Velocity profiling in an extrusion apparatus

• US 6,054,077 A
• Filed: 01/11/1999
• Issued: 04/25/2000
• Est. Priority Date: 01/11/1999
• Status: Expired due to Term

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Leavitt, Paul J, Comb, James W., Rapoport, Edward
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US09/228,095
• Time in Patent Office: 470 Days
• Field of Search: 264/40.7, 425/145, 425/375, 425/376.1
• US Class Current: 264/40.7
• CPC Class Codes: B29C 2948/92076 Position, e.g. linear or angular
• CPC Class Codes: B29C 2948/92304 Presence or absence; Sequence; Counting
• CPC Class Codes: B29C 2948/9238 Feeding, melting, plasticising or pumping zones, e.g. the melt itself
• CPC Class Codes: B29C 2948/92571 Position, e.g. linear or angular
• CPC Class Codes: B29C 2948/9258 Velocity
• CPC Class Codes: B29C 2948/926 Flow or feed rate
• CPC Class Codes: B29C 2948/92876 Feeding, melting, plasticising or pumping zones, e.g. the melt itself
• CPC Class Codes: B29C 2948/92904 Die; Nozzle zone
• CPC Class Codes: B29C 2948/92952 Drive section, e.g. gearbox, motor or drive fluids
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/155 Partial coating thereof
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor

Abstract

An apparatus has an extrusion head for extruding a bead of a liquified material at an extruded pump flow rate, an extrusion head motor for driving the extrusion head at a variable head velocity, a pump for providing liquified material to the extrusion head, and a control for providing control signals to both the extrusion head motor and the pump. The control signals control operation of the extrusion head and the pump so that the head velocity is slaved to an estimated profile of the extruded pump flow rate divided by a predetermined bead cross-sectional area.

Claims

1. An apparatus comprising:

an extrusion head for extruding a bead of a liquified material at an extruded pump flow rate;

an extrusion head motor for driving the extrusion head at a variable head velocity;

a liquifier for liquifying the filament of material;

a filament drive for providing the filament of material to the liquifier; and

a control for providing control signals to both the extrusion head motor and the filament drive, the control signals controlling operation of the extrusion head and the filament drive so that the head velocity is proportional to an estimated profile of the extruded pump flow rate.

2. The apparatus of claim 1 wherein the control provides a step signal as the control signal to the filament drive to cause the extruded pump flow rate to have an exponential response.

3. The apparatus of claim 2 wherein:

the control causes the head velocity during an acceleration phase to be exponentially increased, as a function of a liquifier acceleration time constant; and

the control causes the head velocity during a deceleration phase to be exponentially decreased, as a function of a liquifier deceleration time constant.

4. The apparatus of claim 3 wherein the control causes the head velocity during the acceleration phase to be exponentially increased towards a steady-state head velocity.

5. The apparatus of claim 4 wherein the control causes the head velocity during the acceleration phase to be selectively stopped at an intermediate velocity that is less than a steady-state velocity.

6. The apparatus of claim 3 wherein the control causes the head velocity during the deceleration phase to be exponentially decreased to zero.

7. The apparatus of claim 3 wherein the control causes the head velocity during the deceleration phase to be exponentially decreased to a vertex velocity that is less than a steady-state velocity.

8. The apparatus of claim 3 wherein:

the control causes head velocity during a pre-pump phase to be zero; and

the control causes head velocity during a suck-back phase to be exponentially decreased towards zero, as a function of the liquifier deceleration time constant.

9. The apparatus of claim 8 wherein:

the control causes head velocity to be linearly decreased to zero after head velocity reaches a suck-back trigger velocity during the suck-back phase.

10. The apparatus of claim 3 wherein the liquifier acceleration time constant is less than or equal to about 0.05 seconds.

11. The apparatus of claim 3 wherein the liquifier deceleration time constant is less than or equal to about 0.05 seconds.

12. An apparatus comprising:

an extrusion head for extruding a bead of a liquified material at an extruded pump flow rate;

an extrusion head motor for driving the extrusion head at a variable head velocity;

a pump for providing liquified material to the extrusion head; and

a control for providing control signals to both the extrusion head motor and the pump, the control signals controlling operation of the extrusion head and the pump so that the head velocity is slaved to an estimated profile of the extruded pump flow rate divided by a predetermined bead cross-sectional area.

13. The apparatus of claim 12 wherein the control provides step control signals to the pump to cause the estimated profile of the extruded pump flow rate to fit an exponential function.

14. The apparatus of claim 13 wherein:

the control causes head velocity during an acceleration phase to be exponentially increased towards a steady-state head velocity, as a function of a pump acceleration time constant; and

the control causes head velocity during a deceleration phase to be exponentially decreased towards zero, as a function of a pump deceleration time constant.

15. The apparatus of claim 14 wherein the pump comprises a liquifier that receives and liquifies a filament of material and a filament drive that receives the control signals and responsively provides the filament of material to the liquifier.

16. The apparatus of claim 15 wherein the pump acceleration time constant is less than or equal to about 0.05 seconds.

17. The apparatus of claim 15 wherein the pump deceleration time constant is less than or equal to about 0.05 seconds.

18. The apparatus of claim 14 wherein the control causes the head velocity during the acceleration phase to be selectively stopped at an intermediate velocity that is less than a steady-state velocity.

19. The apparatus of claim 14 wherein the control causes the head velocity during the deceleration phase to be exponentially decreased to a vertex velocity that is less than a steady-state velocity.

20. The apparatus of claim 14 wherein:

the control causes head velocity during a pre-pump phase to be zero; and

the control causes head velocity during a suck-back phase to be exponentially decreased towards zero, as a function of the pump deceleration time constant.

21. The apparatus of claim 20 wherein:

the control causes head velocity to be linearly decreased to zero after head velocity reaches a suck-back trigger velocity during the suck-back phase.

22. In an apparatus having an extrusion head for extruding a liquified material at an extruded pump flow rate, an extrusion head motor for moving the extrusion head at a variable head velocity, and a control for providing control signal inputs to the extrusion head motor, a method for extruding the liquified material in a bead having a predetermined cross-sectional area, the method comprising the step of:

controlling the head velocity according to an estimated profile of the extruded pump flow rate divided by the predetermined bead cross-sectional area.

23. The method of claim 22 wherein the estimated profile of the extruded pump flow rate fits an exponential function, and the step of controlling the head velocity comprises the steps of:

exponentially increasing the head velocity during an acceleration phase; and

exponentially decreasing the head velocity during a deceleration phase.

24. The method of claim 23 and further comprising the steps of:

maintaining the head velocity at zero during a pre-pump phase;

exponentially decreasing the head velocity during a suck-back phase; and

linearly decreasing the head velocity to zero after the head velocity reaches a suck-back trigger velocity during the suck-back phase.