A METHOD FOR CONTROLLING MOBILE 3-D PRINTING ON A VEHICLE

Abstract

A method for controlling an operation of a three-dimensional (3-D) printer included with a vehicle includes receiving an indication of any one of a current force and an expected force affecting the operation of the 3-D printer; comparing any one of the current force and the expected force affecting the operation of the 3-D printer with a given force threshold; and adjusting a printing rate of the 3-D printer based on any one of the current force and the expected force affecting the operation of the 3-D printer.

Claims

1. A method for controlling an operation of a three-dimensional (3-D) printer comprised with a vehicle, wherein the method comprises the steps of: receiving an indication of any one of a current force and an expected force affecting the operation of the 3-D printer; comparing any one of the current force and the expected force affecting the operation of the 3-D printer with a given force threshold; and adjusting a printing rate of the 3-D printer based on any one of the current force and the expected force affecting the operation of the 3-D printer.

2. The method according to claim 1, wherein, if any one of the current force and the expected force affecting the operation of the 3D-printer is above the force threshold, the method further comprises the step of adjusting the printing rate of the 3-D printer to a reduced printing rate.

3. The method according to claim 2, wherein the reduced printing rate corresponds to interrupting the operation of the 3-D printer.

4. The method according to claim 1, wherein the force threshold comprises a threshold lower-level and a threshold upper-level, and wherein the step of adjusting the printing rate of the 3-D printer based on any one of the current force and the expected force affecting the operation of the 3-D printer comprises adjusting the printing rate of the 3-D printer to a first reduced printing rate if any one of the current force and the expected force affecting the operation of the 3-D printer exceeds the threshold lower-level, while interrupting the 3-D printer if any one of the current force and the expected force affecting the operation of the 3-D printer exceeds the threshold upper-level.

5. The method according to claim 1, wherein the force threshold is associated with a quality level of the 3-D printer.

6. The method according to claim 1, further comprising the step of determining a desired quality level of the 3-D printing process, and adjusting the force threshold based on the determined desired quality level of the 3-D printing process.

7. The method according to claim 6, wherein the desired quality level of the 3-D printing process is selected by a user or from a 3-D printer manufacturing instruction.

8. The method according to claim 1, further comprising the steps of determining a quality impact on the operation of the 3-D printer based on the indication of the current force or expected force affecting the operation of the 3-D printer and adjusting the printing rate of 3-D printer based on the determined quality impact of the 3-D print.

9. The method according to claim 1, wherein the indication of the current force or expected force affecting the operation of the 3-D printer relates to any one of a vibration event, a change in direction of the vehicle and a change in velocity of the vehicle.

10. The method according to claim 1, wherein the indication of any one of the current force and the expected force is determined by a sensor device configured to detect a force generating event within a detection capacity of the sensor device.

11. The method according to claim 1, wherein the indication of the expected force is determined by any one of a road map data, gps, typographical data and Real Time Traffic Information (RTTI).

12. The method according to claim 1, further comprising the steps of determining a duration of the current force or expected force affecting the operation of the 3-D printer and adjusting the printing rate of the 3-D printer based on the determined duration of the current force or expected force affecting the operation of the 3-D printer.

13. The method according to claim 12, wherein the step of adjusting the printing rate of the 3-D printer is only activated if the determined duration of the current force or expected force affecting the operation of the 3-D printer exceeds a given time period.

14. The method according to claim 1, in which the steps of the method are performed by a control unit.

15. (canceled)

16. A non-transitory computer readable medium carrying a computer program comprising program means for performing the steps of claim 1 when said program means is run on a computer.

17. A three-dimensional (3-D) printer system for a vehicle comprising a 3-D printer, a control unit arranged in communication with the 3-D printer, and a sensor device configured to detect an indication of any one of a current force and an expected force affecting the operation of the 3-D printer, wherein the control unit is arranged to: receive, from the sensor device, an indication of any one of the current force and the expected force affecting the operation of the 3-D printer; compare any one of the current force and the expected force affecting the operation of the 3-D printer with a given force threshold; and adjust the printing rate of the 3-D printer based on any one of the current force and the expected force affecting the operation of the 3-D printer.

18. A vehicle comprising a 3-D printer system according to claim 17.

19. A vehicle according to claim 18, wherein the vehicle is a semi-truck vehicle comprising a trailer, and wherein the 3-D printer is arranged in the trailer to print parts on route to a user.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of exemplary embodiments of the present invention, wherein:

[0042] FIG. 1 is a side view of a vehicle in the form of a truck, in which a three-dimensional (3-D) printer system may be incorporated and operated to perform a method according to the present invention;

[0043] FIG. 2 is a flow-chart of a method according to an example embodiment of the invention, in which the method comprises a number of steps for controlling an operation of the 3-D printer comprised with the vehicle in FIG. 1;

[0044] FIG. 3 is a flow-chart of additional steps of the method in FIG. 2 according to an example embodiment of the invention, in which the method comprises a number of steps for controlling an operation of the 3-D printer comprised with the vehicle in FIG. 1;

[0045] FIG. 4 is a diagram illustrating an example of a force affecting the vehicle in FIG. 1 when travelling a distance on route to a user, in which the force corresponds to a detected vibration affecting the operation of the 3-D printer installed in the vehicle.

[0046] With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

[0047] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness. The skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. Like reference character refer to like elements throughout the description.

[0048] Referring now to the drawings and to FIG. 1 in particular, there is depicted an exemplary vehicle, here illustrated as a truck 5. The truck typically comprises a propulsion system configured to provide traction power to one or more ground engaging members, e.g. one or more wheels. In this example, the truck comprises an internal combustion engine 12 arranged to provide traction power to the wheels. The engine 12 is only schematically illustrated in FIG. 1. Optional, the propulsions system comprises a transmission (not shown) for transmitting a rotational movement from the engine to a propulsion shaft, sometimes denoted as the driven shaft (not shown). The propulsion shaft connects the transmission to the pair of wheels. Further, the truck in FIG. 1 is a semi-trailer truck comprising a tractor unit 10 and trailer 20 connected to the truck unit.

[0049] In the vehicle illustrated in FIG. 1, there is also installed a three-dimensional (3-D) printer system 22. The 3-D printer system comprises a 3-D printer 30 for printing parts to an end user or a customer. The 3-D printer 30 is fixedly attached to an inner surface of the trailer, as shown in FIG. 1. While the 3-D printer 30 may be arranged to produce a number of different component parts to the end user or the customer, the 3-D printer is here arranged to produce so called temporary replacement parts to a machine-owner or a vehicle-owner. A replacement part in the form of a temporary 3-D printed replacement part typically refers to a component part that has an inherent (associated) characteristic that is different to a corresponding characteristic of an ordinary corresponding part or a corresponding standard replacement part for the ordinary part. Further, the characteristic of the 3-D printed replacement part may be of a different quality than a corresponding characteristic of the ordinary corresponding part. At least for this reason, the 3-D printed replacement part is typically intended for being used in the machine or vehicle for a defined period of time. As such, the 3-D printed replacement part is generally a temporary replacement part. The 3-D printer 30 is here a commercially available standard 3-D printer dimensioned for the space of the trailer 20.

[0050] The 3-D printer 30 arranged in the vehicle is typically a printer configured for additive manufacturing. The process “additive manufacturing”, sometimes also called free-form fabrication, is a method for forming three-dimensional articles through successive fusion of chosen parts of powder layers applied to a worktable. There are several different types of additive manufacturing apparatus. One type of additive manufacturing technology is Powder Bed Fusion (PBF), which produces a solid part using a thermal source that induces fusion (sintering or melting) between the particles of a metal powder one layer at a time. One example of a PDF technology is Electron Beam Melting (EBM), which is an additive manufacturing where an electron emitting cathode in an electron acceleration column is the source for electron beam generation, which in turn is acting as an energy beam for melting the power material. By way of example, the 3-D printed part is obtained by an additive manufacturing process using a metallic powder material.

[0051] Further, the 3-D printer system comprises a control unit 60 arranged in communication with the 3-D printer 30. In this example, the control unit is an electronic control unit comprised on-board the vehicle. The vehicle also includes a number of sensor devices such as a force detecting unit for detecting current forces, up-coming forces and/or force-generating events affecting the vehicle and the operation of the 3-D printer. While it may be enough that the 3-D printer system comprises one single sensor device, the vehicle as illustrated in FIG. 1 comprises a plurality of sensor devices/force detecting units, including a Lidar 14, an ultrasonic sensor 16, a vibration sensor 18 and a Radar 17. Each one of these sensor devices/force detecting units are arranged in communication with the control unit 60. In one example, although not shown, the control unit further comprises a transceiver arranged to receive Real Time Traffic Information (RTTI). Further, each one of these sensor devices and/or force detecting devices is arranged to detect any one of a current force affecting the operation of the 3-D printer and an expected force affecting the operation of the 3-D printer. As the control unit is arranged in communication with the 3-D printer, the vehicle and the sensors arranged to monitor and detect external environmental forces, it becomes possible to transfer information indicative of detected external forces affecting the vehicle to the control unit for further processing so as to determine if such forces may affect the operation of the 3-D printer.

[0052] Moreover, the control unit 60 is arranged to receive an indication of the current force affecting the vehicle and the operation of the 3-D printer and to compare the current force affecting the operation of the 3-D printer with a given force threshold.

[0053] Also, the control unit 60 is typically arranged to adjust the printing rate of the 3-D printer based on the current force affecting the operation of the 3-D printer.

[0054] Alternatively, or in addition, the control unit 60 is arranged to receive an indication of the expected force affecting the vehicle and the operation of the 3-D printer and to compare the expected force affecting the operation of the 3-D printer with a given force threshold. Also, the control unit is typically arranged to adjust the printing rate of the 3-D printer based on the expected force affecting the operation of the 3-D printer.

[0055] Turning now to FIG. 2, there is depicted a flowchart of a method according to example embodiments of the invention. The method 100 is intended for controlling an operation of a three-dimensional (3-D) printer comprised with the vehicle, e.g. the 3-D printer 30 as described in relation to FIG. 1. In this example embodiment, the control unit receives 110 an indication of a current force or an expected force affecting the operation of the 3-D printer. By way of example, the expected force affecting the operation of the 3-D printer may be an upcoming vehicle vibration event potentially causing a detrimental force for the 3-D printer itself or for the 3-D printing process. Such detrimental force may be generated from a number of different sources, such as from a sudden change in direction of the vehicle, an emergency braking event, a general vibration event affecting the vehicle (and the 3-D printer), a change in acceleration of the vehicle, a change in speed of the vehicle etc. As mentioned in relation to the vehicle printing system as described in relation to FIG. 1, there is a number of different types of sensors and devices to accurately detect and determine the magnitude of the current force. In addition, or alternatively, the sensors and devices may be arranged to estimate any possible expected forces affecting the operation of the 3-D printer along the route to the customer or end user. Depending on the type of sensor and type of control unit, data relating to the current force and expected force may either be sent to the control unit for further processing or be further evaluated by the sensor/device itself. However, in this example, any one of the sensors 14, 16, 17 and 18 detects the vibration or current force and transfer associated data to the control unit for further processing. As such, the control unit is typically arranged to determine the level of exposure of the upcoming vibrations and forces on the 3-D printed.

[0056] Typically, the control unit contains pre-stored data relating to critical levels of the forces, including, but not limited to thresholds for determining whether the forces are critical for any one of the vehicle, the 3-D printed and the 3-D printing process. Such data relating to the critical forces may also be updated on a regularly basis and may depend on the type of use of the vehicle, type of vehicle, type of 3-D printer etc.

[0057] In other words, as illustrated in FIG. 2, the control unit further compares 120 the current force or expected force affecting the operation of the 3-D printer with a given force threshold. If the current force or expected force affecting the operation of the 3D-printer is above the force threshold, the control unit adjusts 130 the printing rate of the 3-D printer to a reduced printing rate. In this example, the reduced printing rate corresponds to interrupting the operation of the 3-D printer. However, in other examples, it may be sufficient to merely reduce the printing rate to a lower printing rate than the current printing rate.

[0058] While the threshold may take several aspects into consideration, the force threshold is typically at least associated with a desirable quality level of the 3-D printed replacement part.

[0059] It should be noted that the control unit is generally arranged to take both any current force and any expected force into consideration when adjusting the printing rate of the 3-D printer to an appropriate printing rate. However, it may also be conceivable that the control unit is arranged to only take one of the current force and the expected force into consideration when adjusting the printing rate of the 3-D printer to an appropriate printing rate.

[0060] Another example embodiment of a method according to the present invention is depicted in FIG. 3. Thus, turning now to FIG. 3, which is a flow chart of an extended version of the example embodiment described in FIG. 2, the method comprises one or more additional steps for further controlling the operation of the 3-D printer. The control unit is here further arranged to determine 122 a desired quality level of the 3-D printing process. Thus, the control unit is also arranged to adjust the force threshold based on the determined desired quality level of the 3-D printing process. By way of example, the desired quality level of the 3-D printing process is selected by a user and/or directly from a 3-D printer manufacturing instruction.

[0061] Optionally, although strictly not required, the control unit may also determine a quality impact on the operation of the 3-D printer based on the indication of the current force or expected force affecting the operation of the 3-D printer and adjust the printing rate of 3-D printer based on the determined quality impact of the 3-D print.

[0062] Still further, the control unit is here arranged to determine an impact on the operation of the 3-D printer based on the indication of current force or expected force acting on the 3-D printer. Moreover, the control unit typically adjust any one of the thresholds values based on the determined impact on the 3-D print results.

[0063] In addition, in this example embodiment, the control unit determines 124 a duration of the current force or expected force affecting the operation of the 3-D printer. Subsequently, the control unit is arranged to adjust the printing rate of the 3-D printer based on the determined duration of the current force or expected force affecting the operation of the 3-D printer.

[0064] In one example embodiment, the step of adjusting the printing rate of the 3-D printer is only activated if the determined duration of the current force, or expected force, affecting the operation of the 3-D printer exceeds a given time period.

[0065] Further, the step of adjusting 130 the printing rate of the 3-D printer based on the current force or expected force affecting the operation of the 3-D printer can be performed in several different manners. In this example, if the current vibration event, or the upcoming vibration event, is above a predetermined first vibration threshold, the control unit is further arranged to determine an estimated reduction of the printing rate of the 3-D printer based on the current vibration event (or the upcoming vibration) to ensure an adequate 3-D printed replacement part. Moreover, if the current vibration event, or the upcoming vibration event, is above a predetermined second vibration threshold, the control unit is also arranged to interrupt the operation of the 3-D printer to avoid that the quality of the 3-D printed replacement part becomes critical low compared to a lower threshold.

[0066] This optional estimation of the magnitude of the vibration is illustrated in FIG. 4, which schematically illustrates how vibrations may change in magnitude along a road, i.e. change in vibration magnitude in relation to the vehicle's route to the end user or customer. In this example, the force threshold is associated with a quality level of the 3-D printer. Further, the force threshold comprises a threshold lower-level and a threshold upper-level. The force level of the threshold upper-level is higher than the force level of the threshold lower-level. Accordingly, the control unit is arranged to adjust 130 the printing rate of the 3-D printer based on the current force, or expected force, affecting the operation of the 3-D printer by adjusting the printing rate of the 3-D printer to a first reduced printing rate 131 if the current force, or expected force, affecting the operation of the 3-D printer exceeds the threshold lower-level, while interrupting 132 the 3-D printer if the current force, or expected force, affecting the operation of the 3-D printer exceeds the threshold upper-level.

[0067] As mentioned above, it is to be noted that the steps of the method are typically performed by the control unit 60 during use of the vehicle. Thus, the control unit is configured to perform any one of the steps of any one of the example embodiments as described above in relation to the FIGS. 2-4.

[0068] It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. For example, although the present invention has mainly been described in relation to a truck, the invention should be understood to be equally applicable for any type of vehicle and movable machine.

[0069] Although the figures may show a specific order of method steps, the order of the steps may differ from what is depicted. In addition, two or more steps may be performed concurrently or with partial concurrence. Such variation will depend on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps and decision steps. Additionally, even though the disclosure has been described with reference to specific exemplifying embodiments thereof, many different alterations, modifications and the like will become apparent for those skilled in the art.

[0070] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosed embodiments (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure. Variations to the disclosed embodiments can be understood and effected by the skilled addressee in practicing the claimed disclosure, from a study of the drawings, the disclosure, and the appended claims.