ae) the resulting vibration amplitude (A) exceeds the limiting vibration amplitude (Agrenz). During the cleaning phase, excitation of the object or any further object with an excitation frequency fe and/or with an excitation amplitude (Ae) or with excitation frequencies (fe) and/or with excitation amplitudes (Ae) is avoided if it has been shown that this has led to excessive vibration amplitudes (A) exceeding the limiting vibration amplitude (Agrenz) in the object and/or in the computer-generated model of the object.