BUILDING BLOCK FOR A MECHANICAL CONSTRUCTION

Abstract

The invention provides a building block for a mechanical construction. The invention further provides a bearing and a method of producing the building block. The building block provides a first printed material printed via an additive manufacturing process on or at least partially embedded in a second material. The first printed material is printed in a pattern configured and constructed for cooperating with a sensor for providing position information of the building block relative to the sensor. The sensor may be a magnetic sensor or an optical sensor. The first printed material may include magnetic particles. The method of producing the building block may include a step of adding the first printed material to the second material via the additive manufacturing process under the influence of a predefined magnetic field.

Claims

1. A building block (100, 230, 280, 290, 330, 350) for a mechanical construction, the building block (100, 230, 280, 290, 330, 350) comprising: a first printed material printed via an additive manufacturing process on or at least partially embedded in a second material, wherein the first printed material is printed in a pattern configured and constructed for cooperating with a sensor for providing position information of the building block relative to the sensor, wherein the pattern of the first printed material comprises a first pattern for providing a first signal to the sensor and a second pattern different from the first pattern for providing a second signal to the sensor different from the first signal.

2. The building block according to claim 1, wherein at least a part of the building block is constituted of the second material being second printed material printed via an additive manufacturing process.

3. The building block according to claim 1, wherein the first printed material: comprises magnetic particles for cooperating with a magnetic sensor, or constitutes a reflective pattern for cooperating with an optical sensor, or constitutes a contrasting pattern relative to the second material for cooperating with an optical sensor, or constitutes an opaque pattern surrounded by the second material constituting a reflective surface for cooperating with the optical sensor, or constitutes a transmissive pattern surrounded by the second material being opaque for cooperating with the optical sensor, or constitutes an opaque pattern surrounded by the second material being transmissive for cooperating with the optical sensor.

4. The building block according to claim 2, wherein the first printed material is completely embedded in the second printed material, or wherein the first printed material is covered by a third material.

5. The building block according to claim 1, wherein the pattern of the first printed material is configured and constructed for generating a block-wave signal at the sensor during a relative movement, or wherein the pattern of the first printed material is configured and constructed for generating a sinusoidal-wave signal at the sensor during the relative movement, or wherein the pattern of the first printed material is configured and constructed for generating a saw-tooth signal at the sensor during the relative movement.

6. The building block according to claim 1, wherein the first printed material and/or the second printed material is chosen from a list comprising metals, ceramics, polymers, elastomer and their combination in composite materials.

7. The building block according to claim 2, wherein an interface between the first printed material and the second printed material comprises a functionally graded interface layer, a composition of the functionally graded interface layer is configured to gradually change from the first printed material via a mixture of the first printed material and the second printed material to the second printed material.

8. The building block according to claim 1, wherein the building block is one of: an inner ring for a bearing, an outer ring for the bearing, a seal of the bearing, a traveling unit for an actuator, an encoder disc for an angular sensor, or a gear wheel.

9. A bearing comprising: a building block having; a first printed material printed via an additive manufacturing process on or at least partially embedded in a second material, wherein the first printed material is printed in a pattern configured and constructed for cooperating with a sensor for providing position information of the building block relative to the sensor, wherein the pattern of the first printed material comprises a first pattern for providing a first signal to the sensor and a second pattern different from the first pattern for providing a second signal to the sensor different from the first signal.

10. (canceled)

11. (canceled)

12. (canceled)

13. A method of producing a building block for a mechanical construction, the method comprising: printing of a first printed material via an additive manufacturing process on or at least partially embedded in a second material, wherein the first printed material is printed in a pattern configured and constructed for cooperating with a sensor for providing position information of the building block relative to the sensor, wherein the pattern of the first printed material provides a first pattern for providing a first signal to the sensor and a second pattern different from the first pattern for providing a second signal to the sensor different from the first signal.

14. A method of producing the building block according to claim 13, wherein the first printed material comprises magnetic particles, wherein the method of producing the building block comprises a step of: adding the first printed material to the second material via the additive manufacturing process under the influence of a predefined magnetic field.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter. In the drawings,

[0027] FIG. 1A shows a plan-view of a gear wheel according to the invention, and FIG. 1B shows a gear box comprising the gear wheel,

[0028] FIG. 2A shows a cross-sectional view of a bearing comprising first printed material in a pattern and a second material according to the invention, FIG. 2B shows a partially cut-open outer ring for a bearing according to the invention, and FIG. 2C shows a bearing comprising a seal according to the invention,

[0029] FIG. 3 shows a plan view of an actuator system according to the invention,

[0030] FIG. 4A shows a first embodiment of an additive manufacturing tool in which a liquid resin is used for applying the printed material in the additive manufacturing process,

[0031] FIG. 4B shows a second embodiment of the additive manufacturing tool in which a liquid resin is dispensed from a dispenser for applying the printed material in the additive manufacturing process,

[0032] FIG. 5A shows a third embodiment of the additive manufacturing tool in which the material is granulated into small solid particles which are used for applying the printed material in the additive manufacturing process,

[0033] FIG. 5B shows a fourth embodiment of the additive manufacturing tool in which the granulated solid material is dispensed from a dispenser for applying the printed material in the additive manufacturing process, and

[0034] FIG. 6 shows a fifth embodiment of the additive manufacturing tool in which a melted plastic material is dispensed for applying the printed material in the additive manufacturing process.

[0035] It should be noted that items which have the same reference numbers in different Figures, have the same structural features and the same functions, or are the same signals. Where the function and/or structure of such an item has been explained, there is no necessity for repeated explanation thereof in the detailed description.

DETAILED DESCRIPTION OF EMBODIMENTS

[0036] FIG. 1A shows a plan-view of a gear wheel 100 according to the invention. The gear wheel 100 being a building block 100 according to the invention, comprises a first printed material 110 printed via an additive manufacturing process in a pattern 112, 114. The pattern 112, 114 is configured and constructed to cooperate, in use, with a sensor 140 for generating position information of the gear wheel 100 relative to the sensor 140. In the embodiment shown in FIG. 1A the position information is a rotational position information of the gear wheel 100 relative to the sensor 140 and the pattern 112, 114 of the first printed material 110 comprises an angular encoder for detecting a rotational position of the gear wheel 100 relative to the sensor 140. In the embodiment shown in FIG. 1A, the pattern 112, 114 of first printed material 110 comprises reflective material which reflects light emitted from a light source 142 of the sensor 140 back towards a light sensitive element 144 of the sensor 140. When rotating the gear wheel 100 relative to the sensor 140, the signal received by the sensor 140 is depending on the pattern 112, 114 generated on the gear wheel 100. In one embodiment, the pattern 112, 114 is configured to generate a sinusoidal-wave signal when the gear wheel 100 is rotating at a constant speed in front of the sensor 140. Alternatively, the pattern 112, 114 may be configured to generate a block-wave signal when the gear wheel 100 is rotating at a constant speed in front of the sensor 140. Even further alternatively, the pattern 112, 114 may be configured to generate a saw-tooth-wave signal when the gear wheel 100 is rotating at a constant speed in front of the sensor 140. Due to the fact that the first printed material 110 is printed via the additive manufacturing process, the density of the first printed material 110 in the pattern 112, 114 may be relatively easily be adapted to obtain any of the above indicated signals from the sensor 140 and even many different signals.

[0037] The pattern 112, 114 comprises of a first pattern 112 and a second pattern 114 which is coaxially arranged relative to the first pattern 112 and which is shifted relative to the first pattern 112 and comprises a different number of encoding elements in the pattern 114. Choosing a specific number of encoder elements in the first pattern 112 and the second pattern 114 and having a sensor 114 capable of sensing the signals coming from the first pattern 112 and the second pattern 114 separately, the combination of the two signals may generate an absolute positioning of the gear wheel 100 relative to the sensor 140.

[0038] Alternatively, the first printed material 110 comprises magnetic particles and thus the first pattern 112 comprises a plurality of magnetic angular encoders arranged in a ring shaped symmetrically around the gear wheel 100. In this alternative embodiment, the sensor 140 comprises one or more magnetic sensors, such as Hall-sensors or magneto-resistive sensors. The pattern 112, 114 of magnetic angular encoders together with the sensor 140 form a rotation detection system 130 in which the first pattern 112 of magnetic encoders 112 is arranged coaxially with respect to the second pattern 114 of magnetic encoders 114 having a different number of magnetic poles compared to the first pattern 112. The system 130 may also have a plurality of magnetic sensors 140 each operable to detect the magnetic field of the corresponding first pattern 112 of magnetic encoders and second pattern 114 of magnetic encoders. The sensor 140 is configured for detecting positional information within a single magnetic pole of the corresponding magnetic encoder. A phase difference detector is used for determining the phase difference of magnetic field signals detected respectively by the magnetic sensors 140 detecting the magnetic encoders 112 of the first pattern 112 and the magnetic encoders 114 of the second pattern 114. Using the detected phase difference, an absolute rotation angle of the gear wheel 100 relative to the sensor 140 may be determined.

[0039] The first printed material 110 may be printed on top of the second material 120. Alternatively, the gear wheel 100 may at least partially be produced using the second material 120 which is a second printed material 120. In such a configuration, the first printed material 110 may be embedded, at least partially, inside the second printed material 120. A benefit when the first material 110 is at least partially embedded in the second printed material 120 is that the first material 110 may be protected against the often harsh environment in which a gear wheel 100 operates.

[0040] FIG. 1B shows a cut-open plan-view of a gear box 150 according to the invention. The gear box 150 is connected to a motor 170 via a first shaft 160 and the gear box 150 transfers the rotation speed of the motor 170 to a converted rotation speed of the second shaft 180. The gear box 150 comprises a plurality of gear wheels 100. One of the gear wheels 100 comprises the first printed material 110 in a pattern 112 for cooperating with a sensor 140 for determining a rotational position and/or speed of the gear wheel 100 inside the gear box 150.

[0041] FIG. 2A shows a cross-sectional view of a bearing 200 comprising the second printed material 250, 260 and comprising the pattern 212 (see FIG. 2B) of first material 210. The bearing 200 comprises rolling elements 205 and an inner ring 280 comprising a raceway ring 216 at which the second printed material 250 is bonded. The bearing 200 also comprises an outer ring 290 comprising the pattern 212 of the first printed material 210. The first printed material 210 is fully embedded inside the second printed material 260 such that the first printed material 210 is protected from environmental influences and wear. The pattern 212 of the first printed material 210 as shown in FIG. 2A comprises magnetic particles embedded in the first printed material 210. Each block of first printed material 210 acts as a magnetic encoder cooperating with a magnetic sensor 240 (see FIG. 2B) and the pattern 212 of first printed material 240. The outer ring 290 also comprises the raceway ring 220 to which the second printed material 260 is bonded.

[0042] FIG. 2B shows a partially cut-open outer ring 290 for a bearing 200 according to the invention. The outer ring 290 being a building block 290 according to the invention and comprises a raceway ring 220 to which the second printed material 260 is bonded. The first printed material 210 forms a pattern 212 rotationally arranged on a rim of the outer ring 290. In use, the outer ring 290 may rotate relative to the sensor 240 and the pattern 212 of first printed material 210, for example, comprising magnetic particles generate a signal at the sensor 240 from which a relative position or rotation of the outer ring 290 relative to the sensor 240 may be established. The use of the second printed material 260 provides a very flexible way of producing the outer shape of the outer ring 260 for the bearing 200 and printing the first printed material 210 in the pattern 212 ensures that the accuracy of the pattern 212 and the position of the pattern on the outer ring 290 may be determined relatively accurately.

[0043] FIG. 2C shows a bearing 205 comprising a seal 230 according to the invention. The seal 230 comprises a pattern 212 of first printed material 210 arranged on or at least partially embedded in the second material 265, for example, second printed material 265. The pattern 212 of first printed material 210 may comprise magnetic particles embedded in the first printed material 210 to cooperate with a sensor 240 being a magnetic sensor. Alternatively, the pattern 212 of first printed material 210 may be configured to cooperate with an optical sensor 140 for providing information on a relative position of the seal 230 relative to the optical sensor 140. In a bearing 205 the seal 230 rotates either with the inner ring 280 or with the outer ring 290, depending on the configuration of the seal 230. The pattern 212 may be used to determine an angular position of the seal 230 relative to the sensor 140. Alternatively, the pattern 212 may be used in addition to an angular sensor (not shown), for example, integrated in the outer ring 290 similar as shown in FIG. 2A. In such a configuration, the signal received from the seal 230 may be used to check whether the seal 230 actually rotates together with the outer ring 290. If there is a difference between the rotation speed of the seal 230 and the outer ring 290, this may be used as an indication that the bearing 205 may require maintenance or that the lubrication of the bearing 205 may not be optimal.

[0044] FIG. 3A shows a plan view of an actuator system 300 comprising a static unit 350 and a traveling unit 330. The traveling unit 330 comprises the pattern 312 of first printed material 310 printed on the second material 320. The pattern 312 of first printed material 310 may comprise a magnetic particles distributed in the first printed material 310 to interact with a sensor 340 being, for example, a magnetic sensor 340. Alternatively, the first printed material 310 may be reflective material such that light emitted from a light sensor 340 may be reflected from the pattern 312 of the first printed material 310. The reflected light may be sensed by a light sensitive element 144 (see FIG. 1A) and the signal obtained when pattern 312 of first printed material 310 of the traveling unit 330, in use, interacts with the sensor 340 may be used to determine a relative position between the traveling unit 330 and the sensor. Even further alternatively, the first printed material 310 may be configured to transmit the light emitted from the light sensor and the light sensitive element 144 may be arranged on an opposite side of the traveling unit 330 such that the transmitted light, transmitted by the first printed material 310 is blocked according to the pattern 312 by the second material 320, for example, being second printed material 320.

[0045] FIG. 4A shows a first embodiment of an additive manufacturing tool 400 in which a liquid resin 450 is used for applying the printed material 460 in the additive manufacturing process. Such additive manufacturing tool 400 comprises resin container 430 comprising the liquid resin 450. Inside the resin container 430 a platform 470 is positioned which is configured to slowly move down into the resin container 430. The additive manufacturing tool 400 further comprises a laser 410 which emits a laser beam 412 having a wavelength for curing the liquid resin 450 at the locations on the printed material 460 where additional printed material 460 should be added. A re-coating bar 440 is drawn over the printed material 460 before a new layer of printed material 460 is to be applied to ensure that a thin layer of liquid resin 450 is on top of the printed material 460. Emitting using the laser 410 those parts of the thin layer of liquid resin 450 where the additional printed material 460 should be applied will locally cure the resin 450. In the embodiment as shown in FIG. 4A the laser beam 412 is reflected across the layer of liquid resin 450 using a scanning mirror 420. When in the current layer all parts that need to be cured, have been illuminated with the laser beam 412, the platform 470 lowers the printed material 460 further into the liquid resin 450 to allow the re-coating bar 460 to apply another layer of liquid resin 450 on top of the printed material 460 to continue the additive manufacturing process.

[0046] FIG. 4B shows a second embodiment of the additive manufacturing tool 401 in which a liquid resin 450 is dispensed from a dispenser 405 or print head 405 for applying the printed material 460 in the additive manufacturing process. The additive manufacturing tool 401 again comprises the resin container 430 comprising the liquid resin 450 which is fed via a feed 455 towards the print head 405. The print head 405 further comprises a print nozzle 415 from which droplets of liquid resin 450 are emitted towards the printed material 460. These droplets may fall under gravity from the print head 405 to the printed material 460 or may be ejected from the print nozzle 415 using some ejection mechanism (not shown) towards the printed material 460. The print head 405 further comprises a laser 410 emitting a laser beam 412 for immediately cure the droplet of liquid resin 450 when it hits the printed material 460 to fix the droplet of liquid resin 450 to the already printed material 460. The printed material 460 forming a solid object may be located on a platform 470.

[0047] FIG. 5A shows a third embodiment of the additive manufacturing tool 500 in which the material is granulated into small solid particles 550 which are used for applying the printed material 560 in the additive manufacturing process. Now, the additive manufacturing tool 500, also known as a Selective Laser Sintering tool 500, or SLS tool 500 comprises a granulate container 530 comprising the granulated small solid particles 550. The printed material 560 is located again on a platform 570 and is completely surrounded by the granulated small solid particles 550. Lowering the platform allows a granulate feed roller 540 to apply another layer of granulated solid particles 550 on the printed material 560. Subsequently locally applying the laser beam 512 using the laser 510 and the scanning mirror 520 will locally melt the granulated solid particles 550 and connects them with each other and with the printed material 560 to generate the next layer of the solid object to be created. Next, the platform 570 moves down further to allow a next layer of granulated solid particles 550 to be applied via the granulate feed roller 540 to continue the next layer in the additive manufacturing process.

[0048] FIG. 5B shows a fourth embodiment of the additive manufacturing tool 501 or SLS tool 501 in which the granulated solid material 550 is dispensed from a dispenser 505 or print head 505 for applying the printed material 560 in the additive manufacturing process. The additive manufacturing tool 501 again comprises the granulate container 530 comprising the granulated solid particles 550 which are fed via a feed 555 towards the print head 505. The print head 505 further comprises a print nozzle 515 from which granulated solid particles 550 are emitted towards the printed material 560. These solid particles 550 may fall under gravity from the print head 505 to the printed material 560 or may be ejected from the print nozzle 515 using some ejection mechanism (not shown) towards the printed material 560. The print head 505 further comprises a laser 510 emitting a laser beam 512 for immediately melting or sintering the solid particle 550 when it hits the printed material 560 to fix the solid particle 550 to the already printed material 560. The printed material 560 forming a solid object may be located on a platform 570.

[0049] FIG. 6 shows a fifth embodiment of the additive manufacturing tool 600 in which a melted plastic material 650 is dispensed for applying the printed material 660 in the additive manufacturing process. The additive manufacturing tool 600 shown in FIG. 6 is also known as Fused Deposition Modeling tool 600 or FDM tool 600. Now a plastic filament 630 is fed into a dispenser 610 or melter 610 via a filament feeder 640. The dispenser 610 or melter 610 comprises an extrusion nozzle 615 for melting the plastic filament 630 to form a droplet of melted plastic material 650 which is applied to the printed material 660 where it hardens and connects to the already printed material 660. The dispenser 610 may be configured and constructed to apply the droplet of melted plastic 650 to the printed material 660 under gravity or via an ejection mechanism (not shown). The additive manufacturing tool 600 further comprises a positioning system 620 for positioning the dispenser 610 across the printed material 660.

[0050] Summarizing, the invention provides a building block 290, 280 for a mechanical construction. The invention further provides a bearing 200, an actuator system, a gear box, a system and a method of producing the building block. The building block comprises a first printed material 210 printed via an additive manufacturing process on or at least partially embedded in a second material 260. The first printed material is printed in a pattern 212 configured and constructed for cooperating with a sensor 240 for providing, in use, position information of the building block relative to the sensor. The sensor may be a magnetic sensor or an optical sensor. The first printed material may comprise magnetic particles. The method of producing the building block may comprise a step of adding the first printed material to the second material via the additive manufacturing process under the influence of a predefined magnetic field.

[0051] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments.

[0052] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb comprise and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article a or an preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

LISTING OF REFERENCE NUMBERS

[0053]

TABLE-US-00001 Building block 100, 230, 280, Additive manufacturing tool 400, 401 290, 330, 350 Printable material 450, 550, 650 Pattern 112, 114, 212, Print head 405, 505 312 Print nozzle 415, 515 First printed material 110, 210, 310 Laser 410, 510 Second material 120, 260, 265, Laser beam 412, 512 320 Scanning mirror 420, 520 Optical sensor 140 Resin container 430 Light source 142 Re-coating bar 440 Light sensitive element 144 Liquid resin 450 Magnetic sensor 240, 340 Feed 455, 555 Gear wheel 100 Platform 470, 570, 670 Gear box 150 SLS-tool 500, 501 Motor 170 Granulate container 530 Shaft 160, 180 Granulate feed roller 540 Bearing 200, 205 Granulate material 550 Roller elements 205 FDM-tool 600 Raceway ring 216 Melter 610 Inner ring 280 Extrusion nozzle 615 Outer ring 290 Positioning construction 620 Seal 230 Filament 630 Actuator 300 Filament feeder 640 Traveling unit 330 Liquid plastic 650 Static unit 350