U.S. patent application number 09/960133 was filed with the patent office on 2003-04-03 for melt flow compensation in an extrusion apparatus.
This patent application is currently assigned to Stratasys, Inc.. Invention is credited to Comb, James W..
Application Number | 20030064124 09/960133 |
Document ID | / |
Family ID | 25502826 |
Filed Date | 2003-04-03 |
United States Patent
Application |
20030064124 |
Kind Code |
A1 |
Comb, James W. |
April 3, 2003 |
MELT FLOW COMPENSATION IN AN EXTRUSION APPARATUS
Abstract
Disclosed are a method and apparatus for matching the extrusion
rate of a liquifier which extrudes a flow of material to a
predetermined target output rate. The present invention adjusts the
volumetric rate of material going in to the liquifier to account
for a predicted melt flow component of material being extruded from
the liquifier. Compensating for the predicted melt flow results in
reduced error in an extrusion profile produced by material
deposited along a toolpath followed by the liquifier.
Inventors: |
Comb, James W.; (Hamel,
MN) |
Correspondence
Address: |
KINNEY & LANGE, P.A.
THE KINNEY & LANGE BUILDING
312 SOUTH THIRD STREET
MINNEAPOLIS
MN
55415-1002
US
|
Assignee: |
Stratasys, Inc.
14950 Martin Drive
Eden Prairie
MN
55344
|
Family ID: |
25502826 |
Appl. No.: |
09/960133 |
Filed: |
September 21, 2001 |
Current U.S.
Class: |
425/145 ;
264/40.7 |
Current CPC
Class: |
B29C 48/92 20190201;
B29C 64/209 20170801; B29C 2948/92904 20190201; B29C 2948/92571
20190201; B29C 64/321 20170801; B29C 2948/926 20190201; B29C 48/05
20190201 |
Class at
Publication: |
425/145 ;
264/40.7 |
International
Class: |
B29C 047/92 |
Claims
1. In an extrusion apparatus having a liquifier which receives a
solid element of a material that exhibits thermal expansion, heats
the material, and deposits a flow of the material through a
dispensing tip thereof along a predetermined tool path at an output
rate, said apparatus using a material advance mechanism to supply
the solid element of material to the liquifier at an input rate
which controls the output rate, a method for matching the output
rate to a predetermined target rate which is selected to achieve a
desired extrusion profile of the material deposited along the tool
path, comprising the steps of: predicting a melt flow component
(Q.sub.MF) of the output rate for a time step corresponding to a
segment of the tool path, the melt flow being a rate of flow
attributed to thermal expansion of the material heated in the
liquifier; and commanding the input rate (Q.sub.iS) for that time
step so as to compensate for the predicted melt flow.
2. The extrusion apparatus of claim 1, and further comprising the
step of: repeating the steps of predicting and commanding for
subsequent time steps.
3. The extrusion apparatus of claim 1, wherein the melt flow is
predicted as a function of a melt flow time constant of the
liquifier and a percent thermal expansion of the material.
4. The extrusion apparatus of claim 1, wherein the melt flow over
time is predicted using an exponential model.
5. The extrusion apparatus of claim 4, wherein the exponential
model is a function of a melt flow time constant of the liquifier
(.tau..sub.MF) and a percent thermal expansion of the material
(%.sub.MF).
6. The extrusion apparatus of claim 5, wherein the exponential
model of melt flow over time is given by the equation 8 Q MFS = %
MF * Q iS 1 + % MF * ( 1 - - t MF ) .
7. An extrusion apparatus comprising: a liquifier which receives a
solid element of a material that exhibits thermal expansion, heats
the material, and deposits a flow of the material through a
dispensing tip thereof along a predetermined tool path at an output
rate; a material advance mechanism which supplies the solid element
of material to the liquifier at an input rate (Q.sub.iS) that
controls the output rate; a control for providing control signals
to the material advance mechanism, the control signals commanding
operation of the material advance mechanism so that the input rate
compensates for a predicted melt flow component (Q.sub.MF) of the
output rate.
8. The extrusion apparatus of claim 7, wherein the control contains
an algorithm for predicting the melt flow component as a function
of a melt flow time constant of the liquifier (.tau..sub.MF) and a
percent thermal expansion of the material (%.sub.MF).
9. The extrusion apparatus of claim 7, where melt flow over time is
predicted using an exponential model.
10. The extrusion apparatus of claim 9, wherein the exponential
model of melt flow over time is given by the equation 9 Q MFS = %
MF * Q iS 1 + % MF * ( 1 - - t MF ) .
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] None.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the fabrication of
three-dimensional objects using extrusion-based layered
manufacturing techniques. More particularly, the invention relates
to supplying solid modeling material to a liquifier carried by an
extrusion head, and extruding the material in a flowable state in a
predetermined pattern in three dimensions with respect to a
base.
[0003] Three-dimensional models are used for functions including
aesthetic judgments, proofing a mathematical model, forming hard
tooling, studying interference and space allocation, and testing
functionality. Extrusion-based layered manufacturing machines build
up three-dimensional models by extruding solidifiable modeling
material from an extrusion head in a predetermined pattern, based
upon design data provided from a computer aided design (CAD)
system. Examples of extrusion-based apparatus and methods for
making three-dimensional objects are described in Crump U.S. Pat.
No. 5,121,329, Crump U.S. Pat. No. 5,340,433, Danforth et al. U.S.
Pat. No. 5,738,817, Batchelder et al. U.S. Pat. No. 5,764,521 and
Dahlin et al. U.S. Pat. No. 6,022,207, all of which are assigned to
Stratasys, Inc., the assignee of the present invention.
[0004] A feedstock of either a liquid or solid modeling material is
provided to the extrusion head. Where the feedstock of modeling
material is in solid form, the extrusion head brings the feedstock
to a flowable temperature for deposition. One technique provides
the modeling material to the extrusion head in the form of a
filament strand.
[0005] In the Stratasys FDM.RTM. modeling machines of the current
art which employ a filament feed, modeling material is loaded into
the machine as a flexible filament wound on a supply reel, such as
disclosed in U.S. Pat. No. 5,121,329. A solidifiable material which
adheres to the previous layer with an adequate bond upon
solidification and which can be supplied as a flexible filament is
used as the modeling material. Motor-driven feed rollers advance
the strand of the filament into a liquifier carried by an extrusion
head. Inside the liquifier, the filament is heated to a flowable
temperature. Flowable modeling material is forced out of a nozzle
on the far end of the liquifier, and deposited from the liquifier
onto a base. The motor-driven feed rollers pushing filament into
the liquifier create a "liquifier pump", wherein the filament
itself serves as the piston. As the feed rollers advance filament
into the liquifier, the force of the incoming filament strand
extrudes the flowable material out from the nozzle. The flow rate
of the material extruded from the nozzle is a function of the rate
at which the filament is advanced to the head. The flow rate is
commanded by controlling the speed of advancement of filament into
the liquifier. A controller controls movement of the extrusion head
in a horizontal x, y plane, controls movement of the base in a
vertical z-direction, and controls the rate at which the feed
rollers advance filament. By controlling these processing variables
in synchrony, the modeling material is deposited in "beads"
layer-by-layer along tool paths defined from the CAD model. The
material being extruded fuses to previously deposited material and
solidifies to form a three-dimensional object resembling the CAD
model.
[0006] The extruded material delivered by the liquifier pump has a
bead of a cross-sectional area that should ideally be controlled to
create an accurate model. Usually, a constant bead width is
desired. The bead width is related to the flow rate of material out
of the pump as well as the extrusion head velocity. The bead width
is also affected by the clearance between the extruding nozzle tip
and a previously extruded layer (or the base). If the head velocity
were to change while the flow rate were to stay constant, the bead
width would vary as well.
[0007] One type of rapid prototyping system of the prior art drives
the motion of the extrusion head at a constant velocity along a
tool path comprising a poly-line. A poly-line is a continuous curve
of straight-line segments defined by a list of X-Y coordinate pairs
at each vertex. The head velocity is preselected so as to
accomplish the general goal of moving the extrusion head quickly
along the poly-line while minimizing the displacement from the tool
path. As a result, the head velocity must be set to be slow enough
that the deviation will not exceed the maximum allowable following
error for the largest deflection along that poly-line. Using a
constant head velocity along a tool path, bead width remains fairly
constant but errors arise at start points and end points of the
tool path, for instance, at the location of a "seam" (i.e., the
start and end point of a closed-loop tool path).
[0008] Another type of prototyping system of the prior art varies
the extrusion head speed to increase the throughput of the modeling
machine. The extrusion head speeds up along straight-aways in the
tool path, and slows down where there are deflection angles or
vertices. U.S. Pat. No. 6,054,077 describes one such technique for
varying the extrusion head speed, using X-Y trajectory profiling
that follows the exponential step response of the liquifier pump.
The velocity profile of the extrusion head looks like a "shark
tooth", while the pump profile follows a step function.
[0009] It has been observed that the variable velocity systems of
the prior art introduce greater bead width error, and also have
seam errors. It would be desirable to reduce errors in bead width
and seam quality so as to achieve a desired extrusion profile,
while allowing the higher throughput of a variable rate system.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention is a liquifier pump control method and
apparatus which reduces bead width errors and seams errors observed
in the prior art by accounting for thermal expansion of the
modeling material in the liquifier. The melting of modeling
material is accompanied by its expansion. The present invention
recognizes that the melt expansion produces unanticipated extruded
flow rates from the liquifier during transient conditions. The
present invention predicts a melt flow component of the extruded
flow rate produced by the thermal expansion of the modeling
material, and compensates for the predicted melt flow in a
commanded flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective, diagrammatic view of a liquifier
pump extrusion apparatus in a three-dimensional modeling
machine.
[0012] FIG. 2a illustrates an extrusion profile joined together by
a good seam.
[0013] FIG. 2b illustrates an extrusion profile joined together by
a light or seam.
[0014] FIG. 2c illustrates an extrusion profile joined together by
a heavy seam.
[0015] FIG. 3 is a graphical representation of a liquifier
operating at a minimum flow rate.
[0016] FIG. 4 is a graphical representation of a liquifier
operating at a maximum flow rate.
[0017] FIG. 5a is a view of an extrusion profile extruded by a
prior art liquifier pump operating at a steady state and then
turned off.
[0018] FIG. 5b is a graphical representation of the amount of flow
produced by the liquifier pump of FIG. 5a.
[0019] FIG. 6a is a view of an extrusion profile extruded by a
prior art liquifier pump as it is turned on and then off.
[0020] FIG. 6b is a graphical representation of the amount of flow
produced by the liquifier pump of FIG. 6a.
[0021] FIG. 7a is a view of an extrusion profile extruded by a
liquifier pump in accordance with the present invention as it is
turned on and then off.
[0022] FIG. 7b is a graphical representation of the amount of flow
produced by the liquifier pump of FIG. 7a.
DETAILED DESCRIPTION
[0023] The method and apparatus of the present invention may be
employed with respect to an extrusion system which extrudes
material that exhibits thermal expansion from a liquifier pump.
Particularly applicable are various types of modeling or
prototyping systems which utilize an extrusion head to deposit
"roads" of material heated to be flowable, and which material
shrinks and solidifies upon a drop in temperature to form a solid
model. A preferred material deposition and build-up process is of
the type disclosed in U.S. Pat. No. 5,121,329.
[0024] FIG. 1 shows an exemplary three-dimensional modeling machine
10 having an extrusion head 20 which deposits modeling material
under the control of a controller 25. The extrusion head 20 carries
a liquifier 26 which receives a feed stock of modeling material and
heats it to a temperature desired for extrusion. Molten modeling
material is deposited from a tip 30 of the liquifier 26 in beads 21
onto a planar base 32 (shown in part). In the preferred embodiment
shown, the modeling material feedstock is a flexible filament 14.
Typically, the filament has a small diameter, such as on the order
of 0.070 inches. A spool 12 carrying a coil of filament 14 is
mounted on a spindle 16. A strand of the filament 14 is fed through
a guide tube 18, which routes the strand of filament 14 to the
extrusion head 20. A material advance mechanism 23 comprised of a
pair of feed rollers 22 driven by a motor 24 advances the filament
14 into the liquifier 26 at a controlled rate. Together, the
liquifier 26, the filament 14 and the material advance mechanism 23
form a liquifier pump.
[0025] The liquifier 26 is pressurized by the "pumping" of the
strand of filament 14 into the liquifier 26 by feed rollers 22. The
strand of filament 14 acts as a piston. The pressurization impels
the molten modeling material out of the tip 30. The volumetric flow
rate of liquid material flowing from the pump (Q.sub.oL) is
controlled by adjusting the speed of rotation of the feed rollers
22. As shown, one of feed rollers 22 is a drive roller, driven by
the motor 24 under the control of the controller 25. The other
roller 22 is an idler roller. The controller 25 controls pump flow
rate Q.sub.oL by providing control signals to the motor 24 which
drives the rollers 22.
[0026] The extrusion head 20 is driven along tool paths in a
horizontal x,y plane by an x-y translator 34, which receives drive
signals from the controller 25 in accordance with design data
derived from a CAD model. As the extrusion head 20 is translated in
the x-y plane, molten modeling material is controllably dispensed
from the tip 30 layer-by-layer onto the base 32. After each layer
is dispensed, the base 32 is lowered a predetermined increment
along a vertical z-axis by a z-axis translator 36, which also
receives drive signals from the controller 25. The dispensed
material fuses and solidifies to form a three-dimensional object
resembling the CAD model. Modeling material used to build a support
structure may be dispensed in a like fashion in coordination with
the dispensing of modeling material used to build up the object, to
support portions of the object as it is under construction.
[0027] As will be understood by those in the art, many variations
of the modeling machine and process are possible. For example, any
relative movement in three-dimensions between the extrusion head 20
and the base 32 may be used to built up the object. The feedstock
of modeling material, the liquifier and the material advance
mechanism may take many various forms.
[0028] Materials that may be used as the modeling material include
thermoplastics, metals, ceramics, and waxes. It is also known that
modeling may be water. With the exception of water, most modeling
materials expand when they melt. Prior art flow control methods do
not account for this behavior, resulting in the inability to
maintain a constant bead width in seams or between start and end
points.
[0029] In the prior art, control of the liquifier has been based on
a pressure model. This model takes into account volume changes of
the modeling material due to changes in pressure and pressure drop
across the dispensing tip, but does not account for volume changes
due to changes in temperature. Applying the pressure model,
liquifier flow control is divided into phases, such as those
described in U.S. Pat. No. 6,054,077. The phases include a pre-pump
phase (in which the liquifier pump is commanded on but due to time
delay is not yet extruding material) and a suck-back phase (in
which the liquifier pump is commanded off but continues to extrude
material). It should be understood that the present invention is
most effectively implemented as a compliment to prior art
techniques for flow control.
[0030] FIG. 2a illustrates a desired extrusion profile 40 along a
closed tool path (i.e. a tool path having the same start position
and stop position). The extrusion profile 40 includes a start tool
path portion 42 and a stop tool path portion 44 joined together by
a good seam 46. In extrusion profile 40, the bead width remains
constant, resulting in a smooth transition between start and stop
tool path portions 42 and 44. FIGS. 2b and 2c illustrate errors in
extrusion profiles, which have been observed along a closed tool
path with the prior art pressure model implemented to control the
extrusion rate. FIGS. 2b illustrates a light seam, while FIG. 2c
illustrates a heavy seam. An extrusion profile 50 shown in FIG. 2b
includes a first tool path portion 52 and a last tool path portion
54 joined together by a light, or thin, seam 56. Light seam 56 is
caused by a smaller bead width at the start and stop points of the
tool path than that occurring elsewhere. An extrusion profile 60
shown in FIG. 2c includes a start tool path portion 62 and a stop
tool path portion 64 joined together by a heavy, or fat, seam 66.
Heavy seam 66 is caused by too much material being extruded at the
start and/or stop points of the tool path.
[0031] The present invention recognizes that melt expansion of the
modeling material is a significant cause of errors in the desired
extrusion profile, such as the seam errors illustrated in FIGS. 2b
and 2c. Utilizing the present invention, the melt flow component of
the extruded flow rate is predicted and is compensated for by
adjusting the input rate of solid material, resulting in
significantly reduced errors in bead width and seams.
[0032] The melt flow compensation of the present invention takes
into account the flow history of the liquifier to command a flow
rate that will account for melt flow. FIG. 3 is a graphical
representation of a cross-section of the liquifier 26 operating at
a minimum flow rate. FIG. 4 is a graphical representation of a
cross-section of liquifier 26 operating at a maximum flow rate. The
filament 14 is fed into the liquifier 26 at an input (or commanded)
flow rate Q.sub.iS, heated in the liquifier 26 to a liquid 76 at a
melting rate Q.sub.M, and extruded out of the tip 30 of liquifier
26 at an output flow rate Q.sub.oL. As illustrated, at higher flow
rates, more of the liquifier 26 contains solid modeling material in
the form of filament 14, as compared to melted modeling material
(liquid 76). This is due to limited melt capacity of the liquifier.
If the input flow rate, Q.sub.iS, were to go from a higher to a
lower rate, the amount of liquid 76 in the liquifier 26 will
increase and the output flow rate, Q.sub.oL, will include a melt
flow component, Q.sub.MFL, that is taken into account by the
present invention by way of a downward adjustment of the commanded
input flow rate, Q.sub.iS.
[0033] In order to account for melt flow, the melt flow
characteristic of a given operating system may be modeled by an
equation. The melt rate of a solid rod of material in a cylindrical
liquifier has been observed to be approximately exponential. For a
step increase in solid material input rate, the rate of melting
increases exponentially to an asymptotic value equal to the input
rate of solid material. When the liquifier pump is turned on, the
melt flow rate of material from the liquifier increases
approximately exponentially. Conversely, when the liquifier pump is
turned off, the melt flow rate exponentially decreases to zero.
Accordingly, melt flow can be predicted by an exponential equation
dependent upon a melt flow time constant of the liquifier.
[0034] FIGS. 5a and 5b graphically illustrate flow of material when
a liquifier pump according the prior art is turned off. FIG. 5a
illustrates an extrusion profile 80, while FIG. 5b is a graphical
representation of the amount of flow. In extruding extrusion
profile 80, the extrusion head which carries the liquifier pump is
moving at a constant velocity to the right. At a first tool path
point 82, a commanded flow rate 87 is at a constant rate and the
liquifier pump has been on long enough to reach steady state. At a
second point 84, the flow rate 87 is commanded off (with the
appropriate "suck back" pressure reduction performed) while the
extrusion head continues to move. Even though the pump is commanded
off, the flow continues. This additional flow, which is produced by
the unaccounted expansion of melted material in the liquifier,
results in an excess portion 86 of extrusion profile 80. This
excess portion 86 can be measured and has exponential form. If the
extrusion head were to have stopped moving at point 84, the excess
flow due to expansion would have created a large ball or heavy seam
at that point.
[0035] In FIG. 5b, the commanded flow rate 87 is a step function
representing a target flow. In the target flow, it is desired that
the flow remain constant from the time the pump is turned on until
the time the pump is turned off. Because of the unaccounted for
expansion of material, however, the pump has an actual flow rate 88
that does not equal the commanded flow rate 87. Rather than
immediately dropping to zero, the actual flow rate 88 experiences
an exponential decrease to zero after point 84 when the pump is
turned off.
[0036] FIGS. 6a and 6b graphically illustrate flow of material when
a liquifier pump according the prior art is turned on. FIG. 6a
illustrates of an extrusion profile 90, while FIG. 6b is a
graphical representation of the amount of flow. In the extrusion
profile 90, the extrusion head is moving at a constant velocity to
the right. The liquifier pump remains on until it almost reaches
steady state and then it is commanded off. At a first tool path
point 92, the pump is commanded on at a flow rate 97 which is
constant, but not all of the commanded flow is immediately
extruded. Three time constants later, at a second tool path point
94, the flow rate 97 is commanded off. Along a portion 95 of
extrusion profile 90, between points 92 and 94, the extruded bead
widens as actual flow rate 98 approaches the commanded flow rate
97. At point 94, the actual flow rate 98 catches up to the
commanded flow rate 97. As in the example of FIGS. 5a and 5b, flow
continues after the pump is turned off due to the thermal expansion
of material in the liquifier. The volume of flow missing when the
pump is commanded on equals the excess volume of material extruded
after the pump is commanded off (mass in equals mass out).
[0037] In FIG. 6b, the commanded flow rate 97 is a step function
representing a target flow rate. As described above, when the pump
is turned on at point 92, the actual flow rate 98 does not
initially equal the commanded flow rate 97, but rather
exponentially increases to commanded flow rate 97. The time
required to reach steady state, or the commanded flow rate 97, is
equal to the time it takes for heat from the walls of the liquifier
to be conducted to the center of the solid material. The melt flow
time constant (.tau..sub.MF) for this behavior is between 1 and 3
seconds for filaments with 0.070 nominal diameters, and the time to
reach steady state is equal to about 3 to 4 time constants.
[0038] The output flow rate of liquid material, Q.sub.oL, is
affected by both the rate that material fed into the liquifier
(Q.sub.iS) and the rate that the solid filament melts (Q.sub.M).
The output flow rate of material due to melting (i.e., "melt
flow"), can be predicted by the equation:
Q.sub.MFL=%.sub.MF*Q.sub.M (1)
[0039] Where %.sub.MF is the percent expansion of the modeling
material during melting, and Q.sub.MFL is the output flow rate of
liquid material due to melting. The present invention models the
output flow rate of liquid material Q.sub.oL as the sum of the rate
that the material is fed into the liquifier and the melt flow
component:
Q.sub.oL32 Q.sub.iS+Q.sub.MFL=Q.sub.iS+%.sub.MF*Q.sub.M (2)
[0040] At any given time, the output rate of liquid material
Q.sub.oL may be written as a function of the output rate of solid
material Q.sub.oS according to the equation:
Q.sub.oL=Q.sub.oS(1+%.sub.MF), (3)
[0041] and the output rate of solid material Q.sub.oS may thus be
written as: 1 Q oS = Q oL 1 + % MF = Q 1 S + % MF * Q M 1 + % MF (
4 )
[0042] Equation (4) can be reduced as follows: 2 Q oS = Q iS 1 + %
MF + % MF * Q M 1 + % MF ( 5 )
[0043] At steady state conditions Q.sub.M=Q.sub.iS, and equation
(5) reduces to:
Q.sub.oS=Q.sub.iS (6)
[0044] At non-steady state conditions, equation (5) can also be
simplified by recognizing that the rate of solid material extrusion
due to melting can be predicted by the equation: 3 Q MFS = % MF * Q
M 1 + % MF ( 7 )
[0045] so that the output rate of solid material Q.sub.oS is given
by: 4 Q oS = Q iS 1 + % MF + Q MFS ( 8 )
[0046] The present invention compensates for the melt flow caused
by material expansion in setting the commanded input rate, so that
the output flow rate will approximately match a target flow rate.
In the previous examples, a step input was assumed and the
liquifier pump was on for at least three time constants so that
near steady state conditions were achieved. Any melt flow as a
function of time, however, can be compensated for using the present
invention.
[0047] The melt flow can be represented as a function of time, in
any number of ways that may be suitable for a given operating
system. A suitable expression for the filament pump liquifier of
the exemplary embodiment is the exponential expression: 5 Q MFS = %
MF * Q iS 1 + % MF * ( 1 - - t MF ) ( 9 )
[0048] where .tau..sub.MF is the time constant that defines the
exponential increase in flow rate due to melting, and Q.sub.MFS is
the rate of solid material extrusion due to melt expansion (i.e.,
the flow rate of material due to expansion that has been
re-solidified after extrusion). Taking the derivative of equation
(9), the difference equation .DELTA.Q.sub.MFS is represented as: 6
Q MFS = ( % MF * Q iS 1 + % MF - Q MFS ) * t MF ( 10 )
[0049] Equation (10) is then used to calculate the change in melt
flow from one step in time to the next. This calculation is valid
for any given flow history, and is valid regardless of the form of
the input flow.
[0050] FIGS. 7a and 7b graphically illustrate a flow of material
produced by a liquifier pump, in which melt flow is taken into
account according to the present invention. FIG. 7a illustrates an
extrusion profile 100 extruded by a liquifier pump in accordance
with the present invention, while FIG. 7b is a graphical
representation of the amount of flow produced by the liquifier
pump.
[0051] In extruding extrusion profile 100, the extrusion head moves
at a constant velocity to the right. At a first point 102, the pump
is turned on, with a commanded flow rate 104 set at a rate higher
than the target flow rate. The commanded flow rate 104 is then
exponentially decayed to the target rate. At a second point 106,
the commanded flow rate 104 first reverses direction and then
exponentially decays up to the target flow of zero. In this way,
the extrusion profile 100 has a constant bead width, and an actual
flow rate 108 equals the target flow rate. Importantly, the amount
of excess flow when the pump is turned on equals the shortage in
flow when the pump is turned off.
Method
[0052] The first step in compensating for melt flow rate is to
determine the target output flow rate at each time step. The target
rate is the desired output flow rate of either liquid material or
re-solidified material, selected so as to achieve (approximately)
the desired extrusion profile. For convenience of discussion
herein, the target rate is viewed as the desired output flow rate
of re-solidified material. This target flow rate, along with the
constants representing thermal properties of the operating system
(the melt flow time constant, .tau..sub.MF, and the percent melt
expansion, %.sub.MF), are then used to calculate the commanded
input flow rate at each time step. To calculate a commanded input
flow rate, the melt flow component of the output flow rate from one
time step to another is predicted. The melt flow rate may be
predicted by calculating the change in rate of solid material
extrusion due to melt expansion, .DELTA.Q.sub.MFS, for each time
step. When the liquifier first becomes active after not having
extruded for at least four melt flow time constants, the initial
melt flow rate .DELTA.Q.sub.MFS is assumed to be zero. The change
in melt flow rate .DELTA.Q.sub.MFS is added to the previous value
of melt flow rate to calculate a new value of melt flow rate. This
new melt flow rate is then subtracted from the target flow rate in
the system controller to produce the desired extrusion profile.
This calculation is repeated for every time step until the
liquifier becomes inactive.
Implementation
[0053] An implementation of the present invention can be performed
by identifying for a given operating system the percent expansion
due to melt flow, %.sub.MF, and the melt flow time constant,
.tau..sub.MF; defining equations for several variables:
.DELTA.Q.sub.MFS, temporary variable Q.sub.MFS,t representing the
melt flow component of solid material extrusion at a time t, and
the commanded output variable, Q.sub.iS; providing two input
variables, the time step, .DELTA.t, and the target flow rate,
Q.sub.Target, which is a function of time; and providing an initial
value for Q.sub.MFS,t-1.
[0054] An algorithm for implementing the present invention in an
operating system using a liquifier pump as described in the
exemplary embodiment herein is as follows:
At t=0, Q.sub.MFS,t=Q.sub.MFS,t-1=.DELTA.Q.sub.MFS=0
[0055] At time t, the melt flow component of the rate of solid
material extrusion is given by:
Q.sub.MFS,t=Q.sub.MFS,t-1+.DELTA.Q.sub.MFS (1)
[0056] The input flow rate of solid material that is to be
commanded so as to approximate the target flow rate at the time
step from t-1 to t may then be calculated using equation (8)
derived above for Q.sub.iS:
Q.sub.iS(1+%.sub.MF)*(Q.sub.Target-Q.sub.MFS,t) (12)
[0057] The system controller commands the material advance
mechanism to provide material to the liquifier at the calculated
input flow rate, to achieve the target flow rate for the time step.
The change in melt flow rate from that time step to the next is
given by application of equation (10) derived above: 7 Q MFS = ( %
MF * Q iS 1 + % MF - Q MFS , t ) * t MF ( 13 )
[0058] The calculated change in melt flow rate is then used in
equation (11) and the algorithm is repeated for each time step.
[0059] It should be understood that the percent expansion,
%.sub.MF, and the melt flow time constant, .tau..sub.MFS, are
unique to a given operating system. These properties can be
calculated or they can be empirically measured for a given modeling
material at the operating temperature of a particular operating
system. In the exemplary embodiment illustrated in FIG. 1, the melt
flow time constant for the system may be estimated from a model of
radial heat conduction in a long cylinder. In this case, the
filament is a long cylinder suddenly exposed to an increase in
outer wall temperature by being forced into a hot liquefier. Chart
solutions for this classical heat transfer situation are presented
in many different heat transfer texts, for instance "Temperature
Charts for Induction and Constant Temperature Heating", Heisler, M.
P., Trans. ASME, 69, (1947). The chart line representing the
constant wall temperature boundary condition may be expressed as
being proportional to exp[-(5.31*.alpha.*t)/(r.sub.0.sup.2)], where
.alpha. is the thermal diffusivity of the modeling material and
r.sub.0 is the filament radius. The melt flow time constant in this
situation is given by the equation:
.tau..sub.MF=(r.sub.0.sup.2)/(5.31*.alpha.)
[0060] where .alpha.=material thermal
diffusivity=k/(.rho.*c.sub.p), with k being thermal conductivity,
.rho. being density, and c.sub.p being specific heat.
[0061] In the case of an ABS filament used in Stratasys.RTM.
three-dimensional modeling machines:
[0062] r.sub.0=0.035 inch
[0063] c.sub.p=0.45 BTU/(lbm-F) (average value, 25.degree. C. to
250.degree. C.)
[0064] .rho.=0.0376 lbm/in.sup.3
[0065] k=2.28 E-6 BTU/(sec-in-F)
[0066] Thus, .alpha.=2.28E-6/(0.0376*0.45)=135 E-6 (in.sup.2/sec),
and .tau..sub.MF=(0.035).sup.2/(5.31* 135E-6)=1.7 sec. The specific
volume for a polystyrene material (which is representative of ABS)
changes from 0.96 cm.sup.3/gm at 30.degree. C. to 1.06 cm.sup.3/gm
at 250.degree. C. ("PVT Data for polymers"; Zoller and Walsh,
Technomic Publishing, 1995, page 133). This is an increase of 10%;
thus %.sub.MF=0.10 for this material.
[0067] The values for the melt flow time constant and percent
expansion obtained theoretically are estimates of the actual system
values, made based upon engineering assumptions. These constants
can be modified by physical observations of real errors in
extrusion profiles given by a physical operating system to obtain
values that more accurately characterize the real system responses.
On a Stratasys.RTM. FDM.RTM. three-dimensional modeling machine,
the melt flow time constant for the ABS thermoplastic was
empirically measured as 2.0 seconds, and the melt flow expansion
was measured as 8 percent. On this machine using the empirically
derived constants, the worst case errors in extrusion profile were
reduced by 80-90 percent.
Glossary
[0068] The following table defines some of the variables used
throughout this application:
1 Symbol Definition Q.sub.iS Commanded liquifier input rate of
solid material. Q.sub.oS Output rate of material after it has re-
solidified. Q.sub.M Rate of melting of solid material in the
liquifier. Q.sub.MFL Output flow rate of liquid material due to
melt expansion. Q.sub.oL Output flow rate of liquid material.
Q.sub.MFS Output rate of solid material extrusion due to melt
expansion. Q.sub.Target Liquifier target output flow rate. %.sub.MF
Percent expansion of modeling material due to temperature change,
in decimal form. .tau..sub.MF Melt flow time constant of
liquifier.
[0069] Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention. For example,
the present description focuses on three-dimensional modeling
applications, but it should be understood that the melt flow
compensation of the present invention is applicable in other types
of extrusion systems that seek to achieve a predetermined extrusion
profile. Other fields in which the present invention can be applied
include adhesive dispensing applications (e.g., assembly of cars,
diapers, boxes and clothing) and solder paste extrusion (used, for
example, in fabrication of circuit boards). Further, in the
exemplary operating system described herein, the melt flow rate has
a response that approximates an exponential function dependent upon
the melt flow time constant of the liquifier. Accordingly, in the
preferred embodiment of the invention, the commanded pump flow rate
is determined according to the estimated exponential profile of
melt flow. The exponential function has the advantage of simplicity
while providing sufficient accuracy for most applications. The flow
rate profile for a given operating system may, however, be fitted
to other types of time-responsive functions, for example, a
polynomial function or higher-order equations, which are more
complex but may provide greater accuracy. The melt flow
compensation of the present invention can be implemented using
look-up tables, particularly where a more complex model of melt
flow is used.
* * * * *