EXPLOSION-PROOF WET SEPARATOR VACUUM

A system comprises an intake, a turbine enclosed within an explosion-proof enclosure, an explosion-proof motor enclosed within the explosion-proof enclosure, the explosion-proof motor configured to drive the turbine to create a suction force through the intake to force debris through the intake, a housing configured to contain the intake and the explosion-proof enclosure including the turbine and the explosion-proof motor, a plurality of sensors disposed on the housing and configured to obtain directional data, obtain location data, and debris data, one or more wheels, and a controller configured to control the wheels to move the housing based on at least one of the directional data, the location data, and the debris data.

The present disclosure relates generally to an explosion-proof wet separator vacuum. In additive manufacturing facilities, metal powder tends to accumulate from the additive manufacturing processes. This build-up results in residual powder on the floor that poses a risk to operators, poses a fire risk, and poses a process contamination risk.

Accordingly, there is room for improvement to ensure that residual powder from additive manufacturing is cleaned up.

SUMMARY

One aspect of the disclosure provides a system comprising an intake, a suction arm, a filter, a collection bin downstream from the filter, a turbine enclosed within an explosion-proof enclosure, an explosion-proof motor enclosed within the explosion-proof enclosure, the explosion-proof motor configured to drive the turbine to create a suction force through the intake and the suction arm to force debris through the filter and into the collection bin, a housing configured to contain the intake, the suction arm, the filter, the collection bin, and the explosion-proof enclosure including the turbine and the explosion-proof motor, a lift mechanism attached to the housing and configured to move in an upward direction and a downward direction relative to the housing, a plurality of sensors disposed on the housing and configured to obtain directional data, obtain location data, and debris data, one or more wheels, and a controller configured to control the wheels to move the housing based on at least one of the directional data, the location data, and the debris data.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the controller is configured to move the suction arm. The controller may move the suction arm to debris in response to the debris data.

The controller may move the housing to debris in response to the debris data.

The controller may be configured to control the lift mechanism to move the lift mechanism in the upward direction and the downward direction.

The plurality of sensors may include at least one of a camera, a Lidar sensor, a radar sensor, a sonar sensor, a GPS sensor, an accelerometer, or a gyrometer.

The controller may be in communication with a user device. The user device may be configured to define directional parameters for the controller to control the wheels to move the housing.

Another aspect of the disclosure provides a system comprising an intake, a turbine enclosed within an explosion-proof enclosure, an explosion-proof motor enclosed within the explosion-proof enclosure, the explosion-proof motor configured to drive the turbine to create a suction force through the intake to force debris through the intake, a housing configured to contain the intake and the explosion-proof enclosure including the turbine and the explosion-proof motor, a plurality of sensors disposed on the housing and configured to obtain directional data, obtain location data, and debris data, one or more wheels, and a controller configured to control the wheels to move the housing based on at least one of the directional data, the location data, and the debris data.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the controller moves the housing to debris in response to the debris data.

The system may further comprise a lift mechanism attached to the housing and configured to move in an upward direction and a downward direction relative to the housing. the controller being configured to control the lift mechanism to move the lift mechanism in the upward direction and the downward direction.

The plurality of sensors may include at least one of a camera, a Lidar sensor, a radar sensor, a sonar sensor, a GPS sensor, an accelerometer, or a gyrometer.

The controller is in communication with a user device. The user device may be configured to define directional parameters for the controller to control the wheels to move the housing.

Another aspect of the disclosure provides an autonomous explosion-proof wet separator vacuum comprising an intake, a turbine enclosed within an explosion-proof enclosure, an explosion-proof motor enclosed within the explosion-proof enclosure, the explosion-proof motor configured to drive the turbine to create a suction force through the intake to force debris through the intake, a housing configured to contain the intake and the explosion-proof enclosure including the turbine and the explosion-proof motor, a plurality of sensors disposed on the housing and configured to obtain directional data, obtain location data, and debris data, and a controller configured to move the housing based on at least one of the directional data, the location data, and the debris data.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the controller moves the housing to debris in response to the debris data.

The autonomous explosion-proof wet separator vacuum may further comprise a lift mechanism attached to the housing and configured to move in an upward direction and a downward direction relative to the housing, the controller being configured to control the lift mechanism to move the lift mechanism in the upward direction and the downward direction.

The plurality of sensors may include at least one of a camera, a Lidar sensor, a radar sensor, a sonar sensor, a GPS sensor, an accelerometer, or a gyrometer.

The controller may be in communication with a user device. The user device may be configured to define directional parameters for the controller to control the location of the housing.

DETAILED DESCRIPTION

Referring toFIG.1, an explosion-proof wet separator vacuum100is generally shown. As will become apparent, the vacuum100may be fully autonomous, semi-autonomous, or programmed to operate in pre-defined locations. In some implementations, the vacuum100may be designed to suck up residual powder from additive manufacturing processes. In other implementations, the vacuum100may be designed for any suitable application requiring removal of debris.

The vacuum100includes a housing102, which may be formed from plastic or any other suitable material. The vacuum100includes an intake104disposed at a lower portion of the housing102. The intake104is designed to remove debris from a floor located in proximity to the intake104. In some implementations, the intake104includes a roller or other suitable component to facilitate debris pick up.

The vacuum100includes a turbine106that is driven by an explosion-proof motor108. The explosion-proof motor108may include an enclosure that withstands and contains internal explosion, flame exhaust paths that dampen flames and permit hot gases to escape the enclosure, and/or is free from a surface that exceeds the lowest auto-ignition temperature of the vapor, gas, or dust in the anticipated environment. The turbine106and the explosion-proof motor108may both be enclosed in an explosion-proof enclosure110.

The vacuum100includes a filter112downstream from the turbine106and the explosion-proof motor108. The vacuum100includes a dry collection bin114and a wet reservoir134. In operation, the turbine106pulls a vacuum through the dry collection bin114and the wet reservoir134. In some implementations, the dry collection bin114may include interchangeable reservoirs or multiple reservoirs to hold powders from different areas of the cleaning space that are incompatible (e.g., aluminum and steel, explosive polymers, non-metallic powders, etc.). The vacuum100includes a suction arm116, which, in some implementations, extends out of the housing102or a lift mechanism130, as described below. In some implementations, the suction arm116includes an accessory member118such as, for example, a head, brush, roller, etc., at a distal end of the suction arm116.

The turbine106, when driven by the motor108, creates a suction force through the intake104and/or the suction arm116to draw air and debris through the intake104and/or the suction arm116. In some implementations, the wet reservoir134may separate the wet debris from the dry debris and deposit the dry debris into the dry collection bin114. In some implementations, the vacuum100may include an extractor or other suitable device to separate the wet debris from the dry debris. The vacuum100then passes the dry debris through the filter112and into the dry collection bin114. In some implementations, the vacuum100selectively operates either the intake104or the suction arm116depending on the desired outcome. In other implementations, the vacuum100simultaneously operates the intake104and the suction arm116.

With continued reference toFIG.1, the vacuum100includes a controller120) comprising a computer system. The computer system of the controller120includes a processor122and a memory124. The processor122performs the computation and control functions of the controller120and may comprise any type of processor or multiple processors, single integrated circuits such as a microprocessor, or any suitable number of integrated circuit devices and/or circuit boards working in cooperation to accomplish the functions of a processing unit. During operation, the processor122executes one or more programs contained within the memory124and, as such, controls the general operation of the controller120and the computer system of the controller120, generally, in executing the processes described herein.

The memory124may be any type of suitable memory. For example, the memory106may include various types of dynamic random access memory (DRAM) such as SDRAM, the various types of static RAM (SRAM), and the various types of non-volatile memory (PROM, EPROM, and flash). In certain examples, the memory124may be located on and/or co-located on the same computer chip as the processor122.

The vacuum100includes a plurality of sensors126disposed in or on the housing102. In some implementations, the plurality of sensors126includes a camera, a Lidar sensor, a radar sensor, a sonar sensor, a GPS sensor, an accelerometer, and/or a gyrometer. The sensors126are configured to collect, individually or collectively, a plurality of data, including directional data, location data, and debris data (i.e., detecting the presence of debris). In some implementations, the plurality of sensors126may obtain and track historical data (e.g., areas where powder tends to build up, times at which powder tends to build up, etc.).

The vacuum100includes one or more movement components128that facilitate movement of the vacuum100. In some implementations, the movement components128are wheels. In other implementations, the movement components128are any suitable components, such as tracks, sleds, skis, maglevs, etc.

The vacuum100includes a lift mechanism130disposed at an upper portion of the housing102. The lift mechanism130includes any suitable components (e.g., pistons, pulleys, jacks, etc.) to facilitate movement of the lift mechanism130in an upward direction and a downward direction relative to the housing102. The lift mechanism130is designed to withstand heavy loads and, in some implementations, is configured to lift external components and structures. For example, the lift mechanism130may lift pallets of components or materials, and move them to a desired location. In other implementations, the lift mechanism130is configured to lift the vacuum100so that the vacuum100can go above and over obstacles or other items on the floor. In other implementations, the lift mechanism130is configured to rise up so the suction arm116can reach areas with a higher elevation. The lift mechanism130may combine any of the foregoing implementations as required for a particular application.

The vacuum100includes a magnetic powder capture element (MPCE)132to detect, extract from a surface, and contain ferromagnetic powders. The MPCE132includes a multiplicity of permanent magnets and/or electromagnets to generate a magnetic field of continuously controllable strength, from completely off to maximum power. The MPCE132generates sufficient magnetic field strength to lift ferromagnetic powders from contaminated surfaces, and continuously retain the powder until extracted and deposited into the wet reservoir134. In some implementations, the MPCE132may be submerged in reservoir liquid, with powders still magnetically attached to the capture surface, to passivate the captured powder. The magnetic field of the MPCE132may be turned off simultaneous to exposure to the wet separate vacuum to facilitate easy and complete powder removal.

With continued reference toFIG.1, the controller120may be connected to a user device300via the Internet200, Wi-Fi, Bluetooth®, Near-Field Communication (NFC), or any other suitable wireless communication. The user device300may be a smartphone, tablet computer, laptop computer, etc. The user device300may include a program configured to deliver instructions to the vacuum100. For example, the user device300may define the path of travel for the vacuum100, the time(s) of operation for the vacuum100, the maximum amount of debris that the vacuum100may collect, and areas where the vacuum100should not operate.

Referring toFIG.2, the vacuum100may dock on a docking station400including a dock collection bin402. The vacuum100may automatically dock on the docking station400at predetermined intervals or after the controller120detects that the dry collection bin114is full. In some implementations, a user, via the user device300, may instruct the vacuum100to dock at the docking station. While docked at the docking station400, the docking station400may remove the contents of the dry collection bin114and deposit the contents into the dock collection bin402.

In some implementations, the docking station400may charge a battery of the vacuum100and, while charging, the docking station400may evacuate the wet reservoir134and refill the reservoir134with fresh, clean liquid to facilitate further cleaning. The docking station400may automatically filter out the debris from the liquid and place the debris in a filter bag to recycle/dispose of the debris before offering up the water to be used for a future refill of the vacuum100. In some implementations, the docking station400may have sensors to detect the amount of particulates in the water. Based on data from the sensors, the docking station400may determine whether water should be added the next time the vacuum100docks or ask for fresh, new water/solution/liquid to refill the wet reservoir134.

The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, and/or objects. The term shared processor encompasses a single processor that executes some or all code from multiple modules. The term group processor encompasses a processor that, in combination with additional processors, executes some or all code from one or more modules. The term shared memory encompasses a single memory that stores some or all code from multiple modules. The term group memory encompasses a memory that, in combination with additional memories, stores some or all code from one or more modules. The term memory may be a subset of the term computer-readable medium. The term computer-readable medium does not encompass transitory electrical and electromagnetic signals propagating through a medium, and may therefore be considered tangible and non-transitory memory. Non-limiting examples of a non-transitory memory include a tangible computer readable medium including a nonvolatile memory, magnetic storage, and optical storage.