Patent Publication Number: US-11660676-B2

Title: Housing alignment and vibration isolation

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. § 119 from European Patent Application No. 20177005.4, filed on May 28, 2020, the entire contents of which is incorporated herein by reference. 
     TECHNICAL FIELD 
     The disclosure relates to machines for manufacturing three-dimensional components by layer-by-layer solidification of powdered build-up material with a process jet, and methods for making the machines. 
     BACKGROUND 
     EP 1 925 435 B1 discloses a device for layer-by-layer production of a three-dimensional object. This device comprises a machine frame. A process chamber with a working plane is provided on the machine frame. Furthermore, the machine frame accommodates an energy source for generating a process beam, which is guided into the process chamber via deflecting mirrors and a scanner. In the working plane, a build-up cylinder with a substrate plate that can be moved vertically is provided, on which the three-dimensional object is created by layer-by-layer solidification of a build-up material applied in layers by the process beam. To ensure that this device cannot tip over, support feet are provided on the machine frame and form a three-point support on the substrate. The machine base frame has a triangular design with three base supports to which the support feet are attached. 
     DE 10 2017 124 424 A1 describes a machine for the production of three-dimensional components by layer-by-layer solidification of powdery build-up material by a process beam. This machine comprises a machine frame. All components for the construction of this device are attached to this machine frame. 
     The quality requirements for the production of such three-dimensional components are constantly increasing. 
     SUMMARY 
     The present disclosure provides machines for the manufacture of three-dimensional components, in which an increased positioning accuracy of the process beam is made possible during the production of the three-dimensional components, as well as methods of making the machines. 
     In a first aspect, the disclosure provides machines including a machine frame and a supporting frame that accommodates at least one process chamber with a working plane or at least one construction cylinder. At least one interface is provided between the supporting frame and the machine frame, by which the supporting frame is attached or connected to the machine frame. This interface makes it possible to decouple the supporting frame from the machine frame, and decouples influences from the machine frame, such as thermal stresses, mechanical stresses, vibrations, shocks during transport of the machine, etc. from the supporting frame. This mechanical interface enables the supporting frame to be accommodated in the machine frame without any tension, which enables improved precision in the manufacture of three-dimensional components. In addition, the mechanical interface can decouple heat transfer and/or vibrations that impair quality during the production of three-dimensional components. 
     According to certain embodiments, at least one interface is provided by a three-point support between the machine frame and the supporting frame. This three-point support can be used to ensure stable mounting and alignment of the supporting frame with the machine frame. 
     The three-point support can be designed with detachable connection arrangements, which has the advantage that the supporting frame can be easily assembled to and disassembled from the machine frame. The supporting frame can also be easily adjusted and/or aligned with the machine frame. 
     The supporting frame can be attached or connected to the machine frame only by the three-point support, which enables the supporting frame to be supported by the main frame in a stress-free manner, e.g., the supporting frame can be freely hung in the machine frame. All of the forces resulting from the supporting frame are carried by the machine frame via the three-point support. 
     The detachable connection arrangements can be provided between a support section provided on the machine frame and at least one support portion provided on the supporting frame. The support section and the support portion can be aligned with each other in the vertical direction. This allows for a simple design. 
     The detachable connection arrangements can include a pin that is connected at one end section by a clamp or screw connection to the support section on the machine frame and at the opposite end section by a clamp or screw connection to the support portion on the supporting frame. This detachable connection arrangement is simple in construction, can allow a high mechanical load absorption to carry the weight of the supporting frame together with the components and/or parts absorbed by it, and can transfer the load to the machine frame. 
     The at least one detachable connection arrangement can include at least one compensating element for aligning the longitudinal axis of the pin in the interface. Thus, an angular compensation can be given in the position of the pin between the supporting portion of the machine frame and the supporting portion on the supporting frame. Furthermore, this can reduce tension between the supporting frame and machine frame. These compensating elements can be formed by, e.g., two discs lying one on top of the other, wherein one disc has a convex surface that lies against a concave surface on the opposite disc. 
     In another embodiment, the supporting frame includes a base frame, e.g., a closed base frame, from which two opposing sidewall support structures extend, which are structured with a rear wall and can form a U-shaped frame structure. At least one support portion is provided on each outer side of the sidewall support structures, e.g., on each outer side of each sidewall support structure. This design enables the supporting frame to be constructed in a mechanically stable manner to compensate for the forces occurring during the working process by, e.g., a traversing movement of the substrate plate in the build-up cylinder, a traversing movement of the working cylinder for dispensing a powdery build-up material from a storage container, or the traversing movement of a levelling and compensating element along a working plane in the process chamber. 
     The machine frame of the machine includes a base support on which a supporting frame structure is built up from several longitudinal and/or transverse profiles, e.g., struts. A receiving space for the supporting frame is formed between two longitudinal profiles lying opposite each other in pairs, and at least one support section is provided on each of the pairs of longitudinal profiles. This structure of the supporting structure enables the supporting frame to be easily inserted into the machine frame. The supporting frame can already be completed with the components to be accommodated. 
     The supporting frame can be connected between the support portion of one sidewall support structure and the support section of the machine frame by a single detachable connecting arrangement, and can be connected to the opposite sidewall support structure between the support portion of the support structure and the support section of the machine frame by two detachable connecting elements arranged at a distance from each other. This can provide a stable three-point support and mechanical decoupling between the supporting frame and the machine frame. 
     One detachable connecting arrangement can provided on the one sidewall support structure centrally to the two opposite detachable connecting arrangements of the opposite sidewall support structure, which are arranged at a distance from each other. This allows a statically determined arrangement of the supporting frame to the machine frame. 
    
    
     
       DESCRIPTION OF DRAWINGS 
       The machines and further embodiments are described and explained in more detail below with reference to the drawings. The features to be taken from the description and the drawings can be applied individually on their own or in any combination. 
         FIG.  1    is a schematic view of a machine for the production of three-dimensional components, as described herein. 
         FIG.  2    is a schematic view of a machine base frame of a machine for the production of three-dimensional components with a machine frame and a supporting frame, as described herein. 
         FIG.  3    is a perspective view of the machine frame as shown in  FIG.  2   . 
         FIG.  4    is a perspective view of the supporting frame as shown in  FIG.  2   . 
         FIG.  5    is a perspective view of the supporting frame as shown in  FIG.  4    with components of the device for the production of three-dimensional parts. 
         FIG.  6    is a detailed perspective view of an interface between supporting frame and machine frame. 
         FIG.  7    is a schematic sectional view of a detachable connecting arrangement in the interface as shown in  FIG.  6   . 
     
    
    
     DETAILED DESCRIPTION 
       FIG.  1    shows a schematic view of a machine  11  for the production of a three-dimensional component  12  by successive solidification of layers of a powdery build-up material  29 . This machine  11  comprises a machine base frame  14  and a beam source  15 , e.g., a laser source, arranged on the machine frame  14 . This beam source  15  emits a process beam  16 , e.g., a laser, which is deflected and guided via a beam deflection device  18  onto a working plane  20  of a working surface  21  in a process chamber  22 . The beam deflection device  18  can be designed in the form of one or more controllable mirrors, e.g., in the form of a scanner. Below the working plane  20 , a construction cylinder  24  with a substrate plate  25  is provided, which can be moved within the construction cylinder  24  to create the three-dimensional component  12 . Powdered construction material  29  is provided through a storage chamber  27 , which is adjacent to the construction cylinder  24 . A collecting chamber  28  is provided on the opposite side of the construction cylinder  24 . Powdered construction material  29  is fed to construction cylinder  24  by an application and levelling device  30  from a right-hand starting position shown in  FIG.  1   . The application and levelling device  30  transfers unneeded construction material  29  to the collecting chamber  28  (at the left-hand position) so that it can be processed and reused. 
     The construction material  29  can consist of a metal or ceramic powder. Other materials known in the art and suitable for laser melting and laser sintering can also be used. The process chamber  22  can be hermetically sealed. The process chamber  22  is filled with inert gas for the production of the three-dimensional component  12  to avoid oxidation when melting the build-up material  29 . 
       FIG.  2    shows a perspective view of the machine base frame  14  without further components. This machine base frame  14  includes a machine frame  31  and a supporting frame  32 , which is positioned in the machine frame  31 . The machine frame  31  is made up of several longitudinal profiles  34  and/or transverse profiles  35 . These can be bolted, riveted together, and/or connected by a clamp connection. In an area adjacent to the supporting frame  32 , one or more slide-in modules  37  are formed, e.g., to position electrical components such as a control device and/or data processing device or the like. 
     At least one interface  41  is formed between the machine frame  31  and the supporting frame  32 . This at least one interface  41  makes it possible for the supporting frame  32  to be positioned in a stress-free arrangement (e.g., a deformation-free arrangement) with respect to the machine frame  31 . 
       FIG.  3    shows a perspective view of the machine frame  31  without the supporting frame  32 . The machine frame  31  has a receiving space  42  in which the supporting frame  32  can be inserted. This receiving space  42  is formed by a base support  43 , which has at least two longitudinal profiles  34  on each of its two opposite narrow sides, which form a section of a sidewall or the entire sidewall of the machine frame  31 . The longitudinal profiles  34  and transverse profiles  35  form a supporting framework  36  to which components of the machine  11  can be attached or fastened. At least one support section  44  is arranged on or between two longitudinal profiles  34 . This support section  44  is aligned horizontally and forms one component of the interface  41 . The support section  44  is flat and extends between the two longitudinal profiles  34 . In addition, the support section  44  can be supported by at least one stiffener, which also extends between the longitudinal profiles  34  in the horizontal direction and/or in the vertical direction and can be attached to them. 
       FIG.  4    shows a perspective view of the supporting frame  32 . This supporting frame  32  comprises a base frame  51 , which is, in one example, rectangular in shape. This base frame  51  can be designed as a closed base frame consisting of longitudinal and transverse profiles  34 ,  35 . Stiffening ribs  52  can be provided between the longitudinal profiles  34 . A sidewall support structure  54  is provided on the narrow side of the base frame  51 . This sidewall support structure  54  can be designed as a closed frame. The longitudinal profiles  34  and transverse profiles  35  can also be provided for this purpose. The sidewall support structures  54 ,  55  are connected to each other by a rear wall  56 . This creates a U-shaped frame structure. The rear wall  56  can be designed in the form of a panel. Alternatively, longitudinal or transverse profiles  34 ,  35  can also extend between the opposite sidewall support structures  54 ,  55 . 
     A support portion  58  is provided on each outer side of the sidewall support structure  54 ,  55 . This support portion  58  can be aligned horizontally. This support portion  58  can be attached to a longitudinal or transverse profile  34 ,  35 . This support portion  58  is a further component of the interface  41 . 
       FIG.  5    shows a perspective view of the supporting frame  32  as shown in  FIG.  4    equipped with components of machine  11 . At the upper end of the sidewall support structures  54 ,  55  there are connection surfaces  61 , which serve to accommodate a housing  71  in which the process chamber  22  is provided. This housing  71  can have a door  72  that can be opened from the front side and through which the process chamber  22  is accessible. Working surface  21  is formed on a lower side of the process chamber  22 . This working surface  21  is assigned the storage chamber  27  and an associated lifting cylinder  74  to transfer the stored build-up material to the working plane  20 . The construction cylinder  24  is provided adjacent to the storage chamber  27 . A lifting cylinder  75  for triggering a traversing movement of the substrate plate  25  within the construction cylinder  24  is supported on the base frame  51  of the supporting frame  32 . The same applies to the collecting chamber  28 , which is supported on a connection surface on the base frame  51 . The U-shaped frame structure of the supporting frame  32  is additionally stiffened by the housing  71 . 
     The supporting frame  32  and the components mounted on it can be designed as a pre-assembled unit. This supporting frame  32  equipped with components can be inserted into the machine frame  31 . The supporting frame  32  is connected to the machine frame  31  through the interfaces  41 . After the insertion of the supporting frame  32  into the machine frame  31 , the supporting frame  32  is suspended freely without any connection to the base frame  51  of the machine frame  31 , i.e., the supporting frame  32  is connected to the machine frame  31  only through the interfaces  41 . At least one detachable connecting arrangement  81  is assigned to each interface  41 , and the supporting frame  32  is freely hanging in the machine frame  31  and can be supported only by detachable connection arrangements  81 . 
       FIG.  6    shows a perspective view of at least one interface  41  between the supporting frame  32  and the machine frame  31 . A three-point support  82  is provided between supporting frame  32  and machine frame  31 . This three-point support  82  is formed by three detachable connecting arrangements  81 . At one interface  41 , e.g., at the right-hand side at wall support structure  55 , a detachable connection arrangement  81  is provided. Two detachable connection arrangements  81  are provided at the opposite sidewall support structure  54 . The detachable connecting arrangements  81 , which engage the support section  44  of the machine frame  31  and the support portion  58  of the supporting frame  32 , are aligned with one another in a triangular arrangement. The two detachable connecting arrangements  81  at the opposite sidewall support structure  54  are aligned with a distance between them. The one detachable connection assembly  81  provided on the sidewall support structure  55  can be positioned centrally to the two opposite detachable connection assemblies  81 . By this statically determined attachment of the supporting frame  32  at its upper end section to the machine frame  31 , occurring stresses, deformations, or the like can be decoupled so that they are not transmitted from the machine frame  31  to the process chamber  22 , e.g., to the housing  71  of the process chamber  22 . 
       FIG.  7    shows a schematic sectional view of an embodiment of the detachable coupling assembly  81 . This detachable coupling assembly  81  includes a pin  84 , which is positioned in a hole  85  in the support section  44 . The pin  84  is coupled to the support section  44  by fastening elements  86 , which can be, e.g., screw elements. At least one compensating element  87  is provided between the fastening elements  86  and the support section  44 . Such compensating elements  87  provide angle compensation of pin  84 , e.g., allowing the longitudinal axis of pin  84  to be aligned in different angular positions with respect to a vertical axis of the support section  44 . The opposite end of the pin  84  has a thread  88 , which can be mounted, e.g., screwed, in the support portion  58 . In addition, the pin  84  can have a further fastening element  89  adjacent to the thread  88 . This fastening element  89  is adjustable along the longitudinal axis of the pin  84 , e.g., via a further thread provided on the pin  84 , and is used to support the support portion  58 . Alternatively, the upper end of the pin  84  can be coupled to the support section  58  analogous to the lower end of the pin  84 . Alternatively, the detachable connection arrangement  81  can be rotated 180° to the orientation shown in  FIG.  7   . 
     This design of the detachable connection arrangement  81  allows a distance to be set in the vertical direction between the support section  44  and the support portion  58 . At the same time, the compensating elements  87  can be used to compensate for tolerances if the hole in support portion  58  and the hole in support section  44  are not completely aligned. 
     Other Embodiments 
     A number of embodiments of the present disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the following claims.