PLANT FOR ADDITIVELY MANUFACTURING AT LEAST ONE THREE-DIMENSIONAL OBJECT
20200147685 ยท 2020-05-14
Assignee
Inventors
- Viktor Kremer (Lichtenfels, DE)
- Christoph Schmidbauer (Neustadt bei Coburg, DE)
- Ralf Hetzel (Bad Staffelstein, DE)
- Pascal Krause (Burgkunstadt, DE)
- Benjamin Krausser (Lichtenfels, DE)
Cpc classification
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/30
PERFORMING OPERATIONS; TRANSPORTING
B29C64/386
PERFORMING OPERATIONS; TRANSPORTING
B22F12/82
PERFORMING OPERATIONS; TRANSPORTING
B29C64/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y40/20
PERFORMING OPERATIONS; TRANSPORTING
G05B2219/49018
PHYSICS
B29C64/393
PERFORMING OPERATIONS; TRANSPORTING
B22F12/86
PERFORMING OPERATIONS; TRANSPORTING
B33Y50/02
PERFORMING OPERATIONS; TRANSPORTING
B22F12/88
PERFORMING OPERATIONS; TRANSPORTING
B33Y30/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/307
PERFORMING OPERATIONS; TRANSPORTING
G05B19/4099
PHYSICS
Y02P90/02
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B22F12/80
PERFORMING OPERATIONS; TRANSPORTING
B22F10/28
PERFORMING OPERATIONS; TRANSPORTING
B33Y40/00
PERFORMING OPERATIONS; TRANSPORTING
B22F10/80
PERFORMING OPERATIONS; TRANSPORTING
B22F12/90
PERFORMING OPERATIONS; TRANSPORTING
B29C64/379
PERFORMING OPERATIONS; TRANSPORTING
B29C64/20
PERFORMING OPERATIONS; TRANSPORTING
Y02P10/25
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B22F3/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y40/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y50/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Plant (1) for additively manufacturing at least one three-dimensional object (2), comprising at least one process station (3a-3c) being configured to perform an additive manufacturing process and/or at least one preprocessing process for an additive manufacturing process and/or at least one postprocessing process for an additive manufacturing process; at least one conveying device (19) configured to convey an item (20) between at least two positions (P1, P2) of the plant (1), the conveying device (19) comprising at least one conveying element (22), the at least one conveying element (22) being at least partially bound to ground (23), and at least one conveying carriage (24) being connectable or connected with the conveying element (22) so as to be moveable between at least two positions (P1, P2) of the plant (1), the at least one conveying carriage (24) comprising at least one supporting interface (25) for supporting at least one item (20).
Claims
1. Plant (1) for additively manufacturing at least one three-dimensional object (2), comprising: at least one process station (3a-3c) being configured to perform an additive manufacturing process and/or at least one preprocessing process for an additive manufacturing process and/or at least one postprocessing process for an additive manufacturing process; at least one conveying device (19) configured to convey an item (20) between at least two positions (P1, P2) of the plant (1), the conveying device (19) comprising: at least one conveying element (22), the at least one conveying element (22) being at least partially bound to ground (23); at least one conveying carriage (24) being connectable or connected with the conveying element (22) so as to be moveable between the at least two positions (P1, P2) of the plant (1), the at least one conveying carriage (24) comprising at least one supporting interface (25) for supporting at least one item (20).
2. Plant according to claim 1, wherein the conveying device (19) is a separate device to the at least one process station (3a-3c) which is not physically connectable or connected with the at least one process station (3a-3c).
3. Plant according to claim 1, wherein the at least one conveying element comprises at least one conveying element portion which extends straight and/or comprises at least one conveying element portion which extends curved.
4. Plant according to claim 1, wherein the at least one conveying element (22) is configured to generate a conveying force so as to move the at least one conveying carriage (24) along the at least one conveying element (22).
5. Plant according to claim 1, wherein the at least one conveying carriage (24) is provided with a drive unit, particularly a drive motor, configured to generate a drive force so as to move the at least one conveying carriage (24) along the at least one conveying element (22).
6. Plant according to claim 1, comprising at least one traction carriage (34) being connectable or connected with the at least one conveying element (22) so as to be moveable between the at least two positions (P1, P2) of the plant (1), the traction carriage (34) being provided with a drive unit, particularly a drive motor, configured to generate a drive force so as to move the traction carriage (34) along the at least between the two positions (P1, P2) of the plant (1), the at least one traction carriage (34) comprising at least one connecting interface (35) configured to establish a connection of the traction carriage (34) with at least one further traction carriage (34) and/or with the at least one conveying carriage (24).
7. Plant according to claim 1, comprising at least two conveying carriages (24), each comprising a connecting interface (36) configured to establish a connection with at least one further conveying carriage (24), particularly so as to form a conveying carriage assembly, and/or with at least one traction carriage (34).
8. Plant according to claim 1, comprising a transfer device (39) assigned to the at least one supporting interface (25), the transfer device (39) being configured to transfer a supported item (20) between a first position and/or orientation and a second position and/or orientation relative to a base body (38) of the conveying carriage (24).
9. Plant according to claim 1, wherein the at least one conveying carriage (24) comprises a determination device assigned to the at least one supporting interface (25), the determination device (44) being configured to determine at least one chemical and/or physical parameter of an item (20) supported by the at least one supporting interface (25) and/or determine at least one chemical and/or physical parameter of a substance or an object contained within the item (20) supported by the at least one supporting interface (25), and to generate an information indicating the determined at least one chemical and/or physical parameter.
10. Plant according to claim 1, wherein the at least one conveying carriage (24) comprises at least one determination device (46) configured to determine at least one actual and/or future operating parameter, particularly a conveying parameter referring to a conveying motion of the conveying carriage (24), and to generate an operating information indicating the determined at least one operating parameter and/or to determine at least one actual and/or future position parameter of the at least one conveying carriage (24) and to generate a position information indicating the determined position parameter.
11. Plant according to claim 1, comprising a control unit (45) being configured to control at least one conveying parameter of the at least one conveying carriage (24), particularly on basis of a determined operating information and/or position information.
12. Plant according to claim 1, wherein the at least one conveying carriage (24) comprises a data storage device (47) configured to store at least one information of the conveying carriage (24) and/or at least one information of at least one item (20) conveyed by the conveying carriage (24) and/or at least one information of a conveying path (21) the conveying carriage (24) is intended to be conveyed along.
13. Plant according to claim 1, comprising a communication device (48), particularly assigned to the data storage device (47), the communication device (48) being configured to transmit information from the or a data storage device (47) to at least one communication partner and/or to receive information to be stored in the or a data storage device (47) from at least one communication partner.
14. Plant according to claim 1, wherein the at least one item (20) is or comprises a powder module (5) comprising an inner receiving volume, particularly a build module (5a), an overflow module (5c), or a dose module (5b); or a build plate, particularly a build plate which is insertable in a receiving volume of a build module (5a), configured to support build material and/or an additively manufactured three-dimensional object (2); or an additively manufactured three-dimensional object (2); or a determination device configured to determine at least one chemical and/or physical parameter of at least one additive manufacturing process and/or at least one preprocessing process for an additive manufacturing process and/or at least one postprocessing process for an additive manufacturing process; or a service and/or repair device configured to perform at least one service and/or repair functionality for at least one functional component of the at least one process station (3a-3c); or a cleaning device configured to clean the at least one conveying element (24) and/or at least one functional component of the at least one process station (3a-3c).
15. Conveying device (19) for a plant (1) for additively manufacturing three-dimensional objects (2), the conveying device (19) being configured to convey an item (20) between at least two positions (P1, P2) of the plant (1), the conveying device (19) comprising: at least one conveying element (22), the at least one conveying element (22) being at least partially bound to ground (23); and at least one conveying carriage (24) being moveably supported by the conveying element (22) so as to be moved between the at least two positions (P1, P2) of the plant (1), the at least one conveying carriage (24) comprising at least one supporting interface (25) for supporting at least one item (20).
16. Method for conveying at least one item (20) between at least two positions (P1, P2) of a plant (1) for additively manufacturing at least one three-dimensional object (2) by means of a conveying device (19) according to claim 15.
Description
[0060] Exemplary embodiments of the invention are described with reference to the FIG., whereby:
[0061]
[0062]
[0063] The plant 1 is typically configured for mass or series production of additively manufactured three-dimensional objects, e.g. technical components.
[0064] As is particularly apparent from
[0065] Generally, each process station 3a-3c is provided with suitable functionality for performing its intended functionality, i.e. an additive manufacturing process and/or a preprocessing process and/or a postprocessing process. Thus, each process station 3a-3c comprises a number of functional and/or structural devices which are operable during its operation. Each functional and/or structural device may comprise a number of functional and/or structural units which may comprise a number of functional and/or structural sub-units.
[0066] According to the exemplary embodiment of the FIG., a respective process station 3a configured to perform an additive manufacturing process is an apparatus (apparatus) for additively manufacturing at least one three-dimensional object 2 by means of successive layerwise selective irradiation and consolidation of build material layers, e.g. layer of a metal powder, which can be consolidated by means of being irradiated with at least one energy beam 8, i.e. layers of a build material 4 which can be consolidated by means of being irradiated with at least one energy beam 8. The energy beam 8 may be an electron beam or a laser beam, for instance. The apparatus may be implemented as a selective laser sintering apparatus, a selective laser melting apparatus, or a selective electron beam melting apparatus, for instance. Yet, it is also conceivable that the apparatus is a binder jetting apparatus, particularly a metal binder jetting apparatus, for instance.
[0067] As is apparent from
[0068] As indicated in the FIG., the apparatus comprises a number of functional and/or structural devices which are operable during its operation. Each functional and/or structural device may comprise a number of functional and/or structural units which may comprise a number of functional and/or structural sub-units.
[0069] A first exemplary functional device is a build material application device 10 configured to apply an amount of build material 4 in the build plane 9 of the apparatus so as to form a build material layer which is to be selectively irradiated and consolidated by means of the at least one energy beam 8. The build material application device 10 comprises a build material application element 11, e.g. a recoating element, configured to apply an amount of build material 4 in the build plane 9 of the apparatus so as to form a build material layer which is to be selectively irradiated and consolidated by means of the energy beam 8. As indicated by the double-arrow, the build material application element 11 is moveably supported relative to the build plane 9. A second exemplary functional device is an irradiation device 12 configured to successively selectively irradiate and consolidate respective layers of build material 4 applied in the build plane 9 of the apparatus 1 with at least one energy beam 8. The irradiation device 12 comprises at least one irradiation element 13, e.g. an energy beam generation element and/or an energy beam deflection element, configured to move an energy beam 8 across the build plane 9 of the apparatus so as to electively irradiate and consolidate respective layers of build material 4 applied in the build plane 9 of the apparatus.
[0070] A first exemplary structural device of the apparatus is a support frame structure 14 configured to support at least one functional device and/or at least one further structural device of the apparatus. A respective support frame structure 14 typically comprises at least one support frame element, e.g. bar, rod, etc., configured to support at least one functional device and/or at least one further structural device. Additional functional and/or structural devices are conceivable. A second exemplary structural device is the process chamber 6 of the apparatus. As is apparent from
[0071] An exemplary embodiment of a preprocessing station 3b is a powder module preparation station in which powder modules 5, 5a-5c which are to be used in a forthcoming additive manufacturing process are prepared, e.g. by being filled with build material, cleaned, inertized, etc. A respective powder module preparation station may be built as, comprise or be combined with a sieving station in which fresh build material 4 is sieved and/or mixed with used build material 4 so as to provide a build material composition 4 of desired properties, such as particle size, particle morphology, etc. for a forthcoming additive manufacturing process.
[0072] An exemplary functional device of a respective preprocessing station 3b is a sieving device 15 configured to sieve build material 4. Other functional devices are conceivable.
[0073] An exemplary structural device of a respective preprocessing station 3b is a support frame structure 16 configured to support at least one functional device and/or at least one further structural device of the preprocessing station 3b. A respective support frame structure 16 typically comprises at least one support frame element, e.g. bar, rod, etc., configured to support at least one functional device and/or at least one further structural device. Other structural devices are conceivable.
[0074] An exemplary embodiment of a postprocessing station 3c is an unpacking station in which an additively manufactured three-dimensional object 2 is unpacked from surrounding non-consolidated build material 4. A respective unpacking station may also comprise or be combined with a sieving station in which non-consolidated build material 4 is sieved and/or mixed with fresh build material 4 so as to provide a build material composition of desired properties, such as particle size, particle morphology, etc., for a forthcoming additive manufacturing process. Another exemplary postprocessing station 3c is a thermal treatment station in which an additively manufactured three-dimensional object 2 undergoes a thermal treatment, i.e. particularly a heat treatment, so as to adjust the structural properties of the additively manufactured three-dimensional object 2, e.g. by relieving internal stresses. Another exemplary postprocessing station 3c is a surface treatment station in which an additively manufactured three-dimensional object 2 undergoes a surface treatment, i.e. particularly a chemical and/or physical surface treatment, e.g. by etching and/or machining, so as to adjust the surface properties of the additively manufactured three-dimensional object 2. Another exemplary postprocessing station 3c is a densification station in which an additively manufactured three-dimensional object 2 undergoes a densification treatment so as to adjust the structural properties of the additively manufactured three-dimensional object 2, particularly the density of the additively manufactured three-dimensional object 2. Another exemplary postprocessing station 3c is an infiltration station in which an additively manufactured three-dimensional object 2 undergoes an infiltration treatment so as to adjust the structural properties of the additively manufactured three-dimensional object 2, particularly the strength of the additively manufactured three-dimensional object 2.
[0075] An exemplary functional device of a respective postprocessing station 3c is a build material removal device 17, e.g. a sucking and/or blowing device, configured to remove non-consolidated build material 4 from an additively manufactured three-dimensional object 2. Other functional devices are conceivable.
[0076] An exemplary structural device of a respective postrocessing station 3c is a support frame structure 18 configured to support at least one functional device and/or at least one further structural device of the postrocessing station 3c. A respective support frame 18 structure typically comprises at least one support frame element, e.g. bar, rod, etc., configured to support at least one functional device and/or at least one further structural device. Other structural devices are conceivable.
[0077] As is apparent from the FIG., the plant 1 comprises a plurality of process stations, i.e. at least two process stations 3a-3c distributed in an additive manufacturing environment defined by the plant 1. As is indicated in
[0078] The plant 1 further comprises a conveying device 19 configured to convey an item 20 between at least two positions P1, P2 of the plant 1, particularly along a conveying path 21 extending between the at least two positions P1, P2 of the plant 1 (see double-arrow in
[0079] As is apparent from
[0080] As is indicated in
[0081] An item 20 can be any structural element which needs to be conveyed from a first position P1 to a second position P2, or vice versa, during operation of the plant 1. An exemplary embodiment of an item 20 is a powder module 5, such as a build module 5a, a dose module 5b, or an overflow module 5c, for instance. Another exemplary embodiment of an item 20 can be a build plate, particularly a build plate which is insertable in a receiving volume of a build module 5a, the build plate being configured to support build material and/or an additively manufactured three-dimensional object 2. Another exemplary embodiment of an item 20 can be an additively manufactured object 2. Another exemplary embodiment of an item 20 can be a detecting device (not explicitly shown) configured to determine at least one chemical and/or physical parameter of at least one additive manufacturing process and/or at least one preprocessing process for an additive manufacturing process and/or at least one postprocessing process for an additive manufacturing process. Another exemplary embodiment of an item 20 can be a service and/or repair device configured to perform at least one service and/or repair functionality for at least one functional component of the at least one process station 3a-3c. Another exemplary embodiment of an item 20 can be a cleaning device configured to clean at least one conveying element and/or at least one functional component of the at least one process station 3a-3c. Other exemplary embodiments of items 20 are conceivable.
[0082] The conveying device 19 comprises at least one conveying element 22 defining the at least one conveying path 21. As is apparent from
[0083] As is also apparent from
[0084] The conveying device 19 further comprises at least one conveying carriage 24, e.g. a conveying slide, conveying skid, conveying vehicle or conveying wagon, for instance, being connectable or connected with the conveying elements 22 so as to be moveable along the at least one conveying path 21. A respective conveying carriage 24 comprises at least one supporting interface 25 for supporting at least one item 20.
[0085] The conveying elements 22 and the conveying carriages 24 may interact with each other so as to form a conveying couple allowing for conveying respective items 20 between respective first and second positions P1, P2. Thereby, respective items 20 are (temporarily) supported by a respective conveying carriage 24 and the respective conveying carriage 24 (temporarily) supporting the respective item 20 is moveable along the conveying path 21, i.e. particularly moveably supported by the conveying element(s) (see
[0086] As is apparent from the FIG., the conveying device 19 is a separate device to the process stations 3a-3c which is not physically connectable or connected, i.e. particularly not mechanically couplable or coupled, with the process stations 3a-3c. Hence, the conveying device 19 is to be deemed as a separate device of the plant 1 whose operation is generally, independent from the operation of any process station 3a-3c of the plant 1. Providing the conveying device 19 as a respective separate device is of advantage for installation, modification and operation of the conveying device 19. Hence, the conveying device 19 may be generally, installed, modified or operated independent from any of process station 3a-3c of the plant 1.
[0087] This also applies for the case in which a respective conveying element 21 extends through at least one process station 3a-3c (as indicated in
[0088] A respective conveying element 22 may be provided in any dimensions, i.e. particularly, length, shape, etc. As such, a respective conveying element 22 may comprise at least one conveying element portion which extends straight and/or which comprise at least one conveying element portion which extends curved as exemplarily indicated in
[0089]
[0090]
[0091]
[0092] With regard to the actual conveyance of a respective conveying carriage 24 along a respective conveying path 21, the following exemplary options, which may be arbitrarily combined with each other, are given:
[0093] A respective conveying element 22 may be configured to generate a conveying force so as to move a conveying carriage 24 along the conveying path 21. Hence, the conveying element 22 may be moved itself along a respective conveying path 21. A respective conveying element 22 may be embodied as a conveying band, a conveying belt, or a conveying chain, for instance.
[0094] Additionally or alternatively, a respective conveying carriage 24 may be provided with a drive unit 30, particularly a drive motor, configured to generate a drive force so as to move the conveying carriage 30 along the conveying path 21. Hence, the conveying carriage 24 may be self-driven and thus, moves itself along a respective conveying path 21. A respective conveying element 22 may be embodied as a conveying rail, a conveying rack, or any other non-driven conveying track, for instance.
[0095] Additionally or alternatively, a moveable traction carriage 34 being provided with a drive unit 32, particularly a drive motor, configured to generate a drive force so as to move the traction carriage 34 along the conveying path 21 may be provided. A respective traction carriage 34 is self-driven and thus, moves itself along a respective conveying path 21. As is apparent from
[0096] As is apparent from above, the conveying device 19 may comprise at least two conveying carriages 24 (see e.g.
[0097] As indicated above, a respective conveying carriage 24 may comprise at least one supporting interface 25 configured to support at least one item 20 which is to be conveyed by the conveying carriage 24 along the conveying path 21. A respective supporting interface 25 allows for a temporary support of a respective item 20 to which is to be conveyed by the conveying carriage 24 along the at least one conveying path 21. A respective support interface 25 may be built as or provided with a support compartment 37 of a base body 38 of a conveying carriage 24. Hence, a respective conveying carriage 24 may comprise a base body 38 having at least one support compartment 37 configured to support at least one item 20 which is to be conveyed by the conveying carriage 24 along the conveying path 21. A respective support compartment 37 may form part of a support frame of the conveying carriage 24 or the base body 38, respectively. The dimensions of a respective support compartment 37 may be adapted to the dimensions of an item 20 which is to be conveyed by the conveying carriage 24 along the conveying path 21. Hence, a respective support compartment 37 may be embodied as a receptacle configured to at least partially, particularly completely, receive a respective item 20, for instance. A respective receptacle is typically defined by wall elements of a respective support compartment 37 which may at least partially cover or engage at least one surface of an item 20 which is to be supported by the support compartment 37.
[0098] As is apparent from
[0099] As is apparent from
[0100] As is further apparent from
[0101] As is apparent from
[0102] As is apparent from
[0103]
[0104] A respective locking device 42 may comprise at least one locking element (not explicitly shown) configured to interact, particularly configured to magnetically, mechanically, pneumatically, etc. interact, with an item 20 supported by the supporting interface 25 of a conveying carriage 24. In either case, a respective locking element may generate a locking force stably locking an item 20 supported by the supporting interface 25 of a conveying carriage 24 in place.
[0105]
[0106]
[0107] A respective determination device 44 may additionally or alternatively be configured to determine at least one actual and/or future position parameter of a respective conveying carriage 24 and to generate a position information indicating the determined position parameter. A respective position parameter may refer to a local and/or global position of the respective conveying carriage 24. A respective position parameter may thus, refer to local or global position data, e.g. GPS-data, of the respective conveying carriage 24.
[0108]
[0109] As is further apparent from
[0110] As is further apparent from
[0111] Referring again to
[0112] Even though not shown in the FIG., a respective conveying element 22 may be at least partially housed by a housing structure. The housing structure may represent a tunnel through which the respective conveying element 22 extends. A respective housing structure increases the safety of the conveying device 19 and the plant 1, respectively since personal cannot get in contact with the conveying device 19.
[0113] The plant 1 allows for implementing a method for conveying at least one item 20 between at least two positions P1, P2, particularly along a conveying path 21, of a plant 1 for additively manufacturing at least one three-dimensional object 2, whereby a conveying device 19 as described herein is used for conveying the at least one item 20 between the at least two positions P1, P2 of the plant 1.
[0114] Single, a plurality, or all features mentioned in context with a specific embodiment may also apply to other embodiments. Hence, a single, a plurality, or all features mentioned in context with a specific embodiment may be combined with at least one feature of another specific embodiment.