Fill level sensing devices and additive manufacturing apparatuses including same

Patent metadata

Field	Value
Publication number	US-12429367-B1
Application number	US-202418609427-A
Country	US
Kind code	B1
Filing date	Mar 19, 2024
Priority date	Mar 19, 2024
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

Disclosed herein are particulate separation systems including a filter device that separates particulates from a particulate-laden stream generated by an additive manufacturing apparatus. A collection container is also included which is fluidly connected to the filter device and receives the particulates separated from the particulate-laden stream. A fill level sensor is further included which is fluidly connected to the collection container and detects a pressure change from displacement of an inert gas by the particulates received in the collection container.

First claim

What is claimed is:

1. A particulate separation system, comprising:
a filter device that separates particulates from a particulate-laden stream generated by an additive manufacturing apparatus;
a collection container fluidly connected to the filter device that receives the particulates separated from the particulate-laden stream; and
a fill level sensor fluidly connected to the collection container that detects a pressure change from displacement of an inert gas by the particulates received in the collection container, the pressure change utilized to detect a fill level of particulates within the collection container, wherein the fill level sensor comprises:
an inlet valve to control a flow of the inert gas from an inert gas tank to the collection container;
a reference chamber located downstream of the inlet valve;
an outlet valve to control venting of the collection container and the reference chamber to an ambient environment; and
a reference chamber valve located between the inlet valve and the reference chamber to control a flow of the inert gas from the inert gas tank to the reference chamber; and

an electronic control unit including a processor and a memory module operatively connected to elements of the fill level sensor, the electronic control unit being configured to detect the fill level of particulates within the collection container by:
opening the outlet valve to release pressure from within the collection container;
closing the outlet valve and measuring an initial pressure within the collection container;
opening the inlet valve for a first period of time to pressurize the collection container with the inert gas from the inert gas tank;
closing the inlet valve and opening the reference chamber valve for a second period of time to allow pressure within the collection container and the reference chamber to equilibrate; and
measuring an end pressure within the collection container after equilibration, the reference chamber valve remaining open during measurement of the end pressure,

wherein the initial pressure and the end pressure within the collection container determine the pressure change that is then utilized to detect a fill level of particulates within the collection container.

2. The particulate separation system of claim 1 , wherein the fill level sensor further comprises a pressure sensor fluidly connected to the collection container, and a second pressure sensor fluidly coupled to the reference chamber.

3. The particulate separation system of claim 1 , wherein the fill level sensor further comprises:
a temperature sensor fluidly connected to the collection container, the temperature sensor configured to detect a temperature within the collection container, the detected temperature utilized to determine the pressure change.

4. The particulate separation system of claim 1 , wherein the fill level sensor further comprises a gas flow meter fluidly connected to the collection container.

5. The particulate separation system of claim 4 , wherein a gas volume meter is fluidly connected to the gas flow meter.

6. The particulate separation system of claim 4 , wherein the gas flow meter is located downstream of each of the inlet valve and the reference chamber valve.

7. The particulate separation system of claim 1 , wherein the collection container includes a body and a neck provided at an upper surface of the body, the neck having a diameter less than a diameter of the body.

8. The particulate separation system of claim 7 , wherein the fill level sensor is fluidly connected to the collection container at an inlet connection, the inlet connection extending through the neck of the collection container.

9. The particulate separation system of claim 1 , further comprising:
a user interface,
wherein the electronic control unit is communicatively coupled to the fill level sensor and the user interface, the electronic control unit configured to transmit a signal to the user interface to display a determined fill level percentage within the collection container.

10. The particulate separation system of claim 9 , wherein the electronic control unit is configured to transmit a signal to the user interface to display a determined fill level percentage within the collection container when the determined fill level percentage exceeds a threshold fill level percentage level.

11. The particulate separation system of claim 10 , wherein the user interface initiates an alarm event in which an audio and/or visual alarm is provided when the determined fill level percentage exceeds the threshold fill level percentage level.

12. The particulate separation system of claim 1 , the reference chamber valve also being located between the collection container and the reference chamber to thereby control communication between volumes of the collection container and the reference chamber, wherein the volumes of the collection container and the reference chamber and a temperature within the fill level sensor remain known constants during measurements of pressures within the collection container, such that variations in the pressure change detected are caused only by variations in the fill level of particulates within the collection container.

13. An apparatus comprising:
a collection container having a container interior that receives material used in an additive manufacturing apparatus; and
a fill level sensor fluidly connected to the container interior that detects a pressure change from displacement of an inert gas by the material received in the container interior, the fill level sensor comprises:
an inlet valve to control a flow of the inert gas from an inert gas tank to the collection container;
a reference chamber located downstream of the inlet valve;
an outlet valve to control venting of the collection container and the reference chamber to an ambient environment; and
a reference chamber valve located between the inlet valve and the reference chamber to control a flow of the inert gas from the inert gas tank to the reference chamber; and

an electronic control unit including a processor and a memory module operatively connected to elements of the fill level sensor, the electronic control unit being configured to detect the fill level of particulates within the collection container by:
opening the outlet valve to release pressure from within the collection container;
closing the outlet valve and measuring an initial pressure within the collection container;
opening the inlet valve for a first period of time to pressurize the collection container with the inert gas from the inert gas tank;
closing the inlet valve and opening the reference chamber valve for a second period of time to allow pressure within the collection container and the reference chamber to equilibrate; and
measuring an end pressure within the collection container after equilibration, the reference chamber valve remaining open during measurement of the end pressure,

wherein the initial pressure and the end pressure within the collection container determine the pressure change that is then utilized to detect a fill level of particulates within the collection container.

14. The apparatus of claim 13 , wherein the fill level sensor further comprises a pressure sensor fluidly connected to the container interior, and a second pressure sensor fluidly coupled to the reference chamber.

15. The apparatus of claim 13 , wherein the fill level sensor further comprises a temperature sensor fluidly connected to the container interior.

16. The apparatus of claim 13 , wherein the collection container includes a body and

Assignees

• Concept Laser Gmbh

Inventors

• Betz Florian
• Jäger Olaf

Classifications

• B07B13/18

  Control · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B22F12/70

  Gas flow means · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title