US20200038952A1 - System And Method For Additive Manufacturing - Google Patents
System And Method For Additive Manufacturing Download PDFInfo
- Publication number
- US20200038952A1 US20200038952A1 US16/053,080 US201816053080A US2020038952A1 US 20200038952 A1 US20200038952 A1 US 20200038952A1 US 201816053080 A US201816053080 A US 201816053080A US 2020038952 A1 US2020038952 A1 US 2020038952A1
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- United States
- Prior art keywords
- dispenser
- powder
- binder
- rotational axis
- supporting structure
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/003—Apparatus, e.g. furnaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/10—Formation of a green body
- B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
- B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/30—Platforms or substrates
- B22F12/37—Rotatable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/50—Means for feeding of material, e.g. heads
- B22F12/52—Hoppers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/50—Means for feeding of material, e.g. heads
- B22F12/55—Two or more means for feeding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/60—Planarisation devices; Compression devices
- B22F12/63—Rollers
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- B22F3/008—
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/227—Driving means
- B29C64/241—Driving means for rotary motion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/255—Enclosures for the building material, e.g. powder containers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/321—Feeding
- B29C64/329—Feeding using hoppers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/321—Feeding
- B29C64/336—Feeding of two or more materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/10—Pre-treatment
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- Y—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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present disclosure relates to a system and method for additive manufacturing, and particularly, for additive manufacturing of stators.
- Stators for electric motors can include lamination stacks having alternating layers of magnetically susceptible layers and insulating layers.
- the insulating layers reduce eddy current losses in the stator. Reducing the thicknesses of the layers can further reduce eddy current losses.
- the present disclosure provides a system and method for manufacturing laminated stators (or other laminated components) that allow each individual layer to be formed very thin while also allowing for a variety of features to be formed on or in the stator.
- the present disclosure provides a system that may include a table, a supporting structure, a first powder dispenser, and a second powder dispenser.
- the table may be rotatable about a first rotational axis.
- the supporting structure may be mounted for movement relative to the table.
- the first powder dispenser may be mounted to the supporting structure and may extend radially across the table.
- the first powder dispenser may include a first outlet disposed vertically above the table.
- the second powder dispenser may be mounted to the supporting structure and may extend radially across the table.
- the second powder dispenser may include a second outlet disposed vertically above the table.
- the table may be rotatable about the first rotational axis relative to the supporting structure and the first and second powder dispensers.
- the first and second powder dispensers may be movable with the supporting structure relative to the table in a direction parallel to the first rotational axis.
- the system may include a binder dispenser mounted to the supporting structure and extending radially across the table, the binder dispenser having a third outlet disposed vertically above the table.
- the binder dispenser may be circumferentially spaced apart from the first and second powder dispensers.
- the binder dispenser may be movable with the supporting structure relative to the table in the direction parallel to the first rotational axis.
- the system of one or both of the above paragraphs may include a compacting roller mounted to the supporting structure and disposed vertically above the table.
- the compacting roller may be rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis.
- the compacting roller includes a frustoconical rolling surface.
- the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser.
- the system of one or more of the above paragraphs may include a curing element attached to the supporting structure and extending radially across the table.
- the curing element may be disposed vertically above the table.
- the binder dispenser may be disposed circumferentially between the curing element and the second powder dispenser.
- the system of one or more of the above paragraphs may include a third powder dispenser mounted to the supporting structure and extending radially across the table.
- the third powder dispenser may include a fourth outlet disposed vertically above the table.
- the third powder dispenser may be circumferentially spaced apart from the first and second powder dispensers.
- the third powder dispenser may be movable with the supporting structure relative to the table in the direction parallel to the first rotational axis.
- the first and second powder dispensers are rotationally fixed relative to the first rotational axis.
- the present disclosure provides a system that may include a table, a first powder dispenser, a second powder dispenser, and a binder dispenser.
- the table may be rotatable about a first rotational axis.
- the first powder dispenser may extend radially across the table.
- the first powder dispenser may include a first outlet disposed vertically above the table.
- the second powder dispenser may extend radially across the table.
- the second powder dispenser may include a second outlet disposed vertically above the table.
- the binder dispenser may extend radially across the table.
- the binder dispenser may include a third outlet disposed vertically above the table.
- the binder dispenser may be circumferentially spaced apart from the first and second powder dispensers.
- the table may be rotatable about the first rotational axis relative to the first and second powder dispensers and the binder dispenser.
- the first and second powder dispensers and the binder dispenser may be movable relative to the table in a direction parallel to the first rotational axis.
- the first and second powder dispensers and the binder dispenser may be rotationally fixed relative to each other.
- the system of one or more of the above paragraphs may include a supporting structure supporting the first and second powder dispensers and the binder dispenser and movable with the first and second powder dispensers and the binder dispenser in the direction parallel to the first rotational axis.
- the system of one or more of the above paragraphs may include a compacting roller mounted to the supporting structure and extending radially across the table from the supporting structure.
- the compacting roller may be disposed vertically above the table.
- the compacting roller may be rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis.
- the second rotational axis is disposed at a non-perpendicular angle relative to the first rotational axis.
- the supporting structure is disposed radially inward relative to an inner diameter of the table.
- the first and second powder dispensers, the binder dispenser and the compacting roller may extend radially outward from the supporting structure.
- the compacting roller includes a frustoconical rolling surface.
- the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser.
- the system of one or more of the above paragraphs may include a curing element extending radially across the table.
- the curing element may be disposed vertically above the table.
- the binder dispenser may be disposed circumferentially between the curing element and the second powder dispenser.
- the system of one or more of the above paragraphs may include a third powder dispenser extending radially across the table.
- the third powder dispenser may include a fourth outlet disposed vertically above the table.
- the third powder dispenser may be circumferentially spaced apart from the first and second powder dispensers and the binder dispenser.
- the third powder dispenser may be movable with the first and second powder dispensers and the binder dispenser relative to the table in the direction parallel to the first rotational axis.
- the present disclosure provides a manufacturing method that may include: rotating a table about a first rotational axis; dispensing a powdered magnetically susceptible material onto the table while the table is rotating; dispensing a powdered insulating material onto the table while the table is rotating; dispensing a binder material onto the table while the table is rotating; forming a plurality of first layers of the magnetically susceptible material on the table; and forming a plurality of second layers of the insulating material on the table, wherein each of the second layers is disposed axially between adjacent first layers.
- the method may include removing the first and second layers from the table and subsequently heating the first and second layers in an oven.
- the first and second layers are discrete layers.
- the first and second layers cooperate to form a single, continuous helical coil.
- the method of one or more of the above paragraphs may include: compacting the powdered magnetically susceptible material on the table using a compacting roller; and curing the binder material after compacting the powdered magnetically susceptible material.
- the method of one or more of the above paragraphs may include forming apertures in the first and second layers by ceasing dispensation of the powdered magnetically susceptible material and the powdered insulating material at selected locations radially between inner and outer diameters of the first and second layers.
- the method of one or more of the above paragraphs may include forming an electrically conductive path through the plurality of first and second layers by dispensing powdered conductive material at selected locations on each of the first and second layers.
- FIG. 1 is a perspective view of an additive manufacturing system and layers of a stator being manufactured by the system;
- FIG. 2 is an overhead view of the system and stator
- FIG. 3 is a side view of the system and stator
- FIG. 4 is a partially exploded view of the stator
- FIG. 5 is a partial cross-sectional view of the stator taken at line 5 - 5 of FIG. 4 ;
- FIG. 6 is a partial cross-sectional view of another example stator
- FIG. 7 is a schematic representation of the stator inside of an oven
- FIG. 8 is a partially exploded view of an alternative stator that can be manufactured by the system.
- FIG. 9 is an overhead view of a plurality of the systems attached to each other by a common platen.
- an additive manufacturing system 10 can form a layered or laminated object such as a stator 12 of an electrical motor or a core of a transformer, for example.
- the system 10 can form and bond alternating laminations of different materials.
- the system 10 can form and bond alternating laminations of a magnetically susceptible material (e.g., powdered steel) and an insulating material (e.g., powdered silica and/or nylon).
- the laminated stator 12 can be heated or sintered in an oven or furnace 14 (shown schematically in FIG. 7 ) to coalesce the powdered materials.
- the system 10 may include a rotating table 16 , a supporting column (i.e., a supporting structure) 18 , a first powder material dispenser 20 , a second powder material dispenser 22 , a compacting roller 24 , a binder dispenser 26 , and a curing element 28 .
- the system 10 may include a third powder material dispenser 31 .
- the rotating table 16 can be a disk-shaped platen having an outer diameter 30 and an inner diameter 32 .
- the inner diameter 32 defines a central aperture 34 .
- the table 16 may be mounted to a stationary base or a frame (not shown).
- a first actuator 36 e.g., an electric motor; shown schematically in FIG. 3
- the first actuator 36 may be coupled to the table 16 and is operable to rotate the table 16 about a first rotational axis A 1 relative to the supporting column 18 , the dispensers 20 , 22 , 26 , 31 , the compacting roller 24 , and the curing element 28 .
- the first actuator 36 rotates the table 16 in a clockwise rotational direction viewed from the frame of reference of FIG. 2 .
- the supporting column 18 may support the dispensers 20 , 22 , 26 , 31 , the compacting roller 24 and the curing element 28 above the table 16 .
- the supporting column 18 may be mounted to a stationary base or a frame (e.g., the same base or frame to which the table 16 is mounted or a different frame or base).
- the supporting column 18 may be disposed radially inward relative to the inner diameter 32 of the table 16 .
- the supporting column 18 may extend vertically along the first rotational axis A 1 of the table 16 .
- the supporting column 18 has a cylindrical shape. In other embodiments, the supporting column 18 may have any other suitable shape. As shown schematically in FIG.
- a second actuator 38 (e.g., an electric motor or a hydraulic or pneumatic actuator) may be coupled to the supporting column 18 and may drive the supporting column 18 (as well as the dispensers 20 , 22 , 26 , 31 , the compacting roller 24 , and the curing element 28 attached to the supporting column 18 ) relative to the table 16 in a direction along or parallel to the first rotational axis A 1 .
- one column 18 or a plurality of columns 18 can be attached to a platen that is movable along the first rotational axis A 1 .
- the first and second dispensers 20 , 22 may be fixedly attached to the supporting column 18 and may extend radially outward from the supporting column 18 and across the table 16 (i.e., across the outer and inner diameters 30 , 32 of the table 16 ).
- the table 16 rotates beneath the first and second dispensers 20 , 22 .
- the first and second dispensers 20 , 22 can be any suitable type of powder material dispensers, such as ultrasonic dispensers, for example.
- the first dispenser 20 may dispense the magnetically susceptible material
- the second dispenser 22 may dispense the insulating material.
- Each of the first and second dispensers 20 , 22 may include a material reservoir 23 (that receives powder material from a source of powder material) and one or more nozzles or one or more outlets 25 through which the powder material can be dispensed onto the table 16 as the table 16 rotates.
- the first and second dispensers 20 , 22 can selectively dispense a desired amount of their respective materials at any one or more radial locations along the radial extent of the table 16 between the outer and inner diameters 30 , 32 of the table 16 .
- the compacting roller 24 smooths and compacts powder material dispensed onto the table 16 from the dispensers 20 , 22 .
- the compacting roller 24 may be attached to the supporting column 18 and may extend radially outward from the supporting column 18 and across the table 16 (i.e., across the outer and inner diameters 30 , 32 of the table 16 ).
- the table 16 rotates beneath the compacting roller 24 .
- the compacting roller 24 is circumferentially spaced apart from the first and second dispensers 20 , 22 .
- a bearing 40 ( FIG. 1 ) mounted to the supporting column 18 may support the compacting roller 24 for rotation about a second rotational axis A 2 .
- the second rotational axis A 2 is disposed at an angle (e.g., a non-zero, non-perpendicular angle) relative to the first rotational axis A 1 of the table 16 .
- the compacting roller 24 includes a rolling surface 42 that can rollingly contact the stator 12 on the table 16 .
- the rolling surface 42 may have a frustoconical shape including a first end 44 and a second end 46 .
- the first end 44 may be disposed at or near the inner diameter 32 of the table 16 .
- the second end 46 may be disposed at or near the outer diameter 30 of the table 16 .
- the diameter of the rolling surface 42 increases as the rolling surface 42 extends axially from the first end 44 to the second end 46 .
- This variation of the diameter of the rolling surface 42 allows the linear velocity of the rolling surface 42 (relative to the rotating table 16 ) to be equal at every location along the axial length of the rolling surface 42 . This allows the compacting roller 24 to compact and smooth the powder material equally at all radial positions of the table 16 between the outer and inner and outer diameters 30 , 32 .
- the binder dispenser 26 may be fixedly attached to the supporting column 18 and may extend radially outward from the supporting column 18 and across the table 16 (i.e., across the outer and inner diameters 30 , 32 of the table 16 ).
- the table 16 rotates beneath the binder dispenser 26 .
- the binder dispenser 26 may be circumferentially spaced apart from the compacting roller 24 such that the compacting roller 24 is disposed circumferentially between the binder dispenser 26 and the first and second dispensers 20 , 22 (i.e., powder material dispensed onto the table 16 by the first or second dispenser 20 , 22 is compacted and smoothed by the compacting roller 24 before passing beneath the binder dispenser 26 ).
- the binder dispenser 26 can be any suitable type of dispenser (e.g., a binder jet).
- the binder dispenser 26 may dispense a binder material (e.g., an adhesive) onto powder material that has been dispensed onto the table 16 by the dispensers 20 , 22 and smoothed and compacted by the compacting roller 24 .
- the binder dispenser 26 may include a material reservoir 27 (that receives the binder material from a source of binder material) and one or more nozzles or one or more outlets 29 through which the binder material can be dispensed onto the table 16 as the table 16 rotates.
- the binder dispenser 26 can selectively dispense a desired amount of the binder material at any one or more radial locations along the radial extent of the table 16 between the outer and inner diameters 30 , 32 of the table 16 .
- the curing element 28 may extend radially across the table 16 (e.g., across the outer and inner diameters 30 , 32 of the table 16 ).
- the curing element 28 may be a heat source (e.g., an electric resistance heater with heating coils, a flame source, a laser, a heated roller, etc.) or an ultraviolet (UV) light source, for example.
- the curing element 28 may be circumferentially spaced apart from the binder dispenser 26 such that the binder dispenser 26 is disposed circumferentially between the compacting roller 24 and the curing element 28 (i.e., binder material dispensed onto the table 16 by the binder dispenser 26 passes beneath the curing element 28 ).
- the curing element 28 may at least partially cure the binder material to bind the particles of powder material to each other.
- the third powder material dispenser 31 may be fixedly attached to the supporting column 18 and may extend radially outward from the supporting column 18 and across the table 16 (i.e., across the outer and inner diameters 30 , 32 of the table 16 ).
- the table 16 rotates beneath the third dispenser 31 .
- the third dispenser 31 can be any suitable type of powder material dispenser, such as an ultrasonic dispenser, for example.
- the third dispenser 31 may dispense an electrically conductive material (e.g., copper).
- the third dispenser 31 may include a material reservoir 48 (that receives powder material from a source of powder material) and one or more nozzles or one or more outlets 50 through which the powder material can be dispensed onto the table 16 as the table 16 rotates.
- the third dispenser 31 can selectively dispense a desired amount of powder material at any one or more radial locations along the radial extent of the table 16 between the outer and inner diameters 30 , 32 of the table 16 .
- a control module 52 may be in communication with the first and second actuators 36 , 38 , the dispensers 20 , 22 , 26 , 31 and the curing element 28 .
- the control module 52 may control operation of the first and second actuators 36 , 38 to move the table 16 and supporting column 18 , respectively, as desired.
- the control module 52 may also control operation of the dispensers 20 , 22 , 26 , 31 and the curing element 28 to dispense, bond and cure the desired materials in the desired locations.
- the control module 52 may include processing circuitry configured to execute instructions stored on at least one non-transitory, tangible computer-readable medium.
- an actuator (not shown) can drive rotation of the compacting roller 24 (e.g., rotation about the second rotational axis A 2 ).
- the control module 52 could control operation of such an actuator to drive the compacting roller 24 in desired directions and at desired speeds.
- the compacting roller 24 could be driven by the first actuator 36 (e.g., via a linkage, gears, etc. coupling the compacting roller 24 to the table 16 or directly to first actuator 36 ).
- friction between the rolling surface 42 of the compacting roller 24 and the stator 12 on the table 16 may drive rotation of the compacting roller 24 .
- the system 10 can form and bond alternating laminations of the magnetically susceptible material and the insulating material. Thereafter, the laminated stator 12 can be heated or sintered in the oven 14 ( FIG. 7 ) to coalesce the powdered materials.
- the stator 12 manufactured using the method of the present disclosure includes a plurality of discrete first layers or laminations 60 and a plurality of discrete second layers or laminations 62 .
- the first layers 60 may be formed from the magnetically susceptible material
- the second layers 62 may be formed from the insulating material.
- control module 52 may operate the first actuator 36 to rotate the table 16 and operate the first powder material dispenser 20 to dispense powdered magnetically susceptible material onto the table 16 while the table 16 is rotating.
- the control module 52 can control the first powder material dispenser 20 to dispense appropriate amounts of the powder material at desired radial locations on the table 16 to form a desired thickness of material.
- the compacting roller 24 compacts and smooths the powder material after the powder material is dispensed from the first powder material dispenser 20 , as described above. Thereafter, the compacted powder material passes beneath the binder dispenser 26 , and binder material can be dispensed onto the compacted powder material. Thereafter, the binder material and powder material pass beneath the curing element 28 , which at least partially cures the binder material to bond the particles of powder material to each other.
- the table 16 may continue to rotate and the first powder material dispenser 20 and the binder dispenser 26 may continue dispensing in this manner to form a discrete layer 60 .
- one layer 60 is formed.
- the above steps may be repeated with the second powder material dispenser 22 dispensing the powdered insulating material instead of the first powder material dispenser 20 dispensing the magnetically susceptible material.
- Another complete (360 degree) rotation of the table 16 with the second powder material dispenser 22 dispensing the insulating material will form one of the second layers 62 .
- the supporting column 18 is moved vertically upward again, and another layer 60 can be formed in the manner described above.
- the above steps can be repeated as many times as desired to form as many alternating layers 60 , 62 as desired.
- each of the layers 60 , 62 can include one or more of a variety of different features.
- each of the layers 60 , 62 could include a plurality of apertures 64 and/or a plurality of conductors 66 .
- the apertures 64 can be formed by ceasing the dispensation of powder material from the dispenser 20 , 22 only at the locations at which the apertures 64 are desired to be formed while continuing to dispense powder material from the dispenser 20 , 22 around the locations at which the apertures 64 are desired to be formed.
- the conductors 66 can be formed by ceasing dispensation of powder material from the dispenser 20 , 22 at the desired location for the conductor 66 and instead dispensing powdered electrically conductive material from third dispenser 31 at the desired location.
- selected ones of the apertures 64 in the layers 60 , 62 can be aligned with each other to form internal passages (e.g., coolant passages, air passages, bolt holes, etc.) in the stator 12 .
- selected ones of the conductors 66 in the layers 60 , 62 can be aligned with each other to form larger conductors (e.g., an electrically conductive path) that could (optionally) extend though the axial length of the stator 12 and could replace conventional wires or windings, for example.
- one of more of the layers 60 , 62 could include one or more step features (or out-of-plane features) 68 .
- one or more of the first layers 60 could include one or more step features 68 (formed from the same material as the rest of the first layer 60 ) disposed in the same plane as an adjacent second layer 62 ; and one or more of the second layers 62 could include one or more step features 68 (formed from the same material as the rest of the second layer 62 ) disposed in the same plane as an adjacent first layer 60 .
- Step features 68 in one of the first layers 60 can be formed during the formation of an adjacent second layer 62 by ceasing dispensation of powder material from the second dispenser 22 at the desired location for the step feature 68 and instead dispensing powder material from first dispenser 20 at the desired location.
- step features 68 in one of the second layers 62 can be formed during the formation of an adjacent first layer 60 by ceasing dispensation of powder material from the first dispenser 20 at the desired location for the step feature 68 and instead dispensing powder material from second dispenser 22 at the desired location.
- one or more layers 60 , 62 could be formed in one or more layers 60 , 62 .
- attachment features, splines, and/or other shapes could be formed into any of the layers 60 , 62 .
- one or more layers 60 , 62 of a given stator 12 could have thicknesses that vary and/or thicknesses that differ from the thicknesses of other layers 60 , 62 of the same stator 12 .
- FIG. 6 depicts another example of layers 60 , 62 having step features or out-of-plane features 68 that form an aperture 64 between adjacent layers 60 , 62 and with a conductor 66 between adjacent layers 60 , 62 .
- step features 68 can be formed in any desired shape to produce desired features in or on the stator 12 .
- Some of the out-of-plane features 68 may be supported by un-bonded powder during the deposition of the material forming the out-of-plane features 68 . After the material forming the out-of-plane features 68 is bonded, the un-bonded supporting powder can be removed.
- the resultant stator 12 may be heated or sintered in the oven 14 (shown in FIG. 7 ) to coalesce the powdered materials and bond the layers 60 , 62 to each other.
- some step features or out-of-plane features 68 may be support by a ceramic fixture, for example, or any other suitable fixture. Thereafter, the stator 12 can be removed from the fixture.
- the stator 112 can have alternating layers 160 , 162 (similar to the layers 60 , 62 , respectively). That is, each layer 160 is disposed axially between adjacent layers 162 .
- the layers 160 , 162 can be formed from the same or similar materials as the layers 60 , 62 , respectively, and can be formed with the same or similar features (e.g., apertures 64 , conductors 66 and/or step features 68 ) as the layers 60 , 62 of the stator 12 .
- the stator 112 can be similar to the stator 12 , except the layers 160 , 162 of the stator 112 form a single, continuous helical coil instead of the discrete layers 60 , 62 of the stator 12 .
- Each layer 160 , 162 is a segment of the continuous helical coil. Seams 164 between adjacent layers 160 , 162 could be circumferentially aligned with each other or circumferentially staggered apart from each other.
- the single, continuous helical coil of the layers 160 , 162 can be formed by continuously raising the supporting column 18 during the entire 360 degrees of rotation of the table 16 , rather than raising the supporting column 18 in discrete steps at the conclusion of each 360 degree rotation of the table 16 .
- the layers 160 of the stator 112 may be formed by dispensing powder material from the first powder dispenser 20
- the layers 162 of the stator 112 may be formed by dispensing powder from the second dispenser 22 , as described above.
- the resultant stator 112 may be heated or sintered in the oven 14 .
- a plurality of systems 10 could be operated simultaneously to form a plurality of stators 12 (or a plurality of stators 112 ) simultaneously.
- the supporting column 18 of each of the systems 10 could be mounted to a common platen 70 (shown schematically in FIG. 9 ) or any other suitable structure.
- a single actuator (not shown) could move the platen 70 to simultaneously move all of the supporting columns 18 relative to the tables 16 .
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Abstract
An additive manufacturing system may include a table, a supporting structure, a first powder dispenser, and a second powder dispenser. The table is rotatable about a first rotational axis. The supporting structure may be mounted for movement relative to the table. The first powder dispenser may be mounted to the supporting structure and may extend radially across the table. The first powder dispenser includes a first outlet disposed vertically above the table. The second powder dispenser may be mounted to the supporting structure and may extend radially across the table. The second powder dispenser includes a second outlet disposed vertically above the table. The table is rotatable about the first rotational axis relative to the supporting structure and the first and second powder dispensers. The first and second powder dispensers may be movable with the supporting structure relative to the table in a direction parallel to the first rotational axis.
Description
- The present disclosure relates to a system and method for additive manufacturing, and particularly, for additive manufacturing of stators.
- This section provides background information related to the present disclosure and is not necessarily prior art.
- Stators for electric motors can include lamination stacks having alternating layers of magnetically susceptible layers and insulating layers. The insulating layers reduce eddy current losses in the stator. Reducing the thicknesses of the layers can further reduce eddy current losses. There is a limit, however, to how thin the layers can be made by conventional methods. If the layers are made too thin, conventional manufacturing processes become unreliable and the layers become too fragile to handle and process. The present disclosure provides a system and method for manufacturing laminated stators (or other laminated components) that allow each individual layer to be formed very thin while also allowing for a variety of features to be formed on or in the stator.
- This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
- In one form, the present disclosure provides a system that may include a table, a supporting structure, a first powder dispenser, and a second powder dispenser. The table may be rotatable about a first rotational axis. The supporting structure may be mounted for movement relative to the table. The first powder dispenser may be mounted to the supporting structure and may extend radially across the table. The first powder dispenser may include a first outlet disposed vertically above the table. The second powder dispenser may be mounted to the supporting structure and may extend radially across the table. The second powder dispenser may include a second outlet disposed vertically above the table. The table may be rotatable about the first rotational axis relative to the supporting structure and the first and second powder dispensers. The first and second powder dispensers may be movable with the supporting structure relative to the table in a direction parallel to the first rotational axis.
- In some configurations, the system may include a binder dispenser mounted to the supporting structure and extending radially across the table, the binder dispenser having a third outlet disposed vertically above the table. The binder dispenser may be circumferentially spaced apart from the first and second powder dispensers. The binder dispenser may be movable with the supporting structure relative to the table in the direction parallel to the first rotational axis.
- In some configurations, the system of one or both of the above paragraphs may include a compacting roller mounted to the supporting structure and disposed vertically above the table. The compacting roller may be rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis.
- In some configurations of the system of one or more of the above paragraphs, the compacting roller includes a frustoconical rolling surface.
- In some configurations of the system of one or more of the above paragraphs, the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser.
- In some configurations, the system of one or more of the above paragraphs may include a curing element attached to the supporting structure and extending radially across the table. The curing element may be disposed vertically above the table. The binder dispenser may be disposed circumferentially between the curing element and the second powder dispenser.
- In some configurations, the system of one or more of the above paragraphs may include a third powder dispenser mounted to the supporting structure and extending radially across the table. The third powder dispenser may include a fourth outlet disposed vertically above the table. The third powder dispenser may be circumferentially spaced apart from the first and second powder dispensers. The third powder dispenser may be movable with the supporting structure relative to the table in the direction parallel to the first rotational axis.
- In some configurations of the system of one or more of the above paragraphs, the first and second powder dispensers are rotationally fixed relative to the first rotational axis.
- In another form, the present disclosure provides a system that may include a table, a first powder dispenser, a second powder dispenser, and a binder dispenser. The table may be rotatable about a first rotational axis. The first powder dispenser may extend radially across the table. The first powder dispenser may include a first outlet disposed vertically above the table. The second powder dispenser may extend radially across the table. The second powder dispenser may include a second outlet disposed vertically above the table. The binder dispenser may extend radially across the table. The binder dispenser may include a third outlet disposed vertically above the table. The binder dispenser may be circumferentially spaced apart from the first and second powder dispensers. The table may be rotatable about the first rotational axis relative to the first and second powder dispensers and the binder dispenser. The first and second powder dispensers and the binder dispenser may be movable relative to the table in a direction parallel to the first rotational axis. The first and second powder dispensers and the binder dispenser may be rotationally fixed relative to each other.
- In some configurations, the system of one or more of the above paragraphs may include a supporting structure supporting the first and second powder dispensers and the binder dispenser and movable with the first and second powder dispensers and the binder dispenser in the direction parallel to the first rotational axis.
- In some configurations, the system of one or more of the above paragraphs may include a compacting roller mounted to the supporting structure and extending radially across the table from the supporting structure. The compacting roller may be disposed vertically above the table. The compacting roller may be rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis.
- In some configurations of the system of one or more of the above paragraphs, the second rotational axis is disposed at a non-perpendicular angle relative to the first rotational axis.
- In some configurations of the system of one or more of the above paragraphs, the supporting structure is disposed radially inward relative to an inner diameter of the table. The first and second powder dispensers, the binder dispenser and the compacting roller may extend radially outward from the supporting structure.
- In some configurations of the system of one or more of the above paragraphs, the compacting roller includes a frustoconical rolling surface.
- In some configurations of the system of one or more of the above paragraphs, the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser.
- In some configurations, the system of one or more of the above paragraphs may include a curing element extending radially across the table. The curing element may be disposed vertically above the table. The binder dispenser may be disposed circumferentially between the curing element and the second powder dispenser.
- In some configurations, the system of one or more of the above paragraphs may include a third powder dispenser extending radially across the table. The third powder dispenser may include a fourth outlet disposed vertically above the table. The third powder dispenser may be circumferentially spaced apart from the first and second powder dispensers and the binder dispenser. The third powder dispenser may be movable with the first and second powder dispensers and the binder dispenser relative to the table in the direction parallel to the first rotational axis.
- In another form, the present disclosure provides a manufacturing method that may include: rotating a table about a first rotational axis; dispensing a powdered magnetically susceptible material onto the table while the table is rotating; dispensing a powdered insulating material onto the table while the table is rotating; dispensing a binder material onto the table while the table is rotating; forming a plurality of first layers of the magnetically susceptible material on the table; and forming a plurality of second layers of the insulating material on the table, wherein each of the second layers is disposed axially between adjacent first layers.
- In some configurations, the method may include removing the first and second layers from the table and subsequently heating the first and second layers in an oven.
- In some configurations of the method of one or more of the above paragraphs, the first and second layers are discrete layers.
- In some configurations of the method of one or more of the above paragraphs, the first and second layers cooperate to form a single, continuous helical coil.
- In some configurations, the method of one or more of the above paragraphs may include: compacting the powdered magnetically susceptible material on the table using a compacting roller; and curing the binder material after compacting the powdered magnetically susceptible material.
- In some configurations, the method of one or more of the above paragraphs may include forming apertures in the first and second layers by ceasing dispensation of the powdered magnetically susceptible material and the powdered insulating material at selected locations radially between inner and outer diameters of the first and second layers.
- In some configurations, the method of one or more of the above paragraphs may include forming an electrically conductive path through the plurality of first and second layers by dispensing powdered conductive material at selected locations on each of the first and second layers.
- Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
- The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
-
FIG. 1 is a perspective view of an additive manufacturing system and layers of a stator being manufactured by the system; -
FIG. 2 is an overhead view of the system and stator; -
FIG. 3 is a side view of the system and stator; -
FIG. 4 is a partially exploded view of the stator; -
FIG. 5 is a partial cross-sectional view of the stator taken at line 5-5 ofFIG. 4 ; -
FIG. 6 is a partial cross-sectional view of another example stator; -
FIG. 7 is a schematic representation of the stator inside of an oven; -
FIG. 8 is a partially exploded view of an alternative stator that can be manufactured by the system; and -
FIG. 9 is an overhead view of a plurality of the systems attached to each other by a common platen. - Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
- Example embodiments will now be described more fully with reference to the accompanying drawings.
- With reference to
FIGS. 1-3 , anadditive manufacturing system 10 is provided that can form a layered or laminated object such as astator 12 of an electrical motor or a core of a transformer, for example. Thesystem 10 can form and bond alternating laminations of different materials. To manufacture thestator 12 shown inFIGS. 1-5 , thesystem 10 can form and bond alternating laminations of a magnetically susceptible material (e.g., powdered steel) and an insulating material (e.g., powdered silica and/or nylon). Thereafter, thelaminated stator 12 can be heated or sintered in an oven or furnace 14 (shown schematically inFIG. 7 ) to coalesce the powdered materials. - As shown in
FIGS. 1-3 , thesystem 10 may include a rotating table 16, a supporting column (i.e., a supporting structure) 18, a firstpowder material dispenser 20, a secondpowder material dispenser 22, a compactingroller 24, abinder dispenser 26, and a curingelement 28. In some embodiments, thesystem 10 may include a thirdpowder material dispenser 31. - The rotating table 16 can be a disk-shaped platen having an
outer diameter 30 and aninner diameter 32. Theinner diameter 32 defines acentral aperture 34. The table 16 may be mounted to a stationary base or a frame (not shown). A first actuator 36 (e.g., an electric motor; shown schematically inFIG. 3 ) may be coupled to the table 16 and is operable to rotate the table 16 about a first rotational axis A1 relative to the supportingcolumn 18, thedispensers roller 24, and the curingelement 28. In the particular example shown in figures, thefirst actuator 36 rotates the table 16 in a clockwise rotational direction viewed from the frame of reference ofFIG. 2 . - The supporting
column 18 may support thedispensers roller 24 and the curingelement 28 above the table 16. The supportingcolumn 18 may be mounted to a stationary base or a frame (e.g., the same base or frame to which the table 16 is mounted or a different frame or base). The supportingcolumn 18 may be disposed radially inward relative to theinner diameter 32 of the table 16. The supportingcolumn 18 may extend vertically along the first rotational axis A1 of the table 16. In the particular example shown in the figures, the supportingcolumn 18 has a cylindrical shape. In other embodiments, the supportingcolumn 18 may have any other suitable shape. As shown schematically inFIG. 3 , a second actuator 38 (e.g., an electric motor or a hydraulic or pneumatic actuator) may be coupled to the supportingcolumn 18 and may drive the supporting column 18 (as well as thedispensers roller 24, and the curingelement 28 attached to the supporting column 18) relative to the table 16 in a direction along or parallel to the first rotational axis A1. In some configurations, onecolumn 18 or a plurality ofcolumns 18 can be attached to a platen that is movable along the first rotational axis A1. - The first and
second dispensers column 18 and may extend radially outward from the supportingcolumn 18 and across the table 16 (i.e., across the outer andinner diameters second dispensers second dispensers first dispenser 20 may dispense the magnetically susceptible material, and thesecond dispenser 22 may dispense the insulating material. Each of the first andsecond dispensers more outlets 25 through which the powder material can be dispensed onto the table 16 as the table 16 rotates. The first andsecond dispensers inner diameters - The compacting
roller 24 smooths and compacts powder material dispensed onto the table 16 from thedispensers roller 24 may be attached to the supportingcolumn 18 and may extend radially outward from the supportingcolumn 18 and across the table 16 (i.e., across the outer andinner diameters roller 24. The compactingroller 24 is circumferentially spaced apart from the first andsecond dispensers FIG. 1 ) mounted to the supportingcolumn 18 may support the compactingroller 24 for rotation about a second rotational axis A2. The second rotational axis A2 is disposed at an angle (e.g., a non-zero, non-perpendicular angle) relative to the first rotational axis A1 of the table 16. - The compacting
roller 24 includes a rollingsurface 42 that can rollingly contact thestator 12 on the table 16. The rollingsurface 42 may have a frustoconical shape including afirst end 44 and asecond end 46. Thefirst end 44 may be disposed at or near theinner diameter 32 of the table 16. Thesecond end 46 may be disposed at or near theouter diameter 30 of the table 16. The diameter of the rollingsurface 42 increases as the rollingsurface 42 extends axially from thefirst end 44 to thesecond end 46. This variation of the diameter of the rollingsurface 42 allows the linear velocity of the rolling surface 42 (relative to the rotating table 16) to be equal at every location along the axial length of the rollingsurface 42. This allows the compactingroller 24 to compact and smooth the powder material equally at all radial positions of the table 16 between the outer and inner andouter diameters - The
binder dispenser 26 may be fixedly attached to the supportingcolumn 18 and may extend radially outward from the supportingcolumn 18 and across the table 16 (i.e., across the outer andinner diameters binder dispenser 26. Thebinder dispenser 26 may be circumferentially spaced apart from the compactingroller 24 such that the compactingroller 24 is disposed circumferentially between thebinder dispenser 26 and the first andsecond dispensers 20, 22 (i.e., powder material dispensed onto the table 16 by the first orsecond dispenser roller 24 before passing beneath the binder dispenser 26). - The
binder dispenser 26 can be any suitable type of dispenser (e.g., a binder jet). Thebinder dispenser 26 may dispense a binder material (e.g., an adhesive) onto powder material that has been dispensed onto the table 16 by thedispensers roller 24. Thebinder dispenser 26 may include a material reservoir 27 (that receives the binder material from a source of binder material) and one or more nozzles or one ormore outlets 29 through which the binder material can be dispensed onto the table 16 as the table 16 rotates. Thebinder dispenser 26 can selectively dispense a desired amount of the binder material at any one or more radial locations along the radial extent of the table 16 between the outer andinner diameters - The curing
element 28 may extend radially across the table 16 (e.g., across the outer andinner diameters element 28 may be a heat source (e.g., an electric resistance heater with heating coils, a flame source, a laser, a heated roller, etc.) or an ultraviolet (UV) light source, for example. The curingelement 28 may be circumferentially spaced apart from thebinder dispenser 26 such that thebinder dispenser 26 is disposed circumferentially between the compactingroller 24 and the curing element 28 (i.e., binder material dispensed onto the table 16 by thebinder dispenser 26 passes beneath the curing element 28). The curingelement 28 may at least partially cure the binder material to bind the particles of powder material to each other. - The third
powder material dispenser 31 may be fixedly attached to the supportingcolumn 18 and may extend radially outward from the supportingcolumn 18 and across the table 16 (i.e., across the outer andinner diameters third dispenser 31. Thethird dispenser 31 can be any suitable type of powder material dispenser, such as an ultrasonic dispenser, for example. Thethird dispenser 31 may dispense an electrically conductive material (e.g., copper). Thethird dispenser 31 may include a material reservoir 48 (that receives powder material from a source of powder material) and one or more nozzles or one ormore outlets 50 through which the powder material can be dispensed onto the table 16 as the table 16 rotates. Thethird dispenser 31 can selectively dispense a desired amount of powder material at any one or more radial locations along the radial extent of the table 16 between the outer andinner diameters - A control module 52 (shown schematically in
FIG. 3 ) may be in communication with the first andsecond actuators 36, 38, thedispensers element 28. Thecontrol module 52 may control operation of the first andsecond actuators 36, 38 to move the table 16 and supportingcolumn 18, respectively, as desired. Thecontrol module 52 may also control operation of thedispensers element 28 to dispense, bond and cure the desired materials in the desired locations. Thecontrol module 52 may include processing circuitry configured to execute instructions stored on at least one non-transitory, tangible computer-readable medium. - In some configurations, an actuator (not shown) can drive rotation of the compacting roller 24 (e.g., rotation about the second rotational axis A2). The
control module 52 could control operation of such an actuator to drive the compactingroller 24 in desired directions and at desired speeds. In other configurations, the compactingroller 24 could be driven by the first actuator 36 (e.g., via a linkage, gears, etc. coupling the compactingroller 24 to the table 16 or directly to first actuator 36). In other configurations, friction between the rollingsurface 42 of the compactingroller 24 and thestator 12 on the table 16 may drive rotation of the compactingroller 24. - Referring now to
FIGS. 1-7 , a method of manufacturing thestator 12 using thesystem 10 will be described. As described above, thesystem 10 can form and bond alternating laminations of the magnetically susceptible material and the insulating material. Thereafter, thelaminated stator 12 can be heated or sintered in the oven 14 (FIG. 7 ) to coalesce the powdered materials. - As shown in
FIGS. 4 and 5 , thestator 12 manufactured using the method of the present disclosure includes a plurality of discrete first layers orlaminations 60 and a plurality of discrete second layers orlaminations 62. The first layers 60 may be formed from the magnetically susceptible material, and thesecond layers 62 may be formed from the insulating material. - To form one of the
first layers 60, thecontrol module 52 may operate thefirst actuator 36 to rotate the table 16 and operate the firstpowder material dispenser 20 to dispense powdered magnetically susceptible material onto the table 16 while the table 16 is rotating. Thecontrol module 52 can control the firstpowder material dispenser 20 to dispense appropriate amounts of the powder material at desired radial locations on the table 16 to form a desired thickness of material. - While the table 16 is rotating, the compacting
roller 24 compacts and smooths the powder material after the powder material is dispensed from the firstpowder material dispenser 20, as described above. Thereafter, the compacted powder material passes beneath thebinder dispenser 26, and binder material can be dispensed onto the compacted powder material. Thereafter, the binder material and powder material pass beneath the curingelement 28, which at least partially cures the binder material to bond the particles of powder material to each other. The table 16 may continue to rotate and the firstpowder material dispenser 20 and thebinder dispenser 26 may continue dispensing in this manner to form adiscrete layer 60. - After a complete (360 degree) rotation of the table 16, one
layer 60 is formed. Then, to form asecond layer 62 on top of thefirst layer 60, the above steps may be repeated with the secondpowder material dispenser 22 dispensing the powdered insulating material instead of the firstpowder material dispenser 20 dispensing the magnetically susceptible material. Another complete (360 degree) rotation of the table 16 with the secondpowder material dispenser 22 dispensing the insulating material will form one of the second layers 62. Thereafter, the supportingcolumn 18 is moved vertically upward again, and anotherlayer 60 can be formed in the manner described above. The above steps can be repeated as many times as desired to form as many alternatinglayers - If desired, each of the
layers FIG. 4 , each of thelayers apertures 64 and/or a plurality ofconductors 66. Theapertures 64 can be formed by ceasing the dispensation of powder material from thedispenser apertures 64 are desired to be formed while continuing to dispense powder material from thedispenser apertures 64 are desired to be formed. Theconductors 66 can be formed by ceasing dispensation of powder material from thedispenser conductor 66 and instead dispensing powdered electrically conductive material fromthird dispenser 31 at the desired location. - As shown in
FIG. 1 , whenmultiple layers apertures 64 in thelayers stator 12. Similarly, selected ones of theconductors 66 in thelayers stator 12 and could replace conventional wires or windings, for example. - As shown in
FIG. 5 , one of more of thelayers first layers 60 could include one or more step features 68 (formed from the same material as the rest of the first layer 60) disposed in the same plane as an adjacentsecond layer 62; and one or more of thesecond layers 62 could include one or more step features 68 (formed from the same material as the rest of the second layer 62) disposed in the same plane as an adjacentfirst layer 60. - Step features 68 in one of the
first layers 60 can be formed during the formation of an adjacentsecond layer 62 by ceasing dispensation of powder material from thesecond dispenser 22 at the desired location for thestep feature 68 and instead dispensing powder material fromfirst dispenser 20 at the desired location. Similarly, step features 68 in one of thesecond layers 62 can be formed during the formation of an adjacentfirst layer 60 by ceasing dispensation of powder material from thefirst dispenser 20 at the desired location for thestep feature 68 and instead dispensing powder material fromsecond dispenser 22 at the desired location. - It will be appreciated that a variety of other features could be formed in one or
more layers layers more layers stator 12 could have thicknesses that vary and/or thicknesses that differ from the thicknesses ofother layers same stator 12. -
FIG. 6 depicts another example oflayers aperture 64 betweenadjacent layers conductor 66 betweenadjacent layers stator 12. Some of the out-of-plane features 68 may be supported by un-bonded powder during the deposition of the material forming the out-of-plane features 68. After the material forming the out-of-plane features 68 is bonded, the un-bonded supporting powder can be removed. - Once a desired number of
layers resultant stator 12 may be heated or sintered in the oven 14 (shown inFIG. 7 ) to coalesce the powdered materials and bond thelayers stator 12 can be removed from the fixture. - Referring now to
FIG. 8 , analternative stator 112 is provided that could be formed using thesystem 10 described above. Like thestator 12, thestator 112 can have alternatinglayers 160, 162 (similar to thelayers layer 160 is disposed axially betweenadjacent layers 162. Thelayers layers apertures 64,conductors 66 and/or step features 68) as thelayers stator 12. Thestator 112 can be similar to thestator 12, except thelayers stator 112 form a single, continuous helical coil instead of thediscrete layers stator 12. Eachlayer Seams 164 betweenadjacent layers - The single, continuous helical coil of the
layers column 18 during the entire 360 degrees of rotation of the table 16, rather than raising the supportingcolumn 18 in discrete steps at the conclusion of each 360 degree rotation of the table 16. As with the formation of thelayers stator 12, thelayers 160 of thestator 112 may be formed by dispensing powder material from thefirst powder dispenser 20, and thelayers 162 of thestator 112 may be formed by dispensing powder from thesecond dispenser 22, as described above. - Like the
stator 12, once a desired number oflayers resultant stator 112 may be heated or sintered in theoven 14. - Referring now to
FIG. 9 , a plurality ofsystems 10 could be operated simultaneously to form a plurality of stators 12 (or a plurality of stators 112) simultaneously. For example, the supportingcolumn 18 of each of thesystems 10 could be mounted to a common platen 70 (shown schematically inFIG. 9 ) or any other suitable structure. A single actuator (not shown) could move theplaten 70 to simultaneously move all of the supportingcolumns 18 relative to the tables 16. - The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
Claims (25)
1. A system comprising:
a table rotatable about a first rotational axis;
a supporting structure mounted for movement relative to the table;
a first powder dispenser mounted to the supporting structure and extending radially across the table, the first powder dispenser having a first outlet disposed vertically above the table; and
a second powder dispenser mounted to the supporting structure and extending radially across the table, the second powder dispenser having a second outlet disposed vertically above the table,
wherein the table is rotatable about the first rotational axis relative to the supporting structure and the first and second powder dispensers, and wherein the first and second powder dispensers are movable with the supporting structure relative to the table in a direction parallel to the first rotational axis.
2. The system of claim 1 , further comprising a binder dispenser mounted to the supporting structure and extending radially across the table, the binder dispenser having a third outlet disposed vertically above the table, wherein the binder dispenser is circumferentially spaced apart from the first and second powder dispensers, wherein the binder dispenser is movable with the supporting structure relative to the table in the direction parallel to the first rotational axis.
3. The system of claim 2 , further comprising a compacting roller mounted to the supporting structure and disposed vertically above the table, wherein the compacting roller is rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis.
4. The system of claim 3 , wherein the compacting roller includes a frustoconical rolling surface.
5. The system of claim 3 , wherein the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser.
6. The system of claim 2 , further comprising a curing element attached to the supporting structure and extending radially across the table, wherein the curing element is disposed vertically above the table, and wherein the binder dispenser is disposed circumferentially between the curing element and the second powder dispenser.
7. The system of claim 6 , wherein the curing element includes at least one of a heat source and an ultraviolet light source.
8. The system of claim 1 , further comprising a third powder dispenser mounted to the supporting structure and extending radially across the table, the third powder dispenser having a fourth outlet disposed vertically above the table, wherein the third powder dispenser is circumferentially spaced apart from the first and second powder dispensers, wherein the third powder dispenser is movable with the supporting structure relative to the table in the direction parallel to the first rotational axis.
9. The system of claim 1 , wherein the first and second powder dispensers are rotationally fixed relative to the first rotational axis.
10. A system comprising:
a table rotatable about a first rotational axis;
a first powder dispenser extending radially across the table, the first powder dispenser having a first outlet disposed vertically above the table;
a second powder dispenser extending radially across the table, the second powder dispenser having a second outlet disposed vertically above the table; and
a binder dispenser extending radially across the table, the binder dispenser having a third outlet disposed vertically above the table, wherein the binder dispenser is circumferentially spaced apart from the first and second powder dispensers,
wherein the table is rotatable about the first rotational axis relative to the first and second powder dispensers and the binder dispenser, wherein the first and second powder dispensers and the binder dispenser are movable relative to the table in a direction parallel to the first rotational axis, and wherein the first and second powder dispensers and the binder dispenser are rotationally fixed relative to each other.
11. The system of claim 10 , further comprising a supporting structure supporting the first and second powder dispensers and the binder dispenser and movable with the first and second powder dispensers and the binder dispenser in the direction parallel to the first rotational axis.
12. The system of claim 11 , further comprising a compacting roller mounted to the supporting structure and extending radially across the table from the supporting structure, wherein the compacting roller is disposed vertically above the table, wherein the compacting roller is rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis.
13. The system of claim 12 , wherein the second rotational axis is disposed at a non-perpendicular angle relative to the first rotational axis.
14. The system of claim 12 , wherein the supporting structure is disposed radially inward relative to an inner diameter of the table, and wherein the first and second powder dispensers, the binder dispenser and the compacting roller extend radially outward from the supporting structure.
15. The system of claim 12 , wherein the compacting roller includes a frustoconical rolling surface.
16. The system of claim 12 , wherein the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser.
17. The system of claim 10 , further comprising a curing element extending radially across the table, wherein the curing element is disposed vertically above the table, and wherein the binder dispenser is disposed circumferentially between the curing element and the second powder dispenser.
18. The system of claim 10 , further comprising a third powder dispenser extending radially across the table, the third powder dispenser having a fourth outlet disposed vertically above the table, wherein the third powder dispenser is circumferentially spaced apart from the first and second powder dispensers and the binder dispenser, and wherein the third powder dispenser is movable with the first and second powder dispensers and the binder dispenser relative to the table in the direction parallel to the first rotational axis.
19. A manufacturing method comprising:
rotating a table about a first rotational axis;
dispensing a powdered magnetically susceptible material onto the table while the table is rotating;
dispensing a powdered insulating material onto the table while the table is rotating;
dispensing a binder material onto the table while the table is rotating;
forming a plurality of first layers of the magnetically susceptible material on the table; and
forming a plurality of second layers of the insulating material on the table, wherein each of the second layers is disposed axially between adjacent first layers.
20. The method of claim 19 , further comprising removing the first and second layers from the table and subsequently heating the first and second layers in an oven.
21. The method of claim 19 , wherein the first and second layers are discrete layers.
22. The method of claim 19 , wherein the first and second layers cooperate to form a single, continuous helical coil.
23. The method of claim 19 , further comprising:
compacting the powdered magnetically susceptible material on the table using a compacting roller; and
curing the binder material after compacting the powdered magnetically susceptible material.
24. The method of claim 19 , further comprising forming apertures in the first and second layers by ceasing dispensation of the powdered magnetically susceptible material and the powdered insulating material at selected locations radially between inner and outer diameters of the first and second layers.
25. The method of claim 19 , further comprising forming an electrically conductive path through the plurality of first and second layers by dispensing powdered conductive material at selected locations on each of the first and second layers.
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US16/053,080 US20200038952A1 (en) | 2018-08-02 | 2018-08-02 | System And Method For Additive Manufacturing |
DE112019003901.6T DE112019003901T5 (en) | 2018-08-02 | 2019-07-31 | Additive manufacturing system and process |
CN201980065128.7A CN112805907A (en) | 2018-08-02 | 2019-07-31 | Systems and methods for additive manufacturing |
PCT/US2019/044264 WO2020028451A1 (en) | 2018-08-02 | 2019-07-31 | System and method for additive manufacturing |
US17/155,986 US20210152062A1 (en) | 2018-08-02 | 2021-01-22 | System And Method For Additive Manufacturing |
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US16/053,080 US20200038952A1 (en) | 2018-08-02 | 2018-08-02 | System And Method For Additive Manufacturing |
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Also Published As
Publication number | Publication date |
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CN112805907A (en) | 2021-05-14 |
US20210152062A1 (en) | 2021-05-20 |
WO2020028451A1 (en) | 2020-02-06 |
DE112019003901T5 (en) | 2021-04-15 |
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