Passive Wire Spool Fill Indicator for DED Wire Deposition
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Solution Overview
Problem
Existing devices for indicating the filling level of wire spools in Directed Energy Deposition (DED) processes require an energy source, which is not satisfactory for a passive indication system.
Innovation Solution
A passive indication system using a spindle mechanism with moving and fixed index marks, where the spindle's position depends on the wire spool's filling level, allowing visual indication without electrical energy, utilizing a support, pad, slide link, and restoring element to indicate the filling level through color-coded index marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an electrical or electronic sensor is used to indicate the filling level of the wire spool, then the filling level can be accurately detected, but the system requires an energy source to operate
Solution Approach 1:
The patent replaces the electrical/electronic sensing system with a purely mechanical indication system. A spindle mechanism with index marks physically interacts with the wire spool through a pad that bears against the wire. As the wire spool fills or empties, the pad moves the spindle laterally, and this mechanical displacement is translated into visible index mark positions that indicate the filling level, eliminating the need for electrical energy.
Solution Approach 2:
The mechanical indication system is self-powered by the wire spool itself. The wire spool's own filling and emptying process automatically drives the pad and spindle mechanism, which in turn moves the index marks to indicate the filling level. The system uses the wire spool's operational state to generate its own indication signal without requiring external energy input.
2Use of energy by moving object
If a passive indication system is used to avoid energy consumption, then energy independence is achieved, but the complexity of the mechanical mechanism increases
Solution Approach 1:
The indication system is segmented into distinct functional components: the pad that contacts the wire, the spindle that translates lateral motion, the restoring element that returns the spindle to neutral position, and the index marks that provide visual indication. This segmentation allows each component to be simple in itself while collectively achieving the passive indication function.
Solution Approach 2:
The system uses dynamic elements including the movable spindle that laterally displaces in response to wire spool filling changes, and the restoring element (likely a spring) that provides dynamic recovery to the neutral position. This dynamic mechanical behavior enables continuous passive indication without energy input.
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 a robust, energy-independent indication of the wire spool's filling level, ensuring efficient operation in DED processes without the need for electrical power.
Implementation Method 1
a restoring element configured to relocate the spindle in the direction of the rotational axis
Data Source
AI summary
A device for depositing material in the form of wire including a coil of wire configured to pivot around an axis of rotation as well as at least one indication system including a support, at least one rod oriented in a direction secant to the axis of rotation, a pad connected to the first end of the rod and configured to bear against a wire wound on the coil of wire, a sliding link configured to allow the rod to translate in the secant direction, as well as a return element configured to translate the rod in the direction of the axis of rotation, the rod occupying a position according to a level of filling the coil. This solution makes it possible to obtain a passive type indication system.