GB2523985A - A building block for a mechanical construction - Google Patents

A building block for a mechanical construction Download PDF

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Publication number
GB2523985A
GB2523985A GB1322409.2A GB201322409A GB2523985A GB 2523985 A GB2523985 A GB 2523985A GB 201322409 A GB201322409 A GB 201322409A GB 2523985 A GB2523985 A GB 2523985A
Authority
GB
United Kingdom
Prior art keywords
printed material
building block
pattern
printed
magnetic
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.)
Withdrawn
Application number
GB1322409.2A
Other versions
GB201322409D0 (en
Inventor
Alejandro Sanz
Stellario Barbera
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SKF AB
Original Assignee
SKF AB
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by SKF AB filed Critical SKF AB
Priority to GB1322409.2A priority Critical patent/GB2523985A/en
Publication of GB201322409D0 publication Critical patent/GB201322409D0/en
Priority to PCT/EP2014/078363 priority patent/WO2015091729A1/en
Publication of GB2523985A publication Critical patent/GB2523985A/en
Withdrawn legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/58—Raceways; Race rings
    • F16C33/62—Selection of substances
    • 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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/38—Ball cages
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/46—Cages for rollers or needles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/58—Raceways; Race rings
    • F16C33/64—Special methods of manufacture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/66—Special parts or details in view of lubrication
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/66—Special parts or details in view of lubrication
    • F16C33/6637—Special parts or details in view of lubrication with liquid lubricant
    • F16C33/664—Retaining the liquid in or near the bearing
    • F16C33/6644—Retaining the liquid in or near the bearing by a magnetic field acting on a magnetic liquid
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/72—Sealings
    • 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
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • 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
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • B22F12/53—Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/04—Bearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C19/00—Bearings with rolling contact, for exclusively rotary movement
    • F16C19/22—Bearings with rolling contact, for exclusively rotary movement with bearing rollers essentially of the same size in one or more circular rows, e.g. needle bearings
    • F16C19/34—Bearings with rolling contact, for exclusively rotary movement with bearing rollers essentially of the same size in one or more circular rows, e.g. needle bearings for both radial and axial load
    • F16C19/36—Bearings with rolling contact, for exclusively rotary movement with bearing rollers essentially of the same size in one or more circular rows, e.g. needle bearings for both radial and axial load with a single row of rollers
    • F16C19/364—Bearings with rolling contact, for exclusively rotary movement with bearing rollers essentially of the same size in one or more circular rows, e.g. needle bearings for both radial and axial load with a single row of rollers with tapered rollers, i.e. rollers having essentially the shape of a truncated cone
    • 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

Abstract

The invention provides a building block, or component (290, 280) for a mechanical device such as a bearing 200, an actuator system, or a gear box and a method of producing the building block. The building block comprises a first printed material 210 printed via an additive manufacturing process on or at least partially embedded in a second material 260. The first printed material comprises magnetic particles and is printed in a pattern 212. The pattern may be configured and constructed for guiding, in use, magnetic lubricant material, or may be configured and constructed for blocking at least a part of the magnetic lubricant from crossing the pattern. The method of producing the building block may comprise a step of adding the first printed material to the second material via the additive manufacturing process under the influence of a predefined magnetic field.

Description

A BUILDING BLOCK FOR A MECHANICAL CONSTRUCTION
FIELD OF THE INVENTION
The invention relates to a building block for a mechanical construction. The inventon further relates to a bearing, to an actuator system, a gear box and to a method of producing the building block.
BACKGROUND ART
Additive manufacturing or more commonly called 3D printing is a known production technique in which a three-dmensional solid object is generated from a digital model. The process of additive manufacturing starts with generating the digital model via any known digital modeling methods, such as using a CAD program. Next, the digital model is divided into slices in which each slice indicates for this layer of the digital model where the printed material should be located. The individual slices are sequentially fed into an additive manufacturing tool or 3D printer which deposits the material according to the individual slices and as such generates the complete three-dimensional solid object layer by layer.
In the early days of additive manufacturing, mainly plastic materials or resins have been used as printed material for generating the three-dimensional solid abject, but other processes have been developed in which also other materials, including different types of metal may be deposited in layers using this additive manufacturing technique. A major benefit of this manufacturing technique is that it allows the designer to produce virtually any three-dimensional object in a relatively simple production method. This may be especially beneficial when, for example, an initial model is required of a product or when only a limited number of products are required. A drawback of this manufacturing technique is the speed at which the three-dimensional solid objection is produced.
The use of additive manufacturing in high-quality bearings or actuators has been limited. However the possibilities it may provide seem unlimited.
SUMMARY OF THE INVENTION
One of the objects of the invention is to provide a building block with improved lubricant wetting.
A first aspect of the invention provides a building block for a mechanical construction according to claim 1. A second aspect of the invention provides the bearing according to claim 12. A third aspect of the invention provides the actuator system according to claim 13. A fourth aspect of the invention provides the gear box according to claim 14. And the fifth aspect of the invention provides the method according to claim 15. Embodiments are defined in the dependent claims.
The building block in accordance with the first aspect of the invention comprises a first printed material printed via an additive manufacturing process on or at least partially embedded in a second material, wherein the first printed material comprises magnetic particles and wherein the first printed material is printed in a pattern.
The inventors have realized that the use of printed material in building blocks for mechanical constructions provide the opportunity to include a pattern of first printed material on or at least partially inside the second material. The printing of the first printed material on or at least partially into the second material enables to provide a graded and controlled distribution of the first printed material in the pattern which enables a relatively highly accurate deposition of magnetic material in a pattern on or at least partially into the second material. Other ways of depositing a pattern of first printed material is typically very labor intense and thus very expensive, while the achieved accuracy in patterns manufactured via a different process than the additive manufacturing process typically is less good. Such high quality magnetic pattern may be used, for example, to guide or hold magnetic lubricants such that they will be located at a position where they are needed. As such, the amount of lubricant necessary may be reduced.
The pattern may include a one-dimensional pattern representng a variation of the first printed material and the second printed material along a line or representing a variation of the magnetic particles inside the first printed material along the line.
Alternatively, the pattern may comprise a two-dimensional pattern on a surface of the second printed material in which the first printed material is substantially fully embedded inside the second material and the pattern is formed in a surface comprising both the first printed material and the second material. The pattern may be generated by the first printed material in the second material, and/or by the distribution of the magnetic particles inside the first printed material. Finally, the pattern may be a three-dimensional pattern with grooves and trenches for guiding and holding the magnetic lubricant. The pattern may have any form suitable for maintaining the magnetic lubricant in its place, and even may be substantially random for merely confining the magnetic lubricant to one place. Alternatively, the pattern may comprise a system of channels for guiding the magnetic lubricant through the system and allowing the magnetic lubricant to flow through the system.
In an embodiment of the building block, at least a part of the building block is constituted of the second material being second printed material printed via an additive manufacturing process. The second printed material may, for example, be a polymer or ceramic, while the first printed material may be a metal or may contain magnetic particles to interact with a magnetic sensor. Using the second printed material provides a maximum freedom in design of the building block which may be produced using the additive manufacturing techniques. As such, substantially any three-dimensional building block may be generated having a pattern of the first printed material added for interaction with the sensor.
A further benefit when using the second printed material is that hollow structures may be included in the second printed material for reducing the overall weight of the building block and for using the hollow structures to include other elements into the building block, such as additional sensors, heat transfer channels and hollow structures for providing lubricants.
In an embodiment of the building block, the pattern of the Iirst printed material is configured and constructed for guiding, in use, magnetic lubricant.
As indicated herein above, the guiding and holding of lubricants in a system in which one building block moves relative to another building block may be a challenge. Often lubricants tend to migrate through such a system which may result in a shortage of lubricant at the interface between the two building blocks. Using a pattern of first printed material being magnetic printed material, the pattern may be constructed and configured to guide or hold the magnetic lubricant at the position where it is needed such that a shortage of lubricant is strongly reduced. This would improve the overall reliabHity of such system. It would also obviate the need to use an access of lubricant for such system in which two building blocks move relative to each other. The use of the pattern of magnetic material would confine the lubricants to the location where they are requires.
In an embodiment of the building block, the pattern comprises grooves configured and constructed for attracting and retaining the magnetic lubricant. Such grooves or indentations may be used to retain the magnetic lubricant and may also allow the magnetic lubricant to migrate through the grooves. Thus some circulation of magnetic lubricant may be allowed or even stimulated by using the pattern comprising grooves. Such a pattern may also be used to replenish the lubricants gradually such that the magnetic lubricants migrate from an entrance part of the pattern to an exit part of the pattern. At the exit part of the pattern, the magnetic lubricant may be collected, checked for contaminations and, for example, recycled back to the entrance part of the pattern. Furthermore, the contaminations found in the collected magnetic lubricant may also be an indicator of the quality of the interface between the two moving building blocks. When, the two moving building blocks may, for example, be a ring of a bearing and a rolling element, the magnetic lubricant may migrate through the grooves in the pattern from the entrance part to the exit part and the resulting quality of the lubricant at the exit part may be an indicator whether maintenance of the bearing would be required.
In an embodiment of the building block, at least a part of the pattern is configured and constructed to contribute to a circulation of the magnetic lubricant through or along the building block. As indicated before, such circulation of the magnetic lubricant may be beneficial to have a controlled migration of the magnetic lubricant though or along the building black. Alternatively, the circulation may be used to replenish the magnetic lubricant or clean the magnetic lubricant before recycling the circulated magnetic lubricant back towards the building block.
In an embodiment of the building block, the pattern is configured and constructed for blocking at least a part of the magnetic lubricant from crossing the pattern. When, for example, the pattern of first printed material containing magnetic particles is applied to a lib of a seal, for example, of a bearing, this pattern may be configured and constructed to block at least a part of the lubricant from leaking out of the bearing. This would prevent loss of lubricant and ensure improved relability of, for example, the bearing. Such a pattern may also contribute to reducing the spill of lubricants into the environment.
In an embodiment of the building block, the pattern is applied to a surface of the building block configured for interacting with a further building block.
In an embodiment of the building block, the first printed material is completely embedded in the second printed material.
Alternatively, the first printed material is covered by a third material. This third material may be a coating covering the first printed material or may be a third printed material different from the first printed material and the second printed material.
A benefit of this embodiment is that the pattern of the first printed material is protected from the environment by the second printed material or by the third material. Building blocks according to the invention may be used, for example, in bearings. In such environments, the embedding of the first printed material protects the first printed material from damage from vibrations, wear and fatigue.
In an embodiment of the building block, the first printed material and/or the second printed material is chosen from a list comprising metals, ceramics, polymers, elastomer and their combination in composite materials. The first printed material and/or the second printed material may, for example, be a metal, for example, selected from a list comprising steel, stainless steel, maraging steel, tool steel, low alloy steel, copper alloys, nickel alloys, cobalt alloys, aluminum, aluminum alloys, titanium, titanium alloys. The first printed material may constitute or comprise permanent magnets with or without rare earth doping, paramagnetic material with a permanent magnetic moment, ferromagnetic material, for example, having all magnetic moments the same direction, or ferromagnetic materials alternating magnetic spins of different size leading to a magnetic moment.
In an embodiment of the building block, an interface between the first printed material and the second printed material comprises a functionally graded interface layer, a composition of the functionally graded interface layer is configured to gradually change from the first printed material via a mixture of the first material and the second printed material to the second printed material. A benefit of such functionally graded interface layer is that the bonding between the two materials is relatively strong.
In an embodiment of the building block, the building block is an inner ring for a bearing. In an embodiment of the building block, the building block is an outer ring for the bearing. In an embodiment of the building block, the building block is a seal for the bearing. In an embodiment of the building block, the building block is an traveling unit for an actuator. In an embodiment of the building block, the building block is an encoder disc for an angular sensor. In an embodiment of the building block, the building block is a gear wheel.
The bearing in accordance with the second aspect of the invention comprises the building block according to any of the embodiments.
The actuator system in accordance with the third aspect of the invention comprises the building block according to any of the embodiments.
The gear box in accordance with the fourth aspect of the invention comprises the building block according to any of the embodiments.
The method of producing the building block in accordance with the fifth aspect of the invention comprises a step of: adding the first printed materal to the second material via the additive manufacturing process under the influence of a predefined magnetic field. This magnetic field may be used to set the magnetic property of the first printed material during the additive manufacturing process. In one production method, the first printed material constitutes solid particles comprising magnetic particles which are heated to connect the individual first printed material particles together. During this heating process, the magnetic properties of the first printed material may be influenced by the applied magnetic field. This applied magnetic field may determine the magnetic properties of the solid particle attached via the additive printing process. Alternatively, the first printed material may be applied in liquid form after which it is solidified during the process. Also in such a process, the influence of the magnetic field may be used to determine the magnetic properties of the droplet of first printed material before the droplet is hardened in the additive manufacturing process and as such freezing the orientation of the magnetic particles. As such, a magnetic property of each droplet of first printed material or each solid particle of first printed material may be determined individually -allowing a very high level of control of the magnetic properties of the pattern of first printed material on the buildng block.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter. In the drawings, Fig. 1A shows a plan-view of a gear wheel according to the invention, and Fig. 1 B shows a gear box comprising the gear wheel, Fig. 2A shows a cross-sectional view of a bearing comprising first printed material in a pattern and a second material according to the invention, Fig. 29 shows a partially cut-open outer ring for a bearing according to the invention, and Fig. 2C shows a bearing comprising a seal according to the invention, Fig. 3 shows a plan view of an actuator system according to the invention, Fig. 4A shows a first embodiment of an additive manufacturing tool in which a liquid resin is used for applying the printed material in the additive manufacturing process, Fig. 49 shows a second embodiment of the additive manufacturing tool in which a liquid resin is dispensed from a dispenser for applying the printed material in the additive manufacturing process, Fig. 5A shows a third embodiment of the additive manufacturing tool in which the material is granulated into small solid particles which are used for applying the printed material in the additive manufacturing process, Fig. 5B shows a fourth embodiment of the additive manufacturing tool in which the granulated solid material is dispensed from a dispenser for applying the printed material in the additive manufacturing process, Fig. 6 shows a fifth embodiment of the additive manufacturing tool in which a melted plastic material is dispensed for applying the printed material in the additive manufacturing process, and Figs. 7A and 7B show a schematic cross-sectional view of a cage according to the invention, and Fig. 7C shows a schematic cross-sectional view of a cage and a seal according to the invention.
It should be noted that items which have the same reference numbers in different Figures, have the same structural features and the same functions, or are the same signals. Where the function and/or structure of such an item has been explained, there is no necessity for repeated explanation thereof in the detailed description.
DETAILED DESCRIPTION OF EMBODIMENTS
Fig. 1A shows a plan-view of a gear wheel 100 according to the invention.
The gear wheel 100 being a building block 100 according to the invention, comprises a first printed material 110 printed via an additive manufacturing process in a pattern 112.
The first printed material 110 comprises magnetic particles which are thus arranged in the pattern 112 and form a predefined magnetic field in the vicinity of the pattern 112.
The pattern 112 is arranged on and inside the teeth of the gear wheel 100 and may be configured and constructed for preventing magnetic lubricant from entering the teeth of the gear wheel 100. The pattern 112 is configured and constructed such that the magnetic lubricant is blocked from entering the teeth of the gear wheel 100 such that the teeth may securely engage with teeth of another gear wheel (see Fig. 1 B). The presence of lubricant in the teeth may create additional forces on shafts (see Fig. 1 B) Fig. 1 B shows a cut-open plan-view of a gear box 150 according to the inventon. The gear box 150 is connected to a motor 170 via a first shaft 160 and the gear box 150 transfers the rotation speed of the motor 170 to a converted rotation speed of the second shaft 180. The gear box 150 comprises a plurality of gear wheels 100. One of the gear wheels 100 comprises the first printed material 110 comprising magnetic particles in the pattern 112 for preventing magnetic lubricants from entering in the teeth of the gear wheel 100.
Fig. 2A shows a cross-sectional view of a bearing 200 comprising the second printed material 250, 260 and comprising the pattern 212 of first printed material 210 comprising magnetic particles. The bearing 200 comprises rolling elements 205 and an inner ring 280 comprising a raceway ring 216 at whch the second printed material 250 is bonded. The bearing 200 also comprises an outer ring 290 comprising the pattern 212 of the first printed material 210. The first printed material 210 is fully embedded inside the second printed material 260 and forms grooves inside the second printed material 260. The pattern 212 and the magnetic particles inside the first printed material 210 are configured and constructed for guiding magnetic lubricants to ensure that always lubricant is present between the rolling elements 205 and the raceway surface of the inner ring 280 and of the outer ring 290.
The outer ring 290 also comprises the raceway ring 220 to which the second printed material 260 is bonded.
Fig. 29 shows a partially cut-open outer ring 290 for the bearing 200 according to the invention. The outer ring 290 being a building block 290 according to the invention and comprises a raceway ring 220 to which the second printed material 260 is bonded. The first printed material 210 forms a pattern 212 on the raceway surface of the raceway ring 220, similar as shown on the inner ring 280 of Fig. 2A.
Again the pattern 212 of the first printed material 210 comprising magnetic particles may be configured and constructed to guide magnetic lubricants to a position between the rolling element 205 and the raceway surface of the raceway ring 220 to ensure a smooth rolling of the rolling elements 205 over the raceway surface. The use of the second printed material 260 provides a very flexible way of producing the outer shape of the outer ring 260 for the bearing 200 and printing the first printed material 210 in the pattern 212 ensures that the magnetic lubricants are present, in use, between the rolling elements 205 and the raceway ring 220..
Fig. 2C shows a bearing 205 comprising a seal 230 according to the inventon. The seal 230 comprises a pattern 214 of first printed material 210 arranged on or at least partially embedded in the second material 265, for example, second printed material 265. The pattern 214 of first printed material 210 comprises magnetic particles embedded in the first printed material 210. The magnetic particles inside the first printed material 210 are configured and constructed to prevent magnetic lubricants from passing the lib of the seal 230 and as such are substantially contained inside the bearing 205.
Fig. 3A shows a plan view of an actuator system 300 comprising a static unit 350 and a traveling unit 330. The traveling unit 330 comprises the pattern 312 of first printed material 310 comprising magnetic particles. The first printed material 310 is printed on the second material 320, for example, second printed material 320 printed, for example, in a similar manner as the first printed material 310. The pattern 31201 first printed material 310 comprising the magnetic particles may be completely embedded in the second printed material 320 such that a thin layer of second printed material 320 covers the first printed material 310. In such an embodiment, the first printed material 310 comprising the magnetic particles is sealed inside the second printed material for preventing damage, wear and possibly oxidation of the first printed material 310 or of the embedded magnetic particles. Alternatively, the first printed material may be covered by a third material (not shown) to seal the first printed material 310 from environmental influences and wear. The pattern 312 of the first printed material 310 comprising magnetic particles ensures that magnetic lubricants will be retained at the traveling unit 330, in operation. Often, when the traveling unit 330 has traveled in and out of the static unit 350, lubricants will not be evenly distributed over the traveling unit 330 which may impact the operation of the actuator system 300.
Using the pattern 312 of the first printed material 310 comprising magnetic particles enables a substantially even distribution of the magnetic lubricant over the traveling unit 330, also after extensive use of the actuator system 300.
Fig. 4A shows a first embodiment of an additive manufacturing tool 400 in which a liquid resin 450 is used for applying the printed material 460 in the additive manufacturing process. Such additive manufacturing tool 400 comprises resin container 430 comprising the liquid resin 450. Inside the resin container 430 a platform 470 is positioned which is configured to slowly move down into the resin container 430.
The additive manufacturing tool 400 further comprises a laser 410 which emits a laser beam 412 having a wavelength for curing the liquid resin 450 at the locations on the printed material 460 where additional printed material 460 should be added. A re-coating bar 440 is drawn over the printed material 460 before a new layer of printed material 460 is to be applied to ensure that a thin layer of liquid resin 450 is on top of the printed material 460. Emitting using the laser 410 those parts of the thin layer of liquid resin 450 where the additional printed material 460 should be applied will locally cure the resin 450. In the embodiment as shown in Fig. 4A the laser beam 412 is reflected across the layer of liquid resin 450 using a scanning mirror 420. When in the current layer all parts that need to be cured, have been illuminated with the laser beam 412, the platform 470 lowers the printed material 460 further into the liquid resin 450 to allow the re-coating bar 460 to apply another layer of liquid resin 450 on top of the printed material 460 to continue the additive manufacturing process.
Fig. 4B shows a second embodiment of the additive manufacturing tool 401 in which a liquid resin 450 is dispensed from a dispenser 405 or print head 405 for applying the printed material 460 in the additive manufacturing process. The additive manufacturing tool 401 again comprises the resin container 430 comprising the liquid resin 450 which is fed via a feed 455 towards the print head 405. The print head 405 further comprises a print nozzle 415 from which droplets of liquid resin 450 are emitted towards the printed material 460. These droplets may fall under gravity from the print head 405 to the printed material 460 or may be ejected from the print nozzle 415 using some ejection mechanism (not shown) towards the printed material 460. The print head 405 further comprises a laser 410 emitting a laser beam 412 for immediately cure the droplet of liquid resin 450 when it hits the printed material 460 to fix the droplet of liquid resin 450 to the already printed material 460. The printed material 460 forming a solid object may be located on a platform 470.
Fig. SA shows a third embodiment of the additive manufacturing tool 500 in which the material is granulated into small solid particles 550 which are used for applying the printed material 560 in the additive manufacturing process. Now, the additive manufacturing tool 500, also known as a Selective Laser Sintering tool 500, or SLS tool 500 comprises a granulate container 530 comprising the granulated small solid particles 550. The printed material 560 is located again on a platform 570 and is completely surrounded by the granulated small solid particles 550. Lowering the platform allows a granulate feed roller 540 to apply another layer of granulated solid particles 550 on the printed material 560. Subsequently locally applying the laser beam 512 using the laser 510 and the scanning mirror 520 will locally melt the granulated solid particles 550 and connects them with each other and with the printed material 560 to generate the next layer of the solid object to be created. Next, the platform 570 moves down further to allow a next layer of granulated solid particles 550 to be applied via the granulate feed roller 540 to continue the next layer in the additive manufacturing process.
Fig. 59 shows a fourth embodiment of the additive manufacturing tool 501 or SLS tool 501 in which the granulated solid material 550 is dispensed from a dispenser 505 or print head 505 for applying the printed material 560 in the additive manufacturing process. The additive manufacturing tool 501 again comprises the granulate container 530 comprising the granulated solid particles 550 which are fed via a feed 555 towards the print head 505. The print head 505 further comprises a print nozzle 515 from which granulated solid particles 550 are emitted towards the printed material 560. These solid particles 550 may fall under gravity from the print head 505 to the printed material 560 or may be ejected from the print nozzle 515 using some ejection mechanism (not shown) towards the printed material 560. The print head 505 further comprises a laser 510 emitting a laser beam 512 for immediately melting or sintering the solid particle 550 when it hits the printed material 560 to fix the solid particle 550 to the already printed material 560. The printed material 560 forming a solid object may be located on a platform 570.
Fig. 6 shows a fifth embodiment of the additive manufacturing tool 600 in which a melted plastic material 650 is dispensed for applying the printed material 660 in the additive manufacturing process. The additive manufacturing tool 600 shown in Fig. 6 is also known as Fused Depositicn Modeling tool 600 or FDM tool 600. Now a plastic filament 630 is fed into a dispenser 610 or melter 610 via a filament feeder 640.
The dispenser 610 or melter 610 comprises an extrusion nozzle 615 for melting the plastic filament 630 to form a droplet of melted plastic material 650 which is applied to the printed material 660 where it hardens and connects to the already printed material 660. The dispenser 610 may be configured and constructed to apply the droplet of melted plastic 650 to the printed material 660 under gravity or via an ejection mechanism (not shown). The additive manufacturing tool 600 further comprises a positioning system 620 for positioning the dispenser 610 across the printed material 660.
Fig. 7A show a schematic cross-sectional view of a cage 700 according to the invention. The cage 700 is constituted of the second material 720 on which the first printed material 710 is printed in a pattern 712. The pattern 712 of the first printed material 710 comprises magnetic material which generates alternating magnetic fields (indicated with N for North pole and S of South pole of the magnetic fields). In a gap G between the cage 700 and a ring 730 of a bearing (not shown) a magnetic lubricant 770 is located which is kept in place by the alternating magnetic fields generated by the pattern 712 of the first printed material 710. Both the first printed material 710 and the second material 720 may be produced using a similar additive manufacturing process and so the complete cage 700 may be produced via the additive manufacturing process. Alternatively, the second material 720 may be produced via an alternative process such as injection molding or casting, after which the first printed material 710 is bonded to the second material 720 during the additive manufacturing process.
Fig. 7B shows a schematic cross-sectional view of an alternative embodiment of a cage 702 according to the invention. In this embodiment of the cage 702 the first printed material 710 is only applied in a relatively thin layer between the cage 702 and the ring 730 in the pattern 714. In this case, a different magnetic field created by the pattern 714 of first printed material 710 for maintaining the magnetic lubricant 770 in its place in operation. Again, the second material 720 may be produced via a similar additive manufacturing process or via an alternative process.
Fig. 7C shows a schematic cross-sectional view of a cage 704 and a seal 760 according to the invention. The cage 704 is similar as the embodiments shown in Figs. 7A and 7B in that the cage is constituted of the second material 720 on which the first printed material 710 is printed in a pattern 714, 716, 718. The pattern 714 printed between the cage 704 and the ring 730 is similar as shown in Fig. 76. The pattern 716 arranged between the cage 704 and a seal 770 is constructed for interacting between the cage 704 and the seal 770. As the sliding forces between the cage 704 and the seal 770 may be different, the pattern 716 may be different to ensure that the magnetic lubricant material 770 is maintained between the cage 704 and the seal 770.
The seal 760 is a seal according to the invention. This seal comprises the second material 750 (which may be different from the second material 720 of the cage 704) on which the first printed material 740 (which may be different from the first printed material 710 used on the cage 704) in a pattern 742. In such a configuraton, the cage 704 may not necessarily have a further pattern 718 of first printed material 710 to ensure that the magnetic lubricant 770 is maintained at the interface between the seal 760 and the cage 704. As such, the surface of the cage 704 may be a smooth surface (not shown in Fig. 7C). Alternatively, the cage 704 may comprise an additional pattern 718 of first printed material 710 which may be constructed and configured to cooperate with the pattern 742 of the seal 760 to ensure that the magnetic lubricant 770 is maintained at the interface between the seal 760 and the cage 704.
As can be seen from the different embodiments of Figs. 7A to 7C, many different configurations are possible without departing from the scope of the invention.
Summarizing, the invention provides a building block 290, 280 for a mechanical construction. The invention further provides a bearing 200, an actuator system, a gear box and a method of producing the building block. The building block comprises a first printed material 210 printed via an additive manufacturing process on or at least partially embedded in a second material 260. The first printed material comprises magnetic particles and is printed in a pattern 212. The pattern may be configured and constructed for guiding, in use, magnetic lubricant material, or may be configured and constructed for blocking at least a part of the magnetic lubricant from crossing the pattern. The method of producing the building block may comprise a step of adding the first printed material to the second material via the additive manufacturing process under the influence of a predefined magnetic field.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb "comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim.
The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
Listing of Reference numbers Building block 100, 230, 280, Additive manufacturing tool 400, 401 290, 330, 350, Printable material 450, 550, 650 700, 702, 704, Print head 405, 505 760 Print nozzle 415, 515 Pattern 112,212,214, Laser 410,510 312,712,714, Laserbeam 412,512 716, 718, 742 Scanning mirror 420, 520 First printed material 110, 210, 310, Resin container 430 710, 740 Re-coating bar 440 Second material 120, 260, 265, Liquid resin 450 320, 720, 750 Feed 455, 555 Gear wheel 100 Platform 470, 570, 670 Gear box 150 SLS-tool 500, 501 Motor 170 Granulate container 530 Shaft 160, 180 Granulate feed roller 540 Bearing 200, 205 Granulate material 550 Rolling elements 205 FDM-tool 600 Raceway ring 216 Melter 610 Inner ring 280 Extrusion nozzle 615 Outer ring 290 Positioning construction 620 Seal 230, 760, 770 Filament 630 Cage 700, 702, 704 Filament feeder 640 Actuator 300 Liquid plastic 650 Traveling unit 330 Static unit 350

Claims (15)

  1. CLAIMS1. A building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760, 700, 702, 704, 760) for a mechanical construction, the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) comprising a first printed material (110,210,310, 710, 740) printed via an additive manufacturing process on or at least partially embedded in a second material (120, 260, 265, 320, 720, 750), wherein the first printed material (110, 210,310, 710, 740) comprises magnetic particles and wherein the first printed material (110, 210, 310, 710, 740) is printed in a pattern (112, 212, 214, 312, 712, 714, 716, 718, 742).
  2. 2. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to claim 1, wherein at least a part of the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) is constituted of the second material (120, 260, 265, 320, 720, 750) being second printed material (120, 260, 265, 320, 720, 750) printed via an additive manufacturing process.
  3. 3. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to claim 1 or 2, wherein the pattern (112, 212, 214, 312, 712, 714, 716, 718, 742) of the first printed material (110, 210, 310, 710, 740) is configured and constructed for guiding, in use, magnetic lubricant.
  4. 4. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to claim 3, wherein the pattern (112, 212, 214, 312, 712, 714, 716, 718, 742) comprises grooves (112, 212, 312) configured and constructed for attracting and retaining the magnetic lubricant.
  5. 5. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the previous claims, wherein at least a part of the pattern (112, 212, 214, 312, 712, 714, 716, 718, 742) is configured and constructed to contribute to a circulation of the magnetic lubricant through or along the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760).
  6. 6. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to claim 1, 2 or 3, wherein the pattern (214) is configured and constructed for blocking at least a part of the magnetic lubricant from crossing the pattern (214).
  7. 7. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the previous claims, wherein the pattern (112, 212, 214, 312, 712, 714, 716, 718, 742) is applied to a surface of the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) configured for interacting with a further building block.
  8. 8. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to claim 2 to 7, wherein the first printed material (110, 210, 310, 710, 740) is completely embedded in the second printed material (120, 260, 265, 320, 720, 750), or wherein the first printed material (110,210,310,710, 740) is covered by a third material.
  9. 9. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the previous claims, the first printed material and/or the second printed material is chosen from a list comprising metals, ceramics, polymers, elastomer and their combination in composite materials.
  10. 10. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the claims 2 to 9, wherein an interface between the first printed material (110, 210, 310, 710, 740) and the second printed material (120, 260, 265, 320, 720, 750) comprises a functionally graded interface layer, a composition of the functionally graded interface layer is configured to gradually change from the first printed material (110,210, 310, 710, 740) via a mixture of the first printed material (110, 210, 310, 710, 740) and the second printed material (120, 260, 265, 320, 720, 750) to the second printed material (120, 260, 265, 320, 720, 750).
  11. 11. The building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the previous claims, wherein the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) is -an inner ring (280) for a bearing (200), -an outer ring (290) for the bearing (200), -a seal (230, 760) for the bearing (200), -a cage (700, 702, 704) for the bearing (200), -a rolling element for the bearing (200), -an traveling unit (330) for an actuator (300), -a static unit (350) for the actuator (300), or -agear wheel (100).
  12. 12. A bearing (200) comprising the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the previous claims.
  13. 13. An actuator system (300) comprising the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the claims ito ii.
  14. 14. A gear box (150) comprising the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) according to any of the claims ito ii.
  15. 15. A method of producing the building block (100, 230, 280, 290. 330, 350, 700, 702, 704, 760) according to any of the claims ito ii, wherein the step of producing the building block (100, 230, 280, 290, 330, 350, 700, 702, 704, 760) comprises a step of: -adding the first printed material (i 10, 210, 3i0, 710, 740) to the second material (120, 260, 265, 320, 720, 750) via the additive manufacturing process under the influence of a predefined magnetic field.
GB1322409.2A 2013-12-18 2013-12-18 A building block for a mechanical construction Withdrawn GB2523985A (en)

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PCT/EP2014/078363 WO2015091729A1 (en) 2013-12-18 2014-12-18 A building block for a mechanical construction configured to guide magnetic lubricant and method of its manufacture using additive manufacturing

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