Energy Consumption Study for Multi-Axis Robot Additive
Session Number
Project ID: ENGN 08
Advisor(s)
Suyog Shivajirao Ghungrad
Azadeh Haghighi, University of Illinois at Chicago
Discipline
Engineering
Start Date
17-4-2024 8:15 AM
End Date
17-4-2024 8:30 AM
Abstract
As additive manufacturing (AM) develops into a more mature manufacturing technology, the scope of experimentation with its limits and use cases has broadened. With the increasing implementation of these technologies, the energy usage of these machines is gaining significance, particularly in the context of climate change and conscious material consumption. The potential of AM in space exploration and colonization, where resource limitations are extreme, necessitates a careful balance. The use of multiple mobile or stationary robots to print models larger than the printer’s capacity while maintaining energy efficiency and strength presents a solution. However, this approach also introduces challenges such as robot interference, placement, energy usage, decomposition of large parts, and quality. This study delves into the impact of variables such as model/part position, orientation, speed, and infill on the energy consumption of the robot. A data-driven energy surrogate model for robotic AM, which is trajectory-dependent, is utilized to calculate energy consumption. Two case studies, i.e., door structure and fuel tank models, printed with different print settings for traditional fused deposition modeling (FDM), wire arc additive manufacturing (WAAM), and concrete 3d printing, are studied. Factors such as changing the location and orientation of parts impact these more than factors like the velocity and acceleration of the print head, which have a change in energy efficiency. However, these savings in energy consumption may result in a less structurally sound item.
Energy Consumption Study for Multi-Axis Robot Additive
As additive manufacturing (AM) develops into a more mature manufacturing technology, the scope of experimentation with its limits and use cases has broadened. With the increasing implementation of these technologies, the energy usage of these machines is gaining significance, particularly in the context of climate change and conscious material consumption. The potential of AM in space exploration and colonization, where resource limitations are extreme, necessitates a careful balance. The use of multiple mobile or stationary robots to print models larger than the printer’s capacity while maintaining energy efficiency and strength presents a solution. However, this approach also introduces challenges such as robot interference, placement, energy usage, decomposition of large parts, and quality. This study delves into the impact of variables such as model/part position, orientation, speed, and infill on the energy consumption of the robot. A data-driven energy surrogate model for robotic AM, which is trajectory-dependent, is utilized to calculate energy consumption. Two case studies, i.e., door structure and fuel tank models, printed with different print settings for traditional fused deposition modeling (FDM), wire arc additive manufacturing (WAAM), and concrete 3d printing, are studied. Factors such as changing the location and orientation of parts impact these more than factors like the velocity and acceleration of the print head, which have a change in energy efficiency. However, these savings in energy consumption may result in a less structurally sound item.